General Workshop Safety

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General Workshop Safety

1.0 INTRODUCTION

1.1 Definitions

For the purpose of this guide:

Workshops are non-laboratory situations where machinery and/or tools are used, in an indoor or

outdoor situation. It also applies to fabrication, maintenance or other workshop-type activities not in

the boundaries of a defined workshop area.

Stores are those places where items and/or equipment are held within a building, room, cupboard

or area designated for that purpose. This definition includes depots and stockpiles.

This information is not intended to replace hazard identification. There must be a hazard register for eachworkshop identifying the specific machines and hazards for that area.

1.2 General

All workshops and stores must be under the direct control of a supervisor, who is responsible for ensuringthey are maintained and used in a safe and healthy manner. Only those authorised to do so may enter or

work in workshops or stores, and must comply with the requirements of the supervisor whilst in that area.

All persons using workshops and stores should apply good housekeeping practices, wear appropriateclothing, and use the workshop or store only for its intended purpose.

A tidy workplace makes it easier to spot and avoid hazards, and does not interfere with normal work

operations. Good housekeeping is fundamental to workshop safety management, and the time allocated to a job must include cleaning up afterwards. This applies to both individual and shared areas.

Personal items, food, drink or cigarettes are not to be taken into workshops and stores, unless a clean work-

free area has been set aside for this purpose. Where necessary, lockers should be provided and used.

The store or workshop must be suited to the proposed task. The supervisor shall make the decision as to

what tasks are appropriate for each situation.

2.0 STORAGE

2.1 Hazards

Liquid, solid or gaseous substances, equipment and fittings may all be stored. Corrosion or damage of containers may cause product leakage, which contaminates surfaces below, creates slip hazards and may

react to form a fire or fume hazard. Other items may have a limited shelf life, and become more hazardousas they age.

The physical process of storage also has hazards via manual handling, slips, trips and falls from

inappropriately stored items and objects falling from a height.

2.2 Hazard Management

Wherever practicable, a clean-bench policy should be adopted, with all items returned to their designatedstorage location on completion of a task. This requires suitable and sufficient shelves, cupboards, wall

hangings and space to be available.



Materials used for workshop activities should be held at the work area in appropriate quantities. Bulk

storage at the work area is generally unnecessary and contributes to congestion.

Segregation in storage must be practised for incompatible materials. Flammable substances in particularmust be held within a flammable store, which is suitably constructed, marked and located.

Heavy large or awkward items should be stored so as to avoid bending or excessive reaching when moving

them. They should not be stored above shoulder height or below knee height.

All substances must be clearly labelled to avoid confusion or inadvertent contact with incompatible

substances. When re-using containers, remove or obscure the old label after cleaning the container andrelabel. In particular, food containers must not be used for the storage of solvents or chemicals.

Materials should be stored in appropriate containers. Broken glass and sharps must be held in a labelledsteel or heavy plastic bin (never cardboard). Rigid containers must be used in preference to flimsy

cardboard boxes or cartons.

Shelving must be secure and never overloaded. Ensure that freestanding shelves and cupboards are secured

to walls.

Materials must be stored in such a manner to avoid spillage, leakage, breakage or falls.

Stored items should be periodically reviewed to rationalise their storage and dispose of obsolete items.Effective stock rotation should identify items that are deteriorating, or of no use, or not required.

2.3 Emergency Procedures

Hazardous substance spillage, leakage, escape or exposure - follow MSDS guidance

Major liquid escape - contain and avoid entry into drains where possible and safe to do so. If hazardous

substances are released follow departmental evacuation drill and notify the local council if substance entersthe drains.

Major gas escape - follow departmental evacuation drill, and warn those adjacent and downwind.

Fire - follow departmental evacuation drill

2.4 Further Information

Guidelines for Safe Stacking and Storage (OSH)

Guidelines for the Provision of Facilities and General Safety and Health in Commercial and Industrial

Premises (OSH)

Good Housekeeping in Industry (OSH)

3.0 FIXED MACHINERY

3.1 Hazards

Machines may be hazardous by virtue of their mechanical, electrical, thermal, hydraulic or pneumaticenergy, or via their movement or position. Machine design attempts to prevent operator exposure to these

hazards, but as access to the machine is often necessary, hazards may remain.




Where a machine is not made absolutely safe by design, the operator must exercise caution to avoid hazard

exposure. This will require training, development of skill, or supervision in how to manage machine hazards.However the general principles of machine safety are as follows:

A machine may not be used where the operator cannot effectively manage its hazardous characteristics or

where it presents a hazard to others.

Guards provided must always be in place when operating a machine, and machine parts properly securedand maintained.

