Element 4

Element 4
Work Equipment Hazards and Risk

Control
Green World Group | 95

DRAFT PAGE
TABLE OF CONTENTS
4.1 GENERAL REQUIREMENTS FOR WORK EQUIPMENT�� 99

1. Types of Work Equipment��99
2. Selection and Suitability of Equipment��99
3. Information, Instruction and Training��100
4. Maintenance��101
5. User’s Responsibilities��104
4.2 HAZARDS AND CONTROLS FOR HAND HELD TOOLS�� 106

1. Hand held Non-power Tools��106
2. Portable Power Tools��107
4.3 MECHANICAL AND NON-MECHANICAL HAZARDS�� 109

1. Potential consequences from Mechanical Hazards��109
2. Non-Mechanical Hazards��111
3. Hazards of Different Range of Equipment��111
4.4 CONTROL MEASURES TO REDUCE RISK��115

1. The Safeguarding��115
2. Application of Safeguard��119
SUMMARY�� 122
REFERENCES�� 122

DRAFT PAGE
4.1 GENERAL REQUIREMENTS FOR WORK
EQUIPMENT
1. Types of Work Equipment

All workplaces and activities require some sort of hardware either powered or non-powered to facilitate the activity to
produce the goods and/or perform the services specific to the business. A reasonable definition of work equipment is any
machinery, appliance, apparatus, tool or installation for use at work.
It is not practical to provide a comprehensive list of equipment used as it could vary from industry to industry. However,
the following is a list that is typical equipment:
• Hand tools such as hammers, knives, hand saws, meat cleavers

• Work shop machinery such as drilling machines, milling machines, circular saws
• Office machinery such as photocopiers
• Laboratory equipment such as Bunsen burners
• Lifting equipment such as hoists, lift trucks, lifting slings
• General use equipment such as ladders, steps
• Machines that are assembled together such as a transfer line in an automotive plant
In summary, almost anything used to do a job of work, including employees’ own equipment, is covered under this
definition.
2. Selection and Suitability of Equipment

Stability of the Equipment
Prior to using work equipment risk assessments need to be carried out to see that the work equipment is properly
designed and is fit for the purpose for which it is to be used and it meets all relevant safety requirements and standards
such as CE Marking
The CE marking (an acronym for the French “Conformite Europeenne”) certifies
that an item has met European Union standards, which ensure customer safety.
Producers in the European Union (EU) and abroad must satisfy CE marking
requirements were suitable in order to market their products in Europe.
The employer should also ensure that it should only be used for the purpose for
which it is intended. Work equipment should be properly maintained, and if
logs are required, they are kept up to date.
Source: Wikipedia
After installation of the work equipment, it must undergo inspection before
putting to use and then after at periodic intervals, and in case of any exceptional circumstances and where there is a
particular risk, the use of work equipment should be restricted to specified people who should be adequately trained
The suitability of the safety of work equipment is dealt with from three aspects:
• Its original integrity - Equipment must be suitable, by design, construction or adaptation, for the actual work
it is provided to do.

UNIT GC2: CONTROLLING WORKPLACE HAZARDS
• The place and location of use – The location where the equipment is going to be installed or used must be
examined so that the environment do not affect the equipment and vice-versa. As an example in a wet or moist
atmosphere, electrically powered equipment without sufficient design protection should not be used.
• The use of the equipment – Equipment should be suitable for the particular task. Example: the use of step
ladder to access material at height.
Prior to installing new machinery in the workplace the factors we need to consider what the hazards of the environment
are, like if there are any issues related to extreme temperatures. We must consider what kind of the chemical and
biological hazards could be present. Check if the machine is suitably guarded, and is suitable for the environment for
use.
It’s important to consider if the equipment is capable of being isolated/locked off and whether it could be safely accessed.
Besides these, the availability of trained and competent persons for the use and maintenance must be considered.
Preventing access to dangerous parts
Employers have a duty to ensure that measures are considered to avoid contact with any of the hazardous parts of the
machine and arrest the motion of the dangerous component of the machine before it comes into contact with any part
of a person body.
• The control measures for prevention of access to dangerous parts of machinery are:
• The provision of fixed guards enclosing every critical part or rotating stock-bar
• The provision and use of another type of guards or protection devices such as interlocked guards and pressure
mats
• Provision and use of stock handling devices (jigs, holders, push sticks, etc.) for the operator to use, so that his
hand or body part does not come close to the dangerous point of contact in the machinery .
• Providing adequate information, training, instruction and competent supervision .
Restrict Use and Maintenance
When the employer assesses that the equipment has a possibility of injuring the worker, he must ensure that: safety, the
employer should ensure that only competent people who are authorised to use that equipment are allowed to use them.
Any modification or repair and maintenance work must be carried out by only those competent individuals who are
assigned such tasks. No repair or modifications shall be allowed to be done by the operators, Maintenance to be limited
to individuals who have received adequate training related to any operations
3. Information, Instruction and Training

Information and Instructions
Those who use work equipment should have available to them adequate health and safety information and where
appropriate, written instructions relevant to the work equipment. This may include:
• The conditions in which and the methods by which the work equipment may be used.
• Any foreseeable abnormal situations and actions to be taken
• Any conclusions to be drawn from experience in using the equipment
It is essential that this information is made available to those who supervise or manage the use of work equipment so
that they fully understand the risks and procedures to prevent them.
Training
All users of work equipment should receive adequate training for purposes of health and safety including training in the
method to be adopted when using the equipment. Also training in any foreseeable risks and the precautions to be taken.
100 | Green World Group

