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@ Crown copyright 1991
First published 1991 Reprinted 1999 (twice), 2002, 2003
ISBN 0 7176 1686 X
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the prior written permission of the copyright owner.
Applications for reproduction should be made in writing to: Licensing Division, Her Majesty's Stationery Office, St Clements House, 2-16 Colegate, Norwich NR3 1 BQ or by e-mail to [email protected]
This guidance is issued by the Health and Safety Executive. Following the guidance is not compulsory and you are free to take other action. But if you do follow the guidance you will normally be doing enough to comply with the law. Health and safety inspectors seek to secure compliance with the law and may refer to this guidance as illustrating good practice.
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Health and safety in tyre and exhaust fitting premises
Health and Safety series booklet HSG62
Contents
INTRODUCTION 1
LEGAL DUTIES 1
Statutory examination of plant 2
STAFF TRAINING 2 Training check list 2
REPORTING ACCIDENTS, DISEASES AND OTHER INCIDENTS 3 Immediate notification 3 Reporting in writing 3 Record keeping 3
FIRST AID 6
OCCUPATIONAL HEALTH 6 The Control of Substances Hazardous to Health Regulations 6 Other hazardous substances 8 Noise 9
GENERAL WORKING ENIVORONMENT 9 Heating 9 Lighting 9 Ventilation 10
Exhaust fumes 10
Sanitary accommodation 10 Washing and welfare facilities 10 Housekeeping and safe access 10 Public access 11
STORAGE OF TYRES AND EXHAUSTS 11
UNDER VEHICLE ACCESS 11
Ramps 12 Jacks (including trolley jacks) 13
Props 13 Vehicle lifts 13 Inspection pits 14
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TYRE SERVICING 15 Car tyres 15 Split-rim wheels 16 Commmercial vehicle well-based wheels 20 Extra large tyres 20 Tyre servicing equipment 20 Puncture repair 22
ELECTRICAL SAFETY 23 Fixed electrical installations 23 Portable equipment 23
BATTERY CHARGING 23
MISCELLANEOUS MACHINERY AND EQUIPMENT 24 Abrasive wheels 24 Rolling roads and brake testing 24 Oxyacetylene equipment 25 Fuel tanks and lines 26
ON THE ROAD 26 Moving vehicles and road testing of cars 26 Attending roadside breakdowns 26 Service vehicles 26
FURTHER INFORMATION SOURCES 28
PREFACE TO THE 2003 REPRINT
This guidance demonstrates good practice, and following it will normally be sufficient to meet the requirements of the law.
While the technical issues covered remain largely unchanged since it was first published in 1991, some of the legislation has been updated. In
particular the following new legislation is relevant:
Management of Health and Safety at Work Regulations 1999 Workplace (Health, Safety and Welfare) Regulations 1992 Provision and Use of Work Equipment Regulations 1998 Lifting Equipment and Lifting Operations Regulations 1998 Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1995 Control of Substances Hazardous to Health Regulations 2002 Control of Lead at Work Regulations 1998
Other changes of note include the occupational exposure limit for carbon monoxide, which has been reduced to 35 mg.m-3 (8 hour TWA) - see HSE guidance EH40/02 Occupational exposure limits 2002 ISBN 0 7176 2083 2 (supplied together with Supplement 2003 ISBN 0 7176 2172 3). Simplified arrangements for reporting under RIDDOR are explained in HSE leaflet Reporting incidents to the RIDDOR Incident Contact Centre MISC310(revl ).
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INTRODUCTION
1 This booklet is intended for owners and managers of tyre and exhaust fitting premises, and also for employees and safety representatives. It describes the main risks associated with the use of machinery, equipment, substances and work practices which are found in fitting bays, and what should be done to safeguard workers in the industry. It has been produced by the Health and Safety Executive's Local Authority Unit after wide consultation with employers, trade unions and other interested organisations including the National Tyre Distributors' Association.
2 The Health and Safety Executive (HSE) is responsible for developing health and safety standards nationally and for inspection and enforcement in motor vehicle repair workshops. Local authorities are responsible for inspection and enforcement in motor car tyre and exhaust fitting premises.
3 Further Health and Safety Executive guidance is in
preparation which will cover other health and safety aspects in general motor vehicle repair.
4 The National Tyre Distributors' Association recommends this booklet to all its members, subscribes to its recommendations and will actively promote it within the trade.
5 It should be noted that the illustrations are to assist in understanding the text and are not intended to represent any particular manufacturer's product.
6 While the information contained within this guidance is correct at the time of going to press, a number of directives from the European Community have recently been agreed and others are in preparation which may require detailed changes to UK legislation.
7 Further information and advice (including detailed advice on legal requirements) may be obtained from area offices of HSE or from local authority environmental health departments.
LEGAL DUTIES
8 Under the Health and Safety at Work etc Act 1974 employers have a general duty to ensure, so far as is reasonably practicable, the health, safety and welfare at work of their employees as well as the health and safety of other people affected by their undertaking. This duty includes providing a safe workplace, safe machinery and safe systems of work along with adequate information, instruction, training and supervision. Employees also have a duty to take reasonable care of their own safety and that of others.
9 Businesses which employ five or more people should have a written statement of their policy for ensuring health and safety. This safety policy should help employers decide on priorities, detailing health and safety objectives and outlining the organisation that exists for ensuring they are met. It should also set out how the policy is to be carried out. For example, when dealing with wheel balancing machines the policy will need to detail what the dangers are in using that machine, who will use it, who will train people to use it,
who will carry out the checks on the interlocks and how often this needs to be done.
10 The policy statement should be brought to the attention of all employees. Further advice can be found in the leaflet Writing a safety policy statement (HSC6) and the booklet Writing your health and safety policy statement (see pages 28 and 29 for details).
11 Specific requirements on health, safety and welfare in the workplace are also laid down in the following Acts and Regulations:
(a) the Factories Act 1961;
(b) the Offices, Shops and Railway Premises Act 1963;
(c) the Abrasive Wheels Regulations 1970;
(d) the Fire Precautions Act 1971;
(e) the Highly Flammable Liquids and Liquefied Petroleum Gases Regulations 1972;
(f)
(g)
(h)
(i)
(j)
(k)
(I)
(m)
(n)
the Protection of Eyes Regulations 1974.
the Control of Lead at Work Regulations 1980;
the Health and Safety (First Aid) Regulations 1981;
the Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1985;
the Control of Asbestos at Work Regulations 1987;
the Control of Substances Hazardous to Health Regulations 1988;
the Electricity at Work Regulations 1989;
the Noise at Work Regulations 1989;
the Pressure Systems and Transportable Gas Containers Regulations 1989;
All this safety legislation applies to tyre and exhaust centres. In some premises other regulations will also apply.
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Statutory examination of plant
12 Listed in Table 1 below are the requirements for statutory examination of plant which are likely to be found in tyre and exhaust premises.
STAFF TRAINING
13 Many accidents occur when employees, particularly young employees, use machines, equipment or substances without proper training. No one should be expected to use dangerous equipment or substances unless they have been properly trained. Managers and supervisors will also need suitable training.
14 Information and advice may be obtained from:
(a) the supplier of the material, substance or equipment;
(b) training centres or colleges of further education;
(c) trade associations;
(d) trade unions;
(e)
(f)
(g)
the Health and Safety Executive;
local authority environmental health departments;
professional bodies (eg The Institution of Occupational Safety and Health);
(h) voluntary bodies (eg The Royal Society for the Prevention of Accidents, The British Safety Council).
Training check list
15 The following check list shows what needs to be considered when preparing a typical training programme:
Organisation
Will training be 'on' or 'off' the job?
Who will do the training?
Who will supervise the training?
What records will be kept?
Table 1 Statutory examination of plant under the Factories Act 1961
Plant
Air receiver
Chains, ropes & lifting tackle
Hoists & lifts
Cranes & other lifting machines
Section of Test & thorough Certificate of test Periodic thorough Factories Act examination and examination examination
prior to use
36' No No At least every 26 months (up to 4 years for solid drawn construction)
26 Yes Yes At least every 6 months Except for fibre and Specifying safe working rope slings load
22 No No At least every 6 months
27 Yes Yes At least every 14 months Specifying safe working load
This requirement is superceded by the Pressure Systems and Transportable Gas Containers Regulations 1989. The main features of the Regulations are:
(a) a requirement to have a written scheme of examination certified or drawn up by a competent person which will set out the frequency of examinations and their type in accordance with the degree of risk. This replaces the requirement to have steam and air vessels examined at intervals specified in section 36. (The competent person is usually your insurance company engineer); and
(b) they apply to the whole system as opposed to the pressure vessel only.
These provisions are subject to a long transitional period of four years. During that time users may choose to continue to comply with the Factories Act or move over to the more flexible arrangements in these Regulations.
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Selecting and assessing the trainee
How is the trainee to be selected? - Selection should take account of the physical and mental demands of the job.
How much does the trainee know already about safe working practices?
Basic instruction
For each task prepare a list of all the points training should cover eg:
What equipment or substance to use.
How the equipment or substance works and what it does.
What dangers are associated with its use, including accidental spillage.
What safety precautions are needed and how they protect the user.
