graphic-artsprinting pressesand workshops

Safety guide

01.Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

02.Macroeconomic sector information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

03.Production processes in graphic-arts printing presses and workshops . . . . . . . . . . . . . 53.1. Raw materials storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.2. Pre-press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.3. Ink preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.4. Printing technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.4.1. Typographical or relief printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.4.2. Rotogravure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.4.3. Planographic or lithographic (offset) printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.4.4. Screen printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.5. Finishing processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.6. Packaging and dispatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

04.General risks in graphic-arts printing presses and workshops . . . . . . . . . . . . . . . . . . . . 114.1. Risks to workers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114.2. Fire risk points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.3. Water damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

05.Risks specific to graphic-arts printing presses and workshops . . . . . . . . . . . . . . . . . . . . 165.1. Fire risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.1.1. Paper storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165.1.2. Handling and storage of hazardous products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175.1.3. Production processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185.1.4. Third-party fire damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.2. Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.2.1. Waste management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.2.2. Water pollution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.2.3. Soil pollution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.2.4. Controlling pollution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

06.Loss histories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

07.Protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237.1. Active anti-fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.1.1. Basic level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 7.1.2. Recommended level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7.2. Passive anti-fire protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 7.3. Other protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 7.4. Anti-theft protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

7.4.1. Passive or physical protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 7.4.2. Active protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 7.4.3. Human protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

08.Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Appendix: Hot-work permit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Contents

[2] Safety guide graphic-arts printing presses and workshops

The high fire load represented by paper, aswell as its presence in the form of cuttingsand dust, and also inks, alcohol, and sol-vents in the production processes allgenerate a high fire risk in the industrialactivities of graphic-arts printing pressesand workshops. This Guide aims to help

business people in this sector with thetask of identifying and analysing the risksassociated with the activity and setting upprevention and protection measures inorder to achieve reasonable safety levelsfor people and property.

Printing was invented in China in the 11th century.At the end of the 15th century, Johannes Gutenbergdesigned movable types and the printing press,and thus developed a printing technology that isnow in use throughout the world. Since then, gra-phic arts have experienced spectacular growth andhave gone from simple text printing on paper, totext and other original artwork on paper and othermaterials.

In the present day, the graphic process is linkedwith new trends in the printing market, particularlyin the customisation of marketing, which bringsadded value to graphic products.

PRIMIR (The Print Industries Market Informationand Research Organization) is the premier marketresearch association of the graphic communicationsindustry and it was established in 2005 by the mer-ger of GAMIS (Graphic Arts Marketing Information

Service) and the NPES Market Committee (NationalPrinting Equipment Association).

Both PRIMIR and NPES completed the study “WorldWide Market for Print”, which values a 18.2 % incre-ase of the global market for print by the year 2011, toreach US$ 721 billion. Among the groups of the mar-ket, packaging and labels will be the fastest growingarea with sales ahead near 20%, followed by adverti-sing and then business and transactional printing.

There is certain concern that imports from offshoreagents might grow much more than the printdemand in both North America and Western Europe.In mature national print markets, such as US, Japan,Germany, UK, France, Canada and Spain, there willbe a limited growth of demand, while in emergingnational markets for print, with important social anddemographic changes, annual growth of the demandis forecast to exceed 10%. (See chart 1.)

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A big influence on the demand for print, such as publi-cations, packaging, advertising material or transactio-nal print, is given by the consumer together with theregional demographic and social patterns, for examplethose relative to working and use of leisure time.

The printing industry has historically been a labour-intensive industry, with a strong relation between thetrend in turn over and employment. Machinery design,digitalization and computerisation, etc. have contribu-ted to improving productivity very significantly andtransforming this industry so that growth capacity isno longer linked to direct employment.

In the next years, an important development of socialand demographic trends is expected, including:

• Increase of affluence

• Increasing literacy levels

• Steadily aging populations

• Smaller households

Globally compelling factors for the future growth ofthese markets are the trend towards much shorterrun lengths and ability of digital printers to give solu-

tions for new needs of consumers. By 2011, theshare of the market held by the printing processes isexpected to rise a 21%.

Different environmental requirements, with impor-tant cost implications, will put printers in developedregions at competitive disadvantage compared tothose in emerging countries.

There are some guidelines recommended for prin-ters in developed countries:

• Diversify the offers, in order to give global solu-tions for all the clients needs.

• Move the production or merge with production faci-lities in emerging countries to take advantage oflower labour costs and serve the local demand.

• Investigate in digital impression.

In short, an important evolution of the industry isexpected, in which competence of diverse media, espe-cially electronics, will grow, and additional services thataren’t related directly with graphic arts, will be moreimportant, while market groups as packaging and labelwill increase in importance and digital impression willgrow in relation with other printing processes.

[4] Safety guide graphic-arts printing presses and workshops

Chart 1: Print market growth in developing countries for 2006-2011, source PRIMIR “World Wide Market for Print” 2007.

The main activity carried out in graphic-arts printingpresses and workshops is printing. This can be defi-ned as the art of reproducing any type of text or illus-tration in order to create many copies. The produc-tion process carried out in this type of industrialestablishment is as follows:

• Raw materials storage.

• Pre-press.

• Ink preparation.

• Printing by means of various technologies.

• Finishing.

• Packaging and dispatch.

The basic elements of a printing machine are:

• Mould and corresponding medium.

• Ink reservoir and inking system.

• Paper-feeding device.

• Pressing device for applying the paper against themould.

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[6] Safety guide graphic-arts printing presses and workshops

Raw materials used in graphic-arts printing pressesor workshops include paper reels or fan-fold paper,inks, printing materials, and chemical products.Paper reel storage (table 1) is classified according tothe roll stacking method (vertical or horizontal).

Furthermore, the paper rolls can be identified accor-ding to the protection preventing them from beco-ming frayed (or unrolling). As such, they are classi-fied as:

• Strapped reels, which are provided with one ormore steel rings or strips at both ends.

