IGC 2: ELEMENT 4

WORK EQUIPMENT
HAZARDS & CONTROL

WORK EQUIPMENT
"Work Equipment" is anything used to
do a job of work, including
employees' own equipment;
Hand tools e.g. screw drivers,
wrenches, hammers, handsawsetc.
Power tools e.g. Chainsaws, Drills
etc
Machinery e.g. photocopiers,
concrete mixers, grinders, circular
saws etc

SUITABILITY OF WORK
EQUIPMENT
work equipment has to conform
to some standards:
Initial integrity
The place where it will be used
The purpose for which it will be
used

WHAT DO BUYERS NEED

?!TO CONSIDER

SAFE USE & MAINTENANCE OF

EQUIPMENT
TRAINING, INFORMATION & INSTRUCTIONS
MAINTENANCE: planned preventive / condition based /
breakdown based
INSPECTION
EXAMINATION & TESTING
OPERATION CONTROLS & WORKING
ENVIRONMENT

Manufacturers & suppliers need to make sure the machinery is

safe when supplied and has the CE marking. Manufacturers have
to:
Assess all foreseeable risks & find out about OHS hazard likely to
be present when the machinery is used.
Consider safety issues in design phase & Design the machinery
free of OHS risks is possible.
Provide appropriate safe guards, use warning signs, to warn of
hazards.
Fix CE marking on the machine; to show they have complied with
relevant supply laws.
Provide the buyer with information & instructions to explain how to
install, use & maintain the machinery safely.
Issue a Declaration of Conformity" for the machine; to show it
complies with essential OHS requirements.

Prior to purchasing new equipment,

Buyers need to consider:
What the equipment will be used for.
Where & How it will be used.
Who will use it; skilled personnel, employees
etc.
What OHS risks might come out?
How well OHS risks are controlled by
manufacturers.

Safe Use & Maintenance of Equipment with

specific Risks;
Hierarchy of control:
Eliminating the risks
Taking physical Engineering controls to control risks e.g. guards
Appropriate administrative controls; safe system of work
The Use, repairs, servicing or maintenance of such equipment should
be restricted to designated authorized personnel who:
Received sufficient Training.
Received adequate information & familiar with work instructions.
Have enough experience & sufficient skills to carry out such tasks.

Information, Instruction & Training; personnel

(employees, workers, supervisor, managersetc) using &
maintaining work equipment need to receive sufficient information,
instruction & training which at least should cover:
All OHS aspects
Limitations on the use of equipment
Any foreseeable risks & problems that could occur
Safe methods & controls to deal with such risks & problems
The complexity of equipment, the level of risks involved & the
competence of the person doing the job, will al determine the
amount of training required.

Maintenance:

Has o be done by competent well trained maintenance

personnel.
A safe System of Work to be used; ensure safe environment,
proper isolation procedures, right tools & equipment for the
jobetc e.g. to implement Permit To Work.
Planned Preventive maintenance; regular scheduled
maintenance to replace parts & service as appropriate in a
proactive manner.
Condition Based maintenance; monitoring the condition of
critical parts & carrying out maintenance as necessary.
Break down based maintenance; reactive & only takes place
when failures occur.

Inspection:

After installation for the first time.

After assembly at a new site or a new location.
At reasonable intervals & following incidents.
Prior to each use in high risk equipment & as a part
of the Work Permit procedures.

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Examination & Testing of pressure systems: wide

range of pressure vessels & systems require thorough examination
by a competent person (usually a specialist inspector from a 3 rd
party organization), and employers who operates steam boilers
&/or pressurized hot water plant etc, must ensure:
Equipment is supplied by correct updated written information &
markings.
Properly installed.
There is a written scheme for periodic examination of equipment
is certified by a competent person, a report of periodic examination
with corrective actions provided & implemented.

