The hazards and controls of workplace machinery
March 2023
Workplace machinery is an essential part of modern industrial, manufacturing, and construction settings. It enables us to perform tasks efficiently, accurately, and quickly, but it also poses significant risks to workers if not handled correctly. Without proper maintenance and operation, machinery can cause devastating injuries, resulting in loss of life or disability.
This blog aims to help employers, workers, and safety professionals understand the hazards associated with workplace machinery and the controls necessary to prevent accidents and injuries. We will explore the different types of hazards that machinery can pose, including mechanical, electrical, thermal, and chemical, and their potential consequences. We will also examine the various control measures that can be implemented to mitigate these risks, including engineering controls, administrative controls, personal protective equipment, maintenance, inspection, and training.
By understanding the hazards and controls associated with workplace machinery, workers can operate machinery safely, reduce the likelihood of accidents and injuries, and increase overall workplace safety. Employers and safety professionals can also ensure compliance with regulations and create a culture of safety that prioritizes worker health and wellbeing.
Hazards of Workplace Machinery
Workplace machinery can pose various types of hazards to workers, and it's essential to identify and understand them to prevent accidents and injuries. Here are some of the common hazards associated with machinery:
1. Mechanical hazards
These hazards result from moving machinery parts, such as rotating blades, gears, pulleys, and pinch points. Workers can get caught or crushed between moving parts or struck by flying objects.
Here are some examples of mechanical hazards in different types of machinery:
• Lathes: Lathes use a rotating spindle to cut and shape materials. Workers can get caught between the spindle and the workpiece, resulting in crushing injuries or amputations.
• Power presses: Power presses use a moving punch and die to stamp metal parts. Workers can get caught in the press if it cycles unexpectedly, resulting in amputations or crushing injuries.
• Chainsaws: Chainsaws use a rotating chain to cut through wood or other materials. Workers can suffer cuts, amputations, or lacerations from the chainsaw blade if it comes into contact with their body.
• Punching machines: Punching machines use a hydraulic press to punch holes in metal sheets. Workers can get caught between the sheet and the press, resulting in crushing injuries or amputations.
• Grinders: Grinders use rotating wheels to sharpen or smooth materials. Workers can suffer from flying debris or contact with the wheel, resulting in cuts, burns, or eye injuries.
2. Electrical hazards
Electrical hazards can arise from faulty wiring, exposed electrical parts, or improper grounding. Workers can suffer from electrocution, electric shock, or burns.
Here are some examples of electrical hazards in different types of machinery:
• Welding machines: Welding machines use an electrical current to generate heat to fuse metal parts together. Workers can suffer from electrical shock or burns if they come into contact with the electrical circuit.
• Power tools: Power tools such as drills, saws, and grinders have electrical components that can cause electrical hazards. Workers can suffer from electric shock or burns if they come into contact with exposed wiring or electrical parts
• Heavy equipment: Heavy equipment such as cranes, excavators, and bulldozers have electrical systems that power the machinery. Workers can suffer from electric shock or burns if they come into contact with faulty wiring or exposed electrical parts.
• Conveyor belts: Conveyor belts have electrical components such as motors and sensors. Workers can suffer from electric shock or burns if they come into contact with faulty wiring or exposed electrical parts.
• Industrial machinery: Various types of industrial machinery have electrical components that can cause electrical hazards. Workers can suffer from electric shock or burns if they come into contact with exposed wiring or electrical parts.
3. Thermal hazards
Machinery that uses heat sources, such as ovens, furnaces, or kilns, can cause thermal hazards. Workers can get burned or suffer from heat stress or dehydration.
Here are some examples of thermal hazards in different types of machinery:
• Ovens: Ovens are used in various industries to heat or dry materials. Workers can suffer from burns if they come into contact with the hot surfaces or contents.
• Furnaces: Furnaces are used in industries such as metalworking to melt or shape materials. Workers can suffer from burns if they come into contact with the hot surfaces or contents.
• Kilns: Kilns are used in ceramics and pottery industries to heat materials. Workers can suffer from burns if they come into contact with the hot surfaces or contents.
• Boilers: Boilers are used in industries such as power generation to produce steam for various applications. Workers can suffer from burns or scalding from the hot water or steam.
• Heat sealers: Heat sealers are used in industries such as packaging to seal materials with heat. Workers can suffer from burns if they come into contact with the hot sealing surfaces.
4. Chemical hazards
Chemical hazards result from the use of hazardous materials, such as acids, solvents, or pesticides. Workers can be exposed to toxic substances, which can cause skin irritation, respiratory problems, or even cancer.
Here are some examples of chemical hazards in different types of machinery:
• Cleaning equipment: Cleaning equipment such as pressure washers or parts washers use solvents or detergents to clean machinery parts. Workers can be exposed to hazardous chemicals if they are not properly trained in handling and storing these materials.
• Printing machines: Printing machines use inks, solvents, and cleaning agents that can emit volatile organic compounds (VOCs) or hazardous air pollutants (HAPs). Workers can be exposed to these chemicals through inhalation or skin contact.