• Wrapped reels, which are completely covered (sideand bottom) with high-weight paper.

• Encapsulated reels, which are coated with shrink-wrap plastic.

3.1. Raw material storage

Stacking

Vertical

Horizontal

Distribution

Compact: A minimum of four rows in both directions of the stack (wideand long), so that the maximum distance between contiguous reels ofthe same diameter is less than 100 mm. Open: As above, except that the distance separating adjacent reels isgreater than 100 mm. Standard: In this method, the separation distance between rows is grea-ter than 100 mm but within these, the reels are in contact with each other.

Pyramid. The reels, in contact with each other, are arranged so that theones on the upper level are resting in the spaces left by the reels on thelower level.

Prism. The reels are placed on spacer planks or strips between thelevels.

Hangers. The reels are placed on metal frames acting as shafts.

Paper-reels store room

Vertical stacking of paper reels Strapped reels with steel rings

Table 1: Paper-reel stacking methods

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This phase includes the photomechanical printing(printing procedure obtained from negatives ofphotographic images) performed in the dark room.In photomechanical printing, photolithographs areused, which are positive films that initiate the off-set printing process and act as a replacement forthe negative.

In short, photomechanical printing is the processof separating the four basic colours (cyan,magenta, yellow, and black), with each onehaving a percentage. This process obtains fourpositives, a different one for each colour, and acolour proof that will subsequently be used in theprinting process.

The colour proofs are printing simulations obtainedfrom the photolithographs. This type of proof is veryaccurate and reliable, as it is derived from the samephotolithographs that are subsequently used in theprinting press.

There is now a more modern technology called CTP(Computer To Plate), which circumvents the need toobtain photolithographs, thus enormously improvingthe production process, as printing error correctionscan be made directly on the computer.

The ink composition depends on the printing techno-logy. The inks are normally composed of a carrier(alcohols, esters, ketones, or water), pigments, anddyes, and resins that will form the image. The pig-ments provide the colour, and are prepared using

very diverse chemical products, including heavymetals and organic compounds. Isopropyl alcohol isused to increase the surface tension of the water inorder to increase printing quality. The products aremixed by means of mixer tanks with blades.

3.2. Pre-press

Plate obtained using CTP technology

Prepared ink storage room Ink reservoirs

3.3. Ink preparation

3.4.1. Typographical or relief printing

This technology is based on producing images,generally letters or figures, elevated in relation to abackground or non-printing area. The ink is appliedto the elevated parts, which are then brought intocontact with the paper or medium receiving theimage. There are several ways of creating the reliefimage, such as letter-by-letter composition usingmovable type (linotype), or with text formed bymechanical procedures. These technologies aresuitable for simple and quick printing jobs. The inkscommonly used in these methods are water-basedor solvent-based. New inks that dry by means ofultraviolet (UV) light curing or with the use of otherphysico-chemical agents are being researched andapplied.

Machines that use this technology are called "pla-ten presses", which print sheets of paper by meansof two flat elements (the platen, where the mouldgoes, and the bed, where the sheet to be printed isplaced) which press against each other.

Other machines used are die-cutting presses,which cut, emboss, and score by means of two flatelements, the platen and the bed, by exerting pres-sure on the working material. The material workedby the die-cutting machines is paper, card, rubber,plastic, and other similar materials. The cutter isfitted to the platen and the material to be cut is pla-ced on the bed.

Printing with flexible plates and fluid inks that dry bymeans of evaporation is called flexography. This is adirect system, as the flexographic plate, once inked,transfers the ink straight to the medium. Therefore,when looking at this plate, the image text readsbackwards so that the printed medium is readcorrectly.

The plates have a relief area that prints directly ontothe substrate with light pressure known as "kisspressure". Unlike the heavy metal plates used in theoffset printing system, flexographic plates are adap-table and portable. The risk of fire in flexographicrotary presses is somewhat less, due to the low wor-king speed.

Many pocket books are printed using the flexogra-phic procedure. This printing system is widely usedin packaging, particularly tetrapacks.

3.4.2. Rotogravure

In rotogravure technologies, the image is cut into thesurface of an engraved plate or cylinder. The plate isbathed in ink and the excess is removed with a blade.It is then brought into contact with the paper ormedium in question in order to transfer the image.This technology is suitable for publications requiringlong print runs, such as newspapers and packagingmaterials. Solvent-based inks are usually used forthis purpose, most commonly toluene, which is ahighly flammable product (flashpoint 4 ºC), and thevapour/air mixtures are explosive.

There are two types of rotogravure: sheet or reel.The former is used for books and high-quality photo-graphs, while the reel type is used for long magazi-ne or catalogue print runs.

Chalcography is derived from rotogravure. This pro-cess is used for printing by means of chalcographypresses with copper or zinc plates. The printingforms may be manual (wood engraving) or achievedby means of chemical incisions (etching, aquatint).

Chalcographic forms may be:

• Flat: These are obtained by manual or chemicalengraving, and are used in chalcographic printingwith thick oily inks.

• Cylindrical: These are cylinders with a copperelectrolytic layer engraved using the rotogravureprocedures.

[8] Safety guide graphic-arts printing presses and workshops

3.4. Printing technologies

Flexographic printing

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3.4.3. Planographic or lithographic (offset)printing

The offset system is based on the indirect printingprocedure whereby the paper is run through anintermediate rubber roller. The offset is based on thephysical principle of water-oil repulsion (immiscibi-lity), hence the use of oil-based and water-basedinks in this method. The printing elements acceptoily ink and reject water, and the blank spaces rejectthe ink and accept the water.

The offset system is the most widely used system ingraphic-arts workshops because of the combinationof good quality and savings.

Offset printing consists of the following types:

• Offset typography: With typographic mould

• Offset lithography: With a lithographic mould

• Offset rotogravure (or offset chalcography): With arotogravure mould

Printing machines with the offset system may useone or more colours. This printing system can beused with paper sheets or reels, in the latter casebeing fitted with a cutter and folder.