How to clean equipment safely.
What to do if equipment seems faulty.
What personal protective equipment to wear.
Supervised working
Set the trainee to work under close supervision.
Make sure the supervisor has the time and knowledge to supervise effectively.
Make sure the supervisor watches to see that dangerous practices do not develop.
Final check
Check that the trainee knows how to carry out the work properly and safely. Make sure he/she can be left to work safely without close supervision and monitor performance on a regular basis.
REPORTING ACCIDENTS, DISEASES AND OTHER INCIDENTS
16 Under the Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1985 (RIDDOR) employers have a legal duty to report certain accidents, dangerous occurrences and occupational diseases to their enforcing authority.
Immediate notification
17 The employer should notify the enforcing authority (where the main activity is motor car tyre and exhaust fitting this will be the local authority) as soon as possible, normally by telephone, if:
(a) someone dies or suffers a major injury in an accident connected with their business;
(b) an employee is injured which results in him/her being admitted immediately to hospital for more than 24 hours; or
(c) there is a dangerous occurrence.
Reporting in writing
18 The employer should send a report to the enforcing authority (where the main activity is motor car tyre and exhaust fitting this will be the local authority) within seven days if:
(a) an employee is off work or cannot carry out their normal duties for more than three days as a result of an accident at work;
(b) any death, major injury or dangerous occurrence has previously been notified by telephone; or
(c) a specified occupational disease is certified by a doctor.
19 Reports should be made on Form 2508, for accidents and dangerous occurrences (a reduced copy of Form 2508 is shown at Figure 1). Form 2508A should be used for reporting cases of disease. These forms are available from HMSO bookshops (see back cover for details). Photocopies of the forms may be used.
20 The HSE booklet Reporting an injury or dangerous occurrence gives further advice on the requirements of RIDDOR (see pages 28 and 29 for details).
Record keeping
21 The employer should keep a record of any reportable accident, dangerous occurrence or case of disease. These records should include:
(a) date and time of accident or occurrence;
(b) name, occupation and nature of injury of person affected;
(c) place where incident happened; and
(d) a brief description of the circumstances.
3
O Health and Safety Executive Health and Safety at Work etc Act 1974 Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1985
Report of an injury or dangerous occurrence Full notes to help you complete this form are attached. This form is to be used to make a report to the enforcing authority under the requirements of Regulations 3 or 6.
Completing and signing this form does not constitute an admission of liability of any kind, either by the person making the report or any other person. If more than one person was injured as a result of an accident, please complete a separate form for each person.
A Subject of report (tick appropriate box or boxes) - see note 2
Fatality Specified major injury or
I condition El
"Over three Dangerous Flammable gas Dangerous day" injury j occurrence (J incident (fatality gas
3 1 or major injury 5 fitting or condition)
B Person or organisation making report lie person obliged to report under the Regulations) - see note 3
Name and address - Nature of trade, business or undertaking -
Post code -
Name and telephone no. of person to contact -
If in construction industry, state the total number of your employees - and indicate the role of your company on site (tick box) - Main site Sub Other contractor contractor
7 a
If in farming, are you reporting an injury to a member of your family? (tick box)
C Date, time and place of accident, dangerous occurrence or flammable gas incident - see note 4
Date Time - day month year
Give the name and address if different from above -
Where on the premises or site - and Normal activity carried on there
I I
9
F7 Yes No
Complete the following sections D, E, F & H if you have ticked boxes, 1, 2, 3 or 5 in Section A. Otherwise go
straight to Sections G and H.
D The injured person - see note 5
Full name and address -
Age Sex
(M or F)
Trade, occupation or job title -
Status (tick box) -
Nature of injury or condition and the
part of the body affected -
F2508 (rev 1/86)
Figure 1 Sample copy of Form 2508
Employee
In
Trainee
(other) 13
Self Trainee employed
11 (YTS) it
Any other person
continued overleaf
Spaces below are for office one Only
ENV
4
E Kind of accident - see note 6
Indicate what kind of accident led to the injury or condition (tick one box) - Contact with moving machinery or material being machined
Struck by moving, ncludmg flying or
falling, object
Struck by moving vehicle
Struck against something fixed or stationary
2
3
x
Injured whilst handling lifting or carrying
Slip, trip or fall on same level
Fall from a height'
'Distance through which person fell
5
Trapped by something collapsing or overturning
6
Drowning or asphyxiation
7
8
9
Exposure to or contact with a harmful substance 10 TI
(metres)
Exposure to an explosion
Contact with electricity or an electrical discharge
Injured by an Inmal
Other kind of accident (give details an Section HI
F Agent(s) involved - see note 7
Indicate which, if any, of the categories of agent or factor below were involved (tick one or more of the boxes) - Machinery/equipment for rifting and conveying
Portable power or hand tools
Any vehicle or associated egwpment/ machinery
Other machinery
1
2
3
e
Process plant, pipework or bulk storage
Exposure to fire
5
Live animal
Any material, substance or product being handled, used 6 or stored
Gas, vapour, dust, fume or oxygen deficient atmosphere 7
Pathogen or infected
material
Moveable container or
packagec
of any kind
9
10 10
Floor, ground, stairs or any working surface
8
C 11
eudmng, r , engineering structure or U excavation/underground 12
working
Describe briefly the agents or factors you have indicated -
G Dangerous occurrence or dangerous gas fitting - see notes 8 and 9
Reference number of dangerous occurrence Reference number of dangerous gas fitting
Ladder or scaffolding
12
13 Spaces below are for office
only TA
15
13
Construction formwork, shuttering and falsework Id
Electricity supply cable, wiring,
apparatus or equipment 15
Entertainment or sporting facilities or equipment
Any other agent
H Account of accident, dangerous occurrence or flammable gas incident - see note 10
Describe what happened and how. In the case of an accident state what the injured person was doing at the time -
Signature of person making report Date
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FIRST AID
22 Under the Health and Safety (First Aid) Regulations 1981 workplaces should have first-aid provision. The form it should take depends on various factors, including the nature and degree of the hazards at work, whether there is shift working, what medical services are available, and the number of employees. The HSE booklet First aid at work, contains an Approved Code of Practice and guidance notes to help employers to meet their obligations (see pages 28 and 29 for details).
23 The minimum requirement for any workplace is that at all times when people are at work, there should be at least one person appointed who will take over an emergency situation in the absence of a qualified first aider ie by calling an ambulance. Ideally, it is recommended that an appointed person should have received emergency first-aid training.
24 In the case of tyre and exhaust fitting premises it is recommended that the employer provides a qualified first aider, the deciding factors being the nature of the work and the hazards associated.
25 A first-aid box should be provided and should contain only items that a first aider has been trained to use. It should not contain medication of any kind. It
should always be adequately stocked. A list of recommended contents is shown in Table 2.
26 Notices should be displayed giving the location of first-aid equipment and the name and location of the first aider or appointed person.
27 All cases dealt with should be recorded by the first aider or appointed person. Records should include at least the name of the casualty, date, time and circumstances of the accident with details.of the injury sustained and any treatment given. Employees or their representatives may wish to inspect these records at any time, they should therefore be kept in a suitable place rendering them easily available for inspection.
OCCUPATIONAL HEALTH
The Control of Substances Hazardous to Health Regulations
28 The Control of Substances Hazardous to Health Regulations 1988 (COSHH) and the associated Approved Codes of Practice lay down the essential requirements and a sensible step-by-step approach for the control of hazardous substances and for protecting people exposed to them.
Table 2 Recomended contents of first-aid boxes and kits
Item
Guidance Card
Individually wrapped sterile adhesive dressings(assorted sizes)
Sterile eye pads, with attachment
Individually wrapped triangular bandages
Safety pins
Medium sized individually wrapped sterile unmedicated wound dressings (approx 10 cm x 8 cm)
Large sterile individually wrapped unmedicated wound dressings (approx 13 cm x 9 cm)
Extra large sterile individually wrapped unmedicated wound dressings (approx 28 cm x 17.5 cm)
Individually wrapped moist cleaning wipes (suggested minimum number)
First-aid Travelling boxes first-aid kits
1 1
20 6
2
6 2
6 2
6
2 1
3
10 6
29 The Regulations require all employers to:
(a) assess the risk to health arising from work and what precautions are needed;
(b) introduce appropriate control measures to prevent or adequately control exposure to hazardous substances;
(c) ensure that control measures are used and that equipment is properly maintained and procedures observed;
(d) where necessary, monitor the exposure of workers and, if appropriate, provide or carry out health surveillance; and
(e) inform, instruct and train employees about the risks and precautions to be taken.
Assessment
30 As in tackling any problem, you need to know what the problem is and its extent before deciding what, if anything, you need to do about it.
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31 The assessment should be a systematic review of Table 3 Exhaust fume components - recommended all work undertaken which asks: occupational exposure limits
(a) what substances are present and in what form?
(b) what harmful effects are possible and how would they affect the body? (eg inhalation risks from adhesives, ingestion from lead, skin contact from waste oil)
(c) where and how are substances actually used or handled?
(d) what harmful substances are given off or produced?
(e) who could be affected, to what extent and for how long?
