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Health and Safety Executive
The printer’s guide to health and safety
This is a free-to-download, web-friendly version of ‘The printer’s guide to health and safety’ (Second edition, published 2002). This version has been adapted for online use from HSE’s current printed version.
Youcanbuythebookatwww.hsebooks.co.ukandmostgoodbookshops.
ISBN 978 0 7176 2267 2 Price £12.50
Whatever role in printing, this book can help you comply with the law and reduce the risks of injuries and ill health. The new edition includes safety guidelines on a wider range of processes and up-to-date advice resulting from research into the causes of printing accidents. It also deals with recent changes in legislation and has a comprehensive index.
HSE Books
Page2of187
Health and Safety Executive
© Crown copyright 2002
Firstpublished1998Secondedition2002
ISBN9780717622672
Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans(electronic,mechanical,photocopying,recordingorotherwise)withoutthepriorwrittenpermissionofthecopyrightowner.
Applicationsforreproductionshouldbemadeinwritingto:TheOfficeofPublicSectorInformation,InformationPolicyTeam,Kew,Richmond,SurreyTW94DUore-mail:[email protected]
ThisguidanceisissuedbytheHealthandSafetyExecutive.Followingtheguidanceisnotcompulsoryandyouarefreetotakeotheraction.Butifyoudofollowtheguidanceyouwillnormallybedoingenoughtocomplywiththelaw.Healthandsafetyinspectorsseektosecurecompliancewiththelawandmayrefertothisguidanceasillustratinggoodpractice.
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What is PIAC?
ThePrintingIndustryAdvisoryCommittee(PIAC)wasformedinJuly1979toadvisetheHealthandSafetyCommission(HSC)onmattersconcerningtheprintingindustry.ThemembersofPIACarenominatedbytheCBIandtheTUCandappointedbyHSCtoworktogetherwiththeHealthandSafetyExecutive(HSE)toadvisetheindustryonhealthandsafety.
Why does PIAC exist?
Everyyearpeopleworkingintheprintingindustryareseriouslyinjured.Manyotherssufferillhealthwhichpreventsthemfromdoingtheirnormalwork.Almostallofthesecasescouldbeprevented.
PIACisdeterminedtotakeactiontoimprovehealthandsafetyperformanceintheprintingindustry.AspartofthisprocessPIAChasproducedthisguidancebooktohelpthoseresponsibleforhealthandsafetyintheindustryunderstandtheirresponsibilitiesandtakethenecessaryaction.
Acknowledgements
Assistancefromthefollowinginprovidingphotographsisgratefullyacknowledged:
MatthewsthePrintersHarmsworthQuaysPrintingLtdDeltaDisplaysHeidelbergGraphicEquipmentPrintoWrappingsGossGraphicSystemsLtdPalamaticHandlingSystemsLtdStrategicSafetySystemsHealthandSafetyLaboratoryNewsInternationalNewspapersLtd
Members of the Printing Industry Advisory Committee
MrADPorter Chair,HealthandSafetyExecutiveMrIWilcock BritishPrintingIndustriesFederationMrRAHudspith Graphical,PaperandMediaUnionMrDBarker Graphical,PaperandMediaUnionMrAClarke Graphical,PaperandMediaUnionMrGMcintyre NationalUnionofJournalistsMrGCooper NewspaperSocietyMrGMcNab ScottishPrintEmployersFederationMrBPurkis NewspaperPublishersAssociationMrWStothard BritishPrintingIndustriesFederationMsSWhittaker NewspaperPublishersAssociationMrMGriffiths Graphical,PaperandMediaUnionMrMDWilcock Secretary,HealthandSafetyExecutive
Members of PIAC safety and human factors sub-committee
MrMDWilcock Chair,HealthandSafetyExecutiveMrRAHudspith Graphical,PaperandMediaUnion
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MsZDenmark JarrardPrintingLtdMrPChambers StrategicSafetySystemsMrDWallis GossGraphicSystemsLtdMrPBryant GossGraphicSystemsLtdMrMMcGilly WestFerryPrinters
TheassistanceprovidedbySPeace,SHuggans,JHardy,KMarriottandTStonleyisgratefullyacknowledged.