Depending on specific production needs, the offsetrun can be combined with other graphic-artsmethods. Planographic or lithographic printingtends to use solvent-based inks (i.e. not water-based), although solvent-free preparations arerapidly becoming more common.

3.4.4. Screen printing

Screen printing makes use of a text image mountedon a fine-mesh screen. The ink is applied to the openareas of the screen and is pressed with a scraper onthe open parts and the stencilling. The ink thus pas-ses through the open parts and is applied to themedium beneath the mesh. Screen printing is veryoften used in simple jobs and short print runs, suchas printing on fabrics, posters, presentation mate-rials, and wallpaper. Screen printing uses solvent- orwater-based inks, the choice depends on the printedmedium. As the screen-print covering is usuallythicker than normal, the inks are also more viscousthan in other printing technologies.

This printing technology is widely used in adverti-sing. It may take one of two forms according to theprinting surface: flat or cylindrical. The flat typeprints a range of sizes from small formats to adver-tising panels, posters, etc. The cylindrical type isused for decorating packs, bottles, etc.

The following operations are carried out as part ofthe finishing process:

• Pick-up of printed paper

• Cutting and guillotining

• Folding

• Stapling

• Binding

Offset machine

3.5. Finishing processes

[10] Safety guide graphic-arts printing presses and workshops

Final products from the graphic-arts printing pressesand workshops are very variable with regard to typeand format, and can be classified as follows: publica-tions (e.g. books, magazines, newspapers), adverti-

sing (e.g. labels, posters, catalogues), and sundries(e.g. calendars, stamps, tickets, business cards). Oncethe work is complete, the finished products are takento the dispatch area where orders are prepared.

Books Stamps

3.6. Packaging and dispatch

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The actual activity in graphic-arts printing pressesand workshops brings a number of risks both toworkers and the establishment itself, notably fire,

explosion, and any civil-liability claims resultingfrom accidental spillage.

• Hand and finger cuts and amputations caused bycutting machines. The guillotines are intended tocut stacked sheets of paper. There are two types ofguillotine: conventional guillotines have a singleblade and make straight cuts, while trilateral gui-llotines can cut on the three sides of the leaflet orbook simultaneously. It is important to store andoperate the blades so as to prevent cuts and lace-rations due to negligence. Furthermore, it is advi-sable to fit the machines with safety devices: hand-

guard (moves the operator's body away when theblade falls), dual actuator buttons, and photo-elec-tric cells (prevents assistant from accessing thecutting area).

• Cuts caused by blades used in the ink mixingequipment. The mixing blades and mechanismsmust be protected during the preparation and clea-ning phases. The machines must be fitted with pro-tection devices mounted in the appropriate place.

4.1. Risks to workers

[12] Safety guide graphic-arts printing presses and workshops

• Ergonomic stress due to manual cutting, classifi-cation, and packaging work that cannot be auto-mated. Rotating tasks can partially alleviate thisproblem.

• Trapping in cylinder assemblies or rollers, bothduring normal operation and in maintenance andcleaning operations. A suitable measure would beto fit transparent retractable housing or metal gri-lles to prevent access to the cylinders during nor-mal operation. This housing must be fitted withtrip devices that shut down the machine if the pro-tective housing is opened, while allowing pulseoperation in order to facilitate cleaning.

• Impacts and/or trapping by the printed paper

pick-up and extraction systems. This accident iscaused by the sample-taking operation intended toverify correct finishing of the printing and tocorrect poorly stacked (or transported) sheets.This must be prevented by installing a transparentplastic screen and a grille preventing manualaccess to the printed-paper conveyance elements.This protection will be complemented by the insta-llation of meters leading to automatic shutdown ofthe machine in case the screen is lifted.

• Trapping in platen press and die-cutting machine.The severity of the expected consequences includeimpact, crushing, and amputation depending onwhether the trapping occurs between the bed andplaten or between the bed and mould or die-cutter.The safety devices for these machines include thefollowing:

- Handguard devices, the protective function ofwhich is based on expelling the operator's handsfrom the operating area when the bed closesagainst the plate.

- Safety strip, located at the front of the machine,which shuts down the machine if the operatorcomes too close to the operating area.

- Automatic feed devices, which keep the opera-tor's hands away from the danger area.

A summary is provided below regarding the firerisk points (Table 2) according to the processes andsections of a graphic-arts printing press or works-hop. In section 5, Specific Risks, more detailedinformation is provided and preventive fire-safetymeasures are proposed. Other risk points in thegraphic-arts printing press or workshop are asfollow:

• Auxiliary technical facilities. These facilitieshelp to ensure smooth production operations.Representative examples include the boilerroom and the compressor room, which may beorigin points for a fire and/or explosion on theindustrial site. The compressed-air facilities areused in graphic-arts workshops in operationssuch as paper absorption, sheet stretching, anddrying operations. The main risk of such equip-ment is explosion of the expansion tank in thecompressed-air facility. For this reason, the

compressors are located in a separate enclosureor an outbuilding with one of its partitions pre-pared to release the pressure wave. This com-partmentalisation will be designed to keepdamage to a minimum.

Compulsory annual checks and a pressure testevery ten years are carried out in order to ensurethat this risk factor is properly managed.

Other risks to workers derived from these types offacilities include:

- Loss of hearing caused by the high level ofgenerated noise.

- Accidental particle projections from blastnozzles.

- Direct exposure to compressed-air blast.

Paper guillotine fitted with photoelectric cells as a safety measure

4.2. Fire risk points

The boiler room is another technical auxiliary faci-lity, which is generally used to produce steam orsuperheated water needed for dryers, heating, etc.prepared to burn liquid fuels (generally diesel oil).

The basic risk in boilers is explosion, due to thefact that they operate under high temperature andpressure conditions. Boilers must be located in aseparate room or enclosure, separated from otherareas (e.g production and storage). Furthermore,said area must be provided with a roof built withlight materials (such as fibre cement or similar)which would act to attenuate explosions, that is,through which the energy of an explosion would bereleased.

