A QUALITATIVE STUDY OF THE HAZARDS ASSOCIATED WITH A SMALL ENGINEERING (WELDING)

WORKSHOP AND THEIR CONTROL MEASURES

by

Kurina Baksh

Risk Assessment

Presented to the Faculty of Science and Technology

At the University of the West Indies

In Partial Fulfillments of Requirements

For Advanced Occupational Health and Safety

St. Augustine, Trinidad and Tobago

January 31, 2013

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 TABLE OF CONTENT

1. RISK ASSESSMENT 3

1.1 Identifying the Hazardous Situations 4

1.2 Identifying the Persons at Risk 6

1.3 Risk Assessment Matrix 6

1.4 Recommended Control Measures 8

2. REFERENCES 16

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 1

RISK ASSESSMENT

A risk assessment seeks to identify those hazards, processes and situations that may cause

harm, especially to the human capital. It is the process whereby hazards are identified, the risk

associated with those hazards are analyzed and evaluated, and appropriate ways to control or

eliminate those hazards are determined. Risk assessments are a crucial component of an

effective occupational safety and health management plan. They help to create awareness, as

well as prevent injuries and illnesses. Thus, the purpose of this document is to identify, evaluate

and control the hazards associated with the activities of a small engineering workshop such as

welding and the manufacture of wrought iron gates.

Description of the activity: Small Engineering Workshop Risk Assessment

Person carrying out the assessment: (Name) OESH Student

Date of assessment: December 24, 2012

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1.1 Identifying the Hazardous Situations

The table below illustrates the activities that occur at the small engineering workshop under

study and the hazards associated with each activity.

Engineering Workshop Activity Hazards Associated with Activity

Machining Operations and Powered Machinery o Crushing
o Cutting
o Drawing In
o Ejection
o Entanglement
o Friction/Abrasion
o Impact
o Puncture Wounds
o Noise
o Shearing
o Stabbing
Maintenance of Powered Machinery o Crushing
o Drawing In
o Electric Shock
o Entanglement
Handheld and Portable Power Tools o Abrasions
o Burns
o Cuts
o Electric Shocks
o Dust
o Fires
o Materials
o Noise
o Small Projectiles
o Sparks
o Trips
Hand and Foot Operated Machinery o Cutting
o Crushing
o Shearing
Hot Work and Processes o Burns
(E.g. Welding and Soldering) o Compressed Gas
o Electric Shock
o Fires
o Flashes
o Fumes
o Noise
o UV Radiation

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Table continued illustrating the activities that occur at the small engineering workshop under

study and the hazards associated with each activity.

Engineering Workshop Activity Hazards Associated with Activity

Manual Handling Operations o Abrasions
o Cuts
o Crushing
o Impact
o Musculoskeletal Injury
o Strains
Electricity in the Workplace o Burns
o Electric Shocks
o Fires
Materials/Hazardous Substances o Inhalation of aerosols, dust, fumes and vapours
(E.g. Nickel and Stainless Steel) o Contact with skin and eyes
Compressed Air o Ejection
o Injection
Workplace and Working Environment o Falls, Slips and Trips
o Fires
o Heat Levels
o Hygiene/Infections
o Light Levels
o Noise
o Ventilation
Human Factors o Unsafe Persons
o Unsafe Practices

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1.2 Identifying the Persons at Risk

Individuals at risk include:

Workshop Staff qualified and authorized to working in the engineering workshop.

Cleaning Staff.

Visitors such as Health and Safety Inspectors and Commercial Representatives.

Technical Staff under training.

1.3 Risk Assessment Matrix

This assessment was conducted to identify the level of risk and to help prioritize any control

measures. Firstly, the consequences and likelihood for each of the identified hazards were

evaluated to obtain the risk level according to the table below.