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ContentsIntroduction
What is in this book for me? 11
The law and guidance 11
Chapter 1 Managing health and safety
Relevant legislation 13
Health and safety in the printing industry 13
Setting your policy 14
Organising your staff 15
Planning and risk assessment 15Riskassessment 15
Monitoring 17Inspectionandchecks 17Evaluationofaccidents,illhealthandnearmisses 17
Auditing and review 17
Home working 18
Lone working 18
Accidents and emergencies 18Thelawandreportingaccidents 18Investigatingaccidentsandemergencies 19Dealingwithemergencies 21Firstaid 21
Permits to work 22
Working time 22Theproblem 22ApplicationofWTR 22Workingtimelimits 23Healthassessment 23Nightshiftriskassessment 23Records 23Peoplewithmorethanonejob 24Goodtimemanagementisgoodbusiness 24
Control of contractors 24Thelawandmanagingcontractors 24Fivepracticalstagesforworkingwithcontractors 25Contractorsandyouremployees 27
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Consulting employees on health and safety 27Inspectorsandenforcement 28Powersofinspectors 28
Chapter 2 Training
Relevant legislation 29
Training methods 29
Induction training 30Trainingsafetyrepresentatives 32
Chapter 3 Workplace and transport safety
Relevant legislation 33
Fundamentals of workplace health and safety 33Safeplaceofwork 33Lighting 34Movingaroundthepremises 34Designingworkstations 34Cleanliness 35Hygieneandwelfare 35
Safe movement of vehicles 36
Loading and unloading of vehicles 36
Safe stacking and storing 37Generalprinciples 37Rackinginstallations 38Useofpallets 38Reelstorageandstacking 39Manualbreakingdownofpyramidstacks 40
Lift and clamp trucks 40Thelawandlifttrucks 40Healthproblems 41Safetyguidelinesforlifttrucks 41Safetyguidelinesforautomaticguidedvehicles(AGVs) 43
Asbestos in buildings 43Whereisasbestosfoundinbuildings? 44Whatshouldyoudo? 44
Chapter 4 Health risks
Relevant legislation 45
Occupational health and rehabilitation 46Occupationalhealthservices 47Healthsurveillance 47Rehabilitation 48
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Hazardoussubstances 48Exposurelimits 49AssessmentunderCOSHH 50Preventionorcontrolofexposure 50
Chemical hazards in printing 52
Specific process health hazards 54Designandartwork 54Graphicreproduction 54Platemaking 54Deletionfluids 54Lithographicprinting 54
UK Printing Solvent Substitution Scheme 55Ultraviolet(UV)curablematerials 56
Acrylate Preference Criteria 57Screenprintingandcleaning 60Useofisocyanates 62Disposalofwaste 63
Noise 63Doyouhaveanoiseproblem? 63Measuringnoiselevels 63Noiseandthelaw 63Noisereduction 64Reducingexposure 65Providinghearingprotection 65Commonproblemsandsolutionsforprinters 65Hearingloss 66
Manual handling 67Thelawandmanualhandling 67Riskassessmentfilter 67Whataretherisks? 68Reducingtherisks 69Handlingnewspaperandmagazinebundles 69Training 69Assessingandreducingrisks 71Repetitivehandling 72HowtoassessandtackleULDs 72
Radiation 74Lasers 74Ultraviolet(UV)light 75Infraredsources 76Staticeliminators 77
Skin disease (dermatitis) 77Whatisdermatitis? 77Affectedareas 78Symptoms 78Work-relatedsubstances 78Whyemployersshouldtakeaction 79
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Other health issues 79Workplacestress 79Newandexpectantmothersatwork 80Drugsandalcohol 81Passivesmoking 81Humidifierfever 81Legionellosis 82Asbestos 82
Local exhaust ventilation (LEV) 83Maintenance,examination,testingandthelaw 83Selectionanduse 83MakingthemostofLEV 83CommoncausesofLEVfailure 83