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Equipment
Cranes, hoists and
lifting equipment

Pressure systems

Power presses

Statutory
Inspections
Inspections of

Frequency

All equipment used for lifting

people and lifting accessories

6 months

Other lifting equipment

12 months

Steam plant (boilers)

14 months

Steam receivers

26 - 38 months*

Air receivers

24 - 48 months*

Fixed guards

12 months

Other guards

6 months

Inspection of guards and

protective devices during
work

4 hourly

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HAND TOOLS
HAZARDS:
Misuse & poor maintenance;
Broken handles e.g. can cause a
hammer handle to fly off
Cut wounds on incorrect use of
saws, knives & chisels.
Slipping tools stab wounds
Flying particles that hit the eyes

CONTROL:
All tools to be suitable for
the purpose

Protected & isolated for

electrical use\

Good quality material

which will not chip of fly
off

Regular documented
inspection of hand tools

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HAND-HELD POWER TOOLS

HAZARDS:

CONTROL:

Electrical hazards; shock,

burns etc

Protect against electric

shock; isolation, grounding.

Mechanical entanglement in
rotating parts

Disconnect when not in use.

Regular maintenance,
inspection, check & report &
report defects.

Use the right tool for the job

Maintain clean & tidy work

area.

Dust & particles flying off

cutting or drilling areas;
inhalation & eye injuries.
Cut wounds in case of
contact with sharp blades.

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MACHINERY HAZRADS
MECHANICAL:

CRUSHING

SHEARING

TRAPPING

CUTTING

IMPACT

ENTANGLEMENT

STABBING
EJECTION

Entanglement & trapping

Pulley & belt

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MACHINERY HAZARDS
NON-MECHANICAL:

Manual Handling & Lifting

Electricity / Fire / Explosion

Noise / Vibration

High / Low temperature

Dusts / Fumes / Mists

Biological; bacteria, virus etc

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MACHINERY SAFEGUARDS
FIXED GUARDS:
simple physical barrier prevents access
to dangerous parts of the machine

ADJUSTABLE GUARDS:
User adjusted / self adjusted

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MACHINERY SAFEGUARDS
Two-handed control devices:
require the operator to have both
hands on the controls (safe
place) before the machine can
be operated
Interlocking Guards: movable
guard, whose movement is
connected to the power control
of the machine
Trip devices

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Operation controls & the working place:

Equipment controls to be easily reached from any operating
position.
Not to permit accidental start up of equipment.
Adequate Red Emergency stop buttons
Be clearly marked to show what they do
Equipment should be stable; bolting or clamping
Maintain house keeping (clear & unobstructed) at all times
Adequate light &ventilation, clean & tidy up the equipment if not in
use
Controls to be isolated from high risk operations e.g. put the
controls in a closed glass control rooms, use remote controls
etc.
Provide adequate work instructions & Clear warning signs.

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Hand Tools Hazards

Misuse & poor maintenance;

Broken handles e.g. can cause a hammer handle to fly off
Cut wounds on incorrect use of saws, knives & chisels.
Slipping toolsstab wounds
Flying particles that hit the eyes from breaking up
stones/concrete
Electric shock or burns when using poorly isolated tool in
electrical work.
Incorrect use of hand tools due to lack of training &
instructions.

Hand Tools' Controls

Hand-held Power Tools' Hazards

Electrical hazards; shock, burns etc

Mechanical entanglement in rotating parts
Dust & particles flying off cutting or drilling areas; inhalation
& eye injuries.
Cut wounds in case of contact with sharp blades.
Manual Handling & hand to arm vibration risks.
Tripping hazards; from extended cables.
High noise levels.

All tools to be suitable for the purpose

Protected & isolated for electrical use
Good quality material which will not chip of fly off
Use of safety knives with enclosed blades.
Regular documented inspection of hand tools
Proper storage to prevent damage or corrosion
All users to be properly trained in the use of hand tools.

Hand-held Power Tools' Controls

Protect against electric shock; isolation, grounding.