Supervisors of people using work equipment should be given adequate health and safety training on work equipment
including training in the method to be adopted when using the equipment. Also training in any foreseeable risks and the
precautions to be taken.
There may also be training required for specialised work such as the use of chainsaws.
Training and proper supervision of young persons are of particular importance because of their relative immaturity and
unfamiliarity with the working environment. Training may be required if the task has changed for the individual, new
technology or equipment is introduced and if the system of work changes.
Refresher training should be provided if necessary.
Need for Safe Maintenance
All equipment should be maintained to ensure they function

effectively, efficiently and is safe for use. The maintenance
safety requirement must be considered at the design stage by
the manufacturer to avoid and injury during the equipment’s
maintenance.
Risk assessment should be brought out to identify whether any

additional functions have to be included so that maintenance can
be done without risks to health and safety. Equipment must be
designed so that there will be no risk connected with the
maintenance operation. Lubrication points may be designed so
that they can be accessed safely even while the machine is in
motion, or adjustment mechanisms are placed in such a way that Source: Transportation Charter Services
they can be utilised without opening guards.
Design equipment so that maintenance work can be carried out with the equipment stopped or inactive. If equipment
needs to be running or working during a maintenance operation and this presents risks, measures should be taken to
enable the functioning of the equipment in a way that reduces the risk.
Further safeguards or functions fit into the equipment, such as limiting the power, speed or series of motion that is
offered to dangerous parts or offering protection throughout maintenance operations. Examples are:
• Providing temporary guards

• Limited movement controls
• Crawl speed operated by hold-to-run controls
• By means of a complementary low-powered visible laser beam to align a powerful invisible one
Other measures that can be taken to protect against any residual risk include wearing personal protective equipment and
provision of instruction and supervision
4. Maintenance
The employer should ensure that appropriate measures are taken to ensure that work equipment is constructed or adapted
to enable maintenance to be performed when the equipment is de energised/shut down.
Maintenance operations can be performed without exposing the person carrying them out to a risk to his health or safety.
Suitable actions can be taken for the protection of any individual performing risky maintenance activities.
Machinery Maintenance
During maintenance work, conditions are very different from those usually encountered, and it is essential that everyone
concerned is aware of any hazards and of the correct precautions.

Examples of maintenance work may be:
• Entry into vessels, confined spaces or machines

• Fire or explosion could occur during hot work activities
• Construction work such as work on roofs or in excavations
• Cutting into pipework carrying hazardous substances
• Mechanical or electrical work requiring isolation of power or fuel supplies
• Work on the plant, boilers, etc. which must be effectively cut off from the possible entry of fumes, gas, liquids
or steam.
Maintenance Hazards
While carrying out routine maintenance of machinery, the hazards could be:
• Unintentional starting of machinery

• The release of stored energy e.g. pressure, electrical power.
• Stored potential energies (falls due to gravity)
• Stored pneumatic energies (high or low pressure)
• Limited access/egress
• Residues e.g. Chemicals, Biological, Flammables, Corrosives
• Mechanical hazards
• Heat or cold
• Confined spaces
• Working at height
So prior to undertaking maintenance on machinery factors to be considered include where the equipment is located/
installed and whether it could be safely isolated and locked off. Is there any way to dissipate the stored energy and if the
equipment can be segregated from other parts of the workplace.
Availability of access to the equipment and all necessary PPE required must be considered. It’s also important to consider
the availability of a trained and competent person to perform the maintenance. Other environmental issues like if there
are any extreme temperature issues on the equipment, and whether anyone could get exposed to chemical and biological
hazards.
The possible precautions when undertaking machinery maintenance are:
• Isolate Electrical power

• Permit to work procedures
• locking out and tagging off of any services or piped energy to the machine.
• Dissipate heat energy by allowing machinery to cool.
• Dissipate potential energies by releasing the loads in tension.
• Separate/segregate the machine by barricading and erecting signages.
• Provide suitable and sufficient lighting and means of access
• Provide suitable and sufficient personal protective equipment
• Provide adequate means of ventilation, depending on the size of the area and hazards.
• Competent supervision
• Making sure that only trained, competent and authorised persons to perform the work.
Operational Controls
To operate work equipment safely, it must be fitted with easily reached and operated controls; kept stable; properly lit;
kept clear; and provided with adequate markings and warning signs.
The above applies to all types of work equipment and work areas, particularly if they are high-risk machines.

Debris and rubbish given off from the equipment should be removed quickly. Sometimes there will be a need for special
systems to remove waste to prevent accumulations of dust and/or substances hazardous to health, for example, wood
dust from wood working machinery.
Isolation
Equipment should be provided with efficient means of isolating it from all sources of energy.
In many cases, this source is the mains electrical energy, but it must cover all sources such as steam, compressed air,
hydraulic, batteries, heat, etc.
In some cases, special consideration is necessary where, for example, hydraulic power is switched off, not to let heavy
pieces of equipment like the ram, fall under gravity.
Emergency Stops
The emergency stop must be provided where the other safeguards in place are not adequate
to prevent danger. Where appropriate, there should be an emergency stop at each control
point and at other parts around the machine, so that quick activation can be achieved in
case of emergency,
They should bring the equipment to a halt rapidly, but this should be controlled where
necessary so that they don’t bring in additional hazards. Emergency stop buttons should
be easily reached and operated.
Stability Source: DirectIndustry
Stability is important and is normally achieved by bolting equipment in place

or if this is not possible by using clamps. Some equipment can be tied down, counter-balanced or weighted so that it
remains stable under all operating conditions.
If portable equipment is weighted or counter-balanced, it should be reappraised when the equipment is moved to another
position. If outriggers are needed for stability in certain conditions, for example, to stabilise mobile access towers, they
should be employed whenever conditions warrant the additional support.
In severe weather conditions, it may be necessary to stop using the equipment or reappraise the situation to ensure
stability is maintained.
Lighting
The quality of general and local lighting will