Machine operation must always be within specification.

If a defect is identified or suspected, the machine may not be used until rectified or otherwise made safe.

Operators must be fully conversant with machine operation and likely hazards. In particular, the operatormust know the location and operation of the emergency stop. This must be clearly marked and routinely

tested.

An unobstructed working space of at least 1.0 m is recommended around a machine. Non-slip floor

treatments should applied where necessary.

Machine controls and hazard points must be clearly labelled where appropriate and the machinery must bewell illuminated. There must be no obstruction, spillage, waste or other feature present that would obstructor impair its safe operation.

Where machine operation presents a hazard to others in the vicinity, they must be adequately warned andprotected.

Where there is any possibility of entanglement in moving parts, suitable close fitting clothing must be worn,and ties or long hair restrained. Jewellery can be caught in moving parts.

Where there is a hazard of contact with machine parts, products, or emissions appropriate protectiveclothing must be worn, such as overalls, aprons, gloves, safety boots, eye protection, respirators and barrier

cream. Rings must not be worn.

Hearing protection is required for exposures > 85 dB(A) over an 8 hour working day, but as a general rule,

should be used where any discomfort is experienced.

Safety goggles/glasses or face shields must be used where there is a risk of injury from flying objects,

particularly when using pressurised systems or rapidly rotating machinery.

Machinery must be stopped for loading, unloading, cleaning, adjusting and maintenance operations.

Any machine must be isolated prior to maintenance work involving intimate exposure to machine hazards.Isolation must include electrical, mechanical, pneumatic and hydraulic systems, and any stored energy must

be released prior to working. The person in contact with the machine must be adequately trained and

experienced and have absolute control over its operation. This may be through lock-outs or similar methodsto ensure accidental or inadvertent start-up does not occur.

Hazards associated with machine feedstocks, lubricants, products, waste products and emissions must be

considered, and managed effectively.

Fire fighting appliances must be held in the vicinity of any operating machine.

Combustible materials must not be stored or allowed to accumulate in the vicinity of hot machine parts oremissions.




Ensure machinery is fitted with a clearly visible and accessible emergency stop control.


Manufacturers Operations Guide and Maintenance Specification

Guidelines for Guarding Principles and General Safety for Machinery (OSH)

Guidelines for Commercial and Industrial Premises (OSH)

Guidelines for the Guarding of WorkWorking Machinery (OSH)

Safety Rules for Operators of Circular Saws (OSH)

Safety Rules for the Operators of Spindle Moulding Machines (OSH)

Paper Cutting Guillotines (OSH)

Handbook to the Electricity Regulations 1993

Ergonomics of Machine Guarding (OSH)

4.0 PORTABLE HAND TOOLS

4.1 Hazards

Power tools present hazards of physical contact, electrocution, noise, vibration, and eye injuries from flying

objects.


Tools used outdoors must either be double insulated, or have a good earth connection to the casing. They

may only be used with a residual current device (RCD), isolating transformer, or similar form of protectionagainst electrocution. All portable hand tools must be tested for electrical safety on a 3 monthly basis, as

well as following hire of such equipment or following periods of intense wear and tear such as a week longfield trip.

Power tools must be checked routinely, or following any accident or damage, to ensure they are in good

working order, undamaged and that the cable and plug are correctly connected and in good condition. Adated inspection label must be securely attached to the tool. Inspections may only be performed by persons

holding Electrical Practising Licences

If excessive vibration or 'tingling' is noticed when using the tool, disconnect it immediately and have the toolchecked. Ensure all guards are in place and are functional before use. Always keep the power cable well

clear of the working parts if there is any possibility of penetrating the insulation.

Never apply power tools to objects that are not secured.

Switch on and off at the tool, not at the wall socket.

Turn off the power supply before touching or inspecting the tools moving parts, or fitting blades, bits or

other accessories.

Pneumatic tools should be fitted with an oil mist filter.

Ensure blades, drill bits and other accessories are securely affixed, and keys or other unnecessary items

removed, prior to operation.




In cases of electrocution, do not approach the victim or nearby conducting material until the power source

has been isolated.


Manufacturers Operations Guide and Maintenance Specification


Guidelines for the Provisions of Facilities and General Safety in the Construction Industry (OSH)

Electrical Safety Guide (OSH Booklet)

5.0 PORTABLE WORKSHOP EQUIPMENT

5.1 Hazards

Electrical apparatus may present an electrocution risk, whilst exhaust gases from internal combustionengines may present a hazard to operators of motorised equipment. Portable electrical equipment must be

tested as per the University of Otago testing of portable electrical equipment policy and guidelines.

