2.4 Work equipment hazards and risk control

Question 1

List items classified as work equipment,

Answer 1

• basic hand tools such as hammers, knives, handsaws and meat cleavers;
• drilling machines, circular saws, photocopiers, combine harvesters and dumper trucks;
• laboratory apparatus (Bunsen burners, fume cupboards, etc.);
• lifting equipment such as hoists, lift trucks, elevating work platforms and lifting slings, etc.;
• other equipment such as ladders and pressure water cleaners; and
• an installation of machines connected together, for example production line equipment in a factory or even some scaffolding or similar access equipment.

Question 2

List items not classified as work equipment.

Answer 2

• Livestock.
• Substances (for example, acids, alkalis, slurry, cement, water).
• Structural items (for example, walls, stairs, roofs, fences).
• Private cars that are used on company business.

Question 3

Name the regulations that cover different types of work equipment?

Answer 3

PUWER (Provision and Use
of Work Equipment Regulations 1998), which sets out the general framework of employers’ duties in respect of work equipment.
COSHH (Control of Substances Hazardous to Health
Regulations 2002), DSE (Health and Safety (Display Screen Equipment) Regulations 1992),
LOLER (the Lifting Operations and Lifting Equipment Regulations 1998) and
PPE (Personal Protective Equipment Regulations 1992).

Question 4

What key aspects need consideration according to PUWER?

Answer 4

1. Its initial integrity – it should be fundamentally safe through its initial design, e.g. de-burring sharp edges on metal, strong enough not to collapse when used as the manufacturer intended.
2. The place where it will be used – e.g. portable electric tools in a wet environment.
3. The purpose for which it will be used – a screwdriver being used as a chisel, a swivel chair to reach the top shelf.

Question 5

What is the requirement of CE marking?

Answer 5

Every employer shall ensure that an item of work equipment conforms at all times with any
essential requirements…

Question 6

What does regulation 11 of PUWER state with regard to access of dangerous parts of machinery.

Answer 6

to prevent access to any dangerous part of machinery or to any rotating stock-bar; or
to stop the movement of any dangerous part of machinery or rotating stock-bar (shaft) before any part of a person enters a danger zone.

Measures should consist of:
the provision of fixed guards enclosing
every dangerous part or rotatingstock-bar as far as it is practicable to do so, and where …not practicable to do so, then the provision of other guards or protection devices as far as is practicable. If this cannot be done, then the provision of jigs, holders, pushsticks or similar protection appliances used with the machinery as far as is practicable…

Question 7

What does regulation 7 of PUWER state with regards to use and maintenance of equipment with specific risks?

Answer 7

• the use of such equipment is restricted to those persons given the task of using it; and
• repairs, modifications, maintenance or servicing of that equipment is restricted to persons who have been specifically designated (i.e. authorised) to do so.

Question 8

What information are employers expected to provide in relation to specific risks and persons at risk?

Answer 8

Employers are expected to ensure that anyone using work equipment has been given adequate health and safety information and, where appropriate, written instructions relating to the use of that equipment. In addition, employers must provide this information to those who supervise the use of the equipment. The information and instructions should include information on:
• the normal conditions and methods of use for the work equipment;
• foreseeable abnormal situations and what to do if such situations occur; and
• conclusions drawn from experience in using the work equipment.

It is usual to provide relevant training:
• when an employee starts a new job (i.e. induction) or when they change role in their
existing employment;
• if there are significant changes to the way that a job is done or the equipment that is
used;
• periodically, i.e. refresher courses designed to help prevent complacency; and
• to those who deputise for employees or their managers or supervisors.

Question 9

What is the requirement for maintenance?

Answer 9

Employers must ensure, so far as is reasonably practicable, that maintenance on work equipment can be carried out while the work equipment is shut down. If this can’t be done the maintenance
will have to be done in such a way that risks are avoided and/or appropriate PPE is provided.

Question 10

What considerations should be given for work equipment?

Answer 10

Controls for starting and stopping equipment
There should be controls for starting equipment safely
Starting or restarting of equipment should normally require a deliberate action, for example, simply resetting an emergency stop button should not allow a machine to
automatically restart.
Controls for stopping equipment should bring the equipment to a safe condition in a safe manner. This doesn’t have to be instantaneous in its action; it can bring the equipment to rest in sequence or at the end of an operating cycle if this is better for safety.

Emergency stop controls
Employers need to provide, where appropriate (i.e. where there is a significant risk), one or more readily accessible emergency stop controls for work equipment so that it can be stopped quickly
and safely.
These should override any other controls but should not be used as a primary means of controlling the machine’s operation

Stability
Work equipment (or parts of it) should be stabilised as far as is reasonably practicable to prevent it from falling over, collapsing or overturning. This can be done by bolting, tying, fastening or clamping it in some way or by ballasting or counterbalancing.