(f)
(g)
(h)
under what circumstances would they be affected?
how likely is it that exposure will happen?
what precautions need to be taken to comply with the rest of the COSHH Regulations?
32 All these aspects should be considered in the light of what actually happens in the workplace. In this way assessment conclusions will reflect only what is relevant to the real risk in the particular circumstance. In all but the simplest cases the assessment will need to be written down. Much of the information required should be provided by the supplier of the substances who has a duty to make adequate information available. Most assessments are well within the scope of company staff who should use common sense in following the principles set out.
33 Many substances used within tyre and exhaust premises will be subject to the requirements of COSHH. Degreasing solution, exhaust paste, brake fluid, bleaches, adhesives, etc are all potentially hazardous and work involving them will have to be formally assessed and recorded. The assessments should be kept at each tyre and exhaust centre.
34 Substances arising from the work activity are also covered including used engine oils and exhaust fumes. Exhaust fumes should be controlled so that the individual components are below the occupational exposure limits recommended by the Health and Safety Executive (see Table 3). There is growing evidence of a carcinogenic risk from exposure to exhaust fumes (thought to be associated with the particulates). This reinforces the need to provide effective means to protect employees from exposure. (See section on exhaust fumes, paragraphs 61 to 63.)
Substance Hazard Occupational exposure limit (mg m-3)
Type 8-hour TWA
10 min STEL
Carbon monoxide
Toxic OES 55 330
Nitrogen dioxide
Toxic and irritant
OES 5 9
Nitrogen monoxide
Toxic OES 30 45
Lead Cumulative CLAW 0.10 toxin (tetraethyl lead)
Particulates
Unburnt fuel
May contain carcinogens
Various
0.15 (other forms of lead)
Many other substances present in exhaust fumes also have occupational exposure limits. This table lists only the common ones or those normally present in significant quantity.
OES = refers to an occupational exposure standard as defined by COSHH
CLAW = refers to the occupational exposure limit for lead under the Control of Lead at Work Regulations 1980
TWA = time weighted average STEL = short-term maximum exposure limit
Control
35 When making a COSHH assessment, the employer will need to decide which control measures are appropriate in order to deal effectively with any hazardous substances that may be present. The first aim should be to prevent exposure by removing the hazardous substance. This can be achieved by:
(a) changing the process;
(b) substituting it with a safe or safer substance; or
(c) using it in a safer form.
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36 Where this is not reasonably practicable, employers should ensure adequate control of exposure by, for example:
(a) totally enclosing the process;
(b) using partial enclosure and extraction equipment;
(c) using general ventilation;
(d) using safe systems of work and handling procedures;
(e) using personal protective equipment. However, this is only acceptable as an additional method where adequate control by other methods alone is not reasonably practicable.
Using the controls
37 Employers should ensure that the control measures are properly used or applied.
38 Employees should make full and proper use of the controls and report any defects to their employers.
Maintenance of controls
39 Employers have a duty to ensure that the control measures are kept in efficient working order and good repair. If the control measures consist of engineering controls, they should be examined and tested at regular intervals. For example, local exhaust ventilation equipment should be tested at least once every 14 months and a simple record kept of the results.
Informing employees
40 Employees have to be informed, instructed and trained so that they know and understand:
(a) the risks arising from their work; and
(b) the precautions to be taken.
41 It should be remembered that an employer's obligation under COSHH does not finish with the assessment. This is merely the first stage. After the assessment has been carried out, controls have to be implemented, employees informed and, finally, the whole process should be kept under review to ensure not only that the control measures are being carried out, but also to check whether there have been any significant changes to working practices, materials, etc which would merit reassessment
42 Practical guidance on COSHH is given in some detail in its associated Approved Codes of Practice. Further guidance is also available on specific aspects (see pages 28 and 29 for details).
Other hazardous substances
43 COSHH does not apply to asbestos and lead, both of which are commonly found in tyre and exhaust premises. These substances are subject to specific regulations.
Asbestos
44 Certain parts of vehicles, particularly brake and clutch linings, may contain asbestos. The asbestos is almost invariably white asbestos (chrysotile). Although the asbestos is bound in a resin base, working with vehicle parts which contain asbestos can create airborne asbestos dust which may be inhaled. Dust is also formed by braking and similar operations when the vehicle is in
use. Breathing this dust can be harmful. The more dust breathed in, the greater the chance of harm. Cases of asbestos related cancer have been reported in garage workers. The highest levels of dust are associated with such operations as grinding, sanding (both of which should be carried out under local exhaust ventilation) and cleaning fine dust from brake and clutch assemblies.
45 Before starting any work which may result in
exposure to asbestos dust an assessment should be made of the type and extent of exposure and the appropriate precautions to be adopted. Dust should never be blown from brake drums or clutch housings using an airline. Instead, either proprietary drum cleaning equipment or, failing that, wet rags, should be used. These should be sealed in a polythene bag while wet and disposed of in accordance with the recommendations of the local waste disposal authority. Dust should only be vacuumed using a type H vacuum cleaner which conforms to BS 5415.
46 Work with asbestos is subject to the Control of Asbestos at Work Regulations 1987 and its associated Approved Code of Practice. Employees liable to be exposed to asbestos should be given a copy of the leaflet Asbestos and you (see pages 28 and 29 for details).
Lead
47 Lead is a constituent part of leaded petrol and is therefore likely to be deposited in exhaust systems. During removal it is likely that lead will be released into the atmosphere.
48 A compound of lead is also used as the weights for wheel balancing. Operators should ensure that they wash their hands thoroughly after handling these weights, either before eating or at the end of a working shift.
49 Work with lead is subject to the Control of Lead at Work Regulations 1980 and its associated Approved Code of Practice. It is likely that exposure to lead will not be significant in a typical tyre and exhaust fitting premises (see paragraphs 13 to 14 of the Approved
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Code) and thus lead in air estimations and medical surveillance will not generally be necessary, although employers should assess conditions in their premises to confirm this. Employees should be given a copy of the leaflet Lead and you. (See pages 28 and 29 for details of these publications.)
Noise
50 The only machinery likely to produce a hazardous level of noise in tyre and exhaust premises is the air compressor (especially if it is old and worn) and hand- held compressed air tools. Particular attention may have to be given to these if they are located in small, reverberating workrooms ie the compressor could be placed within a sound-proofed enclosure, put outside, or replaced by a quieter type.
51 The Noise at Work Regulations 1989 require an employer to identify when employees are likely to be exposed to noise levels of 85 dB(A) or more. As a rough guide, an assessment of noise is required when people have difficulty being heard clearly by someone about two metres away, or if they find it difficult to talk to each other.
52 The Regulations lay down three action levels as shown in Table 4 below.
Table 4 Noise at Work Regulations 1989 -
Action levels
Level Action
First action level -
(daily personal noise exposure of 85 dB(A) - Lep,d)
Second action level -
(daily personal noise exposure of 90 dB(A) - Lep,d)
Peak action level -
(peak sound pressure of 200 pascals-140 dB(A))
Employers have to provide information about risks to hearing and ear protectors to employees who ask for them
Exposure should be reduced so far as reasonably practicable by means other than with ear protectors eg noise reduction at source. However, if employees are likely to be exposed to noise at these levels the employer should provide suitable ear protectors and ensure they are properly used.
GENERAL WORKING ENVIRONMENT
Heating
53 It has become customary practice in the industry for centres to operate with doors open, therefore making
it almost impossible to maintain a reasonable temperature during inclement weather conditions. In
such circumstances there should be provided, in a conveniently accessible position, effective means of enabling employees to warm themselves (eg a heated mess room). Suitably placed radiant heaters may assist those personnel who work in fixed positions, while others may require additional clothing ie body warmers.
54 Permanently installed room sealed appliances (such as those with balanced flues) provide the best method of heating from all aspects including health and safety. Many fuels can be used such as mains gas, electricity and liquid petroleum gas (LPG) (supplied from a bulk storage tank situated in a safe place outside the premises). Flues are provided to conduct the products of combustion directly to atmosphere. Occasionally waste oil is used for fuel, but this should only be used in
suitably designed equipment provided with a flue.
55 Portable paraffin or liquefied petroleum gas heaters create the most problems and should only be used in emergency or where it is not practicable to provide a more permanent form of heating.
Precautions
56 The following precautions should be taken with heating equipment:
(a) adequate ventilation should be provided where fumes are generated by a heater;
(b) rubbish and waste materials should not be allowed to accumulate near to heaters;
(c) flammable liquid storage cabinets should not be positioned within four metres of heaters;
(d) all heaters should be correctly installed, adequately maintained and used in accordance with the manufacturer's instructions;
(e) adequate precautions should be taken to ensure portable heaters cannot be overturned; and
(f) tyres should not be placed in front of radiant heaters.
Lighting
57 Suitable and sufficient lighting should be provided to all parts of the premises and not just to the work area. There should be a good level of illumination free from glare. Flickering lamps can cause rotating parts of engines and wheels to appear stationary and therefore could be dangerous. Flicker can be caused by lamps at the end of their life or by instabilities in the electricity supply. Light fittings should be positioned so that light is
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shed evenly throughout the working area and strong shadows are not produced. Purpose designed roving handlamps may be necessary for use under vehicles. Lighting used in pits should be designed and tested to prevent ignition in flammable atmospheres.
