09 Work Equipment Hazards and Risk Controls

Question 1

In terms of the provision of equipment, all items of work should be suitable for the:

Answer 1

• Task it is going to be used
• Environment in which it is to be used

Question 2

Identify the levels of protection of access to dangerous parts of machinery

Answer 2

• Fixed enclosed guarding
• Other guards and protection devices as interlocks or pressure mats
• Protection appliances, such as jigs, holders and push sticks
• The provision of information, instruction, training and supervision

Question 3

Types of maintenance

Answer 3

• Planned preventive maintenance
• Condition based maintenance
• Breakdown maintenance

Question 4

Why Maintenance is exposed to major risk that the rest of operators (8)

Answer 4

Because to do their job they have to:

• Guards and enclosures have to be removed to allow access.
• Safety devices have to be removed or disabled.
• Equipment has to be partially or completely dismantled.
• Power sources may be exposed (e.g. electrical supply).
• Stored power may be accidentally released (e.g. compressed spring).
• Access may be awkward (e.g. space constraints or work at height).
• Handling of parts may be difficult (e.g. heavy parts).
• Additional hazards may be introduced (e.g. power tools).

Question 5

What Additional precautions may be required during maintenance work:

Answer 5

• Maintenance should only be carried out by competent staff.
• Power sources should be isolated and physically locked off (secured).
• Stored power should be released or secured to prevent accidental discharge.
• Where power cannot be isolated, additional precautions are required:

o Cover live parts with insulating material.

o Use additional PPE, such as insulating rubber gloves.

• If dangerous moving parts have to be accessed, additional precautions are required:

o Run at very slow speed (rather than normal operating speed).

o Fit maintenance guards that have been made specifically to allow minimum access to required areas only.

• Precautions should be taken to allow safe access, especially when working at height.
• Handling aids and equipment should be used to reduce manual handling risk.

Question 6

Equipment controls, such as stop and start buttons, should be:

Answer 6

• Well designed so they are easy to use.
• Placed at suitable locations on the equipment.
• Easily identifiable.
• Kept in good working order.
• Compliant with relevant standards.

Question 7

Users of work equipment should:(8)

Answer 7

• Only use equipment they are authorised to use.
• Use equipment in accordance with instruction and training.
• Only use equipment for its intended purpose.
• Carry out all necessary safety checks before using equipment.
• Not use the equipment if it is unsafe.
• Report defects immediately.
• Not use equipment under the influence of drugs or alcohol (this includes some medication that causes drowsiness).
• Keep equipment clean and maintained in safe working order.

Question 8

Simple hand tools, such as a hammer, chisel or screwdriver, present relatively simple hazards:(5)

Answer 8

• The tool may shatter during use, throwing off sharp metal fragments
• The handle may come loose during
• The tool may be blunt leading to use of excessive force which causes loss of control
• Simple human error, where the user misjudges a movement
• The tool may be misused

Question 9

Precautions when using hand tools are (5)

Answer 9

• Tools must be suitable for the task and for the environment
• User must have information and training about how to use it
• Tools must be visually inspected
• Tools must be maintained
• Supervision is important to ensure safe working practice are followed

Question 10

In practice, safe use of a portable power tool requires that:(8)

Answer 10

• Tools and parts are only used for their intended purpose, within their design specification (e.g. the maximum speed of a cutting disc should not be exceeded) and in an environment that they are suitable for.
• Necessary guards and safety devices are always used (e.g. the self-adjusting guard fitted to a portable circular saw).
• Necessary personal protective equipment is always used (e.g. eye protection when using a chain saw).
• Trailing power cables or pipes are carefully positioned so that they do not present a trip hazard and will not be damaged by the tool or passing vehicles, etc.
• Care is taken to ensure that ejected parts do not present a risk to others nearby. This may require that the area is fenced or cordoned off or that the tool is only used at specific times.
• Dust exposure is controlled, either by damping down or by the use of respiratory protective equipment by the operator and others nearby.
• Noise exposure is controlled, e.g. by using hearing protection
• Vibration exposure is controlled, e.g. by job rotation or limiting the duration of tool use

Question 11

Mechanical Hazards (9)

Answer 11

• Crushing
• Shearing
• Cutting or severing
• Entanglement
• Drawing in or trapping
• Impact
• Stabbing or puncture
• Friction or Abrasion
• High-pressure fluid injection

Question 12

Define Crushing

Answer 12

The body is trapped between two moving parts or one moving part and a fixed object (e.g. a hydraulic lift collapses crushing a person underneath it).