Personal protective equipment (PPE) 84PPEandthelaw 84Respiratoryprotectiveequipment(RPE) 85Eyeprotection 86Skinprotection 86StorageofPPE 87
Chapter 5 Process safety
Relevant legislation 88
Basic rules of machinery safety 89Machineryguarding 89Interlockingguards 91Machinecontrols 92Controldefinitionsforpressmovement 93
Safe systems of work 94Safesystemsofworkforpresscleaning 94Otheressentialsafeguards 95
Machinery maintenance 95
Safety hazards by process 95Pre-press 95Digitalprintingandcopying 97Printing 98Publishingrooms 117Envelope-makingmachines 119Guillotines 122Othercuttingmachines 127Looseknifepunchingmachines 128Flat-bedcuttingandcreasingmachines 129Autoplatens 130Hand-fedplatensusedforcuttingandcreasing 130Labelpunchingmachines 132Roundcorneringmachines 132Foldergluermachinesusedinboxmaking 132Bindery 133Booksewing 136Finishingmachines 139
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Acquiring machinery and other work equipment 146Thelaw 146Wordofcaution 147
Chapter 6 Electricity
Relevant legislation 148
General hazards and precautions 148
Particular hazards and precautions for printing 149
Inspection and maintenance 149
Electric shock 150
Chapter 7 Fire and explosion
Relevant legislation 152Riskassessment 152
Fire risk management 152
General fire precautions 155
Process fire precautions 156Mainfirehazards 156Thefiretriangle 156
Charging electrically operated lift trucks 158
Lithographic printing 159Explosionrisksinblanketwashsystems 159
Explosion risks in flexographic and gravure 161
Precautions for dryers 162
Precautions for coating machines 163
Precautions for laminators with glue application 163
Chapter 8 Maintenance
Relevant legislation 165
What needs maintenance? 165
Statutory testing and thorough examination 165MaintenanceandinspectionrequiredbyPUWER98 166
Safety during maintenance work 167Permitstowork 167Isolationandlock-offprocedures 168
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Appendices 1
Appendix1Safeguardingterms 169Appendix2Exampleriskassessmentform 172Appendix3Assessinghazardsinasmallprintworks 173
References 174
Further information 185
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IntroductionEveryyearpeopleintheprintingindustryareinjuredandbecomeillthroughwork.Theaimofthisbooklet,andothersproducedbyPIAC,istohelpallthoseinvolvedinprinting,includingemployers,employeesandsuppliers,toidentifythemaincausesofaccidentsandillhealthandtoexplainhowtoeliminatethehazardsandcontroltherisks.Ifyouareamanager,itwillhelpyoumanagehealth,safetyandwelfareinyourcompanyandcomplywithyourlegalresponsibilities.Ifyouareanemployeeorsafetyrepresentativeintheindustry,itshouldprovideyouwithsomeusefulinformationaboutwhatstandardstoexpectandhowaccidentsandillhealthmightbeprevented.
What is in this book for me?
Thisbookisa‘one-stopshop’givinghealthandsafetyadvicetoprinters.Allprinters,largeandsmall,shouldfindsomethingofinterestinit.Chapters1,2,3,6,7and8covergeneralhealthandsafetyissuesandwillbeusefultoeveryone,fromnewspaperproducerstohigh-streetcopiersordigitalprinters.Chapters4and5aremorespecialisedandcoverspecifichazardsarisingfromsubstancesorprocessesusedbyprinters.Tohelpyoufindyourwayaroundthebook,eachchapteriscolourcodedandacomprehensiveindexcanbefoundattheback.
Asprintingisawide-rangingactivity,thisbookdoesnotdealwitheveryhazardwhichmayariseoreveryprecautionthatcanbetaken.Itdoes,however,outlinesomeofthemoreseriousandfrequenthazardsandwaysofdealingwiththem.
Thereare‘Relevantlegislation’sectionsatthestartofeachchapterwhichlisttheActs,regulationsetcwhichapplyandmayalsocontainsummariesofthemainlegalrequirements.Thesesectionshaveabluebackground.