need to be considered to ensure the safe operation
of the equipment. The level of lighting and its
position relative to the working area are often
critical to the safe use of work equipment.
Poor levels of lighting, glare and shadows can be

dangerous when operating equipment.
Some types of lighting, for example, sodium

lights, can change the colour of equipment,
which may increase the level of risk.
This is particularly important if the colour coding

of pipe work or cables is essential for safety. Source: Cocolabor

Markings
Marking’s on equipment must be clearly visible and durable. They should follow international conventions for some
hazards like radiation and lasers and, as far as possible, conform to recognised signage conventions e.g. UK Signs and
Signals Regulations.
The contents, or the hazards of the contents, as well as controls, will need to be marked on some equipment.
Warning Devices
Warnings or warning devices are required in some cases to alert operators or people nearby to any dangers.
For example:
• ‘Wear hard hats’;

• A flashing light on construction site vehicles; or
• A reversing horn on larger vehicles.
Clear Unobstructed Workplace
The workplace should be kept clean and tidy with no material or equipment obstructing walkway, workspace and access
and egress areas.
Space, where the machine is located, must be large enough to accommodate the required workers so that the place
doesn’t get congested and risk people to get close to dangerous parts of the machine.
There should be regular housekeeping and inspections to ensure workplace remains clear, clean and unobstructed.
5. User’s Responsibilities
Again the definition of ‘use’ is wide and includes all activities that could be carried out with work equipment such as:
• Starting and stopping the equipment;

• Use;
• Modification;
• Repair;
• Maintenance;
• Operation and
• Servicing.
Cleaning and transport of the equipment are also included. It follows that “user” would be the person undertaking any
of these functions.
As determined by international and national legislation or regulation regarding health and safety, a worker (user in this
instance) has a duty to ensure that they do not put themselves and or others at risk due to their acts (things that they do)
or omissions (things that they should do but do not).
A “user” is therefore responsible for making use of all safe systems of work and related precautions provided by the
employer i.e. PPE, safe working arrangements. Reporting to the employer of any unsafe condition regarding the work
equipment.
The employer has a duty to restrict the use of work equipment to only those who have received suitable and sufficient
(adequate) training, instruction, etc. in the safe use of the work equipment and associated systems.
It must also be remembered that international or national regulation or legislation may restrict the use of equipment and
or process in certain circumstances i.e. young persons, women of child bearing age, pregnant or nursing mothers, etc.

Summary of Safe Operation
In summary, the means of achieving safe operation of work equipment are:
• Equipment that has been properly installed, to include fixing, power supply, etc.
• Having adequate unobstructed space around the equipment to undertake the intended tasks
• To know the safe operating limits and the correct operation of any protective devices
• To know the actions in the event of an emergency
• Have suitable, sufficient and properly operable systems of stopping equipment in the event of an emergency
• Have in place clear warning signs, markings and signals with regard to safe operating and safe condition
indication
• To know the fluid contained in the system and any intrinsic hazard it may have, such as high temperature,
flammability or similar
• That any operator has access to a suitable set of operating instructions for the system and have been suitably
trained
• That the system is being used in the means and within the parameters for which it was designed.
• Have adequate general and where necessary local lighting levels so as not to pose additional hazards
• That the system has suitable and sufficient maintenance and that this maintenance is adequately controlled

4.2 HAZARDS AND CONTROLS FOR
HAND HELD TOOLS
1. Hand held Non-power Tools

Hand-held tools are used throughout the industry. Most people will be familiar with them as although they may not
use them in work they will have used them at home. They are tools such as screwdrivers, hammers, chisels, spanners,
electric drill, sander, pliers, etc.
Source: Clickspring
Using hand tools for a purpose for which it was not intended is commonplace in the workplace, and typical examples
could be using a flat screwdriver to remove a Phillips (Socket) screw Or using a screwdriver as a chisel or using a chisel
or claw hammer to lever something off a wall
Misuse of Hand-Held Tools
The misuse of hand-held tools often results in injuries such as lacerations, cuts and may cause amputations of fingers .
One of the problem areas regarding hand held tools is that they are generally in possession of the individual employee
and are not inspected.
If the tools are supplied by the employer, this may not be a problem, but if provided by the employee they are inclined
to hold on to them even if they are damaged.
Condition & Fitness for Use
It is important that the employer has a system for the inspection of hand-held tools for defects which can include:
• Chisels which have become blunt

• Handles in hammers which have not been properly fitted which allows the head to be loose

• Spanners which have become rounded

• Hammer heads which have become worn
Requirements for Safe Use
• Use chisels that have been sharpened to correct angle

• Use hammers with properly fitted head (head should not be chipped) and handle that is not split or broken
• Use right kind of spanner that has a firm grip and fit for the task.
Suitability for Purpose and Location to be Used in Flammable Atmosphere
To prevent the risk of fire, proper tools and controls measures may be the use of intrinsically tools in a flammable
atmosphere. The use of tools that do not create sparks such as alloy hammers and the damping of area will also help to
minimise the risk of fire
2. Portable Power Tools

Portable power tools are another source of hazard
in the workplace. They use a number of different
sources of energy such as electricity, compressed
air (pneumatic) and hydraulic which is the most
common.
Common types of portable power tools are electric

drills, sanders, etc.
The power source itself may lead to hazards such

as electric shock as well as the hazards of the use
of the tool.
Electric Drill
Electric drills are used to drill holes into the

structure. Its components include rotating shaft Source: Contractor Supply Magazine
and drill bit.
Hazard
• Contact with electricity