Disconnect when not in use.
Regular maintenance, inspection, check & report & report
defects.
Use the right tool for the job
Maintain clean & tidy work area.
Only use accessories & parts recommended by manufacturer.
Do not abuse power cables; do not carry the tool by the power
cable, do not pull plug from the cable.
Use correct PPE; safety glasses, gloves, respirators & dust
masks etc

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Mechanical Hazards
EN tanglement
T raps
Shearing, drawing in, crushing
I

mpact

C ontact
Friction, abrasion, cutting and
stabbing, puncture
E jection

Remember: ENTICE
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Mechanical Hazards:
ENtanglement
ENtanglement: Clothing, Hair, Jewellery
getting wrapped around machinery

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:Mechanical Hazards
Traps
:Traps involve

Shearing
In running nips
Drawing in

Crushing
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Mechanical Hazards:
Impact

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Mechanical Hazards:
ContactContact Injuries:
Burns
Lacerations
(tear)
Abrasions
Puncture
wounds
Cuts
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Mechanical Hazards:
Ejection

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Abrasive Wheel
(Grindstone)
Machinery
Mechanical Hazards
Trapping
Ejection

Entanglement

Contact
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Mechanical Hazards
Drawing-In

Drawing in

Crushing

Entangleme
nt

Shearing

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2] Non-mechanical Machinery hazards:

Manual Handling & Lifting
Electricity / Fire / Explosion
Noise / Vibration
High / Low temperature
Dusts / Fumes / Mists
Biological; bacteria, virus etc
Radiation; ionizing/non-ionizing
Psycho-somatic effects
Ergonomics
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Preferred order of Guarding

BS EN ISO 12100-2:2003

Fixed
Interlock
Automatic
Trip (Safety device)
Remember: FIAT
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 Fixed Guards: simple physical barrier

prevents access to dangerous parts of the
machine, difficult to remove & almost
maintenance free. Its limitation is that it's often
left off by maintenance staff.
Adjustable Guards: user adjusted; fixed or
movable which are adjusted by user for a
particular operation, its limitation is that it
needs frequent adjustment. Self adjusting
guards; adjusts itself to accommodate the
passage of material for instance, it still may
allow access to dangerous parts & requires
careful maintenance.
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 Interlocking Guards: movable guard, whose

movement is connected to the power control
of the machine; the machine will not operate
till the guard is closed. Limitation is that they
need constant check to ensure they are
operating.
Trip Devices: detects when a person
approaches close to danger point & stops the
machine before injury occurs. Could be
physical barrier, electrical, Photo-electric with
sensors or pressure-sensitive mats.
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 Two-handed control devices: require the

operator to have both hands on the controls
(safe place) before the machine can be
operated. Limitation is that they only protect
the operator's hands; therefore it is critical
that the machine's design does not allow any
other part of the operator's body to enter the
danger zone during operation.

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-"Bolt on" guards are less effective in

reducing risks, more likely to inhibit normal
operations & may represent hazards in
themselves. It is best to consider "Built in"
guards in the design phase.

34

-It is critical that all users of guarded

machinery get adequate training,
information & work instructions on how to
use & safely deal with guarded machinery
prior to starting operations.

35

Operators' responsibilities:
Take reasonable care of themselves & others
who might be affected by their work.
Use Equipment properly & stick to work
instructions.
Attend proper training & use the information
provided
Report to the employer any hazardous
situations or unsafe conditions
Use provided PPE
Cooperate with the employer & attend safety
meetings
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Basic Principles for Guards & Safety

devices:
Compatible with the process.
Have adequate strength
Allow maintenance & servicing without guard
removal
Does not increase the risk or restrict user's
view
Is not easy to be by-passed

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"The use of PPE is crucial as the last line of

defense to control machinery & hand held tools
hazards;
Coveralls; protects against loose parts of
clothing getting entangled.
Safety Glasses; protects against ejected parts
of material.
Ear protection; protects against machinery
noise
Safety boots; protects against feet crushing by
pieces of work falling onto them
Hair nets; prevent hair from getting entangled
in moving machinery parts.
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Machinery