Consequences
1 Insignificant 2 Minor 3 Moderate 4 Major 5 Catastrophic
Dealt with by in- Medical help Significant non- Extensive Death.
house first aid. needed. permanent permanent Permanent
Treatment by injury. injury. disabling injury.
medical
professional.
A- Almost certain to High (H) High (H) Extreme (E) Extreme (E) Extreme (E)
occur in most
circumstances.
Likelihood

B- Likely to occur Moderate (M) High (H) High (H) Extreme (E) Extreme (E)
frequently.
C- Possible and Low (L) Moderate (M) High (H) Extreme (E) Extreme (E)
likely to occur at
some time.
D- Unlikely to occur Low (L) Low (L) Moderate (M) High (H) Extreme (E)
but could
happen.
E- May occur but Low (L) Low (L) Moderate (M) High (H) High (H)
only in rare and
exceptional
circumstances.

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The table below illustrates the risk assessment matrix for the Engineering Workshop.

Identify Hazards and Subsequent Risks Analyze Risk / Evaluate Risk

Hazards/Issues/Risks Consequence Likelihood Risk Level
Machining Operations and Powered
Machinery Crushing

o Cutting, Drawing In, Ejection,

Entanglement, Friction/Abrasion, 1 B M
Impact, Puncture Wounds, Shearing
and Stabbing

o Noise 4 B E

Maintenance of Powered Machinery

o Crushing, Drawing In and Entanglement 2 D L

o Electric Shocks 2 C M

Handheld and Portable Power Tools

o Abrasions and Cuts 1 B M

o Burns, Electric Shocks, Fires and Sparks 2 D L

o Dust, Materials and Small Projectiles 4 B E

o Noise 4 B E

o Trips 1 C L

Hand and Foot Operated Machinery

o Cutting, Crushing and Shearing 4 D H

Hot Work and Processes

o Burns, Fires, Flashes, Fumes and UV 3 C H

Radiation

o Compressed Gas 2 C M

o Electric Shock 2 C M

o Noise 4 B E

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Manual Handling Operations

o Abrasions, Cuts, Crushing, Impact, 3 B H

Musculoskeletal Injury and Strains

Electricity in the Workplace

o Burns, Electric Shocks and Fires 3 D M

Materials/Hazardous Substances

o Inhalation of Aerosols, Dust, Fumes and 2 B H

Vapours

o Contact with Skin and Eyes 2 C M

Compressed Air

o Ejection and Injection 2 D L

Workplace and Working Environment

o Falls, Slips and Trips 1 C L

o Fires 4 D H

o Heat Levels, Light Levels and Ventilation 1 B M

o Hygiene/Infections 1 E L

o Noise 4 B E

Human Factors

o Unsafe Persons and Unsafe Practices 5 A E

1.4 Recommended Control Measures

The following table illustrates the recommended control measures that can be undertaken to

eliminate, control or reduced the risk of hazards associated with each activity within the

engineering workshop.

