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kap all covers 6/9/03 9:48 am Page Student Workbook LV01 Health, Safety and Housekeeping in a Vehicle Workshop LV01/SWB Student Workbook for Technical Certificates In Light Vehicle Maintenance and Repair MODULE LV01 HEALTH, SAFETY AND HOUSEKEEPING WITHIN A VEHICLE WORKSHOP Contents Page Introduction The Law: Health and Safety Commission and Executive Regulation and Codes of Practice Powers of inspectors Health and Safety Policy Statement Working environment Legislation that affects maintenance and repair Dangerous Substances (COSHH): Types of dangerous substances Labelling Page Accidents: Causes of accidents Direct causes Unsafe acts Unsafe conditions Indirect causes Exercise Accident prevention Reporting accidents Exercise Reporting faulty equipment 23 23 23 24 24 25 26 27 28 29 30 13 13 15 First Aid: Priorities Exercise 31 31 32 Safety Signs: Progress check 16 18 Personal Protective Equipment (PPE): Exercise 19 21 Fire: The Fire Precautions Act (1974) Causes of fire Extinguishing fire Types of extinguishers Exercise Means of escape 33 33 33 34 34 36 36 Employee Duties under the Health and Safety at Work Act (1974) 22 3 (Contd) Page Fire drill Fire hazards within a motor vehicle workshop Petrol fires Other fire hazards Electrical fires Exercise 37 Good Housekeeping: Practice good engineering hygiene What has to be cleaned Cleaning agents and equipment Environment Protection Act (1990) Other cleaning duties 40 41 41 41 42 42 Maintaining Tools and Equipment: Exercise Cleaning equipment Company resources Care of equipment 43 43 44 44 45 Workshop Equipment – The Hazards: Electrical equipment Risks Reducing electrical risk Exercise Safe removal of petrol from vehicles Equipment fro removing petrol 46 46 46 47 48 48 49 Examples of Accidents: Compressed air Hydraulic jacks and axle stands Vehicle lifts Hoists Using pits or sunken workshops Exhaust extraction Abrasive wheels Guards 50 50 51 52 52 53 53 53 54 37 37 37 38 39 Page Welding Equipment: Electric arc Arc eye High current flow Gas welding Exercise 55 55 55 55 56 57 Asbestos: Dangers What does asbestos do? What kind of work creates asbestos dust? 58 58 59 59 Risk Assessment and Record Keeping: Exercise 10 61 62 Points to Remember 64 Introduction The motor vehicle industry is by its very nature hazardous If you are to avoid injury you need to fully understand the nature of the risks that you are exposed to and maintain a very high level of personal awareness – that is, awareness of your environment, your actions and the actions of those around you The Law Health and Safety Commission and Executive The motor vehicle industry is highly regulated The health and safety of the people that work within it is of primary importance, and therefore subject to a number of regulations The Health and Safety Commission has responsibility for: general policy, research and dissemination of information development of law through proposals for regulation and codes of practice and to consult with employer and employee organisations where appropriate The Health and Safety Executive, appointed by the Commission is responsible for: implementation of policy inspection enforcement research, information and advice Regulation and Codes of Practice The Health and Safety at Work Act (HASAWA) was introduced by the Government in 1974 and facilitates regulation to: modify or replace existing legislation provide for new situations as they arise The Act enables approved codes of practice to be introduced and to provide practical guidance Regulations are enforceable by law; codes of practice are not but are admissible in evidence as failure to comply Powers of inspectors HSE inspectors carry out periodic inspection of premises to ensure compliance with the law They have a number of powers and they are able to: enter premises at any reasonable time (accompanied by a police constable if necessary) examine and investigate, and to this end can order premises to be left undisturbed take samples issue improvement and prohibition notices and initiate prosecutions take possession of any dangerous substance or article for examination or use in legal proceedings Upon completion of an inspection, there are a number of options open to the inspector Improvement notice: This is issued by the inspector and used to improve or remedy a situation A time limit for completion is specified Prohibition notice: A prohibition notice is used when an inspector decides that there is a risk of serious injury and directs that certain activities cease until the situation is remedied Fines: In the event of a prosecution-taking place, which could be against a company or any individual from chief executive to vehicle technician, a magistrate can impose heavy fines (unlimited) The offender can also be sent to prison for a maximum of two years Health and Safety Policy Statement An employer must: “Ensure, so far as is reasonably practicable, the health, safety and welfare at work of the people for whom they are responsible and the people who may be affected by the work they do” In order to comply with this requirement, an employer must: prepare a written statement of general health and safety policy set down the organisation and arrangements for carrying out the policy, i.e who is