1]Office
Photocopier

Hazards associated
Contact with moving
parts; when clearing a
paper jam.
Electrical; during
maintenance / clearing
jam
Ultraviolet light
Health hazards; toner &
ozone
Noise & Ergonomics

Appropriate
Safeguards
All enclosing case
Access doors are
interlocked; machine
switches off
automatically when
gaining access.
Isolation of internal
electrics
Maintenance
Use the cover to
protect from UV

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2] Office Document
Shredder

Drawing in between Enclosed fixed

rotating cutters.
guards around the
Contact with rotating cutters
Interlocks fixed to
cutters.
Electrical & Noise
the cutter heads
Possible dust from
Trip device; starts
cutting.
the machine when
paper is fed in.

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3] Manufacturing &
maintenance Bench
top grinder

Contact with the

rotating
wheelabrasion
Drawing in between
the rotating wheel &
a badly adjusted tool
rest.
Bursting
wheelejecting
fragments.
Electrical; faulty
wiring.
Noise & Vibration
Health hazards;
Dusts
Fires due to sparks &
hot fragments.

Wheel enclosed as
much as possible in
strong casing
Adjustable screen to be
fitted over the wheel.
Only proper trained
personnel should use it
Maximum speed to be
marked on the machine
Adjustable tool rest to
be adjusted as close as
possible to the wheel
Implement Portable
Electrical Testing
Dust extraction

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Manufacturing & Entanglement around

maintenance
rotating parts
Contact with drill or
Pedestal Drill
work piece; cutting or
puncturing
Being struck by work
piece
Electrical; faulty
wiring/lack of
grounding
Dusts

Motor & drive to be

fitted with fixed
guards.
Spindle to be
guarded by an
adjustable guard
Use clamp/vise to
secure work piece
Use goggles
Keep the machine
clean, tidy &
unplugged when not
in use

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Agricultural /
Horticultural
Cylinder mower

Contact &
Entanglement with
rotating blades
Trapping of hands
by rotating blades
Health hazards;
dusts, fumes & hay
Noise & Vibration
Manual Handling /
Ergonomics.

Design should
restrict access to
bottom blade trap.
Drives & motor to
be enclosed in fixed
guard
Use suitable dust
mask & only run
engine in open air
Silencers for noise

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Agricultural /
Horticultural
Strimmer

Entanglement with
the rotating part.
Cutting on contact
with the cutting head
Ejection of particles
Noise / Vibration
Ergonomics;
musculoskeletal
Health hazards from
herbicides & or/
animal faeces

Moving engine parts

enclosed
Rotating head to have
fixed top guard
Run engine only in
open air
Proper safety boots
Anti-vibration handles
Dust masks & hearing
protection & gloves

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Retail - Compactor Crushing; between

ram & machine
sides.
Trapping &
Entanglement with
rotating parts
Electrical
Manual Handling

Access doors to
loading area to be
interlocked.
Dives of motors to
be properly guarded
Regular inspection
& testing

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Retail Check out

conveyor system

Drawing in between All traps between

belts & rollers
belt & rollers to
Entanglement
have fixed or
Electrical
interlocked guards
Manual Handling
Emergency Stop
Buttons

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Construction
Cement mixer

Entanglement with
Design should
the moving parts of
allow the user to see
motor
anyone in the
Trapping
trapping area.
Dusts / Noise
Drum gearing to be
Manual Handling
enclosed
Eye injury; in case of No one allowed to
cement splash
stand on machine
Goggles & PPE

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Construction
bench mounted
Circular saw

Contact with the

cutting blade
Ejection of the work
piece
Entanglement with
moving parts of the
motor
Dusts / Noise /
Vibration
Electric; faulty
wiring, grounding.

Fixed guards to the

blade below the
bench
Adjustable top
guard to the blade
above the bench
Extraction
ventilation for wood
dust
Safety glasses &
Dust masks

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