Flammable products may not be stored in the boi-ler room. The only fuel store that may be accepted

in the boiler room is the supply tank feeding theboiler. It is essential to carry out maintenance ope-rations and check for leaks or spills underneaththe supply tank or burner, as such leaks and spillscombined with a source of ignition may lead to afire.

Unit heaters are usually used to heat different sec-tions by exchanging ambient air heat with thesteam or superheated water produced in the boi-lers or, in some cases, thermal oil.

• Batteries. Charging batteries for forklift trucksemits hydrogen. This gas is explosive in concentra-tions of more than 4%, which is why the battery-charging area must be sufficiently ventilated toprevent overheating of the batteries and chargers,and to keep the hydrogen concentration under the

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Sections

• Paper• Inks

• Typesetting• Layout• Engraving

• Cutting, folding, stapling, stitching

• Binding

Process

Storage

Pre-press / mould preparation

Ink preparation

Printing

Finishing

Packaging and dispatch

Waste collection and removal

Risks

Presence of combustible materials

Melting of metal letterpress moulds (high temperature)

Presence of flammable liquids (inks and solvents)

Presence of combustible materials (paper), flammableliquids, and dust (paper and starch)

Presence of combustible materials

Presence of combustible materials and powdery solids

Presence of combustible materials

Table 2: Fire risk points in a graphic-arts printing press or workshop

Compressor room Wall-mounted unit heater

explosive limit. Furthermore, the sulphuric-acidvapour concentration must be below the establis-hed environmental daily-exposure limit (1 mg/m3).In order to prevent or reduce these risks, the bat-tery-charging areas must not be located under-ground and must be kept away from storage areaswhere combustible materials are accumulated.Other risk types related to batteries include burnsfrom electric-arc discharge and sulphuric-acidsplashing. Recommended applicable measuresinclude acid-resistant waterproof flooring and anappropriate slope so that wash water and any acidspillages can run off.

• The electrical installation is one of the most signi-ficant factors in starting and propagating a fire.Preventive measures include: implementingappropriate and well-maintained electrical protec-tion devices, not storing combustible material nearthe electrical switchboards, installing flameproofmaterials where necessary, installing earthsystems, and carrying out thermography for pre-ventive maintenance. Thermography is a techno-logy that uses a camera sensitive to the range ofvalues of the electromagnetic spectrum corres-ponding to infrared, to measure the surface tem-perature of different elements. Thermographicinspection therefore helps early detection, evenmonths before, of defective aspects of the electri-cal installation such as overheating or loose con-nections, which may lead to faults or even fire.

• Diesel forklift trucks can also act as a source ofignition. It is therefore advisable to fit them with anarc extinguishing device in the exhaust pipe (a sim-ple metal grille in the end section of the pipe willbe enough to prevent arcs from escaping). Itshould also be noted that diesel oil tanks used for

fuelling forklift trucks represent an explosion orfire risk. Preventive measures for diesel oil tanksinclude: avoiding storage of combustible materialsnearby and locating the tanks outside the building.

• Cutting and welding work. Even though welding isnot a common process in graphic-arts workshop orprinting presses, this type of work is often neces-sary for maintenance on machinery and for expan-sion work among other things. Claim records atindustrial sites indicate that such jobs create risksituations due to the projection of molten metalaround the workplace, resulting from the hot elec-trodes and tools or the effect of heat conductionthrough metal (structural elements, metal pipes,etc.) even if not close to the welding point.

It is especially dangerous to weld or carry out hotwork in the presence of:

- Combustible products located within reach ofwelding sparks.

- Combustible products in contact with the con-duits or pipes being worked on.

- Paper sheets or cuttings, and paint within reachof the sparks or in contact with hot conduits.

- Combustible construction elements, particularlysandwich-type panels with polyurethane orpolystyrene insulation used in partitions.

- Conduits with combustible heat insulationmaterials.

In order to prevent such work from creating sourcesof ignition, Action Protocols must be implementedfor welding work carried out by the company's own orsubcontracted personnel. The appendix at the end ofthis manual includes a Hot-Work Permit template.

[14] Safety guide graphic-arts printing presses and workshops

Diesel oil supply tank with spill basin

Battery charging with combustible materials (printed paper) nearby

[15]

In graphic-arts printing presses and workshops,there are also external factors that may causedamage both to the premises themselves and to thegoods therein. Measures are therefore required tominimise the consequences of a possible loss.

• Water and flood damage: These can cause consi-derable damage both to printing machines and tostored raw materials and finished products(books, magazines, labels, stamps, newspapers,etc.). It is important for stored goods to be kept onpallets or shelves (at least 10 cm high) and notplaced directly on the floor, thus reducing any

damage that may be caused by rain, spillage fromconduits, etc. Protection measures against floodsinclude proper maintenance of downpipes, drains,and fluid and/or rain conduits to ensure that thesechannels are not broken or crushed. It is alsonecessary to take into account the consequencesof flooding in the industrial site and the subse-quent clean-up work, as such consequencesinclude certain work-related risks, such as con-tact with high-voltage cables, possible structuralinstability, or pollution of the environment due tospillage of hazardous substances into the publicnetwork.

4.3. Water damage

5.1.1. Paper storage

It is important to note that compact reels and reams(packs of 500 sheets) of paper are difficult to ignite(being comparable to solid wood). The packagingmaterial, however, is easy to set alight. If a fireoccurs, the high fire load of the paper (10,000MJ/m3) can lead to the collapse of the buildingstructure. As a result, if a metal structure is used, itmust be protected by intumescent paint, sprayedwith mortar, or fitted with plates to prevent loss ofstability from fire or heating.

The main causes of fire in paper-reel store rooms(chart 3) are: fires caused by third parties, negli-gence by smokers, electrical, and to a lesser extent

fires caused by battery charging for forklift trucks,sparks from machinery, and lightning strikes.

