Workshop safety

When identifying hazards in an engineering factory or workshop, the following issues come up repeatedly:

• machine guarding
• noise
• hazardous chemicals
• welding
• first aid
• supervision
• passive smoking
• manual tasks
• high risk work licences
• floors, passageways, stairs, ladders
• confined spaces

Machine guarding

Has your machinery and equipment been reviewed to determine whether guarding is needed, and whether existing guarding is effective?

A simple survey of machinery in the workplace will identify equipment has guarding in place, whether it be interlocking devices, physical barriers or other methods, and machinery which does not. Machinery and plant which does not have guarding can be identified by inspection, observation of the process, and discussion with people operating it.
 
A question to ask yourself when trying to identify unprotected machinery is 'Could someone put their hand into it while it is in operation?' Answering this question for every piece of machinery or plant will help you to identify unsafe and safe equipment.
 
Example of machinery found in workplaces include various saws, presses, guillotines, and metal-bending machines.
 
Having machine guarding in place will not be sufficient if it is not checked regularly for effective operation, and maintained or serviced regularly, so these need to be part of your management system for safety.

Noise

 
High noise levels are common in workshops, and it is good practice to test the workplace noise levels periodically, and particularly after new equipment or processes are introduced. If excessive noise levels are identified, appropriate steps can be taken to control the risk of unwanted effects on people in the workplace. Any noise at or exceeding 85dB(A) would indicate that noise control measures are needed.
 
Where there is doubt or uncertainty about noise levels, testing should be carried out to determine what the levels are in the workplace. Professional expertise is required for proper assessment of workplace noise levels.
Hazardous chemicals
 
Hazardous chemicals include not only packaged chemical substances, but also fumes and some dusts, and these can be generated from welding or other processes in the workplace. It is important to look at control measures such as ventilation, personal protective equipment and clothing, shields and screens, location of the exhaust emitting from the ventilation system, access by others in the area, and precautions to protect against fires and other emergencies.
 
Other chemicals in the workplace need to be labelled in sealed containers and safety data sheets should be available. Workers need to be trained in the safety precautions when working with them.

Welding

 
Welding processes create their own degree of risk, which must be managed to avoid short- and long-term effects such as 'welding flash' and other eye injuries, burns, and inhalation of fumes which can cause longer term illness.

First aid

 
There may be occasions when first aid is required. Employers and other people conducting a business or undertaking must provide first aid equipment and ensure that all workers have access to it. An adequate number of workers must be trained to administer first aid. Generally, a first aid kit is needed, with someone nominated to provide first aid. A register of injuries book is required, for recording all workplace injuries.
 
For a comprehensive listing of first aid requirements throughout Australia, see our first aid section.

Supervision

 
Supervising the performance of work tasks is essential in all workplaces, including the engineering trades. The degree of supervision required may vary between workplaces, however, by law, there needs to be supervision for safety. For example, to make sure that safe systems of work are used, correct personal protective equipment is being used, that shields and guards are in place, that chemicals are used according to the label or safety data sheet (available from the supplier) and that people are safe in their work tasks.

Passive smoking

 
People who smoke in the workplace expose others to the risk of smoking-related illness, for which the employer may be vicariously liable, ie the employer is liable for the actions of an employee in causing harm to others at the workplace.
Smoking is banned in all enclosed (indoor) workplaces in Australia, and a variety of restrictions apply to workplaces that are not enclosed. These vary according to the type and location of the workplace.

Hazardous manual tasks

 
The lifting and moving of materials in a workshop could cause an injury if it is not done properly and safely, so manual handling tasks should be assessed to determine the safest way to handle a load.
 
Materials, tools, equipment, and finished product and all likely to be handled in a workshop.
 
It is common to see forklifts, cranes, hoists, trolleys, automation, rollers/conveyors and team lifting being used to minimise the risk of injury in these workplaces.

High risk work licences

 
Certificates of competency and subsequently high risk work licences were introduced to standardise a national system to ensure the competence of people working with plant such as scaffolding, dogging, rigging, crane and hoist operation, pressure equipment operation, and loadshifting equipment.

Examples of loadshifting equipment which could be found in a workshop include forklifts, cranes, materials hoists and others.
 
Operators of any of this equipment need to have a valid licence or a certificate of competency, or be under training, completing a logbook, and receiving supervision from a competent person.

Floors, passageways, stairs, ladders

 
The condition of the workplace floors is important in avoiding injury from manual handling tasks, tripping on obstacles or uneven surfaces, slips on oil or other material, and also emergency access and egress.
 
The floor in the workplace should be kept clear and unobstructed and regularly swept. Where persons stand in the same position on concrete, brick, metal, stone etc the floor must be covered, where practicable, with a semi-resilient, thermally non-conductive material.
 
Guard railing is required around openings in the floor, or edges, such as mezzanine storage areas. Toe boards may also be required in these instances.

Ladders should also be checked for damage and removed or repaired as required.

Confined spaces

 
Spaces that are not generally designed as working areas may have atmospheric contaminants and may present the risk of burial, actuation of machinery, or oxygen deficiency. These are generally classified as confined spaces.
 
These places pose a serious safety risk and therefore entry into them must be controlled, with specific actions taken before, during and after entry into the space. Part 4.3 of the Work Health and Safety Regulations sets out detailed legal requirements for work in confined spaces. AS 2865-2009 Confined spaces offers useful guidance for any businesses performing work in confined spaces.
 
In a workshop, this could extend to the manufacture of tanks, containers, enclosed truck bodies, and involvement in other activities.

Regular inspection will help to determine whether safety precautions adopted are actually working.