• Entanglement: loose clothing or hair become entangled with rotating shaft
• Injection: puncture of skin by drill bit
• Contact : contact with rotating shaft and drill bit
• Ejection: hit by flying debris or broken drill bit
Controls
• Pre-use check to ensure there is no damage and is fit for the task
• Ensure there are isolation measures
• Ensure drill bit is sharp
• Ensure material is clamped down securely
• Wear personal protective equipment such as goggles, hearing protection, gloves, safety shoes, etc
Portable Electric Sander
This is used to provide a smooth finish on various surfaces such as wood, marble, concrete, etc

Hazards
• Noise emitted by the sender

• Vibration resulting in musculoskeletal disorder
• Dust
• Contact with electricity
• Trailing electric cable
• Abrasive disc – contact may lead to cuts and skin abrasion
• Manual handling of sander
Controls
• Purchase quality low vibration sander

• Regular maintenance
• Pre-use check to ensure sander is not damaged and is fit for use
• Use of local exhaust ventilation system
• Wearing personal protective equipment like eye protection goggles, face mask, hearing protection, etc.
• Take regular breaks to avoid vibration injuries
• Replace sanding disc when worn out
• Care to be taken that electric cable does not create a tripping hazard
Precautions for the Portable Power Tools
The general precautions include the use of leakage current protection like RCDs and ensure that the cord is properly
protected from any physical damage. A good practice will be the remove the equipment from the power source when
they are not in use.
Using tools using pneumatic energy, must have secure joints and connections to prevent whiplash. Do not pull the airline
or plug of any cord for disconnection. There must be the suitable procedure to avoid accidental starting. If possible
secure all work pieces to prevent movement.
Suitable PPE such as eye protection to be worn, and all tools to be regularly inspected and maintained. Damaged tools
to be removed from use. There must be user-friendly procedure for reporting and replace damaged tools

4.3 MECHANICAL AND NON-MECHANICAL
HAZARDS
BS EN ISO 12100-2:2003 lists 2 main hazards of machinery which are mechanical hazards and non-mechanical hazards.
Mechanical hazards are the inherent hazards originating from the machine parts and components, whereas the non-
mechanical hazards are the potential hazards of operation of the equipment.
1. Potential consequences from Mechanical Hazards

Mechanical hazards are those that can be caused by the machinery itself and are:
Entanglement
Entanglement involves hair, clothing rings, limbs, etc., becoming entangled in revolving shafts drills, etc.
Examples of Entanglement
Traps
This means being drawn in between the machine and any rotating parts such as two revolving rollers
The trapping point is known as “an in running nip”.
Examples of Drawing in Traps

In running nips
Trapping can also lead to shearing and crushing.
Shearing (Crushing) Shearing (Crushing)
Impact
Impact means being struck by the movement of a machine part e.g. robot arm, movement of the machine bed, etc.
Example of Impact
Contact
This means part of the body coming in to contact with the machine e.g.
• Burns from exposed surfaces

• Lacerations from sharp edges
• Friction and abrasion from abrasive wheels etc
• Puncture wounds from drills, sewing machines, etc
• Cutting by contact with circular saws, Band saws or edges of moving sheet metal

Ejection
This means being struck by particles ejected from the material being worked on or a part of the machine itself e.g.
abrasive wheel
2. Non-Mechanical Hazards
Machinery may also present other hazards. The type and hazard level will be considered to decide the protection
measures for people. The various sources of danger other than mechanical hazards include the following:
• Electricity – shock and burns

• Hot surfaces/fire also cold surfaces
• Dust and fumes from the exhausts
• Fire/explosion due to the fuel
• Noise and Vibration
• Biological hazards from contamination
• Hazardous chemicals being handled
• Radiation while operation
• Access and Egress
• Obstructions and projections
• Manual handling
3. Hazards of Different Range of Equipment

In all types of business, there is machinery used. Some maybe single motion machinery and others could be an array
of machinery. Irrespective of the type of machinery, the mechanical and non-mechanical hazards could be grouped as
discussed earlier. Some of this equipment are:
• Office Machinery (Photocopiers/Shredders)

• Manufacturing/maintenance machinery (Grinder/pedestal drill)
• Agricultural/Horticultural (Strimmers/Mowers/Chain saws)
• Retail Machinery (Compactors, Checkout conveyors)
• Construction Machinery (Cement Mixers, Bench mounted circular saws)
There will be common hazards to each type in the industrial sectors referred to, and there will also be particular hazards
both mechanical and non-mechanical to each type of equipment.

Office Machinery
Office machinery: Photocopier and Shredder
Machinery Common Hazard Other Hazards

Drawing in
Trap between moving parts
Photocopier Chemicals
Electricity Ultra violet light/heat
Ergonomic Manual handling
Noise
Stability of machine Drawing into cutters
Document Contact with cutters
Shredder Dust Source: Ryman
Noise
Table Source: GWG
Manufacturing/Maintenance Industry
Bench top grinder/pedestal drill.