[16] Safety guide graphic-arts printing presses and workshops

5.1. Fire risk

Electrical

9%

Cutting and

welding

6%

Smokers

11%

Others

20%

Unknown

24%

Caused by

third-parties

30%

Chart 3: Causes of fire in paper-reel store rooms

The factors that can influence the progress andseverity of a fire in a paper storage area are asfollows:

• Storage height. The higher the items are stored,the greater the damage caused by the fire and thewater used to extinguish it. An appropriate preven-tive measure would be to store items while obser-ving a minimum distance of one metre to the lightfittings of the premises.

• Storage type. In the event of fire, the reels maybecome frayed, which contributes to the spread ofthe fire. Another negative factor becomes relevantwhen items are not stored uniformly, as spacesbetween stored items promote air circulation andheat radiation between stacks. Recommendedmeasures include metal strapping of the reels andwrapping them in high-weight paper to delay theprogress of the fire.

In the case of both vertical and horizontal stacking,the reels must never be stored up to the wall, asthis arrangement of items creates inaccessibleareas enormously complicating the manual strug-gle against fires.

• Paper weighting. Combustion of low-weightpaper, such as tissue paper (toilet paper, napkins,etc.) greatly facilitates the start and subsequentprogress of fire, which is why the expected dama-ge is much greater than in the case of high andmedium-weight paper.

5.1.2. Handling and storage of hazardousproducts

In order to carry out storage and handling operationsfor hazardous products (inks, solvents, etc.), workinginstructions must be established regulating aspectssuch as:

• Work area and activity carried out

• Identification of the hazardous substance

• Human and environmental risks

• Action and first-aid in the case of accident

• Waste removal and management

The following recommended measures are worthnoting for storage and handling of flammablematerials:

• Decanting and mixing of flammable materialsmust be done in safe containers, taking special

care to choose the correct mixing, ventilation,and drainage equipment, and also the aspectsrelated to the tidiness, cleanliness, maintenance,and specific prohibitions for maintaining safetylevels.

• In light of problems of self-combustion, spillagesmust not be neutralised with sawdust but ratherwith inert substances such as sepiolite. For thesame reason, cloths soaked in flammable subs-tances must be put away in metal containers withlids, to be emptied at the end of the day.

The ink-mixing and solvent/ink-recovery rooms

should consist of enclosures partitioned off from therest of the industrial site. Access to these roomsmust be restricted and appropriately labelled withpictograms of the associated hazards. They mustalso be provided with forced ventilation and a flame-proof electrical installation.

Atmospheric humidity and conductivity have a directeffect on static electricity. Therefore, in conditions oflow humidity, the materials dry out and becomegood insulators (in which static-electricity chargesaccumulate), whereas if humidity is high, the mate-rials in question achieve a humidity balance with theenvironment, promoting conductivity and preventingthe accumulation of static electricity. Both in theink-mixing room and in the solvent/ink-recoveryroom, electrical charges may be generated whenrunning solvents through plastic hoses or in contactwith air. In closed rooms subject to the risk of staticelectricity, relative humidity should be between 50and 70%.

Ink dryers are the primary cause of fires in graphic-arts printing presses and workshops. There aremany types of dryers: linear direct-flame dryers,hot-air/direct-flame combination dryers, gas-burnerradiation dryers, electrical dryers, hot-air dryers,hot-air and steam-cylinder combination dryers, andso on. As a safety measure, the ink dryers must beprovided with an automatic shut-off device that acti-vates itself when the machine stops, and alsomanually-operated or automatic CO2 extinguishersystems.

Storage rooms. Flammable-product (e.g. alcoholsand solvents) storage rooms must be buildings, orpart thereof, exclusively dedicated to storage andwhose structures, roofs, and walls connected toother adjacent sections or buildings have a fire-resis-tance grading of 120 minutes (REI-120) (See section7.2). Access to other sections must consist of auto-matic fire-proof doors with at least fire-resistancegrading REI-60, and it is recommended that the floorhave a slight slope draining to a safe area. The stora-ge rooms shall also be provided with light partitio-

[17]

[18] Safety guide graphic-arts printing presses and workshops

ning to the exterior (e.g. openings, windows, and ven-ting areas) to enable venting in the event of explosion.

When handling and storing hazardous substances, itis essential for the electrical installation to be provi-ded with increased security and good ventilation. Inthe presence of flammable products, such as sol-vents or alcohols, the electrical installation must beflameproof.

5.1.3. Production processes

• The rotary reel machines are used for long news-paper print runs. Fire risk is considerable due to

the accumulation of large amounts of ink andpaper cuttings, as well as the formation of suspen-ded ink mist adhering to the walls and ceiling ofthe premises.

• During binding, dust gradually accumulates on themachinery, structural elements, and air ducts. Itshould be noted that starch dust is combustible,with a considerable fire load up to 2,000 MJ/m2.The risk is increased by the use of combustibleglues and paper dryers.

• The cutting and guillotining operations producelarge amounts of paper cuttings and waste, aswell as considerable accumulation of paperdust. An appropriate measure would be to installcutting suction systems which separate thewaste by means of a cyclone action depositingthe paper cuttings in a silo outside the produc-tion section.

• Explosions may occur in the printing room, espe-cially in the presses that use inks with a low flas-hpoint. The hot air from the dryers is frequentlyrecirculated, leading to solvent vapour concentra-tions in the dryers and their auxiliary conduitsexceeding the lower explosive limit. After ignition,the resulting explosion may trigger another moreviolent dust explosion in the accumulations ofstarch (used to prevent printed sheets fromcoming into contact with each other) and of paperdust on the machinery.

5.1.4. Third-party fire damage

In the event that the industrial site partially occupiesa building or is adjacent to or near other buildingsused for industrial or other purposes, said buildingsmay be affected by a fire started in the graphic-artsworkshop. This manual therefore presents recom-mendations aimed at the safety of the actual occu-pants and protection against third-party damage.

Alcohol tank

5.2.1. Waste management

Graphic-arts printing presses and workshops gene-rate waste that has to be managed in compliancewith legal requirements regarding waste handlingand management, as improper separation and sto-rage may create a serious threat to the environmentand personal health.