responsible and for what revise and update this policy as necessary bring the policy and arrangements to the notice of all employees The company health and safety policy is in short a statement answering the following questions: 1) What are they going to do? 2) Who is going to it? 3) How is it going to be done? The working environment Your employer must provide: a safe place of work safe systems of work safe equipment to work with a healthy and safe environment to work in Without active support, any attempt at organised accident prevention will be useless Avoidance of accidents requires a sustained, integrated effort from all departments, managers, supervisors and workers in any organisation Only management can provide the authority to ensure everything is coordinated, directed and funded but every employee has a responsibility to ensure that they their bit - this includes you! Management’s influence will be seen in the policy made, the amount of scrutiny given to it and the ways in which violations are handled The company policy should contain references to other arrangements not contained in the safety policy itself, which should include: training - identification of training needs the environment - heating, ventilation, lighting, good housekeeping, cleaning schedules emergencies – fire, accident and violent behaviour reporting procedures - accidents, near misses and hazards first aid rules and procedures for using and maintaining equipment COSHH – mostly chemicals and dust (see next section) Legislation that affects vehicle maintenance and repair The Control of Substances Hazardous to Health Regulations (1988) (COSHH) This regulation requires that any risk arising from the use of substances within the workplace is studied and the information made available to all affected persons i.e those employees who may come into contact with such substances COSHH data sheets must be made available so that any employee, who has doubts about the safety of any substance and its use, can study the relevant information The availability of such data sheets should not be considered as an acceptable substitute for training To be suitable and sufficient, the assessment must consider any risks arising from the use (or generation of) hazardous substances A collection of supplier’s data sheets will not suffice as a COSHH assessment Only the employer can establish the risk of exposure, as this arises from the way that the substance is actually used COSHH assessments must be formally reviewed at least every five years Other than in the most simple of cases, a COSHH assessment should be recorded in writing The Health and Safety (Display Screen Equipment) Regulations (1992) Employers must assess the risk to health and safety arising through the use of display screen equipment, in particular, the risks of muscular-skeletal injury, eye problems and mental stress A record should be kept in retrievable form except where the workstation is temporary, no significant risk was found, or the assessment is easily repeatable The Manual Handling Operations Regulations (1992) Where a hazardous manual handling operation cannot be avoided, a thorough assessment of risk must be undertaken and measures must be introduced to reduce risks of injury to an acceptable level The assessment must take into account the tasks, the loads, the working environment, individual capability and other factors Records of the assessment must be kept unless: the handling operation is short lived there are no significant risks the assessment is easily repeatable The Control of Asbestos at Work Regulations (1987) A thorough assessment must be taken before commencing work in an environment where exposure to asbestos may occur The type of asbestos should be established, as should appropriate control measures The effectiveness of control measures should be monitored, with records kept for at least five years Where the regulations require health records to be maintained, these must be kept for a minimum of 40 years The Personal Protective Equipment at Work Regulations (1992) Prior to selecting personal protective equipment (PPE), the employer or selfemployed person must ensure that an assessment has been made to ascertain whether the proposed equipment is suitable The assessment must take account of risks to health or safety that have not been avoided by other methods, the sort of performance and characteristics necessary for the equipment to be effective and comparison of the proposed equipment with the required performance and characteristics When a person dons PPE, it is only this equipment that provides a barrier to the risk Could this risk have been eliminated by other means? Other record keeping requirements There are many other situations in which records must be kept in addition to those mentioned thus far Accident books must be kept for a minimum of three years and under COSHH, local exhaust ventilation inspection records must be kept for a minimum of five years Other records which should be kept but without specific time scale include records of electrical equipment inspection, details of examinations of hoists and lifts, lists of authorised lift truck drivers and details of those qualified in first aid The European Directive Known as the ‘Framework Directive’ it deals generally