Contact with rotating wheel
Drawing into the trap
between the tool rest and
wheel
Benchtop Grinder
Ejected parts of wheel or
workpiece
Electricity Fire and sparks
Ergonomics Vibration/Noise
Dust
Stability of machine Entanglement (Hair/
Manual handling Clothing)
Contact (Stabbing/puncture)
(Hand under drill)
Pedestal Drill
Impact from an unsecured
Source: Makro
workpiece
Cutting from swarf
Ejection of a bit or materials
Table Source: GWG

Agricultural and Horticultural Industry
Cylinder mower, strimmer and chainsaw

Biological e.g. animal droppings
Chemicals e.g. herbicides Contact with rotating blades
Cylinder Mover
Electricity Entanglement in blades
Fire/explosion if petrol
Ergonomics
Manual handling Contact with cutter/saw
Strimmer/ Chainsaw Noise and vibration Entanglement with cutter/saw
Ejection of materials
Table Source: GWG
Mowers and trimmers are used to maintain roadside verges, and the additional hazards could be getting struck by
vehicles and exposure to exhaust fumes.
PPE is required when using this equipment and common to all is:
• Hearing protection
• Safety helmet/Full face visor
• Gloves
• Footwear
However, for chainsaws, other clothing required is: Specialist body clothing and Forestry boots
Apart from PPE other control measures when using chainsaws may include proper barriers at road edges, use of properly
maintained equipment to prevent harmful exhaust fumes and also proper training and use of competent staffs.
Retail Machineries
Waste Compactor/ Checkout Conveyor
Impact
Waste Compactor Crush
Electricity
Biological infection from waste
Ergonomics
Manual handling Drawing in traps
Check out Conveyor
Non-ionising radiation (Scanner)
Table Source: GWG

Construction Machinery
Cement Mixer/Circular Saw
Dust Entanglement
Cement Mixer Electricity Chemicals
Stability of machine Manual handling
Ergonomics
Trapping between fixed and moving Drawing into rotating blade
parts Contact
Circular Saw Noise Ejection of materials
Manual handling Vibration
Table Source: GWG

4.4 CONTROL MEASURES TO REDUCE RISK
1. The Safeguarding
Safeguarding the dangerous parts of machinery with different types of moving part is a very important design and
operational control. The choice of guards will depend on many factors, including where the moving parts are located,
what type of machinery movement does the equipment use, the need to access these areas and also the competence of
the person using and handling it.
There are many types of guard available. The selection depends on the dangers from which personnel are to be protected.
All guards and protection devices should be:
• Suitable for the purpose for which they are provided

• Of good design and built, sound material and adequate strength
• Maintained in an effective state and working order and in good repair
• Not create any increased risk to health or safety
• Not be quickly bypassed or disabled
• Be situated at sufficient distance from the risk zone
• Not block the view of the operating cycle of the machinery
• Eliminate the possibility of any part of a worker’s body accidentally entering into contact with such parts.
• Compatible with the kind of activity/processes it handles. Like dust resistant, chemical resistant, etc.
• Allows maintenance without removing the guard, e.g. by provision of lubrication / greasing points outside the
guard
Minimum (safe reach) Distances for Fixed Guards
The aim of minimum reach distances is that no part of the body can reach the hazard. The distances are determined by
tables, (i.e. measurements of parts of the body such as the length and thickness of fingers and arms). The distances are
statistically calculated so that 99.9% of the working population would be safe at the given distance.
The safe distance is determined from the start of entry / exit, e.g. a tunnel guard, to the position of the dangerous moving
parts. In the case of mesh or slatted guards, the distance of the guard from the hazard depends on the size of the gap.
Example of Safety Distance - Diameter of opening, e.g. tunnel or mesh size

Source: GWG
The Hierarchy of Controls for Machinery Guarding
Employers should take adequate steps to prevent access to the dangerous parts of a machine or stop their movement
before any part of the person enters a danger zone.
The most preferred guard at all circumstances is a fixed guard. However, due to its own inherence drawbacks, it can’t be
used at all dangerous sites on a machine and therefore, another type of guards and protection devices. For ex. Interlocks,
pressure sensitive devices, etc. are considered. Thereafter the user protective appliances. Examples such as holders, jigs
and push sticks should be considered.
Irrespective of the type of guard that has been provided, adequate information, training, instruction and competent
supervision on safe use of the machinery.
The British Standard gives a preferred order of guarding incorporating the 4 main types which are:
• Fixed Guards
• Interlock Guards
• Automatic Guards
• Trip Devices
Fixed Guard
This is the type of guard to be used whenever practicable. This guard is designed to prevent access to a dangerous part
of a machine and provides a physical barrier with no moving parts, is not linked to the controls or motion of the machine
and requires a tool to remove it.
Advantages Disadvantages
Creates a physical barrier No protection if removed
Requires an instrument to remove it Requires a tool to remove
It does not have any moving parts and would require If solid hampers visual inspection
minimum maintenance. If solid may cause problems with heat
Easy to inspect
Table Source: GWG
Interlock Guard
This is a guard so connected to the machine that until the guard is in the fully closed position the machine will not
operate. Interlocking systems may be Mechanical, Electrical, Hydraulic or Pneumatic or combinations of these.