The main waste generated on this type of site are:

• Municipal solid waste: Food waste, bottle glass,paper and cardboard, plastic, office materials,packaging waste, non-hazardous product contai-ners, tins, etc.

• Inert industrial waste: Cables, wooden pallets,aluminium sheets, photo negatives, etc.

• Hazardous waste: Used oil, alcohols, fluorescentmaterials, photographic developing chemicals,contaminated containers (e.g. inks and solvents),aerosols, toner waste, contaminated absorbentmaterials (used to contain spillages), cloths soa-ked with solvents and inks, and so on.

5.2.2. Water pollution

Some spillages may cause pollution of water,such as:

• Water with oil and grease waste

• Water from parts and tools cleaning

• Accidental spillage of hazardous substances

• Wash water resulting from cleaning the remains ofpolluting substances on the floor

5.2.3. Soil pollution

The main activities that may lead to soil contamina-tion are:

• Changing oil or replacing parts on unpaved ground

• Storing oils, inks , or alcohols in non-watertighttanks

• Storing metal waste (scrap) soaked with lubricantsand oils, and located in areas not having the neces-sary characteristics to prevent pollution (coating,paving, waterproofing, containment systems, etc.).

5.2.4 Controlling pollution

In order to prevent water pollution, it is essential tocomply with the limits set out by the correspondingdumping authorisation and prevent any spillage of

[19]

5.2. Environment

Waste paper compacter

Isopropyl alcohol is highly flammable and an irritant

[20] Safety guide graphic-arts printing presses and workshops

toxic or hazardous substances that may reach vulne-rable areas such as unpaved soil, sewage pipes, orsanitation networks.

Preventive and protective measures for preventingsoil pollution must include paved areas and meansfor containing and collecting any spillages of hazar-dous substances.

Furthermore, it is recommended to carry out emis-sion checks on volatile organic compounds (VOCs)when solvents are used in cleaning operations.

Hazardous substances such as oils, solvents, oralcohols must be provided with safety basins to con-trol any leaks from tanks. It would be an appropriatemeasure to clearly indicate and mark off the storagearea for hazardous products and waste.

Generated waste must be managed by a manage-ment entity authorised to recycle said waste. Thewaste may not remain on the industrial site for morethan six months.

Absorbent material for containing spillages Collection point for used ink containers

[21]

The following conclusions were obtained from astudy on losses in graphic-arts workshops (Chart 4):

• Fires are caused both when the printing machineis in operation and when it is undergoing cleaningoperations and the machine has been shut down.

• The main deficiencies are: machine not cleanedsufficiently, lack of locking mechanisms for inkdryers, and defective electrical and mechanicalmaintenance.

• Fires in rotogravure rotary machines were causedby ignition of flammable solvent vapours, short-circuits, or electrostatic discharges.

[22] Safety guide graphic-arts printing presses and workshops

22%

22%

16%

11%

9%

6%

6%

5% 3% Gas and infrared dryers

Arcs and discharges in electrical equipment

Electrostatic discharges

Lights and spot lamps

Spontaneous ignition in oily waste

Friction in mechanical components

Smokers

Cutting and welding

Others

Chart 4: Sources of ignition in graphic-arts workshops

The most frequent type of fire in graphic-arts prin-ting presses and workshops is derived from solidcombustible materials (class A fires), such aspaper, cardboard, wooden pallets, dirty cloths, andplastic. There are also combustible liquids used inthe production processes that can cause fires(class B fires), such as inks, alcohols, oils, andsolvents.

The most frequent sources of ignition on this type ofsite and which can trigger outbreaks of fire aremainly the dryers and elements linked to the electri-cal installation, e.g. sparks (electrostatic discharges,electric arcs, or light fittings.

In light of the combined presence of combustiblematerials and sources of ignition, preventive measu-res must also include a set of control and fire-extin-guishing means (active protection). The recommen-dations for fire protection can be prioritised into twodifferent levels.

7.1.1. Basic level

Once a fire starts, the extinguisher devices must stopit from propagating, especially if the factory containsa large density of combustible or flammable mate-rials, as in the case in question. The protective mea-sures that we deem essential are:

[23]

7.1. Active fire protection

[24] Safety guide graphic-arts printing presses and workshops

• Extinguishers. It is important to fit the buildingout with a provision of handheld extinguishers foruse by people properly trained for this purpose(Table 3).

There must be enough ABC multi-purpose drychemical extinguishers so that the actual distanceto be covered between any occupiable point and anextinguisher is no more than 15 m. Furthermore,CO2 extinguishers shall be fitted near electricalswitchboards and to attack fires in machinery withelectronic components, as they are more effectivein fighting electrical fires, and the multi-purposepowder (which has a larger extinguisher capacity)is corrosive and may affect installations not invol-ved in the outbreak but which are touched by thecloud of dust generated when the device is dis-charged.

• Fire detection and alarm systems. It is recom-mended to install these systems on industrial sitesin case of outbreaks of fire that may develop at anytime when the premises are not occupied. It is par-ticularly advisable to install them when the builtarea is greater than 3,000 m2. Smoke detectors andfire alarm push buttons will be installed, and thelatter shall be located so that the maximum dis-tance to be covered is no more than 25 m. Thedetection centre must be located in a place super-vised 24 hours a day with a connection to an exter-nal communication centre (ECC), which is able tointervene or issue the proper notices and deployvisible and audible sirens covering the entire areaand ensuring evacuation of all occupants.

• Fire-hose cabinets. It is recommended to install45-mm fire-hose cabinets. All areas must be loca-ted at a distance of less than 25 m from a fire-hosecabinet. It is important that company personnel betrained to use them.

• Emergency lighting and signage. The evacuationroutes shall be provided with emergency lightingand markings so that all occupants can evacuatesafely.

• Signage for fire equipment, which facilitates andexpedites extinguishing.

Type

Multi-purpose dry chemical ABC

CO2

Water

Minimum efficacy1

34A-144B

89B

21A – 113B

Observations

For use with any kind of combustible material.