Lighting
Suitable and sufficient lighting should be provided to enable safe use and maintenance of work equipment. The requirements will vary, for instance the general lighting levels may be adequate for most tasks. If, however, a task involves detailed work (e.g. precision measurements), then additional lighting would likely be needed.

Markings and warnings
Employers need to ensure that work equipment is clearly and visibly marked in respect of hazards and risks. This would include, for example, the identification of stop and start controls, the maximum rotation speed of an abrasive wheel, and safe working loads of lifting equipment

Clear unobstructed workspace
Being too close to moving parts of machinery or indeed other hazards is not desirable. Work equipment should therefore be installed, located and used in such a way as to reduce risks to
users of work equipment and for other workers

Responsibilities of users
• the need for users to adhere to general health and safety rules and procedures in the workplace
• following procedures in respect of the operation of the work equipment concerned,
including specific operating instructions for the use of the equipment

Question 11

What 2 aspects should be considered when selecting handheld tools?

Answer 11

• The design of the equipment itself, which requires that it is properly selected in the first place for the intended application.
• The safe use of the equipment. This requires appropriate training to ensure that only competent persons use the tools and that they know what the requirements are for correct maintenance, inspection and use of PPE.

Question 12

What are the requirements of safe use for handheld tools?

Answer 12

• Hammers – avoid split, broken or loose shafts and worn or chipped heads
• Files – should be fitted with a proper handle to prevent the tang from stabbing the
user.
• Chisels – the cutting edge should be sharpened to the correct angle to make cutting more efficient and reduce the force required.
• Screwdrivers – should not be used as chisels and hammers should not be used on them. The correct size screwdriver should be used for the job and the end (blade) must be kept square and in good condition
• Spanners – should be thrown away if the jaws are badly worn or splayed

Question 13

List some hazards from an electric or compressed air drill?

Answer 13

Puncture from drill bit
Flying swarf or dust
Electricity
Compressed air
Drill bit jamming causing
equipment to twist in hand
Entanglement of clothing /
hair
Noise / vibration
Slips, trips and falls when
working

Question 14

Nmae ten types of mechanical hazards?

Answer 14

1. Entanglement – where an item of clothing gets caught on the rotating part of a machine.
2. Friction or abrasion – where a person comes into contact with a fast moving abrasive surface
3. Cutting or severing – where a sharp-edged part of the machinery comes in contact with the person.
4. Shearing – where a part of the body is trapped between two moving parts of a machine or a moving part and a fixed surface
5. Stabbing or puncture – where some sharp part of the machine or process penetrates the person such as with an electric drill
6. Impact – where a powered part of a machine hits the person but does not penetrate or crush.
7. Crushing – where a part of the body is trapped between two moving parts of a machine or a moving part and a fixed surface
8. Drawing in or trapping – where a part of the body is caught between two moving parts and drawn into the machine.
9. High pressure fluid injection hazard – where a sudden release of hydraulic fluid
   penetrates the skin and tissues of a person
10. Ejection of flying materials –e.g. swarf
    from metal being turned on a lathe

Question 15

List some non-mechanical hazrads?

Answer 15

• Electricity – electric shock or burns are an ever-present danger.
• Noise – this can cause hearing damage.
• Vibration – this can affect the functioning of various parts of the body, e.g. causing pain, loss of sensation or dexterity in the fingers, vibration white finger, etc.
• Temperature – heat can cause burns or drowsiness, leading to error.
• Radiation – both ionising (e.g. x-rays) and non-ionising (e.g. lasers).
• Ergonomic / manual handling – e.g. from the posture or effort that is required to operate certain types of equipment.
• Hazardous substances – associated with the equipment, e.g. dust from wood, chemicals that are required as part of a process, biological hazards.
• Slipping, tripping and falling – as with ergonomic hazards, these might arise from
the circumstances of use, e.g. branches protruding when using a chainsaw in a tree,
housekeeping around work equipment.
• Hot surfaces such as petrol engines.
• Coolants and other chemicals that can cause skin diseases, and dusts and fumes that can cause respiratory and eye diseases.
• Hot tools and workpieces.
• Housekeeping (e.g. clearing away spilt coolant or lubricants, and tidying trailing cables and other trip hazards).
• Working alone.

Question 16

List 5 works equipment and the mechanical and non-mechanical hazards associated with them as well as the controls?

Answer 16

Photocopier 
• Drawing-in – fixed guard. • Hot surfaces – fixed guarding.
• Toner / fumes – fixed guarding
(toner cassette) but alsoventilation.
• Electricity – interlocked guards.
• Light – adjustable guard (i.e.
photocopier lid).

Document shredder • Cutting from blades – fixedguarding.
• Drawing-in – fixed guarding.
• Electricity – fixed guarding.
• Manual handling –
information, training and
instruction.
• Dust – fixed guarding and
ventilation.