Interlocking guards should, as far as possible, remain attached to the machinery when open. These interlocking devices
shall either prevent starting of the machinery function when the guards are open; and/or stops the running machine when
the guards are opened.
Advantages Disadvantages
Convenient for access More complex and therefore, potentially unreliable/can
Give flexibility of design fail to unsafe condition
A time delay can be built in Harder to inspect/test
Difficult to maintain/subject to wear
Subject to operator abuse
If a gate operator can step inside
Table Source: GWG
Automatic (Push away) Guard
This is a guard designed to physically remove from danger any part of a person exposed to that danger. These guards
are often called ‘push away guards’ because on the operation of the machine the guard moves backwards and upwards
physically pushing the operator away. This type of guard is used on large power presses with slow long strokes and
some guillotines etc.
These guards are suitable only for slow stroke machines like lathe, printing press, etc.
Trip Guard
These include suitably located bars, telescopic probes, trip wires, pressures sensitive mats or pressure sensitive cables
which, if operated, either brake or stop the machine (whether or not with an accidental braking system).
Note:- Trip guards are safety devices. The accident may be underway when the device operates and so minimises the
injury.
Other Types of Guard
• Adjustable
This is basically a “craftsman’s” guard being used mainly in tool rooms, machine shops and wood working shops where
periodic adjustment of the guard is necessary owing to different sized jobs. This type of guard is very much open to
abuse and requires supervision to ensure correct use. They can be readily adjustable without the use of tools.
• Self-Adjusting Guard
This is a guard which prevents accidental access of a person to a danger point. Once the operation is over, the guard
would automatically come back to its position, so that no one comes into contact with the hazardous component.
• Two Hand Control Devices
These devices ensure the operator is standing away from the danger area when causing dangerous movements. They
force the operator to use both hands to operate the machine controls. They are specifically installed and designed to
protect the operator of the machine.
Additional protection can be integrated with such devices like the use of light curtains at the point where the operator
hands or body parts comes into contact with the dangerous part of the machine.

• Photoelectric devices
These are usually called light curtains or light beams. They operated by a beam of light being emitted from a light source
received by another device and bounced back. If anything breaks the beam, the machine is stopped. They do not protect
anyone inside the beam and must be timed to stop the machine quicker than a person can cross the protected area to
reach the dangerous moving parts. They can apparently fail to danger if the beam is not monitored.
• Pressure Sensitive Pads/Mats
These devices operate by pressure. If an operator is standing on the pad/mat, this prevents the machine from operating.
They are normally installed on dangerous machines or robotic operations, so that once the operator or anyone else comes
close to these machines, the pressure mat trips and controls the machine movement either by bringing it to a stop or
shutting down the power.
To ensure adequate maintenance of guards during normal operations the guards should be inspected by operators,
supervisors, or if thought necessary, maintenance personnel. Whoever carries out the inspection must have received
sufficient information and/or instruction on what to look for during the inspection. Defects, whether of a minor or major
nature, should be reported immediately. Regular and more detailed examinations should be carried out as part of a
planned maintenance system.
Other Protection Appliances
• Jigs
A jig is a device into which the work piece can be fitted and takes it into the dangerous part of the machine in the correct
position.
• Holders
A holder is a hand holding a device that secures the work piece in such a way that it can be placed into the dangerous
part of the machine without risk to the operator’s hands e.g. tongs.
• Push Stick
A push stick is a device which is used to push the item being used as the dangerous part of the machine without danger
to the operator’s hands e.g. a stick used to push wood into a circular saw.
Information, Instruction, Training and Supervision
Employers should ensure that workers have received the necessary training, information and instructions to perform the
work competently and safely. Taking into account information provided by the manufacturer and supplier
It would be necessary to provide specific detailed training to the operator regarding machine related hazards. The topic
to be covered in such training shall include but not limited to the following:
• An explanation and identification of the hazards associated with the use of the particular machines
• Operation and working of various safe guards and devices and the purpose for which they are installed.
• Appropriate use of provided safeguards and why they must be used.
• Who is authorised to remove, install or maintain the guards and under what conditions these can be disabled/
removed?
• Actions to be taken when they discover that the safeguard is missing, damaged and/or not able to have the
adequate protection. Provide the contact persons details and numbers to contact.
• The selection and use of PPE
Such training will be essential for all new operators of the machines, or maintenance and installation personnel where

they may be required to uninstall, modify or reinstall new devices or if an operator is assigned to use another new
equipment.
Training, instruction and information should be carried out in an appropriate manner using written, oral, visual and
participative approaches in order to ensure that workers have understood the material, and should be delivered in a
language of their choice and their understanding.
The extent of the training and instruction received and required should be reviewed and updated simultaneously with the
review of the working systems and practices.
Personal Protective Equipment
Whenever engineering controls are not entirely able to protect the workers, an extra measure of protection is necessary
- workers must be provided with the appropriate personal protective equipment.
Where PPE is required to protect the safety and health of employees, it should be fit-for-purpose, suited to the individual
and provided at no cost to employees. Employees should be consulted in its selection and trained in its use.
For the maximum effectiveness of the PPE, the choice of them must be appropriate for the particular hazards and
maintained in the excellent state. PPEs must be appropriately stored when not in use, to prevent damage or loss and kept
in a clean, hygienic and fully functional condition.
2. Application of Safeguard
Below are the examples of application of Safeguards to the range of equipment listed in 4.3 above
Equipment/ Machinery Controls/Guards

The internal parts of the photocopiers are fully enclosed, and the access doors are
interlocked to guarantee that the machine comes to a stop when the doors are opened
Office Machinery -
for maintenance work or clearing paper jams.
Photocopiers
A program schedule of PAT (Portable Appliance Testing) be implemented
Ensure room containing machines is suitably ventilated (e.g., open windows,
extraction fans)
Ensure all guards are fitted, secure and functional. Do not operate if guards are
missing or faulty:
Fixed guards are used to enclose the cutters which only allow access to the paper.
The cutter head is fitted with interlock guard which switches the shredder off when
Office Machinery – the door is open to access the waste bin.
Shredders The trip guard is used to triggering automatic starting of the machine to start
shredding the paper.
Ventilate the area to control dust problems. Depending on the amount of shredding
and the size of the machines dust extraction may be needed.
Confirm all the guards are positioned and secured properly before using a grinder
Wheels to be encased with fixed guard to prevent ejection of pieces of broken wheel
Manufacturing/ Install adjustable guard with toughened glass over wheel to protect the operator
maintenance machinery – Adjust tool rests as close as possible to wheels. Never adjust rests while wheels are
Bench Top Grinder moving
Extract ventilation is fitted to the wheel encasing to remove dust at source
Use appropriate PPE: goggles, gloves, safety boots, etc.