For use with combustible liquids and electrical fires.

For combustible solids and, if it contains a percentage of foam,combustible liquids.

1 Fire extinguishing capacity during a test standardised in accordance with UNE 23110-1, on type A combustible solids and/or type B combustible liquids.

Table 3: Characteristics of handheld extinguishers

45 mm fire-hose cabinet

Examples of emergency markings

[25]

7.1.2. Recommended level

The following are also indicated as recommendedmeasures to improve the protection level in the gra-phic-arts printing press or workshop in the event offire:

• Fire-extinguishing carts. In addition to the hand-held extinguishers, every 1,000 m2 of surface areashould be provided with a 50 kg ABC-powder cart

or two of 25 kg, located by the main entrance ofthe enclosure, the main site entrance door, or ifthere are various sets of stairs, by the most centralentrance door.

• Automatic CO2 fire-extinguishing systems for pro-tection from electrical fire risks, such as: electricgenerator room (if there is one), low-voltage room,processing centre, etc.

• Fixed foam extinguisher system with total cove-

rage of flammable stores. Foams are especiallyuseful for fighting fires from combustibles in liquidphase. Applying foam to a flammable liquid pre-vents oxygen from reaching its surface, thus hel-ping to extinguish the fire.

• Hydrants. It is recommended to set up a networkof hydrants if the site surface area is greater than2,000 m2.

• Automatic water sprinklers. As with the hydrantnetwork, if the largest fire sector is greater than2,000 m2, it is recommended to install an automa-tic water-sprinkler extinguishing system, espe-cially in paper storage areas, given the high ther-mal load.

• Supply of water for use against fires. It is recom-mended to have a reliable supply of water for useagainst fires. If it is not possible to guarantee asufficient supply from the public system, a priva-te supply must be used to ensure pressure andflow rate to the fire-hose cabinets or, if applica-ble, the external hydrant or automatic sprinklernetwork.

• Self-protection plan. It is important to draw up aself-protection plan in order to guarantee perso-nal safety in cases of emergency (e.g. fire, bombthreat, health emergency, or evacuation). Thisdocument includes the actions to be carried outin the event of emergency, allocation of self-pro-tection equipment, and drawings with the distri-bution of available protection means. The self-protection plan shall be properly implemented bydeveloping training courses, establishing extin-guishing practices, and carrying out regular drills(simulated triggering of emergencies) in order totrain personnel.

In addition to the fire control and extinguishingsystems (active protection), it is important that thisactivity be provided with physical elements (e.g. walls,doors, and floor structures) that limit or hinder theprogress of the fire (passive protection). This protec-tion philosophy consists of establishing a surface areaor part thereof, during the design phase, in which thefire can spread to its maximum extent without affec-ting all the other areas. At the same time, it must beensured that the structure supporting the buildingguarantees a minimum fire resistance (time in which itmaintains its load-bearing capacity), so that its occu-pants can be evacuated and fire fighters can intervene.

Graphic-arts printing presses or workshops may belocated in buildings with other uses (e.g. industrialor residential) or even adjacent to one or more otherbuildings. From this point of view, the graphic-artsprinting press or workshop should constitute a sepa-rate fire sector, and therefore its structural partsmust be designed so that if a fire is started within

said sector, it cannot propagate to the borderingestablishments. Furthermore, the structure suppor-ting these premises must be fire stable for at leastninety minutes. In the case of buildings shared withother uses, minimum stability may be greater if sorequired by regulations for the other activitiescarried out in the building (industrial or residential).

In relation to sectorisation or compartmentalisation,it is recommended that all premises where hazar-dous activities are carried out or where there is aconsiderable fire load be constituted as fire sectors,capable of resisting and confining the fire, and pre-venting it from spreading to adjacent sectors orareas. Such premises include the following:

• Flammable-product stores (alcohols, machine-cleaning solvents, etc.). REI-180 grading is recom-mended for such cases, that is, 180 minutes ofstructural stability, sealed against smoke, and withheat insulation.

7.2. Passive fire protection

[26] Safety guide graphic-arts printing presses and workshops

• Paper storage (printed and/or reels). REI-180 isrecommended.

• General facility enclosures, such as air compres-sors, air-conditioning equipment, boilers, mainelectrical switchboard, transformers, electricgenerator sets, and a pump room. REI-90 isrecommended.

• Office, presentation, and sales areas. If eachof these exceeds 250 m2 then REI-90 is recom-mended.

• In general, doors shall have a fire resistance ofat least half that of the fire sector in which theyare located. Compartmentalisation must not belost in the service conduits passing through thewalls or floor structures, fire dampers, fibrosi-licate panels, and rockwool, etc. may thereforebe fitted.

• Cable raceways, channels, and service conduits

passing through walls or floor structures shall bespecially treated to ensure that the intended com-partmentalisation is not compromised at thosepoints. Elements such as special mortars,panels, and intumescent sacks can be used forthis purpose.

There are various sources of ignition, flammable pro-ducts, and large quantities of paper (combustiblematerial with a high fire load) in graphic-arts printingpresses and workshops, which is why it is essential tokeep them tidy and clean by means of the followingrecommended standards of good practice:

• Carrying out inspections and risk assessments forsubsequent prevention, control, and minimisation.

• Applying the right maintenance schedule to theoperating equipment, installations, and machines.

• Putting up "You are here" plans with evacuationroutes and safety instructions.

• Preventing areas of saturation in storage areasand providing adequate waste management, forwhich purpose classified waste containers wouldbe an appropriate collection measure.

• Applying appropriate cleaning standards in theareas surrounding machinery that produces com-bustible dust (paper and starch).

• Establishing procedures to inform contractors,visitors, and hauliers of the basic prevention andaction measures in the case of emergencies at thefacilities.

Compartmentalisation with EI doors in flammable-materials stores

Paper cutting collection

7.3. Other protections

[27]

• In the workplace, indicatingthe personal protection gearand anti-fire protectionmeans.