58 Further details can be found in the booklet Lighting at work and in the Guidance Note Selection and use of handlamps (see pages 28 and 29 for details).
Ventilation
59 Ventilation is required for one of two reasons:
(a) Exhaust ventilation to remove dusts, fumes etc, before they enter the general atmosphere of the workshop; and
(b) General ventilation to create a comfortable working environment, in
conjunction with heating, by achieving the correct level of humidity and air movement.
60 General ventilation can be used to remove concentrations of dust and fumes from the workroom which are well below any potentially harmful level. It
should not, however, be relied upon as a primary source of controlling high levels of harmful emissions.
Exhaust fumes
61 Vehicle exhaust fumes are toxic and subject to the Control of Substances Hazardous to Health Regulations 1988 (COSHH) (see paragraphs 28 to 42). They contain a wide range of substances, the most important of which are summarised in Table 3. The proportion of the components varies with the fuel, the condition of the engine and its state of tune. The fumes from cold or intermittently run engines are likely to contain greater quantities of unburnt fuel and particulate matter.
62 Under COSHH there is an overall duty to prevent exposure to exhaust fumes, or if that is not reasonably practicable, to control it. For some components of exhaust fumes occupational exposure limits apply and these should be complied with if adequate control is to be achieved. (See Table 3.)
63 Vehicle engines should not be run indoors (except to move vehicles to and from work positions) unless arrangements have been made to remove the fumes. This can be done by coupling flexible ducting to the exhaust outlet. The best systems incorporate extraction fans which draw fumes through ducting connected to the vehicle exhaust and discharge them to a safe place. A
number of proprietary systems of this type are available. Clearly there is less concern where a single vehicle engine is run with the exhaust outlet close to wide open doors, but even here care should be taken that fumes do not enter the workroom.
Sanitary accommodation
64 Suitable and sufficient sanitary conveniences should be provided for people employed in and around the workshop. In most tyre and exhaust centres one water closet each should be provided for male and females.
65 Sanitary conveniences should be:
(a) well ventilated and not communicating directly with workrooms;
(b) undercover: partitioned off for privacy and with suitable doors and fastenings;
(c) readily accessible to the workrooms;
(d) so screened, that the interior is not visible from the workshops when the door to the toilet is open; and
(e) provided with conspicuous notices indicating the sex for which the conveniences are provided.
Washing and welfare facilities
66 Washing facilities should be provided which are both adequate and suitable. The wash hand basins should be deep enough to allow forearms to be washed. Supplies of running hot and cold water should also be provided together with soap or other proprietary hand cleansers and suitable drying facilities. Barrier creams will help in the care of hands.
67 Drinking water should be provided at conveniently accessible points. This should not be within a compartment containing a water closet or urinal.
68 Suitable accommodation for workwear and clothing not worn at work should be provided as well as arrangements for drying wet clothing.
Housekeeping and safe access
69 Many accidents at work are caused by people falling, not from great heights but by tripping and falling over items left lying on the floor. It follows that work areas, offices, mess rooms, storage areas, washing and toilet facilities should be kept clean and tidy at all times.
70 All floors, passages, steps and gangways should be properly maintained and kept free from obstruction and any substance likely to cause people to slip. Floors should be kept free of airlines, tyres, tubes etc and spillages of oil or water should be cleaned up immediately. Overhead retractable airlines should be used wherever possible to prevent airlines crossing the workshop floor.
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71 Stocks of tyres should be placed in racks with large tyres at or near ground level. Tyres should not be allowed to project into gangways and passages. If scrap tyres are stored inside the premises they should be stacked safely. They should not be allowed to accumulate in large numbers, unless stored in a specially designated area, and they should be kept clear of exits, particularly fire exits.
72 Suitable handrails should be fitted to staircases and open sided stairs should be fitted with handrails and banisters. Openings in floors should be securely fenced unless the nature of the work makes fencing impracticable.
Public access
73 The Health and Safety at Work etc Act requires an employer to ensure, so far as is reasonably practicable, the health and safety of his employees and others. That includes members of the public who may visit the premises ie customers.
74 It has become customary practice in the industry to allow the customer to inspect his/her vehicle before and after the work has been carried out. This obviously involves customers walking through the workshop area, thereby exposing themselves to possible hazards.
75 While the customer is in the workshop he/she should be accompanied by an employee at all times. A waiting room should be provided where the customer should remain until the work has been completed.
STORAGE OF TYRES AND EXHAUSTS (See Figure 2)
76 The requirements for safe storage vary according to the type and quantity of tyres and exhausts involved, but the basic principles for their safe movement and storage are as follows:
(a) adequate lighting and the avoidance of deep shadow are essential for safety in the storage and movement of stock. All light failures or deficiencies should be remedied as soon as possible;
(b) purpose-designed racking of adequate and correct dimensions should be provided for the storage of both tyres and exhausts;
(c) properly secured steps and ladders should be provided and should be used to reach upper levels of stock. They should be easy to use and readily moved from one location to another. Loose ladders should be provided with hooks or other devices at the upper end to fix on the racking to prevent the ladder from slipping or twisting when in use.
Heavier items should be stored on lower racks. Stock should not be stored so as to protrude into gangways. Stock should never be retrieved by climbing the racking;
(d) If an upper or mezzanine floor is used for storage, a mechanical lifting device may be required to move stock. Where this is the case the safe working load of the lifting device should never be exceeded and it should only be used for carrying stock and never personnel. If the lifting device is attached to the mezzanine floor structure it is essential that it is installed by a competent person to ensure that the structure is capable of supporting both the lifting device and its safe working load. All lifting devices should be properly maintained and be inspected by a competent person at the intervals set out in Table 1 on page 2. Damaged gates, lift switch gear or equipment should be repaired immediately. Where mechanical lifting devices are not used, only light easily manageable materials should be stored on upper floors. Precautions should be taken to ensure that upper floors, particularly mezzanine floors, are not overloaded with stock etc. It may be necessary to provide a notice stating the safe working load;
(e) all openings on upper floors should be guarded to prevent any goods or people falling. It is particularly important that any sections of the guard which are removable for loading (eg by fork lift truck) are replaced as soon as loading is complete. A system of guarding is available which allows goods to be transferred to and from mezzanine floors while maintaining adequate protection against falls;
(f) where the manual handling of tyres and exhausts cannot be avoided personnel should receive training in lifting and handling techniques and the working environment should be laid out in such a way as to reduce the risk of injury to the lowest level achievable. Tyres should not be rolled, particularly down a slope, unless totally under control at all times. Personnel should not attempt to move heavy tyres on their own and should be made aware that in many circumstances rolling them can be particularly dangerous.
UNDER VEHICLE ACCESS
77 A degree of risk exists whenever a person enters the space beneath a vehicle and therefore the choice of equipment used should be carefully considered. Adequate maintenance of this equipment is essential, particularly for the more sophisticated types such as vehicle lifts, which contain a variety of moving parts, suspension components, etc.
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78 Vehicle lifting devices should only be used by authorised and trained personnel as special care is necessary when manoeuvring vehicles, positioning chocks, jacks, props, etc.
79 Various devices and means are used to gain access to the underside of a vehicle. Points to remember on each type are listed as follows.
Ramps
80 These are usually fixed in position. A short portable version will merely maintain a vehicle in a tilted position, while a longer ramp will enable a vehicle to attain an elevated horizontal position. The ramps have no moving parts and safety in their use is achieved via their intrinsic design/strength; along with commonsense procedures such as careful manoeuvring of vehicles, braking/chocking of wheels, etc.
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Jacks (including trolley jacks)
81 These are standard items of lifting equipment. While many possess built in safeguards, their simplicity and mobility may induce carelessness in those operators using them. Certain conditions need to be met to ensure jacks are used safely when lifting vehicles. These are:
(a) under no circumstances should any person work beneath a vehicle supported only by a jack or jacks;
(b) the correct jack for the job should be used. It
should be capable of taking the load of the vehicle to be lifted and be applied to the correct part of its underside;
(c) the jack should only be used to raise the vehicle prior to inserting appropriate stands, chocks, etc. It should not be relied upon as the sole support for work underneath or close beside a vehicle;
(d) jacks should only be used on firm, level ground;
(e) wheels of the vehicle still in contact with the ground should be chocked;
(f) routine checks and maintenance should be carried out to ensure the jack is in good working order; and
(g) personnel should be trained in their correct use.
Props
82 These are vitally important items of equipment. When used properly they make it safer for people to work beneath vehicles which have been raised by lifting devices such as trolley jacks. Under no circumstances should any person work beneath a vehicle supported only by a jack or jacks.
83 Props may be used to support a raised vehicle in a wheel free condition, after the vehicle has been lifted by a number of jacks. They should only be used on firm, level ground and should be designed to adequately carry the loads placed on them.
84 A common type of prop is the axlestand or axletree. When supplied, such equipment is provided with the appropriate pins to adjust the height of the stand. When these pins are lost or damaged they should be replaced with pins to a similar specification, and not screwdrivers, tyre valves, or other unsuitable devices.