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 Hazards and Subsequent Risks
Hazards/Issues/Risks
Machining Operations and Powered
Machinery Crushing
o Cutting, Drawing In, Ejection,
Entanglement, Friction/Abrasion, Impact,
Puncture Wounds, Shearing and
Stabbing
Recommended Control Measures Required
Further action needed
Opportunities for improvement
o Ensure that implemented guards are either
permanent fixtures or guards that can be fitted
to the machinery as required.
o Ensure that the guards are correctly adjusted and
used by operators to prevent injury from actions
such as the moving or rotating of the machine
parts, the moving or rotating of the cutting tools
and blades, the moving or rotating of the work
pieces, the flying of cuttings and coolants, as well
as abrasive wheels and belts.
o Ensure that work pieces are held securely by
chucks, clamps, fixtures and vices.
o Ensure that all emergency stop or brake
mechanisms are appropriately fitted to all
machinery.
o Ensure that there is adequate space available
around all machineries to facilitate safe
movements between the machinery.
o Ensure that only trained and competent persons
are allowed to mount and dress abrasive wheels.
o Ensure that only trained and competent persons
are allowed to properly set the work-rests on
bench and pedestal grinders.
o Ensure that machine operators wear suitable
personal protective equipment such as
protective clothing including coveralls, boiler
suits and eye and face protection.
o Ensure that loose clothing and jewellery are not
worn by the Staff.
o Ensure that all Staff with long hair tie-back their
hair before operating any machinery.
o Ensure that all machinery is kept in good working
conditions by performing regular maintenance
and cleaning checks.
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 o Noise
Maintenance of Powered Machinery
o Crushing, Drawing In and Entanglement
o Electric Shocks
Handheld and Portable Power Tools
o Abrasions and Cuts
o Burns, Electric Shocks, Fires and Sparks
o Dust, Materials and Small Projectiles
o Ensure that machine operators are provided with
suitable personal protective equipment such as
ear plugs to protect them from noise levels
higher than 85 dB (A).
o Ensure that all machinery is not functional and
that drive component covers are interlocked to
prevent machinery operation during
maintenance checks.
o Ensure that all machinery is not functional and
electrically isolated to prevent machinery
operation during maintenance checks.
o Ensure that only qualified and competent
persons are allowed to perform electrical fault
finding and safety testing with live equipment.
o Ensure that all workers have access to and
provided with personal protective equipment
such as coveralls to prevent them from abrasions
and cuts from abrasive wheels, cutters, drills,
saw blades and other sharp edges.
o Ensure that implemented guards are either
permanent fixtures or guards that can be fitted
to the machinery as required.
o Ensure that all portable electrical equipment and
power tools are maintained, inspected and
tested every 6 months in compliance with the
Engineering Workshops Safety Policy.
o Ensure that all workers have access to, provided
with and use personal protective equipment
such as fire resistant boiler suits, face shields,
gloves and safety glasses.
o Ensure that all workers are provided with and
use a flexible extraction arm for welding
activities.
o Ensure that all workers are provided with and
use dust masks for respiratory protection.
o Ensure that all workers are provided with and
use safety glasses.
o Ensure that there is a designated area that is
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o Noise
o Trips
Hand and Foot Operated Machinery
o Cutting, Crushing and Shearing
Hot Work and Processes
o Burns, Fires, Flashes, Fumes and UV
Radiation
cordoned off for angle grinding work to be done.
o Ensure that machine operators are provided
with suitable personal protective equipment
such as ear plugs to protect them from noise
levels higher than 85 dB (A).
o Ensure that walkways are cleared of all obstacles
and electrical cords are firmly secured to the
floor.
o Ensure that implemented guards are either
permanent fixtures or guards that can be fitted
to the machinery as required to prevent access
to shear blades and punch tools.
o Ensure that machine operators wear suitable
personal protective equipment such as gloves
and safety footwear to provide protection
against cuts.
o Ensure that suitable tools for holding and
moving hot work-pieces are provided and used
to prevent burns and fires.
o Ensure that suitable welding shields and goggles
are supplied and used to protect the eyes from
flames and sparks during welding and soldering
activities.
o Ensure that suitable fire resistant overalls and
gloves are provided and used to protect the skin
against burns from hot surfaces, flames, sparks
and UV radiation.
o Ensure that working combustible materials and
waste are kept in covered containers.
o Ensure that welding benches are constructed
from non-flammable and heat resistant material
to prevent fires.
o Ensure that access to welding area is restricted
to authorized and qualified persons only.
o Ensure that all workers are provided with and
use a flexible extraction arm for welding
activities.
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 o Compressed Gas
o Electric Shock
o Noise
Manual Handling Operations
o Abrasions, Cuts, Crushing, Impact,
Musculoskeletal Injury and Strains
Electricity in the Workplace
o Burns, Electric Shocks and Fires
o Ensure that gas cylinders are securely stored in a
designated area.
o Ensure that gas cylinder valves are turned off
when not in use.
o Ensure that gas welding torches and hoses and
regularly checked and maintained to comply
with HSE standards.
o Ensure that welding equipments and earthing
circuits are checked and tested regularly to
comply with HSE requirements.
o Ensure that electric welders are checked
periodically in accordance with the Engineering
Workshops Electrical Safety Policy.
o Ensure that workers are provided with suitable
personal protective equipment such as ear plugs
to protect them from noise levels higher than 85
dB (A).
o Ensure that materials are stored in a manner
that minimizes moving and handling.
o Ensure that staff has been trained in manual
handling tasks.
o Ensure that adequate lifting and moving
equipment is available and used in accordance
with manufacturers operational manual.
o Ensure that all workers have access to, provided
with and use personal protective equipment
such as gloves, safety glasses and safety shoes to
protect against cuts and impacts.
o Ensure that appropriate staff receives specific
training on handling of compressed gas
cylinders.
o Ensure that only competent electrical
technicians are allowed to perform maintenance
checks and test fixed and portable electrical
equipment.
o Maintenance checks and test should be
performed in accordance with the Engineering
Workshops Safety Policy.
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Materials/Hazardous Substances
o Inhalation of Aerosols, Dust, Fumes and
Vapours
o Contact with Skin and Eyes
Compressed Air
o Ejection and Injection
Workplace and Working Environment
o Falls, Slips and Trips
o Ensure that hazardous substances are used in
compliance with MSDS.
o If possible, ensure that dusts, fumes and vapours
should be extracted at source.
o Where possible, ensure that an appropriate
coolant is used.
o Ensure that all workers have access to, provided
with and use personal protective equipment
such as face masks.
o Ensure that specific risk assessments are carried
out for nickel and steel.
o Ensure that all workers have access to, provided
with and use personal protective equipment
such as gloves, safety glasses and face shields.
o Ensure that all substances are properly labelled.
o Ensure that all workers are provided with and
use safety glasses to protect eyes from dust
when cleaning.
o Ensure that machine operators wear suitable
personal protective equipment such as
protective clothing including coveralls to protect
skin against the injection of fluids from blow
guns.
o Ensure that only trained and experienced
technicians are allowed to handle compressed
gases.
o Ensure that housekeeping is done on a weekly
basis to prevent the walkways from being
obstructed.
o Ensure that spills or leaks are dealt with
promptly.
o Ensure that the storage area is separated from
the workspace.
o Ensure that floor surfaces are made of a non-slip
material.
o Workspaces, storage areas and walkways should
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 be delineated by markings on the floor.