• Fitting filters at the entranceof the extraction conduits ofthe newspaper printingrooms. The conduit must beprovided with easy-to-open

panels or traps for periodicinspection and cleaning.

• Solvents used to clean the

presses must have a high

flashpoint (at least 38 ºC). In order to clean hotsurfaces, the flashpoint must be at least 10 ºCabove the surface temperature.

• Not blocking access to the extinguishers, hoses,and other general elements for fighting fires.

• Implementing preventive measures for workersafety, such as:

- Using safety gloves for handling ink containers.

- Wearing tight-fitting work clothes, and avoidingthe use of bracelets, chains, or other personalitems to prevent the risk of trapping.

- Fitting safety showers with emergency eyebaths.

- First-aid kits.

- As regards the rotary newspaper machines, ope-rating with several machines at once generateshigh noise levels. It is therefore recommended touse ear plugs or defenders.

Any industrial establishment with customer-facingoffices and/or sales premises is provided with elec-tronic office-automation equipment and in somecases metallic money, which may be targeted bythieves. An appropriate measure would be to installa safe located in an area away from windows orwalkways from which it would be visible or easy to

access. Apart from money, this safe must contain thecompany's important documents such as deeds andinvoices. It is also recommended to take the neces-sary security measures to prevent the removal ofpre-press files, phototypesetting items, and printingplates given their strategic importance to the pro-duction process.

Indications for anti-fireprotection means

Emergency eyes wash

7.4. Anti-theft protection

[28] Safety guide graphic-arts printing presses and workshops

7.4.1. Passive or physical protection

The aim of passive anti-theft protection is to act as adeterrent or hindrance to intrusions into the areabeing protected. This, in turn, can be subdivided asfollows: peripheral protection (e.g. walls, fencing,bollards, and enclosure lighting), perimeter protec-tion (e.g. doors, metal locks, grilles, and securityglass), and internal or specific protection for metallicmoney (safes), computer equipment, documentation,machinery, tools, and merchandise.

7.4.2. Active protection

The purpose of active protection is to detect the pre-sence of intruders in the industrial establishment andsend an alarm signal to the anti-theft centre.Examples of active protection include external peri-pheral detection (e.g. infrared barriers), internal peri-pheral detection (e.g. magnetic contacts), volumetricdetection (e.g. infrared or dual-technology sensors).

The alarm devices must be connected to the anti-theft centre of the establishment, and also with anexternal centre managed by an accredited securitycompany. It is recommended that the connectionbetween both centres be established by means of asupervised communications system (e.g. Intranet,Internet, or mobile telephony - GPRS, UMTS) or withanti-sabotage devices.

7.4.3. Human protection measures

Human protection measures include the company'sown or subcontracted security guards. The companymay enter into an assistance-service agreementwith an external security company.

In general, anti-theft protection is based on the con-trol of three complementary aspects:

Safe Anti-intrusion centre keyboard

Physical security

Electronic security

Organisational security

• Fencing• Grilles• Doors• Security glass• Etc.

• Alarm devices

• Security personnel• Safekeeping of keys• Control of security codes

[29]

There is a significant risk of fire in graphic-arts prin-ting presses and workshops, hence the importance

of establishing effective measures appropriate toeach type of hazard.

Risk type

Fire

Incident in graphic-arts printing

presses and workshops

• High accumulation of fire load (paper)• Solvents• Flammable inks• Alcohols• Explosive atmospheres due to paper and

starch dust, or flammable vapours• Various sources of ignition (e.g. machinery

and electricity)• Smokers

Protective measures

• Extinguishers• Fire-hose cabinets• Fire detection• Compartmentalisation of production and

storage areasUpper level:• Fire-extinguishing carts• Fixed CO2 extinguisher systems in technical

rooms• Fixed foam extinguisher system in flamma-

ble stores• Automatic water sprinklers in paper stores• Compartmentalisation in technical rooms

[30] Safety guide graphic-arts printing presses and workshops

Risk type

Theft

Other material damage

Civil liability

Work risks

Incident in graphic-arts printing

presses and workshops

• Cash, documentation, computer equipment• Damage resulting from theft

• Water damage (water-channel overspills,blocked downpipes, etc.)

• Weather damage: lightning strikes, wind,torrential rain, snow, hail, etc.

• Fires affecting third parties• Explosions affecting third parties• Environmental• Occupational accidents

• Cuts, amputations, trapping, and impactsfrom extraction systems and printed-papercollection systems.

• Contact with harmful substances• Electrical discharges• Hearing problems• Ergonomic stress due to repetitive manual

work

Protective measures

• Safes• Volumetric sensors, magnetic contacts,

alarm communication centre.• Anti-sabotage systems• Supervised communications systems (e.g.

Intranet, Internet, mobile telephony –GPRS,UMTS-) between the alarm communicationcentre and that of the security company

• Maintaining downpipes, drains, and rainwa-ter channels in good condition

• Installation of lightning rods in areas with ahigh lightning-strike rate

• Effective sectorisation from third parties• Own active and passive protection measures

against fire• Waste management and pollution control• Safe hazardous-goods storage• Work risk prevention plans

• Development of work risk prevention• Handguards, dual actuation control, and pro-

tective screen• Emergency self-protection equipment• Warning signs• Instructions for use• Correct equipment maintenance• Ear plugs or defenders• Rotating rosters for repetitive tasks

[31]

> Appendix

[32] Safety guide graphic-arts printing presses and workshops

Title: Graphic-arts printing presses and workshops Safety Guide.Published by: Mapfre RE© ITSEMAP Servicios Tecnológicos MAPFRE, S.A.© MAPFRE RE Compañía de Reaseguros, S.A.Printed by: Imagen Gráfica de Ávila, S.L.Printed in SpainSpanish legal deposit: AV-134-2008

All rights reserved. This publication may not be reproduced, recorded nor transmittedin any manner or by any means without the publisher's consent.

Pº Recoletos, 2528004 Madridwww.mapfre.com M

od. M

Re-

SGG

A/0

9-08