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All change with workshop safety
Page 122
Page 123
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The same types of accidents cause deaths in the workshop every year, while new materials create fresh problems. We talk to the Health and Safety Executive about accidents and regulations affecting workshops.
• Forty-three fitters died while working on vehicles in the three years 1978 to 1980. While that figure that must be reduced, it must be emphasised that more people die of ill health caused through work than from accidents at work. New tougher legislation, the Control of Substances Hazardous to Health (COSHH), coming into effect on 1 October, is designed to reduce all types of health risk.
Matthew Toulinin, a factory inspector with the Health and Safety Executive, divides the hazards into the immediate, which he defines as "blood on the floor", and long term, such as lung complaints or cancer caused by exposure at work.
Any accident causing an employee to have three or more days off work must be reported to the HSE. In three years up to April '89 there were 330 such accidents reported in the motor vehicle repair industry; 23 of these were fatal.
Of the immediate hazards, Toillmin identifies two main problem areas: vehicle movements — especially heavy trucks, and petrol handling. Out of the 23 fatalities, 14 involved vehicle movements and virtually all were commercial vehicles. Petrol fires caused another five deaths and falls accounted for a further three. The grim statistics are shown in the table.
Many of these accident can and should be prevented, according to TouImin, by better management. Those in charge should ensure that overcrowding does not lead to fitters squeezing between parked vehicles — they may be about to move. Keeping pedestrian and vehicle entrances separate would prevent any possibility of getting trapped between a vehicle and a door pillar. Despite all the warnings, people are still being killed when un-propped tipper bodies fall on them while they are working on the vehicle — again, strong management should ensure that props are always used.
Petrol fires and explosions are preventable by using simple measures. All fitters are aware of the danger petrol poses and take precautions when handling the liquid itself. However, recent changes cause new problems. Vehicle manufacturers are now fitting plastic fuel pipes. There have been incidences of these being melted at some distance from an area of hot work by heat conducted along chassis rails. Plastic pipes must be unclipped and lagget before any hot work starts.
Petrol in the tanks of vehicles being baked following a respray has exploded. The HSE recommends that tanks art syphoned out so that they are substantial. ly empty before putting vehicles in tilt oven to prevent a full tank overflowing when the contents get warmed up.
Gross leakage of fuel can also occtu when fuel systems are deliberately discon, nected (eg because the engine or an ele, ment of the fuel system has been re moved) or because of a sudden failure o an element of the fuel system (eg becaus( of an increase of the internal pressor( within a system itself). As operating temperatures in the unit increase, tto need for precautions to prevent gross leakages becomes more important. Furth er advice is available from the USE or information document No. HSE 803/45.
Vapour from petrol is heavier than ah with a result that it will collect in tlo bottom of a vehicle inspection pit and re,
main there for a considerable time. Todmin warns that petrol tanks must never be drained over an inspection pit.
Vehicle lifts and inspection pits are a major hazard in themselves. Since April 88 there have been 21 incidents involving vehicle lifts and 12 with inspection pits. Good housekeeping, again inspired by management, will keep trailing leads and other items to a minimum, so preventing falls. Inspection pits must remain boarded at all times when not in use.
There are two problems with vehicle lifts. The first is that of vehicles falling of an elevated lift, and the second is the lift collapsing with a fitter underneath. Vehicles falling off is generally caused by the engine being started while still in gear. Sudden failure of a lift is usually caused either by putting too heavy a vehicle on it or by lack of proper maintenance. All lifts should be inspected at least every six months by a competent person as recommended by BS AU 161.
Long-term health hazards are more difficult to spot and evaluate. One of these hazards is that of contracting asthmatic problems caused by breathing isocyanates when spraying two-pack paints. Isocyanates are what is known as a respiratory sensitiser; once affected, the victim would suffer severe asthmatic attacks whenever breathing even the slightest amount of the substance in the air. In Toulmin's experience all people affected have been forced to leave the industry. Compensation claims for loss of livelihood are very expensive for insurers who in turn push up premiums.
In addition, after 1 October when COSHH comes into affect, there is also the possibility of a prison sentence for any employer convicted of not providing the correct equipment for employees. A lot of the longer-term health hazards can be removed by having clean air in the workshop and this is covered in another article in Workshop.
Solvents and other chemicals do not only cause problems of air pollution, there is also a potential hazard with absorbtion through the skin. This usually causes either de-fatting of the skin or an allergic reaction like dermatitis. Whenever any chemicals or solvents are in use, gloves and barrier cream must be available.
The new COSHH regulations imposes three specific legal requirements on the employer: 1, Assess all activities which involved the use of substances hazardous to health; 2, Prevent exposure or establish proper controls; 3, Train and inform all employees.
The assessment must not only look at activities like welding and spraying, but also, for example, at the amount of exhaust and welding fumes in a workshop. Lf the employer is unclear about his obligations then there are three free leaflets explaining COSHH which are available from the HSE inquiry points at Sheffield (0742) 752539; Bootle (051) 951 4381 and London (01) 221 0870.
After 1 January 1990, whenever Health and Safety inspectors enter any commercial premises they will expect to see a written assessment of these risks and the ways they are kept under control.
Preventing a hazard may be achieved by switching to a safer substance. If this cannot be done then specific limits, Occupational Exposure Limits (OELs) and Maximum Exposure Limits (MELs) must be adhered to. Again the HSE publishes a guidance note, No EH40, which lists all OELs and MELs. Information is also avaible from HMSO in the form of two books, COSHH Assessments price 22 and COSHH Approved Code of Practice at 24. Anyone failing to meet these new regulations risks prosecution and a prison sentence.
New regulations on noise are due in January 1990. These will probably require that above 90dB(A), noise should be reduced by mechanical means like an enclosure. Where this is not possible, ear de fenders must be issued and the employees will have a legal obligation to wear them. When noise levels are between 85c1B(A) and 90dB(A) then ear defenders must still be provided, but there will not be the same obligation on the part of the employee to wear them.
Many of these new regulation are designed to bring us into line with the rest of Europe in the run-up to 1992. For the 250,000 people employed in the vehicle repair and maintenance industry in the UK, these regulations provide a greater degree of protection againt the long-term health risks.
Employers and small businesses need not worry too much about the cost or any subsequent loss of competitiveness as this is a Europe-wide regulation so everyone in the industry will be competing on equal terms. For those who already provide a good and safe working environment there is no investment needed; for those who fall far short of the required standard, they may be forced out of business, but if they are that unsafe then their passing should be welcomed by the industry's employers and workers alike.