Hot surfaces, high pressures, high speed moving parts, exposed blades, belt and chain drives, dust, noiseand vibration are also hazards commonly associated with portable mechanical apparatus.


When using portable electrical apparatus, ensure that the power cable does not present a trip hazard, or isplaced where it may be severed. For long term use (> 2 days), more comprehensive steps should be taken

to protect the cable (eg. feed from overhead, or cover).

When using petrol powered apparatus, be aware that carbon monoxide in the exhaust gas is a toxic gas.

Petrol powered units must never be used in confined spaces or poorly ventilated areas. Poorly tuned dieseland LPG power units will also produce carbon monoxide. Any internal combustion engine powered plant

must therefore be used only in well ventilated situations.

Where the noise emission from a power unit, or reverberation around the workplace is uncomfortable, earprotection should be worn. Hearing protection is mandatory above 85 dB(A) Leq.

Portable gas or electric air blowers should be carefully directed to avoid scorching, ignition or melting of

adjacent materials.

Portable compressors must be regularly checked to ensure the integrity of the pressure vessel. They should

also be fitted with condensate traps.

Contacts, connections and power transmission points on apparutus must be checked regularly to ensurethey present no hazard to operators.

High pressure water jets are also hazardous and in extreme cases may cause amputation. Never direct high

pressure water sprays to the head or bare skin. The aerosols generated when using such equipment mayalso be hazardous, particularly when cleaning hazardous material contamination, or using hot water or

steam lances. Appropriate respiratory protection should be worn in such situations.


In cases of electrocution, do not approach the victim or nearby conducting material until the power sourcehas been isolated.






6.0 MECHANICALLY POWERED NAIL GUNS AND STAPLERS

6.1 Hazards

Inappropriate or careless use of nail-guns and staplers cause a large number of avoidable injuries each yearin workshop situations. Even cuts may lead to Tetanus or other secondary infection.


Only trained operators are to use nail guns or staplers. Powder-actuated fastening tools may only be

operated by a person with a Certificate of Competence as Powder-Actuated Tool Operater.

Apparatus should be maintained as per manufacturers instructions, and stored and transported in aprotective case. It should be operated within manufacturers recommended specifications.

Pneumatic lines should be fitted with moisture filters or self feed lubricators, and routinely maintained.

All pneumatic tools must be marked with maximum air/gas pressure or operating voltage, whichever isapplicable.

Eye protection must always be worn when operating nailers/staplers, and ear defenders worn.

Always assume the tool is 'loaded', and never point the tool toward yourself or anyone else.

Disconnect the tool when reloading with nails or staples.

Horseplay with such tools is extremely dangerous, and can be fatal. This will not be tolerated.



Approved Code of Practice for Powder-Actuated, Hand-held Fastening Tools

AS/NZS 1873:1994 Powder-actuated hand-held fastening tools, fasteners and explosive charges

Portable Mechanically Powered Nailers and Staplers (OSH)

Powder-powered Tools Guide 1982 (OSH)

7.0 HOT WORK

7.1 Hazards

Hot work conducted outside of a workshop environment must have a permit issued. Never commence hot

work in a laboratory situation without a work permit and discussion with the Laboratory Manager.

Hot work includes gas cutting, torch welding, arc welding, brazing and soldering. (Other than limitedsoldering of electronic components).



The main hazards from these operations are fire, burns (flame, surface contact or radiation), toxic fumes

and eye damage.

Hot work on enclosed vessels such as drums and tanks may give rise to ignition of their internalatmosphere. Even substances not normally considered flammable at room temperature (eg grease) may

explode under such circumstances.


Alternatives to hot work should always be considered, such as manual cutting, or cold soldering (adhesives

and fillers).

Only suitably trained and equipped personnel may use gas cutting and welding operations.

Before starting hot work, the operator must be satisfied that the equipment is in good working order, and

that the surrounding environment and other people are protected from hazards which may arise from theproposed work.

Flashback arrestment devices must be fitted to gas bottles used in welding operations.

All equipment must be checked thoroughly before use. In particular, gas hoses must be checked for leaks

using a a detergent/water mix, and the insulation on arc welding sets checked.

Oil or grease must not be used to lubricate the threads on oxygen cylinders, as high pressure oxygen may

react explosively with it.

Acetylene bottles must never be tilted more than 45 degrees from their upright position. This is because theliquid within them may foul the valve assembly, and cause a dangerous situation.

When transporting gas cylinders other than on an appropriate trolley, fit valve caps and ensure the cylinders

are securely mounted.

Do not drag, bump, drop, roll, heat, or otherwise damage compressed gas cylinders.