o Fires o Ensure that a full detection fire alarm system is

in place, maintained and tested in accordance
with fire regulations.

o Ensure that there are adequate fire escape

routes that are signed and cleared of
obstructions.

o Ensure that emergency lighting is provided.

o Ensure that fire drills are performed every 6

months.

o Ensure that fire extinguishers are accessible at

strategic points in the workshop and properly
maintained.

o Ensure that workers are trained in the use of fire

extinguishers.

o Ensure that all combustible waste materials are

disposed of on a daily basis.

o Heat Levels, Light Levels and Ventilation o Ensure that fan assisted convector heaters are in
installed.

o Ensure that natural and artificial lighting is

provided to appropriate standards.

o Ensure that fume extraction is provided in

welding area.

o Hygiene/Infections o Ensure that personal hygiene facilities such as a

sink, soap, towels and water are provided.

o Ensure that toilet facilities are available nearby

and are kept sanitary.

o Ensure that workers are provided with lockers

and a changing room.

o Ensure that workers have access to a common

room for the consumption of food and drink.

o Ensure that workers have access to a clean

supply of drinking water.

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 o Noise o Ensure that workers are provided with suitable
personal protective equipment such as ear plugs
to protect them from noise levels higher than 85
dB (A).

o Ensure that noise surveys are conducted when

Human Factors
o Unsafe Persons and Unsafe Practices
necessary.
o Ensure that only people who are adequately
trained or are experienced and deemed as
competent by the workshop supervisor are
allowed to work independently in the workshop.

o Ensure that all trainees are closely supervised if

working in the workshop.

o Ensure that a range of Personal Protective

Equipment is provided and instructions on how
to use them is provided as easily understood, as
well all workers are trained in its proper use.

o Ensure that workers are continually trained to

meet changes in the requirements of OSH in the
workshop.

o Ensure that workers are aware that they are not

allowed to working alone in the workshop.

o Ensure that the workshop is locked when not in

use and only accessed by authorised personnel
who control the keys to the workshop.

o Ensure that electrical power is isolated when

workshop is closed and machinery controlled by
keys.

o Ensure that workers are aware that the

consumption of food or drink is not allowed in
the workshop.

o Ensure that workers are aware that the use of

mobile phones is not permitted in the workshop.

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 REFERENCES

University of Southhampton. 2010. Workshop Risk Assessment. Accessed December 24, 2012.

http://www.southampton.ac.uk/healthandsafety/guidance/workshoprisk.html.

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