Question 13

Define Shearing

Answer 13

A part of the body (usually the fingers) is trapped between two parts of the machine, one moving past the other with some speed. The effect is like a guillotine, cutting off the trapped body part.

Question 14

Define Cutting or severing

Answer 14

Contact is made with a moving sharp-edged part such as a blade (e.g. the blade of a handsaw).

Question 15

Define Entanglement

Answer 15

Loose items such as clothing or hair get caught on a rotating machine part and the person is drawn onto the machine.

Question 16

Define Drawing in or trapping

Answer 16

A part of the body is caught between two moving parts and drawn into the machine, e.g. at “in-running nips” where two counter-rotating rollers meet.

Question 17

Define Impact

Answer 17

The body is struck by a powered part of a machine (this is similar to crushing, but there is no fixed structure to trap the person; the speed and weight of the object does the damage).

Question 18

Define Stabbing or puncture

Answer 18

Sharp parts of the machine, or parts or material ejected from the machine, penetrate the body (e.g. swarf, sewing machine needle, abrasive wheel fragments, nails from a nail gun).

Question 19

Define Friction or abrasion

Answer 19

Contact is made with a fast-moving surface which may be smooth (e.g. touching a spin dryer) or rough (e.g. touching a belt sander).

Question 20

Define High-pressure fluid injection

Answer 20

Fluid at very high pressure is ejected from the machine and penetrates the skin (e.g. hydraulic fluid escaping from a burst hydraulic hose).

Question 21

Non-mechanical hazards of machinery:(10)

Answer 21

• Electricity.
• Noise.
• Vibration.
• Hazardous substances (contained or used by the machinery e.g. oils, or produced as by-products e.g. fumes)
• Ionising radiation.
• Non-ionising radiation.
• Extreme temperatures.
• Ergonomics.
• Slips, trips and falls.
• Fire and explosion.

Question 22

Machinery Safeguarding methods (9)

Answer 22

• Fixed guards

• Adjustable or self-adjusting guards
• Interlock Guards o Power to the machine is disabled o Either the machine needs to be locked shut to allow the guard to open
• Sensitive Protective Equipment (Trip devices)

o Pressure mats

o Trip bars

o Photoelectric devices

• Two hand controls
• Hold to Run Controls
• Emergency Stop Controls
• Protective Appliances
• PPE

Question 23

Hazards (4) and Controls (3) of a Photocopier

Answer 23

Hazards

• Drawing in and entanglement from contact with moving parts.
• Electricity.
• Contact with hot parts.
• Health hazard from ozone (irritant gas).

Controls

• Fixed and interlocking guards enclosing all mechanical hazards.
• Routine inspection and portable appliance testing.
• Use in a ventilated room.

Question 24

Hazards (3) and Controls (2) of a Paper Shredder

Answer 24

Hazards

• Cutting and drawing in (in-running nip between cutter blades).
• Electricity.
• Ergonomic hazard from handling of waste.

Controls

• Fixed and interlocking guards enclosing all mechanical hazards.
• Routine inspection and portable appliance testing.

Question 25

Hazards (8) and Controls (15) of a Bench-Top Grinder

Answer 25

***Hazards*** * Abrasion on contact with rotating abrasive wheel. * Drawing in at nip-point between wheel and tool rest. * Ejection of parts of the wheel during normal use or if it bursts. * Entanglement with the spindle on which the wheel is mounted. * Electricity. * Hot parts caused by friction (especially the work piece being ground). * Health hazard from dust. * Noise and vibration ***Controls*** * Secure grinder in position. * Fixed enclosing guards around motor and part of abrasive wheel. * Adjustable polycarbonate eye-guards over exposed part of wheel. * Tool rest adjusted to minimise nip-point between rest and wheel. * Use and setting restricted to trained operators only. * Eye protection (impact resistant). * Hearing protection may be necessary. * Installation of local exhaust ventilation (LEV ) may be required to control dust. * Routine maintenance, including inspection and portable appliance testing for electrical safety. * Regular checks of the grinding wheel. * Regular checks to ensure the correct grinding material has been selected. * Operators to avoid loose clothing which may become entangled. * If used for prolonged periods, job rotation may be appropriate to reduce exposure to noise and vibration. * Use restricted to trained operators only.