Bench mounted grinder
• Friction and abrasion – fixed guarding.
• Entanglement – fixed
guarding.
• Drawing-in – adjustable guard (i.e. tool rest).
• Ejection of materials – adjustable guard (i.e. visor).
• Heat – information, training and instruction (and PPE).
• Noise – information, training and instruction and PPE.
• Electricity – fixed guarding.
• Hazardous substances – information, training and instruction and PPE.

Pedestal drill (pillar)
• Entanglement in chuck – adjustable guard.
• Puncture – information, training and instruction.
• Ejection of swarf – adjustable guard.
• Ejection of the chuck key –
information, training and instruction.
• Drawing-in – fixed guarding.
• Electricity – fixed guarding.
• Heat (of drill bit) – information, training and
instruction

Petrol cylinder mower
• Cutting from blades – some fixed guarding, two-handed controls and information,
training and instruction.
• Ejection of stones etc. – fixed guarding and information, training, instruction and PPE.
• Noise – information, training and instruction and PPE.
• Vibration – information, training and instruction and PPE.
• Dust – information, training and instruction and PPE.
• Manual handling – information, training and instruction.
• Weather conditions, e.g. sunburn – information, training and instruction and
PPE.
• Fire when refuelling (petrol) – information, training and instruction.

Question 17

List the hierarchy of control for reducing risks from machinery hazards?

Answer 17

• Fixed guard (preferably enclosing but could also be a distance guard).
• Interlocking, where frequent access to machinery is often required.
• Automatic guards, which are in position during the machine cycle.
• Trip devices, which interrupt the machine operation if danger is sensed.

Question 18

What are the merits and limitations of fixed guards?

Answer 18

They can be designed so that nobody can gain easy access to any mechanical hazard
• Permanently physical barrier in position
and needs tools to remove.
• Can often be fabricated at low cost, e.g.
welded mesh – low maintenance.
Limitations
• Machine still operates with guard
removed.
• Can restrict vision of equipment.
• Can cause heat build up, poor ventilation.
• Does not always protect against nonmechanical
hazards, e.g. dust, noise.

Question 19

What are the merits and limitations of interlocking guards?

Answer 19

Interlocked guards allow safe access to operate and maintain the machine without dismantling the safety devices. e.g.
passenger lift or hoist
• Controls of machine cannot be operated
without guard in position.
• Ease of access for routine operations
such as cleaning, unblocking jams, etc.
• Some interlocks can be very difficult to
override.
Limitations
• Some interlocks can be fairly easy to
override or people may step inside the
danger zone and then close the gate.
• Only switches off control circuits; the
main power to machine may still be
present.
• Machinery may not stop immediately so
additional braking may be required.

Question 20

What are the merits and limitations of automatic guards?

Answer 20

These guards operate to protect people during the dangerous parts of the machine
cycle

• Difficult to defeat.
• Dangerous areas of machine are
protected by design so it doesn’t rely on
humans doing the right thing.
Limitations
• May be complex to manufacture.
• Restricted to certain types of machinery,
i.e. slow-cycling.

Question 21

What kinds of trip devices are there and their merits and limitations?

Answer 21

Trip devices
Two-handed controls
Both hands are needed to operate the machine thus ensuring that they are in a place of safety when the machine is in use.

• Ensures operators’ hands are safe by
position during machine use.
• Only protects the operator (e.g. other
persons in the vicinity of the chainsaw
are not protected).

Hold-to-run devices
These devices work by ensuring that a button, pedal or handle is held in position to allow a machine to operate. If released, the machine will stop.
• Operator is in a safe position during
machine use.
• Only protects the machine operator.
• Doesn’t necessarily stop the machinery
immediately.

Sensitive protective equipment (trips)
These devices are found in different forms
such as telescopic rods, infra-red beams, pull cables running alongside long conveyor belts, and pressure mats.
• Can reduce or prevent injury.
• May supplement physical guarding or
other protection measures, e.g. pressure
mat can be used to switch off a machine
before a person gets too close.
• Some types can be overridden, e.g.
jumping over the pressure mat.
• May not completely prevent harm, e.g.
can still get caught in the machine before
the trip brings it to a halt.

Question 22

What are the basic requirements for guards and safety devices according to PUWER regulation11?

Answer 22

• Suitable (and compatible with process) i.e. it doesn’t stop the operation of a machine and will protect against the foreseeable risks.
• Of adequate strength (e.g. to contain ejected materials). Guarding and protection
devices must be of good construction, sound material and adequate strength
• Maintained i.e. so that their integrity remains intact
• Such that they do not increase risk e.g. through preventing the operator seeing
someone at risk or creating ergonomic issues for the operator
• Not easily by-passed or disabled either accidentally or deliberately
• Sufficient distance from the danger zone they are protecting.
• Placed so that they don’t unduly restrict the view of the operating cycle of the machinery.
• Constructed to allow for maintenance operations