Youmayfindthisbooktellsyouallyouneedtoknow,butifnot,the‘References’sectionwillhelpyoufindoutmore.Thisisstructuredinchapterordertomakeiteasiertouse.Seethe‘Furtherinformation’sectionforusefuladdresses.
Lookingatyourbusinessinthewaythisbooksuggestswillhelpyoustaysafe.Followingtheadviceinitwillmeanthatyouaregoingalongwaytosatisfyingthelaw.
The law and guidance
Theterm‘reasonablypracticable’isusedinmuchofUKhealthandsafetylawandwillbefoundinthisbook.Thismeansthatthedegreeofriskinaparticularjoborworkplaceneedstobebalancedagainstthetime,trouble,costandphysicaldifficultyoftakingmeasurestoavoidorreducetherisk.Inotherwords,itwouldhavetobeshownthataparticularriskisinsignificantinrelationtothesacrificeneededtoreduceit.Thisbookwillhelpyoudecidewhatisreasonablypracticableforyourcompany.
Theword‘must’indicatesadefinitelegalrequirement.‘Do’sanddon’ts’,‘shoulds’and‘shouldnots’andotherrecommendationsrepresentbestandgoodpracticewhichwillleadtocompliancewithwhatisreasonablypracticable.However,theremaybeotherlegallyacceptablewaysofachievingthesameobjective.TherequirementsofanApprovedCodeofPractice(ACOP)haveaspecialstatusinlaw;acourtwillfindfaultifyouhavenotfollowedtheCodeordonesomethingequallyeffective.
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‘Thinkabout’,‘consider’andsimilarphrasescontainatiporhintwhichmaynotamounttoapreciselegalrequirementbutindicateanapproachtoahealthandsafetyproblemwhichoughttobeconsidered.
A‘safeguard’isameansofreducingrisktohealthand/orsafety.
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Chapter 1 Managing health and safetySee the ‘References’ section at the back of the book for details of publications which relate to Managing health and safety
Relevant legislation
TheHealthandSafetyatWorketcAct1974(HSWAct)andtheManagementofHealthandSafetyatWorkRegulations1999placedutiesoncompaniesandindividualstoensurethatadequateprovisionsaremadeforhealthandsafetyatwork.Directors,managersandotherresponsiblepeopleallhavedutiesundertheAct.Commitmenttotheeffectivemanagementofhealthandsafetyshouldcomefromthetop.
Youmustensure,sofarasisreasonablypracticable,thehealth,safetyandwelfareofyouremployeesandanyotherswhomaybeaffectedbywhatyoudo.Thiswillincludethosewhoworkforyouascasualworkers,part-timers,traineesandotherswhovisityourpremises,egcustomersorcontractors.Itwillalsoincludethosewhomaybeaffectedbywhatyoudo,egneighbours,clients,salespeople,membersofthepublicandthosewhouseproductsorequipmentyoumake,supplyorimport.
Inaddition,employersmust:
n identifythemeasurestheyneedtotakebycarryingoutariskassessment(andifyouemployfiveormoreyouwillneedtorecordthemainfindings);
n haveawrittenhealthandsafetypolicy(ifyouemployfiveormorepeople);n haveadequatearrangementsforhealthandsafetyand,inparticular,forthe
effectiveplanning,organisation,control,monitoringandreviewofthepreventivemeasuresrequiredunderhealthandsafetylaw;
n provideemployeeswithanynecessaryinformationandtraininginsafepractices;
n appointoneormorecompetentpersonstohelpthemtakethemeasuresnecessarytocomplywiththeirlegalduties.ThisincludesrequirementsimposedbytheFirePrecautions(Workplace)Regulations1997.Acompetentpersonisregardedasapersonwhohashadenoughtraining,experienceorknowledgeandotherqualitiestoenablethemtoprovideeffectivehelp.Employersshouldappointtheirownemployeesforthisroleifpossible.
Health and safety in the printing industry
TheprintingindustryisasignificantemployerintheUnitedKingdom.Thereareapproximately340000workersemployedinover15000companies,makingtheindustryoneofthelargestemployersinthecountry.