Question 26

Hazards (9) and Controls (7) of a Pedestal Drill

Answer 26

***Hazards*** * Entanglement with the rotating drill bit or chuck. * Stabbing or puncture by the drill bit during normal use or if the bit breaks. * Puncture by swarf ejected during metal cutting. * Impact if struck by the work piece if the bit jams and the work piece rotates. * Drawing in at nip-points between motor and drive belts. * Electricity. * Noise. * Hot parts (especially the drill bit). * Health hazard from cutting fluid (e.g. dermatitis). ***Controls*** * Fixed guards over motor and drive mechanisms. * Adjustable (possibly interlocked) guard over chuck and drill bit. * Clamp to secure workpiece to base. * Eye protection (impact resistant). * Hearing protection may be necessary. * Routine maintenance, including inspection and portable appliance testing for electrical safety. * Use restricted to trained operators only.

Question 27

Hazards (8) and Controls (7) of a Cylinder Mower (Petrol Driven, Ride-On Type)

Answer 27

***Hazards*** * Cutting on contact with moving blades. * Impact or crushing if struck by the mower. * Entanglement with various rotating parts. * Drawing in at various nip-points. * Noise. * Vibration. * Fire and explosion from petrol (fuel). * Health hazard from sensitization to grass sap, pollen, etc. ***Controls*** * Fixed guards over drive mechanism. * Safety switch under seat to ensure that driver is in seat before machine will operate. * Use restricted to trained operators only. * Hearing protection. * Refueling carried out in well-ventilated area. * Job rotation may be necessary to limit vibration exposure. * Use restricted for workers who are sensitive to vibration.

Question 28

Hazards (9) and Controls (11) of a Strimmer or Brush-Cutter (Petrol Driven)

Answer 28

***Hazards*** * Cutting on contact with moving cutting head. * Entanglement with rotating cutting head. * Puncture by objects ejected by cutting head (e.g. stones). * Noise. * Vibration (into hands). * Fire and explosion from petrol (fuel). * Ergonomic from repetitive movement, twisting, carrying. * Health hazards from sensitisation to grass sap, pollen, etc. * Health hazard from ejected animal faeces. ***Controls*** * Fixed enclosing guards over motor and drive mechanism. * Partial side guards fitted around cutter head. * Safety interlocked throttle trigger to prevent accidental operation of throttle. * Face and eye protection (impact resistant). * Hearing protection. * Robust gloves, boots (steel toe-cap), trousers and shirt. * Job rotation may be necessary to limit vibration exposure. * Harness to support and balance weight of machine. * Refuelling carried out in well-ventilated area. * Use restricted to trained operators only. * Use restricted for workers who are sensitive to vibration.

Question 29

Hazards (10) and Controls (8) of a Chainsaw (Petrol Driven)

Answer 29

***Hazards*** * Cutting on contact with moving blade. * Entanglement with moving blade. * Drawing in at nip-point between blade and casing. * Puncture by ejected parts (especially broken blade fragments). * Burns from the hot exhaust system. * Noise. * Vibration (into the hands). * Fire and explosion from petrol (fuel). * Ergonomic from handling. * Health hazards from dust, fumes and lubricating oils. ***Controls*** * Appropriate PPE (see Topic Focus). * Fixed enclosing guards over motor and drive mechanism. * Hand guard for front hand grip. * Chain brake to stop chain in event of kick back. * Safety interlocked throttle trigger to prevent accidental operation of throttle. * Job rotation may be necessary to limit vibration exposure. * Refuelling carried out in well-ventilated area. * Use restricted to trained operators only.