Empty gas cylinders must be treated with the same caution as full ones, as they may still contain an

explosive residual atmosphere.

A fire extinguisher must be available for all hot work. Sparks from gas cutting operations may be an ignitionhazard within a 10m radius of the work. Conduction of heat may also cause ignition of adjacent

combustibles. All combustible materials within this radius should thus be removed, shielded or otherwiseprotected.

Screen torch operations to reduce the risk of fire, and to avoid eye irritation to those nearby. When arewelding, protection is required for all those within 15m of the work.

Overalls, gloves, apron, eye protection, filter respirators and long boots are required to be worn for welding

operations. Overalls should fit tightly at the neck and wrist. Nylon overalls or jackets and clothing withexposed pockets may not be worn. Goggles must be worn for gas welding operations, and a face shield for

arc welding. Head protection is optional. Gloves or gauntlets are necessary when arc welding to protectagainst shock, burns and radiation exposure.

When soldering using lead solder, a lead fume is generated. For prolonged or routine soldering operations, it

is necessary to install local exhaust ventilation to remove this fume or to wear respiratory protectionequipment specific for lead fumes.



Never point a torch toward clothing, whether lit or otherwise, as gas trapped in the fabric of clothing can

cause severe burns if ignited.

Dispose of hot welding rod stubs, slag and off-cuts in a safe manner, such as into sand.

Welding and cutting operations may generate toxic metal fumes, ozone, nitrogen dioxide and carbonmonoxide. Such work must therefore be done in a well ventilated area, preferably using a local exhaust

ventilation unit. Respirators should always be worn by the operator.

Electric arc welding units must have an effective earthing arrangement using an earthing clamp or bolted

terminal, which should be checked regularly. Arc welding must not be attempted if hands are wet or floorsare damp. When arc welding ensure that the unit is served by an isolating transformer, (whether integral or

separate).

Brazing in particular produces corrosive and toxic fumes, whilst the vaporisation of grease, paint and other

coatings on the metal will add further components to the fume generated.

Never weld or cut a barrel or container that contains hazardous or flammable material, residues as a

flammable or toxic atmosphere may be generated during the heating process. Flammable vapours may arisefrom:

volatile liquids

non-volatile oil, tar, grease soap

acids which react with metal to form hydrogen

combustible solid powders (eg wood dust, coal dust)

The following are some of the more commonly encountered substances stored in drums or tanks which maybe hazardous when heated.

Acetone Amyl acetate

Amyl alcohol

Ammonia and Compounds

Chloroform

Dichloromethane

Formaldehyde Hydrochloric acid

Isopropyl alcohol

Kerosene Methyl alcohol

White spirit

Mineral turpentine

Nitric acid

Phenol

Hydrocarbon solvents

Sulphuric acid

Trichlorothane

Toluene Xylene

Methyl ethyl ketone

Organochlorine insecticides

Drums and tanks should not be welded or cut without special safety precautions. If they contain even asmall amount of flammable liquid, sludge or solid they may explode. To avoid this danger such containers

need to be thoroughly cleaned and tested before any hot cutting or welding is carried out.



Recommended cleaning methods are:

Soluble residues - repeatedly fill and drain with water or an appropriate solvent.

Non-soluble residues - inject low pressure steam into the upturned container for at least 30

minutes, until condensate is clean. Earth the tank and steam pipe if highly flammable residues. -

completely immerse tank in a boiling water bath so that the tank fills. (30 minutes minimum).

If it is not possible to effectively remove hazardous residues, water or an inert gas or continuous

steaming must be used to fill the vessel during the hot work.


For further information on the Permit to Work system see:


Hot Work on Drums and Tanks (OSH Booklet)

Welding Safety (OSH Booklet)

NZS 4781: 1973 Code of practice for safety in Welding and Cutting

8.0 COMPRESSED GAS

8.1 Hazards

Compressed gas (even air) directed to the head or skin may cause serious injury, and can be fatal.Compressed air must never be used to clean-down clothing or remove swarf from benches or inaccessible

areas.


Always fit valve caps when transporting compressed gas cylinders, and take care when handling them toavoid dropping them, and also avoid foot or back injury.

If a leak is noted which cannot be stopped by simply tightening a valve or nut, remove it to a well ventilatedoutdoor location, and label the cylinder as unserviceable. Detergent in water should be used to locate a leak(never a flame).

The formation of ice on the exterior of a cylinder indicates that the gas release rate is excessive and shouldbe reduced.


On release of a toxic, flammable or asphyxiant compressed gas, evacuate immediately and raise the alarm.