AccordingtoHSE’sannualstatistics,theprintingsectorhasaloweraccidentratethanassociatedindustriessuchaspaperandboardproduction.However,thereareaspectsoftheprintingsector’shealthandsafetyrecordwhichcauseconcern,inparticularahighrateofmachinery-relatedaccidents(fivetimeshigherthaninotherindustries)andthenumberofcontractorsinvolvedinaccidents.Therearealsosignificanthealthrisks,suchasdermatitisandotherproblemsassociatedwiththeuseofsolventsthatneedtobeconsidered.
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Detailedanalysisofthepatternofaccidentsintheprintingindustryshowsmanysimilaritiestoindustryingeneral,buttherearekeysector-specificdifferences.Particularpartsofthemanufacturingprocess-printingitself,andwarehousing,yardandwastedisposalactivities,consistentlyemergeasthemainareaswhereaccidentsoccur.
Theproportionofaccidentsattributabletofinishingvariesconsiderablyfrom13%inthenewspapersectorto40%inbookbindingandfinishing.Almostaquarterofallaccidentsresultfrommanualhandling,usuallylifting.Manyarealsocausedbycontactwithmovingmachinery.
Foraccidentsdirectlyinvolvingsomeformofmachinery,almostthree-fifthsoccurwhiletheinjuredpersoniscleaningorpreparingtheprintingmachinery,ie‘make-ready’.Oneinfivesuchaccidentsoccurastheinjuredpersonisattemptingtofreeablockageintheirmachine.Cuts,strainsandpinchinjuriesarethemostcommontypeacrosstheindustry.Manyoftheseaccidentscanbeeasilyprevented.Mostwarehouseaccidentsinvolveworkplacetransportorresultfrommanualhandling.
Employersintheprintingsectorneedtolookcarefullyattheirriskassessmentsandthecontrolmeasurestheyusesuchasphysicalsafeguards,safesystemsofworkandtraining.Comparewhereyouarenowwiththebenchmarkstandardsfortheindustrydescribedinthisbook.Thispublicationgivesyouagoodstartingpointforallyourhealthandsafetyneeds.
Setting your policy
Ifyouemployfiveormorepeople,youmusthaveawrittenstatementofyourhealthandsafetypolicy.Itneedstobeacarefullyprepared,well-thought-outandup-to-datedocumentbasedoncommitmentatseniormanagementlevel.
Thestatementshouldbespecifictoyourfirm,settingoutyourgeneralpolicyforprotectingthehealthandsafetyofyouremployeesatworkandspecifyingtheorganisationandarrangementsforputtingthepolicyintopractice.Theprimarypurposeofthisdocumentistosetoutyourbasicactionplanonhealthandsafetyanditshouldleadtobetterstandardsintheworkplace.
Thepolicyneedsto:
n statewhatyourgeneralaimsarewithregardtoyouremployees’healthandsafety.Thestatementshouldbesignedanddatedbyseniormanagementtomakethefirm’scommitmenttothepolicyclear;
n clearlyshowwherethedutiesforhealthandsafetylie.Responsibilityforhealthandsafetyrestsatthehighestmanagementlevel,however,individualsateverylevelwillhavetocontributeandacceptsomeresponsibilityforcarryingoutthepolicy;
n describethesystemsandproceduresinplaceforensuringthehealthandsafetyofyouremployees.Youcanlinkthistootherdocumentssuchasriskassessments,fireprecautionsandyourCOSHHassessment(seeChapter4),inwhichyouwillhaveconsideredtherisksthatariseinyourworkplaceandtheactiontocontrolthem.Yourpolicyshouldbeclearlysetout;
n bebroughttothenoticeofyouremployees,egbygivingthemacopy;n bereviewedandifnecessaryrevisediftheorganisationchangesornew
hazardsarise;n besupportedbysufficientresources,egenoughfinance,peopleandtimeto
translatethepolicyintoaction.