Inspect equipment before use, for damaged parts and cords

Ensure all guards and shields in place – motor and drive enclosed by fixed guard
The spindle must have an adjustable guard and must be in place before operating the
drill
Work-piece must be clamped securely in vice and / or to table
Manufacturing/
Use cutting fluids where possible to reduce friction and cutting forces.
maintenance machinery -
Use the correct cutting speed for drill bit size and material
Pedestal drill
If the drill speed is to be altered by means of gears or other arrangements, the guard
should be interlocked by the suitable power to avoid the inadvertent starting of the
machine when the guard is open.
Drill bit to be securely clamped in the chuck
Goggles, gloves and safety boots to be worn by operator
Agricultural/Horticultural
Cutting blade or cutting string/line to be protected with fixed top guard
– Strimmers
Ear protection, goggles, safety boots and long pants to be worn by operator
Mowers to have cut-off switch

Blades to be protected with fixed guard
Agricultural/Horticultural
Motor and hot surfaces to be completely encased with fixed guard
- Mowers
Ensure there are no loose fittings, damaged guards or aprons
Avoid carrying or picking them up while it is running.
Agricultural/Horticultural Engine part of the chain saw to be encased by fixed guard
- Chain Saws Electrical cables to be double insulated
Interlocked guards to be installed on access doors leading to loading area
Retail Machinery -
Motor to be encased by fixed guard
Compactors
Emergency button to be installed
Motor to be encased by fixed guard
Traps between belt and rollers to be encased by fixed guard or interlocked guards
Emergency stop button accessible by operator
Retail Machinery -
Install interlocking devices that shut down the conveyor during an electrical or
Checkout Conveyors
mechanical overload such as product jam or another stoppage.
Sensor fitted to conveyor to stop within pre-determined distance from operator when
products are loaded on the conveyor
Construction Machinery - Motor to be enclosed by fixed guard
Cement Mixers Interlocked guards to be installed to rotating part of machine
Motor and drives to be fitted with fixed guard
Construction Machinery - Saw blade to be mounted with adjustable guard
Bench Mounted Circular Machinery should, wherever possible, be equipped with mechanical feeding devices.
Saws Push sticks are an additional device used to keep hands away from the blade.
Emergency stop button accessible by operator
Appropriate PPE such as ear protection, goggles, safety boots to be worn by operator
Table Source: GWG

Basic Requirements for Guards and Safety Devices
The design and construction of guards must be appropriate to the risks identified and the mode of operation of the
machinery in question.
The key factors are robustness and its strength as they should be able to resist the forces and vibration involved and able
to withstand impact (where applicable). It should not be too heavy or too big in size for the need remove and replace the
guard during maintenance. The other factors are listed below:
• Compatibility - With materials being processed and lubricants, etc.

• Hygiene - Comply with all food safety regulations and standards ;
• Visibility - It may be necessary to see through the guard for both operational and safety reasons;
• Noise attenuation - Guards often utilised to reduce the noise levels produced by a machine.
• Conversely, the resonance of large un-damped panels may exacerbate the noise problem;
• Enabling a free flow of air- Where necessary (e.g. For ventilation);
• Avoidance of additional hazards - Here for example free of sharp edges;
• Ease of maintenance and cleanliness; - To be ensured so that operatives are not put at risk,
• Where possible equipment should be able to be maintained without the need for guard removal,
• Guards must not increase risks or restrict views if viewed is deemed necessary
• Guards must be designed and installed in such a way as not to allow easy by-passing.
• Openings - The size of openings and their distance from the dangerous parts should not allow anyone to be able
to reach into a danger zone. These values can be determined by experiment or by reference to standard tables.
• If doing so by experiment (trial), it is essential that the machine is first stopped and made safe (e.g. by isolation).
Irrespective of the type of guard and/or device that is being used on machinery, it is very critical that suitable risk
control systems must be put in place to ensure that the guards remain safe and effective. It requires an active regime
of inspection, testing, maintenance and other behavioural controls like signages, information, instruction and training.