Warn those who may be threatened in adjacent areas or downwind.

Do not switch off electrical apparatus as the resultant spark may ignite flammable gases.

For toxic gas release, use 'escape' breathing apparatus where available.

Obtain medical assistance for injuries arising from contact with compressed gas/air.





9.0 LIFTS, HOISTS AND CRANES

9.1 Hazards

The hazard associated with static lifts and hoists is that of failure under load, which may lead to a fallingweight or a flailing cable. There is also the potential for crush injury where personnel come between the

moving load (or crane) and a fixed object.


All lifting tackle (hoists, jibs, slings, lifts, cranes, cables, etc) must undergo routine testing and certificationto ensure they are fitted to operate. All such apparatus must be marked with its safe working load (SWL),and this load never exceeded.

Only suitably trained and certified personnel may use mechanical lifting apparatus, and are responsible forensuring it is operated in a safe manner.

Security of the load is paramount, as an unstable load is a danger to all in its vicinity. Even where a load is

secure, never stand beneath an elevated load.

When guiding a moving load, it may be necessary to stand close to it. In such cases, avoid standing in thedirection of load movement, and never stand between the load and a fixed object such as a wall, barrier or

machine if there is a possibility of crush injury.

When lowering a load, keep feet well clear. Persons in the vicinity of moving loads must wear safety bootsand helmets.

Palletised loads should be restrained by banding or otherwise where required, and the pallet constructed towithstand slipping and lateral displacement.

When using slings or straps, loads must be well balanced, and arranged so that the load cannot slip through

the sling. Wherever present, lifting lugs must be used in preference to slinging a load.

Shackle pins must be securely screwed into place before lifting when used.

Any chains, cables, pulley blocks and other apparatus used must be capable of safety lifting the planned

load.

Once the load has been raised very slightly, the security of the slinging/shackling arrangement and thestability of the load must be assessed. Only if this is satisfactory may lifting continue.


If apparatus is suspected to be unsafe, has failed, or is out of certification, it should be labelled as such and

rendered inoperable. This restriction will stay in force until the apparatus is repaired and inspected.


Code of Practice for Cranes and Lifting Appliances (OSH)

10. FORKLIFTS

10.1 Hazards



Forklifts, share the hazards of fixed machinery (see previous section), but also have the additional hazards

associated with vehicle movement, namely pedestrian or vehicle impacts, overturning, and load instability.


Forklifts must only be driven by trained and certified operators.

No person may 'ride' on mobile plant other than the driver.

The forklift must be fitted with suitable overhead protection to shield the operator from falling loads.

Travel with the load down, (and mast retracted) and do not lift or lower whilst travelling.

Drive backwards down inclines or when forward vision is obscured by the load or mast.

Do not overload the truck.

Be aware of overhead clearances both when travelling or when transferring loads to and from racking

locations.

Forklifts must never operate within 4.0m of overhead electric cables, unless the power supply has beenisolated.

Be aware of pedestrians.

Do not extend arms out of the driver compartment, as they may be crushed against fixed objects.

Never raise a person on the forks, unless in a properly constructed and securely affixed safety cage.

Cross slippery or uneven surfaces with extreme caution.


If the truck begins to overturn, do not attempt to jump clear. The seat is the safest place. Where instabilityof racking or a pallet load is noted at height, do not attempt to rectify it using the forks.


Forklift Trucks - Safety Code for Operators (OSH)

11.0 ELECTRICITY

11.1 Hazards

Electrocution is an ever-present hazard in workshops, when using power tools and machines, or whenotherwise exposed to an electricity supply.


Domestic scale applications are served by 1 phase supply (230v), whilst industrial situations may require 2or 3 phase supply (400v).



Fuses or circuit breakers are primary protection against electrical overload, although they also protect the

user from gross electrical faults.

A fuse or circuit breaker may break the circuit if it is overloaded. If after unplugging an appliance on thecircuit, the circuit breaks again, an inspection by an electrician is necessary.

In dry, indoor situations, earthing of appliances is achieved by the earth wire in the power cable. This is not

sufficient protection for industrial and construction situations, where double insulation, Residual CurrentDevices, isolating, transformers or other safeguards are required.

Double insulation appliances have insulation between exposed metal parts and the insulation of the current-carrying parts. These may be used in wet conditions, but supplementary protection (eg isolating

transformer) is recommended as double insulation does not protect against faulty leads or plugs.

Isolating transformers protect single phase portable electrical appliances. They must be located as close to

the supply as possible, and each appliance requires a dedicated isolating transformer.

Residual Current Devices (also called Earth Leakage Devices) detects faults in the circuit where electricity is

leaking to earth, and automatically breaks the circuit.