with the introduction of measures to encourage improvements in the health and safety of people at work It is based on article 118A of the Treaty of Rome and is activated largely by the management regulations in the UK The Offices, Shops and Railway Premises Act (1963) With the implementation of the Health and Safety at Work Act (1973) the general health and safety of all persons at work was protected However, much of the specific legislation contained in The Offices, Shops and Railway Premises Act (1963) is still in force for those specific premises covered by it and follows closely the provisions identified in the Factories Act such as machine guarding, ventilation, cleanliness and provision of sanitary conveniences Section 27 makes it an offence for an employee to misuse or interfere with the facilities provided to meet with the requirements of the Act The Electricity at Work Regulations (1989) This regulation introduces a control framework incorporating principles of electrical safety applying to a wide range of plant, systems and work activities They apply to all places of work and electrical systems at all voltages All electrical systems must be constructed and maintained at all times to prevent danger The Abrasive Wheels Regulations (1970) These regulations not apply to new equipment taken into use after the January 1993, which is subject to the Provision and Use of Work Equipment Regulations 1992 This regulation was introduced for a number of reasons mainly due to the number of injuries arising from the use of abrasive wheels in industry, a high proportion of which were due to faulty mounting of the wheel Under these regulations every person who changes an abrasive wheel must be trained, competent and appointed in writing to so The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (1985) (RIDDOR) The main purpose of RIDDOR is to provide enforcing authorities with information on specific injuries, diseases and dangerous occurrences arising from work activities covered by the Health and Safety at Work Act The authorities are not able to investigate all of these, so the regulations aim to bring the most serious to their attention quickly Examples of Accidents An employee suffered severe burns (62%) when petrol leaked from the tank while he was changing the sender unit The tank was not pumped out before work began and a hand lamp ignited the petrol Fire also caused extensive damage to the premises The deceased was changing a sender unit, working on a vehicle over a small inspection pit He drained some petrol from the tank into a plastic bucket The petrol vapour in the pit ignited The source of ignition was thought to be a light fitting Four people were in a small railway arch garage with the door closed Petrol ignited while being drained from a car tank Two died and two received severe burns During the removal of a faulty sender unit from a fuel tank, a vehicle was raised on a hoist and two men were soaked in petrol when the unit was removed The tank was nearly full and petrol ignited by a gas fire about five metres away Both died in the resulting fire Compressed air There are three types of health problems, which can occur when working with compressed air: Barotrauma - where a change in surrounding pressure causes damage to aircontaining cavities in the body directly connected to the surrounding atmosphere, principally ears and sinuses Decompression illness - which involves pains around the joints or more rarely as a life threatening condition which may affect the heart and lungs Dysbaric osteonecrosis - which is a long term chronic condition damaging the long bones, hip and shoulder joints Never direct compressed air onto exposed areas of skin - the air can penetrate and cause heart failure! Hydraulic jacks and axle stands These items are regularly used in motor vehicle workshops The following actions must be observed: check that the jack is not leaking or has any damage ensure that the jack you propose to use is safe for the job (safe working load - SWL) ensure the handbrake is applied and the grounded wheels are chocked not use any unsafe packing i.e bricks or soft wood for maximum safety ensure axle stands are correctly placed and if you are working under the vehicle inform others that you will be working there ensure all operating levers are not in such a way that they may be accidentally released never lift the vehicle onto more than two axle stands at one time Vehicle lifts When working on a vehicle supported by a lift ensure that: the lift has a sufficiently high safe working load (SWL) the vehicle is central no-one ever works above you the area below the vehicle is free from equipment the vehicle is secured on the lift and unable to roll Hoists Hoists are commonly used to aid the removal of heavy assemblies such as engines and gearboxes A few factors must be taken into account during their use: never exceed the SWL ensure that the boom pin is fitted securely never remove the boom pin in order to gain extra extension use on flat, level ground ensure that all ancillary equipment such as chains and shackles are serviceable and have a suitable SWL Using pits or sunken workshops Remember: wear protective headgear and goggles not drain petrol from a vehicle over a pit apply the handbrake inform your work