Vehicle lifts
85 These devices raise the whole of the vehicle above floor level. In tyre and exhaust premises the four-post runway type of wheel-supporting lift is most commonly used. Lifts are often provided with special attachments which allow axles, wheels etc to be removed. It is recommended that lifts that comply with British Standard AU 161 (Part 1): 1983 and British Standard AU 161 (Part 2): 1989 are provided (see page 29 for details).
86 Several accidents occur every year from the use of lifts. These range from vehicles falling off, to failure of wire ropes or the hydraulic/pneumatic mechanism. Overloading can also result in the failure of the lift.
Because of these factors, adequate training of employees in respect of the use of any lift is essential.
87 Where lifts that do not comply with the British Standard are being used the following features should be incorporated:
(a) each lift should show the maximum working load in
a conspicuous place with letters not less than 50 mm high;
(b) the lift should be positioned so that any moving part is a minimum of 600 mm from the nearest fixed structure;
(c) in order to prevent injuries to toes, by trapping them between the lift platform and the floor, the following should be provided when the lift descends to its lowest level:
(i) a minimum clearance space of 120 mm x 75 mm - 50 mm (see Figure 3) or;
(ii) hinged flaps of at least 120 mm width. The flaps should not be capable of being rotated below the horizontal or by more than 75 degrees in the upward direction. After rotation the flaps should return to the horizontal position automatically (see Figure 4);
(d) automatic chocks, at least two at each end of the lift, should be provided at the approach and departure ends of wheel supporting runways. However, where approach and departure is from the same end, the opposite end can have permanent chocks;
(e) approaches to the lift should not exceed 20 degrees from the horizontal.
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88 The two-post body supporting lift which achieves 'wheel-free lifting' via four jacking points on the underside of the chassis of the vehicle, is sometimes found in tyre and exhaust centres. It is important that:
(a) the vehicle manufacturer's recommendations regarding vehicle lifting are known and observed;
(b) vehicle chassis and chassis jack points are identifiable and in a satisfactory condition;
(c) the support arm pads are in good condition and (where necessary) are set at the correct height before the vehicle is raised;
(d) the weight distribution of the vehicle is considered, eg front/rear engined, loads within car/boot, absence of major components such as engine, gearbox;
(e) the effect on the stability of the vehicle caused by the removal of major components or by the application of forces, via tools, etc is considered.
89 Periodic thorough examination of lifting devices by a competent person should be carried out, at least every six months. Recommendations for maintenance and examination of vehicle lifts are contained in British Standard AU 161: 1983 (see page 28 for details). Manufacturers' advice should also be followed.
Inspection pits
90 Inspection pits are sometimes used to gain access to the underside of vehicles, although this method is not normally used in tyre and exhaust fitting premises. Pits are particularly hazardous and therefore serious consideration should be given to their replacement by purpose-designed vehicle lifts.
91 The principal hazards are those of fire, people falling into the pit, a vehicle falling on an employee in the pit, or of asphyxiation.
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92 The following safeguards should be implemented until such time as the pit can be replaced:
(a) guard rails and/or pit boards should be provided for each inspection pit. Guard rails or covering boards should be used whenever there is no vehicle above the pit subject to point (b) below. A vehicle parked over an unused pit may reduce the risk of a person falling in;
(b) there are bound to be times when a pit will be left uncovered or unfenced. Such times should be kept to a minimum, determined by the nature of the work being done;
(c) if pits are to be left uncovered or unfenced for even a short time it is important that all people, whether employees or members of the public, can readily see the opening (and there should be no tripping hazards within the vicinity of the pit). The use of pit lighting during working hours and the marking of pit edges, for example by black and yellow bands, may be of help (see (f) below). Removable post and chain fencing around the area would allow vehicles to use the pit but prevent other people from inadvertently approaching its edge;
-(d) people not engaged in the work eg members of the public and uninvolved employees should be kept away from any unfenced pit;
(e) a safe means of access and exit should be provided at each end of the pit;
(f) unless a handlamp is of a special construction and has been designed and tested to prevent ignition in flammable atmospheres, it will not be suitable for use in places where vapours such as petrol and flammable solvents may have accumulated, eg in inspection pits. Any fixed lighting in the pit should be of a design for use in a potentially explosive atmosphere and should conform to a recognised standard such as British Standard 5345 (see page 28 for details).
93 Further details can be found in HSE Guidance Notes Electrical installations in MOT vehicle repair premises and Selection and use of electric handlamps (see pages 28 and 29 for details).
94 A fire/explosion in an inspection pit may occur if
petrol vapour (which is heavier than air) collects in the bottom of the pit and is subsequently ignited by electrical or welding equipment. Similarly asphyxiation may occur if petrol or petrol vapour enter the pit. For this reason, petrol tanks should not be emptied or removed and fuel line work should not be undertaken over a pit. The accidental 'flooding' of engines may also result in petrol
vapour entering a pit. Similarly, portable LPG heaters should never be used in or near pits.
TYRE SERVICING
95 Tyre servicing is a potentially hazardous job and should only be tackled by skilled personnel who have been thoroughly trained. The two main hazards which can arise during tyre inflation are:
(a) violent separation of the component parts of the wheel; or
(b) an air blast from a ruptured or burst tyre.
Car tyres
96 The following procedures should be carried out during removal and fitting of car tyres:
(a) a check should be made that the vehicle handbrake is on before the vehicle is jacked and that wheels in
contact with the ground have been chocked;
(b) the jack should be used only for raising the vehicle, axlestands should then be properly positioned to support the vehicle;
(c) before starting work on a tyre change or repair to a wheel the valve core should be removed to ensure that the tyre is fully deflated;
(d) bead lubricants should be used when removing and fitting a tyre to a wheel rim;
(e) the wheels and tyres should be examined before fitting and any that are visibly damaged discarded. Care should be taken to ensure that the wheel, associated parts, tyre and tube are the correct size and type before fitting. Proper examination of tyres and wheels at roadside breakdowns is particularly important;
(f) apart from special tyres, where manufacturers' advise otherwise, tyres should be inflated slowly to no more than 15 psi. A check should then be made to ensure that the whole assembly is fitting correctly. If at that pressure the assembly is not seating properly then the tyre should be deflated and the procedure started again, checking that all components are compatible. Under no circumstances should increased air pressure be applied to force a fit. The manufacturer's recommended pressure for the size of tyre should then be observed. The tyre pressure for the size and ply rating of the tyre should not be exceeded, and in any event, no car tyre should be inflated above 40 psi;
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(g) with car and other small tyres on solid wheels that are inflated to pressures of less than 40 psi it is not necessary to use a tyre cage but airlines should be fitted with a minimum of six feet of hose between the clip-on-chuck and the airline control. Operators should stand well clear of the wheel during inflation;
(h) only a pneumatic tool with a socket end of the correct size or a suitable wheel brace should be used to replace wheel nuts. These should then be tightened to the correct torque for the particular vehicle using a calibrated torque wrench. When using a pneumatic tool to replace the wheel nuts care should be taken to ensure they are not over tightened.
Split-rim wheels
97 The most hazardous activity undertaken in tyre fitting is in relation to split-rim wheels. Numerous serious accidents including fatalities have been caused as a result of the violent separation of this type of wheel. Normally such accidents are associated with larger commercial vehicles but they can also occur during tyre changing operations with smaller wheels such as wheelbarrows, fork-lift trucks etc. Tyre removal should not be undertaken unless the tyres have been totally deflated and inflation should be undertaken following the precautions detailed below, which are in addition to those for car tyres.
98 There are two basic types of split-rim wheel assemblies:
(a) divided wheels; and
(b) multipiece wheels.
Figure 5 A divided wheel
Divided wheels
99 Less common, but still encountered on cranes, fork lift trucks, dumper trucks, wheelbarrows, scooters and caravans as well as on many military vehicles.
100 The wheel consists of two parts bolted together with an outer ring of rim studs, the whole assembly then being bolted to the vehicle hub by an inner ring of hub studs (see Figure 5).
Associated hazards
101 Loosening the wheel nuts with the tyre under pressure has resulted in violent separation of rim halves. This has caused fatal injuries. Loosening of the hub studs can have the same result if there has been damage or unauthorised repair to the wheel.
102 Before removing any divided wheel from a vehicle it must be completely deflated. This can only be achieved by removal of the valve core. Inflation should only take place when effective measures have been taken to contain the wheel components in the event of violent separation by the use of:
(a) a strong, firmly-secured cage;
(b) a horizontal stool and associated clamping mechanism; or
(c) complete separation by a substantial screen.
(See Figure 6)
103 On no account should the bolts, which hold divided rim wheels together, be secured in position by welding of the bolt head to one half of the wheel. This is likely to lead to weakening of the bolt, and may give rise to explosion if carried out with the tyre still on the wheel.
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Figure 9 De-mountable rims
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Figure 11 Typical well-based wheel used on heavy goods vehicles
Figure 12 Typical well-based wheel used on light commercial vehicles
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Multipiece wheels
104 This category includes large commercial wheels. The most common types are:
(a) The three-piece wheel (see Figure 7)
rim and disc assembly separate flange lock ring
(b) The two-piece wheel (see Figure 8) rim and disc assembly spring flange
(c) De-mountable rims (see Figure 9) - three-piece collapsible rim in which the disc
is formed by short spokes forming part of the hub.