• Agricultural equipment: Agricultural equipment such as sprayers or fertilizer spreaders use pesticides and fertilizers that can be toxic to humans. Workers can be exposed to these chemicals through inhalation or skin contact.
• Manufacturing machinery: Various types of manufacturing machinery use hazardous materials such as acids, solvents, or adhesives. Workers can be exposed to these chemicals through inhalation, skin contact, or ingestion.
• Laboratory equipment: Laboratory equipment such as centrifuges or distillation apparatus use hazardous chemicals for experiments or testing. Workers can be exposed to these chemicals through inhalation, skin contact, or ingestion.
Risk Assessment and Control Measures
Risk assessment is an essential part of identifying and evaluating hazards associated with workplace machinery. A risk assessment should be conducted before work begins on a new machine or when changes are made to existing equipment. Here are the steps involved in conducting a risk assessment:
1. Identify the hazards associated with the machinery
The first step in assessing the hazards associated with machinery is to identify the potential hazards. This can be done by conducting a thorough inspection of the machinery, including its components, operation, and maintenance procedures. The hazards that may arise from the machinery can include mechanical, electrical, thermal, or chemical hazards.
For example, a saw may have sharp blades that can cause cuts or amputations, while a forklift may have pinch points that can crush a worker's limbs. Similarly, a conveyor belt can have exposed electrical parts, while an oven may produce heat that can cause burns.
2. Evaluate the risk level of each hazard
Once the hazards have been identified, the next step is to evaluate their risk level. This involves determining the likelihood and severity of harm that can result from each hazard. This information can be used to prioritize the hazards and determine which ones require immediate attention.
For example, a saw with dull blades may pose a lower risk than one with sharp blades, while a conveyor belt with exposed electrical parts may pose a higher risk than one with proper guarding.
3. Determine appropriate control measures to mitigate the risk
The next step is to determine appropriate control measures to mitigate the risks. These measures can be divided into three types: engineering controls, administrative controls, and personal protective equipment (PPE).
• Engineering controls involve physical modifications to the machinery or workplace to reduce the risk of hazards. For example, adding guards or interlocks to machinery to prevent workers from accessing hazardous areas or implementing emergency stops.
• Administrative controls involve changes to work procedures or policies to reduce the risk of hazards. For example, providing training to workers on safe operating procedures or displaying warning signs near hazardous areas.
• Personal protective equipment (PPE) involves the use of protective gear, such as gloves, eye protection, or hearing protection, to protect workers from hazards. PPE should be used as a last line of defense after engineering and administrative controls have been implemented.
4. Implement and maintain control measures
The final step is to implement and maintain the control measures. This involves making the necessary modifications to the machinery or workplace, providing training to workers, and ensuring that PPE is available and properly used. It is also important to periodically review and update the control measures to ensure their effectiveness and make any necessary changes.
Maintenance and Inspection
Regular maintenance and inspection of machinery is critical to ensuring safe and efficient operation. Proper maintenance can help identify potential hazards and prevent breakdowns or malfunctions, while regular inspection can identify any issues or problems before they become a hazard.
Here are some examples of maintenance and inspection activities:
Maintenance activities:
• Lubrication: Machinery often has moving parts that require regular lubrication to prevent friction and wear. Lubrication helps maintain the machine's efficiency and prolong its lifespan. For example, lubricating a conveyor belt's bearings can help prevent them from seizing up, causing the belt to stop and potentially leading to accidents.
• Cleaning: Regular cleaning of machinery can help prevent dust and debris buildup, which can cause machines to malfunction. For example, cleaning a saw's blade can help prevent it from becoming clogged, which could cause the saw to malfunction and potentially injure the operator.
• Replacing worn parts: Machinery parts can become worn or damaged over time, which can lead to malfunctions or accidents. Regular inspection can help identify worn parts that need replacement, which can prevent accidents and improve the machine's performance. For example, replacing worn forklift tires can help prevent accidents caused by a loss of traction or control.
Inspection activities:
• Checking electrical components: Electrical components are critical to the operation of many types of machinery. Regular inspection can help identify potential electrical hazards, such as frayed wires or loose connections, that could cause electrocution or other injuries. For example, inspecting a welder's electrical connections can help prevent electrical hazards while operating the machine.
• Verifying machine settings: Incorrect machine settings can lead to accidents or poor performance. Regular inspection can help ensure that machines are set up correctly and functioning safely. For example, verifying the blade depth on a table saw can help prevent accidents caused by the blade being set too high.
• Inspecting safety guards: Safety guards are designed to protect workers from moving parts or other hazards. Regular inspection can help ensure that safety guards are in place and functioning correctly, which can prevent accidents and injuries. For example, inspecting the safety guards on a drill press can help prevent accidents caused by clothing or body parts getting caught in the machine's moving parts.
Encouraging workers to report problems with machinery is essential for maintaining a safe work environment. Workers who operate machinery regularly are in the best position to identify potential hazards or malfunctions. By promptly reporting any issues they encounter, workers can help prevent accidents or injuries before they occur.