colleagues that you are in the pit under the vehicle in case of emergency always leave one end of the pit free from obstruction as a means of escape not work in the pit if it is untidy, dirty or oily Exhaust extraction Motor vehicles generate through the process of combustion many noxious gases Amongst these is Carbon Monoxide (CO) CO is highly poisonous Continued exposure to CO can have a severe affect on your health If you intend to run the engine on a vehicle in a confined space such as a workshop, always use exhaust extraction equipment Abrasive wheels Severe friction burns; crushed fingers and loss of eyesight are common injuries arising from accidents that occur when using abrasive wheels The main hazards arise from the ejection of pieces of the wheel or work piece, contact with the wheel, and trapping of fingers between the wheel and work rest In one case an apprentice mechanic lost the sight in one of his eyes when it was struck by debris from a disintegrating wheel The wheel was poorly fitted and was operated at a greater speed than its design speed A burst wheel can kill! Never replace wheels on such equipment unless you are trained and authorised to so Never use the side of the wheel unless the equipment is specifically designed for that purpose Always ensure that the tool rest is as close to the wheel as possible without fouling the wheel To ensure that the tool rest does not foul the wheel, always spin the wheel by hand before switching on Be aware that grinding wheels take a considerable time to stop once switched off Guards Guards are fitted to machinery that poses a risk to the operator through its action Guards when fitted must always be used Do not treat guards as a substitute for eye protection (or vice versa) If guards are making work difficult due to damage such as scratches, report it so the guards can be replaced Do not wait until someone is tempted to use such machinery without the guards in place Welding Equipment Welding equipment presents its own unique combination of hazards There are numerous different types of welding equipment but most can either be categorised as electric arc or gas Electric arc All welding equipment represents a fire risk In addition to this, electric arc welding equipment presents the following hazards: Arc eye The light rays given off are a combination of infrared, ultraviolet, and visible radiation If you look at the arc you will damage your eyes This damage is not normally permanent but feels like someone has rubbed sand and chilli into your eyes! It should be noted that reflected light radiation from an arc welder is just as likely to cause arc eye Never look at the arc either directly or indirectly without the protection of approved welding lenses Always shield other workers from the arc through judicious use of screens and put warning signs up High current flow When welding a vehicle, always disconnect the vehicle battery Never use an arc welder on systems that contain flammable gas - the current flow could cause a spark when you least want one Gas welders Treat the bottles with respect They are often very heavy and somewhat unstable Only move the bottles through the use of a recognised trolley and always ensure that the bottles are chained securely to the trolley Never repair acetylene welding equipment with copper components - it reacts with the gas to create an explosive compound Exercise Guarding Identify machinery likely to be found in a motor vehicle workshop, which, in your view, has dangerous parts which should be guarded: Which, if any, of these machines are permitted by a regulation to have dangerous parts partially exposed? Name a machine used in some large vehicle workshops, which is impossible to guard effectively and still use: Asbestos The Asbestos at Work Regulations 1987 requires asbestos to be substituted where practical, and the substituting material safer than asbestos From the 1st October 1999 it has not been permissible to: fit asbestos brake linings to any new motor vehicle to fit replacement brake linings containing asbestos to any motor vehicle first used after the end of 1972 to supply motor vehicle brake friction materials containing asbestos or to hold such materials for supply for fitment to any motor vehicle first used after the end of 1972 It is understood that there are asbestos-free substitutes available now as replacements for all vehicles originally designed to use asbestos brake parts Only if garages or vehicle operators are unable to obtain asbestos-free parts from any source for a particular application, is it permissible to fit asbestos products If anyone is found to have supplied or fitted asbestos brakes simply because they are cheaper this would be seen as a breach of the control of Asbestos at Work Regulations and legal proceedings would be considered by the HSE There are three types of asbestos: chrysotile, which is white and found in brakes amosite, which is brown crocidolite, which is blue Dangers This is an asbestos fibre in the lung Many people die of lung cancer - most deaths are due to smoking An unknown proportion of those may have been occupational deaths, for example caused by asbestos Working with asbestos can release small fibres into the air Breathing in these fibres can cause fatal diseases Although the