Associated hazards
105 Failure of the locking ring/flange to seat correctly can lead to violent separation of the component parts of the wheel under pressure. Such assemblies should only be inflated when effective measures have been taken to contain any fragments in the event of a violent separation. This can be achieved by:
(a) a strong, firmly-secured cage;
(b) a horizontal stool and associated clamping mechanism; or
(c) complete separation by a substantial screen.
Commercial vehicle well-based wheels
106 This single-piece wheel is mainly used with tubeless tyres. Figures 10 and 11 show typical wheels used on heavy goods vehicles. Figure 12 is typical of a type used on light commercial vehicles.
Associated hazards
107 Tyre failure is occasionally experienced when inflating tyres of this type and can lead to a severe air blast. Precautions taken should be the same as for car tyres except a cage should be used if inflating above 15 psi.
Extra large tyres
108 Extra large tyres are found on certain equipment used in construction, agriculture etc and will pose additional hazards during repair. They are too large to fit into conventional cages and it may not be reasonably practicable to provide purpose-built cages of adequate strength, particularly for work on site where most of these activities will take place. The main safeguard
during tyre inflation is therefore likely to be the keeping of personnel at a safe distance. Repair work on this type of tyre should only be carried out by personnel who have received specific additional training and it is recommended that they be appointed in writing. As with all other wheels, hot work, such as welding, should not be carried out with a tyre in position (inflated or deflated) as a severe explosion could result.
Tyre servicing equipment
109 Several pieces of equipment are used in tyre servicing procedures. The hazards and precautions associated with each are outlined below.
Bead breakers
110 There are two types of bead breaker in common use, which can be free standing or combined with a tyre changing machine. With one type the bead is broken by a pneumatic arm pressing against the tyre. The tyre is then taken off the rim manually using a lever against a centre post in the middle of the wheel. With the other type the arm revolves, both breaking the bead and removing the tyre. Fitting the tyre is the reverse operation using a different tool on the end of the lever. The machines are activated by a foot pedal and operated by compressed air in excess of 100 psi.
Figure 13 Typical tyre changing machine
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111 The machine has the potential to trap operatives' fingers and precautions should be taken to prevent the operator being distracted, for example, by positioning the machine away from main thoroughfares in an unobstructed, tidy and well lit work space. The operator should be fully trained in the safe use of the machine, as outlined in paragraphs 13 to 15.
112 On those machines where the foot used to refit tyres incorporates a roller, regular checks should be carried out to ensure that it rotates freely and has not been affected by tyre/soap deposits etc. Failure to do so may lead to tyre damage.
Wheel balancing machines (See Figure 14)
113 Various designs of these machines are in use in
tyre and exhaust premises. The wheel and tyre is placed on a vertical or horizontal hub which is sensitive to varying pressures. The hub rotates at speed and the balance required is read off, the machine is stopped and the appropriate weights are hammered onto the rim.
114 There are various hazards associated with this machine. Loose objects (weights, mud, stones) may fly off the wheel, and drive machinery may be exposed, with the possibility of clothing becoming caught during rotation.
115 Before any wheel is balanced, it should be carefully checked for loose stones, weights, etc. All drive shafts and the rotating road wheel should be effectively guarded. Machines should be fitted with a fully-
interlocked cover which protects the wheel while it is in
motion and which will immediately brake the wheel if it is lifted. Any failure of the interlock should be reported to the manager and the machine not used again until it has been properly repaired. The interlock should be checked at regular intervals and a record kept. The electrical controls should be positioned so that the operator does not have to reach across the machine to use them.
Compressed air equipment
116 Compressed air is used extensively in tyre and exhaust premises for several functions including:
(a) inflating tyres;
(b) supplying pneumatic handtools, which include air guns, for removing wheel nuts from vehicles; and
(c) supplying air to pneumatic tyre removers.
117 The danger associated with such equipment is not always immediately obvious. Precautions are as follows.
118 The pressure of the compressed air supplied from the receiver should be as low as practicable. Where there is a large disparity in the pressures required (ie between air guns and bead breakers) separate lines should be used via reducing values and an associated safety valve. Where possible different designs of connectors should be used to ensure that a low pressure item cannot be connected to the high pressure line. Where this is not possible the supply points should be clearly labelled and colour coded. Water traps should be provided in all lines.
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119 Airlines should be fitted with a minimum of six feet of hose between the clip-on chuck and pressure gauge/control. Personnel should stand well clear and to the side of wheel assemblies during inflation.
120 The pressure gauge/control valve should never be jammed in the open position. Airlines attached to tyres should never be left unattended as air seepage may over inflate the tyre.
121 Flexible airlines can be subject to considerable mechanical damage and flexing which can cause them to rupture, particularly at connection points. This can lead to sudden discharge of compressed air and may cause unsupported lengths of hose to 'whip' or 'snake' dangerously. All airlines should be checked frequently for signs of damage. Hoses above 10 mm bore, more than 10 m long, or subject to a pressure over 7 bar, should be fitted with a coupling which has a self-venting socket. The socket should release any downstream pressure before allowing disconnection.
122 The pressure gauges and compressed air metering devices should be checked regularly ie once a month.
123 The drive and other moving parts of the compressor should be guarded to prevent all hand and finger access to the dangerous parts from any direction.
124 Compressed air should never be used to clean up filings, chips, dust etc. (See section on asbestos, paragraphs 44 to 46.)
125 Compressed air should never be used to dust oneself down. Injuries can be caused by discharging guns with the nozzle close to the skin. If the air enters at a natural opening - mouth, nose, ear or anus - then a serious if not fatal surgical emergency may be created. These injuries are usually associated with horseplay and are totally avoidable. Evidence of such horseplay should be dealt with promptly and severely.
126 Compressed air should never be used to blow brake dust from car wheels or from brake drums, due to the risk of asbestos or similar dust being blown around the workshop.
127 Further advice on compressed air safety is contained in the HSE booklet Compressed air safety (see pages 28 and 29 for details).
Puncture repair
128 Many tyre and exhaust premises carry out minor puncture repairs. Cold cure systems are generally used for this purpose; this involves 'gluing' a precured rubber
plug into the hole in the tyre casing using rubber solution. Prior to patching, the inside surface of the casing is buffed using a pneumatic handtool fitted with a wire brush. A buff cleaning solution (generally a mixed hydrocarbon solvent) is then applied.
129 The main hazards associated with this work are:
(a) Exposure to solvent fume from cleaning and rubber solutions
(i) where small quantities are applied by brush, adequate control can generally be achieved by good standards of general ventilation in
the working area. If solvent is sprayed, local exhaust ventilation may be required;
(ii) skin contact with solvents should be avoided; use of barrier together with after- work creams is recommended;
(b) Exposure to dust from buffing operations
(i) where there is heavy use of buffing equipment the provision of local exhaust ventilation is preferable; this may be integral to the hand-buffing tool but more usually a flexible section of ducting is inserted into the casing close to the area being buffed;
(ii) only where this is not reasonably practicable should reliance be placed on the use of suitable respiratory protective equipment;
(iii) abraded dust should not be blown from inside the tyre casing with a compressed airline as this renders the dust airborne; a vacuum line should be used instead;
(iv) flying rubber particles present a risk of eye injury and suitable eye protection should be worn during buffing operations.
130 The extent of exposure to solvent fume and rubber dust, together with the adequacy of the control measures implemented, should be assessed on an individual basis as required by the COSHH Regulations. Where puncture repair work is intermittent and of short duration, as is the case at most tyre and exhaust fitting premises, good standards of general ventilation should be adequate.
131 A few premises may use an alternative method of puncture repair where an uncured rubber patch or plug is cured in situ using electrically heated pressure pads. The rubber fumes generated by the localised heating are an additional hazard to be assessed under COSHH. However this process is becoming increasingly uncommon.
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ELECTRICAL SAFETY
132 The use of electricity at tyre and exhaust premises is subject to the Electricity at Work Regulations 1989.
133 Electricity can not only cause shock, but can also cause burns and start fires. It should therefore never be treated lightly. All electrical equipment within work premises should be installed and maintained by a competent electrician and should be provided with the correct fuse (or other protective device such as a circuit breaker) in accordance with the current rating of the equipment.
134 Standard electrical equipment should not be used in wet conditions.
Fixed electrical installations
135 All fixed electrical installations should be designed, installed, operated and maintained (including being inspected and tested) in accordance with the current edition of the Regulations for Electrical Installations published by the Institution of Electrical Engineers (The IEE Wiring Regulations) where these apply.
136 The electrical wiring should be protected against mechanical damage. This can be achieved by using PVC insulated wires in conduit or trunking or by PVC steel-wire armoured cable with an outer PVC sheath.
137 Each machine supplied via a permanent cable should have its own switch suitable for electrical disconnection and isolation from the electrical supply. This switch should always be used to disconnect the machine prior to cleaning and maintenance work.