SUMMARY
This element discussed the General requirements for work equipment. In particular:
• Types of work equipment including: hand tools, power tools and machinery, its suitability as it relates to
provision of equipment; including the requirement for CE (Conformité Européenne) marking within the UK
and Europe.
• Prevention of access to dangerous parts of machinery and the need to restrict the use and maintenance of
equipment with specific risks.
• Extent of information, instruction and training to be provided in relation to specific risks and persons at risk (eg
users, maintenance staff and managers).
• The need for equipment to be maintained and for maintenance to be conducted safely.
• Importance of operation and emergency controls, stability, lighting, markings and warnings, clear unobstructed
workspace.
• Hazards and misuse of hand-held tools whether powered or not; requirements for safe use, condition and fitness
for use, suitability for purpose and location to be used in (eg flammable atmosphere). Hazards of portable
power tools (eg, drill, sander) and the means of control.
• Main mechanical and other hazards as identified in BS EN ISO 12100 -1 and how harm may arise. Hazards
presented by a range of equipment including office machinery (eg, photocopier, document shredder);
manufacturing/maintenance machinery (eg, bench-top grinder, pedestal drill); agricultural/horticultural
machinery (eg, cylinder mower, strimmer / brush cutter, chain-saw); retail machinery (eg, compactor, checkout
conveyor system); construction machinery (eg, cement mixer, bench mounted circular saw).\
• Control measures for reducing risks from machinery hazards. The basic principles of operation, merits and
limitations of the following:
• guards: fixed ; interlocking; self-closing and adjustable/self-adjusting
• protective devices: two-hand; hold-to-run; sensitive protective equipment (trip devices), emergency stop
controls
• jigs, holders, push-sticks
• information, instruction, training and supervision
• personal protective equipment
Basic requirements for guards and safety devices: - compatibility with process, adequate strength, maintained,
allow for maintenance without removal, not increase risk or restrict view, not easily bypassed.
REFERENCES
UK references
1. Statutory provisions
2. The Health and Safety (Safety Signs and Signals) Regulations 1996
3. The Personal Protective Equipment at Work Regulations 1992 (as amended)
4. The Provision and Use of Work Equipment Regulations 1998
5. The Supply of Machinery (Safety) Regulations 2008 (as amended)
6. Other references
7. Personal Protective Equipment at Work Regulations 1992 (as amended). Guidance on
8. Regulations, (L25), HSE Books, ISBN: 978-0-7176-6139-8 www.hse.gove.uk/pubns/priced/l25.pdf
9. Safe Use of Work Equipment, ACoP and guidance (part II in particular), L22, third edition
10. 2008, HSE Books, ISBN: 978-0-7176-6295-1 www.hse.gove.uk/pubns/priced/l22.pdf
11. The Health and Safety (Safety Signs and Signals) Regulations 1996, Guidance on
12. regulations, second edition 2009, L64, HSE Books, ISBN: 978-0-7176-6359-0

13. www.hse.gove.uk/pubns/priced/l64.pdf
14. Buying new machinery, INDG271(rev1), HSE http://www.hse.gov.uk/pubns/indg271.pdf
15. Supplying new machinery, INDG270(rev1), HSE http://www.hse.gov.uk/pubns/indg270.pdf
EU/International references
1. Ambient factors in the Workplace, ILO CoP, ISBN 92-2-11628-X
2. http://www.ilo.org/safework/info/standards-and-instruments/WCMS_107729/lang--en/index.htm
3. Directive 2006/42/EC - machinery directive
4. http://eur-lex.europa.eu/LexUriServ/LexUriServ.do?uri=OJ:L:2006:157:0024:0086:EN:PDF
5. Directive 2009/104/EC - use of work equipment
6. https://osha.europa.eu/en/legislation/directives/workplaces-equipment-signs-personalprotective-equipment/
osh-directives/3
7. Graphical symbols – Safety colours and safety signs used in workplaces and public areas - ISO 7010:2003,
International Organisation for Standardisation (ISO)
8. Safety and health in the use of machinery, ILO CoP
9. http://www.ilo.org/wcmsp5/groups/public/---ed_protect/---protrav/--safework/documents/
normativeinstrument/wcms_164653.pdf
10. Safety of machinery – General principles for design – Risk assessment and risk reduction,
11. ISO 12100:2010, ISBN: 978-0-580-74262-0

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Work Equipment Hazards and Risk

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4.1 GENERAL REQUIREMENTS FOR WORK EQUIPMENT����������������������������������������������������� 99

4.2 HAZARDS AND CONTROLS FOR HAND HELD TOOLS����������������������������������������������������� 106

4.3 MECHANICAL AND NON-MECHANICAL HAZARDS���������������������������������������������������������� 109

4.4 CONTROL MEASURES TO REDUCE RISK������������������������������������������������������������������������������115

Green World Group | 97

1. Types of Work Equipment

• Hand tools such as hammers, knives, hand saws, meat cleavers

2. Selection and Suitability of Equipment

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Preventing access to dangerous parts

Restrict Use and Maintenance

3. Information, Instruction and Training

100 | Green World Group

Refresher training should be provided if necessary.

Need for Safe Maintenance

All equipment should be maintained to ensure they function

Risk assessment should be brought out to identify whether any

• Providing temporary guards

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Examples of maintenance work may be:

• Entry into vessels, confined spaces or machines

• Unintentional starting of machinery

The possible precautions when undertaking machinery maintenance are:

• Isolate Electrical power

102 | Green World Group

Stability Source: DirectIndustry

Stability is important and is normally achieved by bolting equipment in place

The quality of general and local lighting will

Poor levels of lighting, glare and shadows can be

Some types of lighting, for example, sodium

This is particularly important if the colour coding

Green World Group | 103

• ‘Wear hard hats’;

Clear Unobstructed Workplace

• Starting and stopping the equipment;

104 | Green World Group

Summary of Safe Operation

In summary, the means of achieving safe operation of work equipment are:

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1. Hand held Non-power Tools

Misuse of Hand-Held Tools

Condition & Fitness for Use

• Chisels which have become blunt

106 | Green World Group

• Spanners which have become rounded

Requirements for Safe Use

• Use chisels that have been sharpened to correct angle

Suitability for Purpose and Location to be Used in Flammable Atmosphere

2. Portable Power Tools

Common types of portable power tools are electric

The power source itself may lead to hazards such

Electric drills are used to drill holes into the

• Contact with electricity

Portable Electric Sander

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• Noise emitted by the sender

• Purchase quality low vibration sander

Precautions for the Portable Power Tools

108 | Green World Group

1. Potential consequences from Mechanical Hazards

4.1 GENERAL REQUIREMENTS FOR WORK EQUIPMENT�� 99

4.2 HAZARDS AND CONTROLS FOR HAND HELD TOOLS�� 106

4.3 MECHANICAL AND NON-MECHANICAL HAZARDS�� 109

4.4 CONTROL MEASURES TO REDUCE RISK��115