Monitored earth protection is used for two-phase supplies, and monitors circuit integrity using a low voltagecurrent which detects when the earth connection is broken, and automatically breaks the circuit.


Electrocution - if possible, turn off the power source or disconnect the victim.

Do not touch the victim or any conducting material in the vicinity until this is done.

12.0 HAZARDOUS SUBSTANCES

12.1 Hazards

A wide range of substances are encountered in workshop and store situations. They may be in solid, liquid

or gas form, and exposure to them may be via skin contact, inhalation, ingestion or inoculation. They maybe hazardous because they are toxic, flammable, corrosive, asphyxiant, carcinogenic or biohazard.

Good working practices are designed to ensure that no exposure is such that adverse health effects arise.

However, accidents, spillages or unknown health effects all present a danger to those who may be exposed.

Exposure itself may be acute or chronic. Acute exposure is generally easy to detectand health effects maybe clearly visible. Chronic exposure may however be via many years of low level exposure, and theresultants health effects may not be directly attributable to the exposure.


As a general rule, all substances should be considered hazardous unless it is known otherwise.

All staff must be informed about the hazardous substances they may encounter and their precautions foruse and procedures to be followed in an emergency.

Hazardous substances may be present as proprietary chemicals, or as waste product emissions from aprocess. They may even result from the reaction between otherwise harmless chemicals.

A further factor to consider is whether the substance is at extreme temperature, or high pressure.




As prescribed in Material Safety Data Sheets for exposure or spillage/leakage.


Material Safety Data Sheets

Safety with Corrosive Chemicals (OSH Booklets)

Dangerous Goods Act 1974 and Regulations

Workplace Exposure Standards and Biological Exposure Indices for New Zealand

Code of Practice for the Safe Use of Isocyanates (OSH Booklet)

Toxic Substances Act 1983 and Regulations

13.0 WOODWORKING AND METAL WORKING MACHINES

13.1 Hazards

In addition to direct contact with rotating machine parts and blades, there is the risk of flying objects,

entrapment of loose clothing, dust or aerosol inhalation, eye injury, cuts to hands, electrocution, and noiseinduced hearing loss.


Machinery may only be operated by trained personnel and in accordance with manufacturers instructions

and legal requirements. All machines must be fitted with appropriate guards, electrical protection andemergency stop devices. Hot surfaces or other dangers should also be labelled where the hazard is not

obvious.

In addition to the machine itself, consideration should be given to handling of raw materials, machineemissions (dust, swarf/turnings, waste lube oil, noise etc), and the effect they may have on others nearby.

Operators are responsible for routine inspection of the machine to identify defects prior to operation. Whereany machine is deemed to be unsafe, it must be rendered inoperable and labelled as such.

Operators must wear close fitting overalls, eye and hearing protection, and shielding or other protectionprovided where other persons would be exposed to a machine based hazard.

When unattended, machinery should wherever possible be left in such a condition that it is unable to move(zero energy status) or cause injury via inadvertent operation.

13.3 Emergency Provisions

Isolate machinery before attempting to assist any person suffering from machine entanglement. Aprominent and accessible emergency stop control must be available for this purpose where necessary.



Safety Principles for Metal Cutting Guillotines (OSH)

Guarding of Transmission Machinery (OSH)

A Employers Guide to Occupational Noise (OSH)

Noise Induced Hearing Loss (OSH)



Ergonomics of Machine Guarding (OSH)

13. DISC CUTTERS, GRINDERS AND ABRASIVE WHEELS

Hazards

In addition to eye or other injury via operator contact with blades or fast

moving rotating machinery, abrasive wheels may 'burst' when operating, or

entrap tools. Sparks generated during their use may also provide an ignition

source for combustible materials, whilst entanglement of loose clothing may

lead to severe injury for operators.

Hazard Management

This requires the selection of correct items (wheels, motors etc), routine

inspection of their condition, use of guards where required and correct

operating practice.

Abrasive wheels in particular require careful attention, due to the risk of

injury through 'bursting. This may arise from uneven wear, grooves,

localised heating, imbalance, use of a tapered spindle, 'heavy' use or

excessive speed. Side-grinding, and braking of the wheel by contact with the

wheel itself are dangerous practices

Abrasive wheels must be marked with their maximum operating speed

(rpm), and only fitted to machines which will not exceed this. Where the

maximum operating speed at the periphery is in m/s, the conversion is:

rotation speed = peripheral speed x 60,000

(rpm) _ x diameter (mm)

Work-rests must be placed as close as possible to the wheel, to minimise therisk of tools being 'grabbed' by the wheel.