138 'Start' buttons should be recessed or shrouded in order to prevent unintended operation while 'Stop' buttons should be coloured red and protrude for easy operation. They should be sited within easy reach of the operator.
139 In line with the IEE Wiring Regulations, it is recommended that the fixed electrical installation should be tested at least once every five years by a competent electrician who should then advise of any defects and prepare a certificate once satisfied.
140 All electrical switchgear controlling machinery should be clearly and unambiguously labelled and identified to indicate which machine is controlled by which switchgear.
Portable equipment
141 Working areas should have sufficient socket outlets to avoid trailing cables across floors. Industrial types of plugs and sockets (complying with BS 4343)
should be used as these are more robust and can stand up to the conditions of tyre and exhaust premises better. Where a number of pieces of equipment require electrical supplies in the middle of the work area, consideration should be given to the provision of overhead sockets.
142 All flexible cables should be suitable for their environment. You may require specialist advice as to which cable is most suitable for your premises.
143 Efficient cable or cord grips should be used both at the plug and where the cable enters the equipment. Cables should be positioned and protected so that they cannot be damaged by heavy equipment or materials and should be checked regularly for any signs of damage. Damaged cables should generally be replaced completely but, if they are repaired, this should be by means of a suitable coupler. Never carry out makeshift repairs to cables. Further information is available in HSE Guidance Note Flexible leads, plugs, sockets etc (see pages 28 and 29 for details).
144 All extension cables which are terminated in
conventional 13 amp three-pin fittings (plugs & sockets) should be three-core cables with an earth (protective) conductor. This conductor should always be terminated in accordance with the manufacturer's instructions.
145 Handlamps should be 'all insulated', 'double insulated' or be of the low voltage type with any bulb protected by a robust cage or transparent insulating material. it should be remembered that these lamps (except those designed for use in potentially explosive atmospheres) do not give any protection against the risk of igniting petrol or other flammable vapours and therefore should not be used in inspection pits or other areas where such vapours may exist.
146 Electrically powered hand-held tools should preferably be supplied from a 110 volt AC centre-tapped earth supply (see BS CP 1017). In some cases battery- operated tools offer an alternative choice. Where conventional 240 volt AC hand-held tools are used, it is preferable that they are of double-insulated construction and supplied from an electrical circuit controlled via a residual current device with a tripping current not exceeding 30 milli-amps and complying with BS 4293: 1983. It should be noted that no conventional electric tools and machines are suitable for use in
potentially flammable or explosive atmospheres.
BATTERY CHARGING
147 During the charging or recharging of lead acid batteries hydrogen is given off from the cells and there is a risk of explosion. This is commonly caused by a spark between the battery terminals and the connectors igniting the hydrogen.
23
148 The acid also presents a hazard to skin and eyes (the Protection of Eyes Regulations 1974 apply). Face masks or goggles, gloves and protective aprons should be used whenever there is a risk of splashing eg during acid diluting or battery filling etc.
149 The following general precautions should be adopted:
(a) the battery should be removed from the vehicle before charging. The earth lead should always be disconnected first and reconnected last to avoid an accidental short circuit to the chassis. Insulated tools should be used;
(b) charging areas should have good natural ventilation located at high level immediately above the batteries;
(c) electrical apparatus and any other potential sources of ignition should be kept well to one side and/or sited below the level of the battery, but not in a position where any spillage of electrolyte could fall on to it;
(d) the area should be designated 'No-smoking' and 'No naked lights';
(e) to avoid sparks, the charging circuit should be switched off before the battery terminals are connected or disconnected from it. Before switching on, the connections should be checked to ensure they are properly made and tight. This may be achieved by the use of proprietary spring-loaded shaped connectors rather than 'crocodile clips'. If 'crocodile clips' are used special care should be taken to ensure a good connection. The connections should not be adjusted or interfered with in any way without first switching off. Metal objects should never be allowed to rest or fall on to the battery terminals. The operator should not wear dress rings, chains or metallic watch bracelets;
(f) the battery charging room should be of an adequate size with a sink or drain and tap connected to the main water supply. If a piped water supply is not available a supply of clean, fresh water in clean containers should be kept available at all times so that any splashing can be washed immediately. Similarly, facilities for eye-washing should be provided.
MISCELLANEOUS MACHINERY AND EQUIPMENT
Abrasive wheels
150 The Abrasive Wheels Regulations 1970 and the Protection of Eyes Regulations 1974 apply if abrasive wheels are used.
151 This item of equipment is commonly found in tyre and exhaust premises in the form of a bench mounted motor which drives a spindle. On one end of the spindle is an abrasive wheel and on the other, a wire brush. The Regulations seek to prevent injuries occurring due to contact with the rotating wheel or, in the event of a wheel breaking (bursting), from pieces of the wheel being thrown from the machine at high speed and striking operators.
152 These Regulations require:
(a) the maximum permissible speed of abrasive wheels to be marked on the wheel and the speed not to be exceeded;
(b) the proper mounting of abrasive wheels by appointed trained operatives;
(c) the training and appointment of people permitted to change wheels;
(d) the provision and maintenance of guards and other protection for abrasive wheels;
(e) suitable controls to be provided for machines on which abrasive wheels are used;
(f) the securing and adjustment of rests for the workpiece at abrasive wheels;
(g) the fixing of cautionary notices concerning the use of abrasive wheels and the precautions to be observed;
(h) so far as is reasonably practicable, where there are machines on which abrasive wheels are mounted, the condition of floors should be maintained in a good and even state and kept clear of loose material and prevented from becoming slippery;
(i) that suitable eye protection such as goggles, fixed shields or approved shields are provided.
Anyone required to change an abrasive wheel should be familiar with the requirements of these Regulations.
153 Further advice on abrasive wheels is contained in the HSE publications Safety in the use of abrasive wheels and Training advice on the maintaining of abrasive wheels (see pages 28 and 29 for details)
Rolling roads and brake testing
154 Many tyre and exhaust premises now also offer MOT testing services and so should contain a rolling road.
155 Several fatal accidents have occurred during the use of rolling road/brake testing equipment. While it is not normally practicable to prevent access to the wheels of the vehicle under test, or to the rollers of the test equipment, it may be possible to prevent inadvertent contact with the rotating parts by guard rails or fencing. This would not, however, cater for deliberate approach, and therefore a safe system of work should be developed and adhered to.
156 The system of work should include adequate instruction, training and supervision and ensure that only authorised people have access to the testing area. It is very important to ensure that the rolling road is only used for testing and not for carrying out repairs or adjustments, unless the machine has been stopped and precautions have been taken to prevent it from being set in motion.
157 The brake test equipment should be isolated from the mains when not in use and the cover plates replaced over the rollers. It should also be fitted with 'deadmans' controls. The running surfaces of the rollers should be properly maintained as badly worn surfaces may allow wet tyres to slip. Under no circumstances should any attempt be made to dry tyres or rollers while they are in motion.
158 Where brake testing equipment is sited over a pit, people should be prevented from entering the pit while a test is in progress.
Oxyacetylene equipment
159 Misuse of oxyacetylene equipment accounts for a significant number of incidents in workshops. Correct storage, operation, maintenance and use of such equipment is therefore an important factor in workshop safety.
160 The equipment includes two gas cylinders one (painted black) containing oxygen and the other (painted maroon) containing acetylene. Gas is fed to a hand-held torch via rubber hoses and gas regulators. The unions of the connecting hoses should be left-hand and right-hand threaded respectively to prevent interchange of fitments. The acetylene hose should be fitted with a flashback arrester, and each hose should be fitted with a one-way valve at the end attached to the torch.
161 Cylinders in use and spare cylinders kept inside workrooms should be secured to a wall or mounted on suitable trolleys. The number of cylinders inside workrooms should be kept to a minimum. Gas cylinders should always be transported on a suitable trolley to avoid undue manual handling and the acetylene cylinders should never be allowed to rest horizontally.
162 Additional spare gas cylinders should be kept in a
safe secure place preferably in the open air, separated from buildings, boundaries or fixed sources of ignition by at least one metre. A lockable wire cage is recommended. Where open air storage is not reasonably practicable cylinders should be kept in a well ventilated storeroom. This should be located in a safe place away from buildings and should be of fire-resisting construction. Acetylene cylinders should always be stored and used in an upright position. Oxygen cylinders and their fittings should not be contaminated by oil or grease as these materials will ignite violently if exposed to oxygen under pressure.
163 Gas cutting operations emit a great deal of heat and light and the following protective equipment should always be worn:
(a) tinted eye protection to BS 1542: 1982, as required by the Protection of Eyes Regulations 1974;
(b) suitable gauntlet type welder's gloves and, where necessary, a leather apron and spats;
(c) the overalls or boilersuit should be of a suitable material which is of a dense weave ie cotton. Hot particles which are often ejected during cutting operations will melt through nylon overalls;
(d) because the operator is obliged to use tinted eye protection, he/she will be unable to see anything but the intense light coming from the actual site of the cutting operation. Furthermore he/she is often beneath the vehicle, unable to observe the effects of the operation. For these reasons it is recommended that no cutting operation with oxyacetylene equipment should be undertaken unless a second person (an observer), also protected as appropriate, is present throughout. No cutting or welding operation should start unless an appropriate fire extinguisher is ready to hand. The local fire authority will advise on suitable types of fire extinguisher.