body will rid itself of most of the larger fibres that can enter the nose and mouth, tiny fibres can pass into the lower parts of the lung They can stay there for years and in some cases work their way through the lung lining The body naturally gets rid of any asbestos fibres that you might take in with food and water and asbestos fibres cannot be absorbed through the skin What does asbestos do? Breathing in asbestos fibres can eventually lead to a number of diseases These include: asbestosis or fibrosis (scarring) of the lungs lung cancer mesothelioma, a cancer of the inner lining of the chest wall or abdominal cavity There is no cure for any asbestos-related disease Repeated low-level exposure such as could occur during routine repair work, may lead to asbestos-induced cancers The amount of exposure is unclear, but the more you inhale the greater the risk to your health What kind of work creates asbestos dust? Some processes or products give off dust more easily than others, but work on any of the following is likely to produce some: the removal of old asbestos insulation materials from buildings or machinery; this should be carried out by a contractor licensed by the HSE the manufacture of products wholly or partly made from raw asbestos the installation, maintenance, repair and general handling of products containing asbestos for example asbestos cement products, insulating board and friction materials such as brake pads and clutch linings routine installation, repair and maintenance work by plumbers, electricians and carpenters If you have to work with this dangerous material, ensure you protect yourself by: wearing a mask/respirator and wear protective clothing which you must not take home contaminated with asbestos keep the asbestos damp wherever possible and ensure all waste material is put in a polythene bag and labelled with the asbestos warning sign don’t eat drink or smoke in the working area Don’t take any chances with this deadly material Risk Assessment and Record Keeping Where the employer has five or more employees, significant findings of an assessment must be recorded, together with details of any group of employees found to be especially at risk No record is necessary where risk is clearly so small as to be insignificant The record should include: the significant hazards found as a result of the assessment the control measures in place the population exposed to the risks, including any group of people especially at risk A record of the employer’s health and safety arrangements must be kept If it is found appropriate to carry out health surveillance, individual health records should be kept A record of those appointed as “competent persons” to assist the employer should be maintained Records not have to be in written form, but it must be possible to readily retrieve information when required Such a requirement may arise from a request by a safety representative or an inspector from the enforcement authority Records may be kept separately, or can form part of the same document as that containing the health and safety policy required by s.2(3) of the Health and Safety at Work Act (1974) Exercise 10 Complete the following risk assessment checklist for your current job role Risk assessment checklist Detail of activity / process: Date of assessment: Who by: What are the hazards to health and safety? Do these present a risk? (Yes/No) What is the risk to people? Risk to property? Likely severity of injury? What are the present procedures and control measures? What additional action we need to take? How urgent is this? When we need to review our assessment? Practical health and safety Look out for risks in the workshop Use the inspection checklist while in the workshop, noting the item and observation Then complete the reason, risk factor and consequence An example has been completed on the first line for you Inspection checklist ITEM OBSERVATION REASON RISK FACTOR H/M/L CONSEQUENCE Fire exits Doors locked Means of escape High Persons could become trapped if there was a fire Points to Remember Although health and safety may sometimes seem to take the fun out of what you do, you should now understand the importance of your own actions and those of your colleagues Hundreds of people have been killed or injured in the motor vehicle industry; many of the accidents could have been avoided It may not feel ‘cool’ to wear a pair of safety goggles, but how much value you place on your sight? Gloves may hinder you, but not as much as painful blistered hands Never forget that no matter how expensive the car is that you are working on, it is not as valuable as you Please remember what you have learnt and NEVER take any chances! ... 27 28 29 30 13 13 15 First Aid: Priorities Exercise 31 31 32 Safety Signs: Progress check 16 18 Personal Protective Equipment (PPE): Exercise 19 21 Fire: The Fire Precautions Act (19 74) Causes... Light Vehicle Maintenance and Repair MODULE LV 01 HEALTH, SAFETY AND HOUSEKEEPING WITHIN A VEHICLE WORKSHOP Contents Page Introduction The Law: Health and Safety Commission and Executive Regulation... UK The Offices, Shops and Railway Premises Act (19 63) With the implementation of the Health and Safety at Work Act (19 73) the general health and safety of all persons at work was protected However,