Enclosures, guards or shields must be used to protect the operator and

others from flying objects. Adjustable visors are preferable to personal eye

protection as they also offer some protection for the face. Respiratory

protection may also be required. Where grinding fluids are used, these must

be compatible with the wheel. Never allow a wheel to stand partly immersed

in grinding fluid, as this will unbalance it.

Any new wheel must be suitably guarded (protecting all personnel in the

vicinity), the work-rest positioned, and the wheel tested at maximum speedfor a short period. As a wheel wears, it must be routinely checked, and

where necessary, rebalanced.

Dressing tools must be securely clamped wherever possible, rather than

being hand held.

For hand held abrasive tools, never use more than one wheel per spindle.

Operators must wear close-fitting clothing, tie up long hair and other items



which could otherwise become entangled in rotating machinery. Personal eye

protection and respiratory protection may also be required.

Emergency Procedures

Removal of a foreign body from the eye should only be done by medical

personnelFurther Information

Safety hints for operators of Abrasive Wheels (OSH)

14. PAINTING AND SURFACE PREPARATION

Hazards

In addition to respiratory irritation from the solvents and paint aerosols

released during paint spraying, there is also likely to be a flammability

hazard which requires control of electrical apparatus and other ignition

sources in the vicinity.

Isocyanate paints are particularly hazardous for operators, and it is possible

to become 'sensitized' to them.

Manual application of paints may lead to dermatitis, although this is often

through contamination during the use of solvents such as mineral

turpentine, used in cleaning operations.

Surface preparation methods which generate dust, fragments or fumes can

present a hazard to the operator (eg sanding, sand blasting, blowtorch

removal), particularly for lead paints. Chemical removal can present a

harmful fume which may cause respiratory or skin irritation.

The residues left in soil and buildings from surface preparation work may

alsopresent a public health hazard where the paint has a high lead content.

Hazard Management

Surface preparation must be preceded by an assessment of the paint lead

content, removal method, and the persons who may be exposed to hazards

arising (both during the work and afterwards).

Abrasive blasting must not be used for the removal of lead based paint, due

to the high lead exposure risk to operators, and difficultly in cleaning up

contaminants after removal. Where abrasive blasting is done, suitable

respiratory and hearing protection must be worn. Water blasting is

preferable to dry abrasive blasting, as this does not generate a fine dust.

Paint application by spray gun must be preceded by an assessment of the

flammability and inhalation hazards associated with the substances used,

based on Material Safety Data Sheets. Spray applications should only be

done in a specially constructed spray booth.

When working in confined locations, ensure fume build-up is prevented by



enhancing local ventilation, and that appropriate filter respirators are used.

When using flammable paints or solvents ensure that steps are taken to

prevent the accumulation of a flammable atmosphere, or that all ignition

sources are controlled.

Barrier creams, overalls and gloves protect the skin from adverse effectswhich may arise from using paints, solvents or other cleaning materials.

They should be used where required.

When using isocyanates, supplied-air breathing apparatus must be worn, in

conjunction with full body suit for skin protection. All spraying operations

must be within a spray booth with extract ventilation and suitable electrical

protection.


Where excessive exposure to lead based paint dust or fumes is suspected,

blood tests should be carried out to assess actual dose. If this is excessive,

subsequent exposure must cease, and the cause of the uncontrolled

exposure investigated.

If nausea or dizziness is experienced during painting, remove affected

persons to fresh air and ventilate the area. If symptoms persist, obtain

medical assistance.

Annual respiratory checks are required for those working with isocyanates.

Further Information

Manufacturers Information

Material Safety Data Sheet

Guidelines for the Management of Lead-Based Paint (OSH / PHC)

Code of Practice for the Safe Use of Isocyanates (OSH)

Practical Guidelines for the Safe Use of Organic Solvents (OSH)

15. PRINTING, BINDING & REPROGRAPHICS

Hazards

A variety of hazards are present in printing, copying, developing and binding

operations, ranging from hazardous substances (inks, glues, solvents,

cleaning materials) to dangerous machinery (presses, clamps, guillotines,

lifts and transmission apparatus); atmospheric contaminants, occupational

overuse syndrome, noise, storage hazards, manual handling and congestion.

Hazard Management

Management of electrical and mechanical hazards is largely addressed by

the design of modern equipment, although older apparatus may require

safety features to be retro-fitted, such as guards and interlocks. Unguarded

belts, pulleys, chains and blades must be guarded. Operators must be fully



conversant with the operation of any machinery they use, and aware of

potential exposure to hazards.