Question 30

Hazards (6) and Controls (4) of a Compactor

Answer 30

***Hazards*** * Crushing if a person is inside during operation. * Shearing between moving arms during operation. * Crushing or impact by ejected bale or container lorry. * Electricity. * High pressure fluid ejection from hydraulic system. * Ergonomics from handling material during loading. ***Controls*** * Fixed perimeter guard around loading area and mechanism. * Interlocked guard to allow access to loading area. * Routine inspection and portable appliance testing. * Use restricted to trained operators only.

Question 31

Hazards (6) and Controls (4) of a Checkout Conveyor System

Answer 31

***Hazards*** * Drawing in at nip-points on belt system (e.g. where belt meets counter top). * Entanglement with motor or rollers driving the belt. * Friction on contact with moving belt. * Electricity (motor). * Ergonomics from handling items whilst seated. * Non-ionising radiation from laser bar-code scanner. ***Controls*** * Fixed and interlocked guards on motor and drive mechanism. * Trip fitted to conveyor to prevent drawing in. * Routine inspection and portable appliance testing. * Use restricted to trained operators only.

Question 32

Hazards (6) and Controls (4) of a Cement Mixer

Answer 32

***Hazards*** * Entanglement with rotating drum or drive motor. * Drawing in at nip-point between motor and drive mechanism. * Crushing between drum and drum stop when tipping. * Friction or abrasion on contact with moving drum. * Electricity. * Ergonomics and manual handling injuries during loading. * Health hazard from cement dust inhalation (irritant) and contact with wet cement (corrosive). * Hazards due to the fuel (electricity or petrol). * Being struck by vehicles operating in the area. ***Controls*** * Location of the mixer on firm, level ground. * Location away from traffic or where traffic is controlled. * Fixed guards to motor and drive mechanism. * Routine inspection and portable appliance testing, and use of residual current device (RCD) for electrically powered equipment. * Safe storage of petrol and control of ignition sources for petrol-powered equipment; avoid use in confined spaces due to emission of exhaust gases. * Reduction in manual handling or positioning of cement bags close to the equipment. * Use restricted to trained operators only. * Hand protection, respiratory protection, overalls and eye protection (splash resistant). * Hearing protection to reduce noise exposure.

Question 33

Hazards (7) and Controls (8) of a Bench-Mounted Circular Saw

Answer 33

***Hazards*** * Cutting on contact with blade. * Entanglement with drive motor. * Drawing in at nip-points between motor and drive belt. * Ejection of work piece during cutting. * Electricity. * Noise. * Health hazard from inhalation of wood dust. ***Controls*** * Fixed guard fitted to motor and bottom of cutting blade. * Adjustable top guard fitted above blade. * Riving knife fitted behind blade (prevents the timber from pinching shut on the saw blade after it has been cut – which can lead to the timber being kicked back towards the operator). * Hearing protection. * Eye protection (impact resistant). * Extraction ventilation or respirator may be necessary. * Routine inspection and portable appliance testing. * Use restricted to trained operators only.

Question 34

Personal protective equipment when using a chainsaw (7)

Answer 34

* Face (visor) and eye protection (impact resistant). * Hearing protection. * Head protection (hard hat) may be necessary. * Robust gloves. * Boots with good grip and steel toe-caps. * Cut-resistant trousers or chaps (trouser covers). * Robust shirt.

Question 35

Basic requirements of a guard or safety device:(11)

Answer 35

* Suitability for the intended purpose - e.g. if it is intended to also contain dusts then a mesh guard is unsuitable. * Meets relevant standards – with regards to preventing contact with dangerous parts, e.g.located at the correct distance from the danger zone. * Strong and robust - to withstand the forces it may be subjected to, e.g. ejection of parts. * Compatible – must not interfere with machine operation. * No rough or sharp edges. * Not easy to defeat or bypass. * Vision – must not interfere with any need to see in to the machine. * Ventilation – must not block any air flow required. * Ease of maintenance – should be easy to maintain. * Removal for maintenance – ideally the guard should not have to be removed to allow maintenance on the machine to take place. * Does not increase overall risk to the operators.