164 When using cutting and welding equipment in tyre and exhaust depots, particular attention should be paid to the risk of igniting any flammable materials which may be present. These include the petrol or diesel in the vehicle's fuel system, plastic fuel lines, plastic foam, other combustible material used in the construction of the vehicle and any flammable materials present in the workplace. Fuel tanks should never be subjected to heat unless adequate precautions have been taken to remove all traces of the fuel and they have been certified to be safe by a competent specialist.
165 Where flammable materials form part of the vehicle, care should be taken to ensure that a cutting torch does not cause accidental ignition. Surfaces
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coated with underseal are also a fire risk and should either be shielded or the underseal compound removed from the area around the hot work.
166 Oxyacetylene cutting and welding, or indeed any hot work, should never be carried out on any part of a wheel when the tyre is on the wheel. It is not safe to do such work with the tyre still on the wheel but deflated. The heat from cutting and welding can vapourise bead lubricants and inner-tyre surfaces in the air space within the tyre, producing explosive mixtures at high pressures within the tyre.
167 Explosions may occur to the inflated tyre, or when the tyre is subsequently inflated. There have been a number of incidents involving such tyre bursts which have killed repair workshop employees. The risk increases with the size of tyre, so it is particularly important for employees working on wheels of large earth-moving vehicles and tractor wheels to know of this hazard and follow a safe system of work. It is recommended that the suppliers are contacted regarding the use of nitrogen inflation, as a further safeguard, but it
should be remembered that this is not a safe alternative to removal of the tyre for hot work.
Fuel tanks and lines
168 Precautions should be taken to prevent heat damage to fuel lines especially plastic fuel lines which require special care. Where extensive hot work on the underside of motor vehicles is performed the petrol tank and fuel supply pipe should be removed. However, where hot work is being done on a small scale, eg the freeing of rusty exhaust pipes, it may not be reasonably practicable to remove the tank. In such a case the following precautions should be taken:
(a) the course of the petrol pipe should be identified, paying particular attention to pipe runs inside box sections or concealed by structural members or layers of underseal compound;
(b) the fuel line and tank should be shielded with fire resisting material such as fire resistant building board or a proprietary heat shield to protect them from flame impingement, although this will offer no protection from conducted heat. Where heat conduction is likely to be a problem, the fuel system should be drained and the tank removed;
(c) if the petrol tank is not to be removed, it is generally safer to keep petrol in it to ensure a petrol vapour concentration above the upper flammable limit. The tank should be shielded against the risk of accidental flame impingement, although the shielding will not protect against conducted heat;
(d) if the tank outlet has a tap, it should be closed while work is in progress. A mechanical clamp on a flexible fuel pipe may also be used providing that the type of pipe used does not crack when the clamp is tightened.
169 If fuel tanks need to be drained this should be done safely and carefully. Under no circumstances should draining be carried out by removing a fuel sender unit located on the side of a tank, since the petrol flow cannot be controlled. Many fatal accidents have occurred due to the ignition of uncontrolled spillages of petrol.
170 Petrol tanks should be drained in the open air and petrol removed via a properly designed fuel retrieval system into a receptacle which is large enough to take the contents of the tank. Do not attempt to repair petrol tanks by any hot process as this should only be carried out by specialists after the tank has been cleaned, tested and certified free of flammable vapour.
ON THE ROAD
Moving of vehicles and road testing of cars
171 There is a need to manoeuvre vehicles within the confines of workshop premises and accidents have occurred while doing this. A number of these accidents involved young unqualified drivers who should not be allowed to move vehicles. The employer should ensure that the road testing of cars is done by people who are competent and responsible drivers with skill and experience appropriate to the car and the tests to be carried out, and in particular:
(a) it may be necessary to give instruction on driving cars with automatic clutches; and
(b) to prohibit the testing of high performance cars by young employees, especially those aged under 18, until it has been clearly established that they will not be a danger to themselves or other road users.
Attending roadside breakdowns
172 Some companies attend breakdowns where work is carried out on vehicles at the roadside or on the hard shoulder of motorways. This can be a particularly hazardous operation if basic safety precautions are ignored. Where possible the vehicle should be taken to a depot, or at least moved to a place of relative safety.
Service vehicles
173 Service vehicles should be clearly visible and easily distinguishable by both day and night. The use of
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reflective markings will be a great benefit. They should also be fitted with either revolving amber roof lights or high-level flashing hazard lights. In addition to its repair equipment, each service vehicle should be equipped with :
(a) protective clothing including high visibility reflective coats;
(b) a first-aid kit;
(c) traffic cones;
(d) lighting for illuminating the working area;
a correct vehicle jack;
axlestands or timbers; and
a portable safety cage;
174 Only staff who have been given specific training on how to undertake roadside breakdowns should carry out this work. They should wear clean reflective clothing throughout the operation and particular care should be taken when working on the offside of the vehicle.
175 The service vehicle should be placed between the operative and the oncoming traffic at least 20 to 25 ft away. It should, if possible, be parked at an angle with its nose into the nearside of the road with the steering wheel turned to the left on full lock. Where possible, advance warning signs and cones should be used.
176 On motorways and trunk roads, where the vehicle is in a dangerous position, or when a dangerous load is being carried, the police should be informed before work starts.
27
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FURTHER INFORMATION SOURCES
Guidance Notes
PM 38 Selection and use of electric handlamps 1992 ISBN 0 11 886360 6
EH 40/98 Occupational exposure limits 1998 ISBN 0 7176 1474 3
EH 58 The carcinogenicity of mineral oils 1990 ISBN 0 11 885581 6
Guidance Booklets
HSG17 Safety in the use of abrasive wheels 1992 ISBN 0 7176 0466 7
HSG38 Lighting at work (revised) 1997 ISBN 0 7176 1232 5
HSG39 Compressed air safety (revised) 1998 ISBN 0 7176 1531 6
L3 Noise at Work Part 1 & 2 Regulations 1989 ISBN 0 7176 0454 3
L108 Reducing Noise at Work: Guide on Noise at Work Regulations 1989 ISBN 0 7176 1511 1
HSR 4 Guide to the Offices Shops and Railway Premises Act 1963 (revised) 1989 ISBN 0 11 885463 1
HSR 23 A Guide to RIDDOR ISBN 0 7176 1432 2
L73 A Guide to RIDDOR ISBN 0 7176 1012 8
HSR 25 Memorandum of Guidance on the Electricity at Work Regulations 1989 1989 ISBN 0 11 883963 2
HSR 30 Guide to the Pressure Systems and Transportable Gas Containers Regulations 1989 1990 ISBN 0 7176 0489 6
Writing your health and safety policy statement ISBN 0 7176 424 1
Approved Codes of Practice
COP 2 Control of lead at work (revised) 1998 ISBN 0 7176 1506 5
COP 37 Safety of pressure systems: Pressure Sytems and Transportable Gas Containers Regulations 1989 1990 ISBN 0 11 885514 X
COP 38 Safety of transportable gas containers: Pressure Systems and Transportable Gas Containers Regulations 1989 1990 ISBN 0 11 885515 8
L74 First Aid at Work ACOP ISBN 0 7176 1050 0
HSE Leaflets
HSC 6 Writing a safety policy statement: advice to employers 1987 (revised)
British Standards
BS AU 161: Part 1 a 1983 Specification for fixed lifts
BS AU 161: Part 2 1989 Specification for mobile lifts
BS CP 1017: 1969 Distribution of electricity on construction and building sites
BS 1542: 1982 Specification for equipment for eye, face and neck protection against non-ionising radiation arising from welding and similar operations
BS 4293: 1983 Specification for residual current- operated circuit breakers
BS 4343:1968 Specification for industrial plugs, socket-outlets and couplers for ac and dc supplies
BS 5345: Code of practice for selection, installation and maintenance of electrical apparatus for use in
potentially explosive atmospheres
BS 5415: Section 2.2 1986 Specification for type H industrial vacuum cleaners for dusts hazardous to health
Available from: British Standards Institution, 389 Chiswick High Road, London W4 4AL, Tel: 020 8996 9001 Fax: 020 8996 7001 Website: www.bsi-global.com
The future availability and accuracy of the references listed in this publication cannot be guaranteed.
28
29
Printed and published by the Health and Safety Executive C17.5 1/04
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AV HSE BOOKS
MAIL ORDER HSE priced and free publications are available from: HSE Books PO Box 1999
Sudbury Suffolk CO10 2WA Tel: 01787 881 165
Fax: 01 787 31 3995 Website: www.hscbooks.co.uk
RETAIL HSE priced publications are available from booksellers
HEALTH AND SAFETY INFORMATION HSE InfoLine Tel: 08701 545500 Fax: 02020 e-mail: hseinlormationservices(a'natbrit.com or write to: HSE Information Services Caerphilly Business Park Caerphilly CF83 3GG
HSE website: www.hse.gov.uk
HSG62
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Formerly ISBN 0-I 1-885594-8
ISBN 0-7176-1686-X
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