Management of hazardous substances is dictated by their properties and

modes of exposure to them. Material Safety Data Sheets (MSDS) often

provide the best guidance in effective hazard management. Contact (skin,inhalation or ingestion) with any potentially harmful substance must be

strictly controlled, and the use of protective equipment such as overalls and

gloves must be worn.

Inhalation of solvents, aerosols, ozone or dust etc is best controlled by

filtering emissions at source, or by local exhaust ventilation..

Manual handling of bulky or heavy items may result in injury where loads

are awkward, frequent, heavy or unstable. Mechanical or human assistance

as appropriate must be used where required. A review of stock storage

relative to delivery and use points may identify where stock movement can

be eliminated or rationalised, thus reducing the need for manual handling.

Noise in printing operations may be sufficiently loud or uncomfortable to

warrant the use of hearing protection. These should only be used (ear plugs

or ear defenders) where it is not practicable to control the noise at source.

Lack of available space or poor use space may increase the risk of machine

entanglement or impact injury.

Ultra Violet light emissions from reprographics equipment may be sufficiently

powerful to cause eye damage (eg cataracts) following long term exposure.

To prevent operator exposure, covers and shields must always be worn

when using equipment.

General ventilation and temperature control in a machine room may require

the installation of localised exhaust and fresh air make-up ventilation to

maintain a comfortable working environment for operators.


As per Material Safety Data Sheets for hazardous substance exposure.

All hazardous machinery must be provided with a prominent and accessible

emergency stop device.

Further Information

Material Safety Data Sheets

Guidelines for the Provision of Facilities and General Safety and Health in

Commercial and Industrial Premises (OSH)

Atmospheric Conditions in the Workplace (OSH)

Planning the Workplace (OSH)

Good Housekeeping in Industry (OSH)



The Ergonomics of Machine Guarding (OSH)

Electrical Interlocking of Machinery Guards (OSH)

Occupational Overuse Syndrome- Guidelines for Prevention & Management

(OSH)

Manual Handling- Guidelines for the Workplace (OSH)Safe Stacking & Storage (OSH)

Practical Guidelines for the Safe Use of Organic Solvents (OSH)

Code of Practice for Safety and Health in the Manufacture of Paint, Printing

Ink and Resins (OSH)

Approved Code of Practice for the Use of Visual Display Units in the Place of

Work (OSH)

The Pocket Ergonomist- Industrial/Retail Version (OSH)

16. CLEANING, SECURITY AND CUSTODIAL ACTIVITIES

Hazard

Cleaners, security and custodial personnel are likely to have access to all

parts of the University's facilities, including restricted access areas. In doing

so they may be exposed to a wide variety of hazards ranging from unknown

substances in laboratories through to falling from height and entanglement

in machinery. These staff may not be aware of hazard management

principles applied by the daytime occupants. Furthermore, solo working in

remote parts of buildings, or on the campus after dark introduces the hazard

of assault.

Cleaners will also use chemical cleaning materials and electrical apparatus in

their work, which present further hazards. They are also likely to be involved

in repetitive manual tasks which may give rise to occupational overuse

syndrome.

Hazard Management

It is essential to ensure good communication between all users of a facility.

Hazard management principles used by the daytime occupants are likely to

be equally as necessary to those present outside normal working hours.

Consequently the effects on cleaners, security and custodial personnel must

be considered when developing hazard management strategies. As these

staff are likely not to have an active involvement in processes etc, this may

be achieved simply by the use of warning signs or memos, but may require

denial of access or other means to isolate such staff from hazards.

By contrast, these staff must also go about their work in such a way as to

minimise their exposure to possible hazards. Not touching apparatus or

materials unless it is clearly safe to do so is a basic rule. Where potential



hazards are encountered, they should be 'flagged', and brought to the

attention of the Departmental Health and Safety Officer as soon as

practicable.

Cleaners must ensure they are familiar with the hazardous properties of the

materials they use, and possibly harmful reactions when two or more comeinto contact. Where required, protective clothing (gloves, eye protection and

filter respirators) must be used.

Portable electrical apparatus must be served by a residual current device

(RCD) or similar to prevent the possibility of electrocution. That apparatus

used must be regularly checked for damage or wear, and maintained or

replaced as necessary.

Where solo working is practised, staff should have a pre-arranged

rendezvous with others at the completion of their work or at agreed periods

throughout the shift.

It is important to have an effective means of emergency communication for

after-hours staff. All staff should have access to a telephone and be familiar

with the after hours security number.


Where a person does not report to a predetermined rendezvous, steps

should be taken to trace them. If no trace of the person is discovered via a

preliminary search, assistance from Security Staff should be requested

General Workshop Safety

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