To ensure workers feel comfortable reporting problems, employers should create a culture of safety where workers are encouraged to speak up and feel confident that their concerns will be taken seriously.
In addition, employers should establish clear reporting procedures, so workers know who to contact and how to report any issues. This can include creating a system for submitting written reports, using a mobile app or online platform for reporting, or setting up a hotline for workers to call in case of emergencies.
By involving workers in the reporting and inspection process, employers can identify potential hazards early and take appropriate action to prevent accidents or injuries. This can help create a safer work environment for everyone involved.
Training and Education
Training and education are essential components of preventing accidents and injuries associated with workplace machinery. By providing workers with the knowledge and skills necessary to operate machinery safely, employers can significantly reduce the risk of accidents.
Training and education can take various forms, including classroom instruction, hands-on demonstrations, and refresher courses.
1. Classroom instruction
This type of training is typically conducted in a classroom or online setting and involves theoretical instruction on the hazards associated with machinery and safety procedures to follow. Workers may learn about safety regulations, hazard identification, emergency response procedures, and the proper use of personal protective equipment (PPE). Classroom instruction is often an effective way to provide workers with a broad understanding of the potential hazards they may face in the workplace.
2. Hands-on demonstrations
Hands-on training involves giving workers practical experience in operating machinery safely. This type of training can take place in a simulated environment, such as a training facility, or on-site with the actual equipment. Workers can learn about equipment operation, proper maintenance and inspection techniques, and hazard identification and mitigation. Hands-on training is particularly useful in helping workers identify potential hazards that may not be evident in a classroom setting.
3. Refresher courses
Refresher courses are essential to ensure that workers stay up-to-date with changes in equipment, procedures, and regulations. These courses are typically brief and focus on a specific topic, such as new safety regulations, changes in equipment operation, or updates to emergency response procedures. Refresher courses can help reinforce workers' knowledge and skills, and ensure that they remain aware of potential hazards in the workplace.
In all forms of training and education, it's important to ensure that workers receive the necessary information and practical experience to operate machinery safely. Supervisors and managers play a critical role in ensuring that workers receive adequate training and education. They are responsible for identifying training needs, scheduling training sessions, and monitoring worker performance to ensure that safety procedures are being followed correctly. By promoting a culture of safety and investing in training and education, employers can create a safer workplace and reduce the risk of accidents and injuries associated with machinery.
Conclusion:
In conclusion, workplace safety is a crucial aspect of any organization. Employers have a responsibility to provide their workers with a safe and healthy working environment, and this includes the use of machinery. Implementing hazard controls, such as engineering controls, administrative controls, and personal protective equipment, is an essential step in mitigating the risk associated with machinery. Regular maintenance and inspection can also help identify potential hazards and ensure that machinery is in good working condition.
Training and education are critical in preventing accidents and injuries. By providing employees with the necessary knowledge and skills to operate machinery safely, they can avoid potential hazards and mitigate the risks associated with machinery. Adequate training and education can also improve workers' confidence, productivity, and overall job satisfaction.
Ultimately, prioritizing worker safety is not only the right thing to do but also makes good business sense. Workplace accidents and injuries can lead to costly legal battles, lost productivity, and decreased employee morale. By implementing hazard controls, conducting regular maintenance and inspections, and providing adequate training and education, organizations can create a safer and healthier work environment, resulting in a more productive and motivated workforce.
Find out how to manage your business' health and safety better
RIDDOR and COVID-19
Many employers are concerned about their reporting obligations for COVID-19/Coronavirus/SARS-CoV-2 under RIDDOR in the ongoing pandemic. You may be pleased to know that you do not have to report everything to the Health and Safety Executive (HSE). We'll provide more info about when, what, and how to report.
The most common concern we've seen recently from employers is whether they need to report all COVID-19 and coronavirus testing results to the HSE. The short answer is no. According to the HSE: “There is no requirement under RIDDOR (The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 2013) to report incidents of disease or deaths of members of the public, patients, care home residents or service users from COVID-19. The reporting requirements relating to cases of, or deaths from, COVID-19 under RIDDOR apply only to occupational exposure, that is, as a result of a person's work.”
Generally speaking, the ordinary RIDDOR rules already cover COVID-19. You should only make a report under RIDDOR when one of the following circumstances applies:
• an accident or incident at work has or could have caused the release of coronavirus (SARS-CoV-2). (Report as Dangerous occurrence)
• a worker is diagnosed with COVID-19 due to occupational exposure. (Report as Disease)
• a worker dies because of occupational coronavirus exposure. (Report as Work-related death due to exposure to a biological agent)
The bottom line is that existing rules cover most COVID-19 measures, and most of the COVID-19 guidance comes from public health authorities rather than the HSE. The environment remains chaotic, but you can minimize your legal exposure by continuing your existing compliance steps. This will include communicating with your insurer about risks, following public health guidance, and communicating regularly with your workers or unions on any of their concerns.
© Gavin Coyle, 2021