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Organising your staff
Thefour‘Cs’ofapositivehealthandsafetycultureare:
n competence-inrecruitment,trainingandadvisorysupport;n control-byallocatingresponsibilitiesandsecuringcommitment;n co-operation-betweenindividualsandgroups;n communication-includingoral,writtenandvisibleforms.
Askyourself:
n Dopeopleknowwhattheyshouldbedoingandhowtodoit?n Doyouconsultandinvolveyourstaffandthesafetyrepresentativeseffectively?
(See‘Consultingemployeesonhealthandsafety’laterinthischapter.)n Doyourstaffhaveenoughinformationabouttheriskstheymaybeexposedto,
thecontrolsprovidedandhowtousethem?n Doyouhavetherightlevelsofexpertise?Areyourpeopleproperlytrained?
(SeeChapter2.)n Doyouneedspecialistadvicefromoutsidetheorganisationandhaveyou
arrangedtoobtainit?
Planning and risk assessment
Systematicplanningforhealthandsafetyisneededsothathazardscanbeidentified,risksassessed,controlmeasuresandprioritiesdeterminedandthenecessaryresourcesallocated.Askyourself:
n Doyouhaveahealthandsafetyplan?n Ishealthandsafetyalwaysconsideredbeforeanynewworkisstarted?n Haveyouidentifiedhazardsandassessedriskstoyourstaffandthepublic,
andsetcontrolstandardsforpremises,plant,substances,procedures,peopleandproducts?
n Doyouhaveaplantodealwithseriousorimminentdangers,egfires,orchemicalspills?
n Arethestandardsimplementedandriskseffectivelycontrolled?
TheManagementofHealthandSafetyatWorkRegulations1999setoutbroadgeneraldutiesaimedatimprovinghealthandsafetymanagement.Amongotherthings,theyrequireprecautionstobeidentifiedbymeansofriskassessmentscarriedoutintheworkplaceandacompetentpersontobeappointedtohelpemployerscarryouttheirduties.
Risk assessmentThepurposeofriskassessmentistohelpemployersorself-employedpeopledeterminewhatmeasuresshouldbetakentocomplywithlegalduties.ThisincludesgeneraldutiesundertheHSWActandthemorespecificdutiesinotherActsandregulations.Oncedetermined,actionwillneedtobetakentoputthenecessarypreventiveandprotectivemeasuresinplace.
Formostcommonchemicals,PIAChasalreadydonemostoftheworkforyou.(SeeCOSHH essentials for printersandChapter4fordetails.)
Theriskassessmentneedstoconsider:
n thelevelofrisk;n whomightbeharmed;n whethersignificantrisksarebeingadequatelycontrolled.
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Ahazardisanythingwiththepotentialtocauseharm,andriskisthechanceofharmactuallybeingdone.Forexample,acanofhighlyflammableliquidstoredinaclosedmetalcabinetinaworkroommaybeaflammablehazardbecauseofitsnaturebutthereislittleriskasitisstoredsafely.Theriskincreasesiftheliquidispouredintoanopencontainerbecausethereisthenadangerofspillage.Therisksignificantlyincreasesifpeoplearesmokinginthearea.
Thefollowingfivestepsneedtobefollowedwhencarryingoutariskassessment:
Step 1 Identify the hazards
n Takeacarefullookatwhatyoudoandhowyoudoit.Remembertoincludeeverythingliketransport,solventstorage,housekeepingandworkequipment.Youwillidentifynumeroushealthandsafetyhazardswiththehelpofthisbook.
n Thinkaboutwhatcangowrong,howpeoplecanbeharmedandwhereitmighthappen.Forexamplepeoplebeinghitbyavehicle,trappedinamachineorexposedtohazardouschemicals.
n Considertheworst.Couldtheybekilled,willtheylosealimborsimplybebruised?Thiswillhelpyoulaterwhenyouneedtoworkoutwhatactionyouneedtotakefirst.
Step 2 Decide who might be harmed and how
n Considerwhocouldbehurtifthingsgowrong.Includeyouremployees,contractorsandnewuntrained,unskilledoperativesandothervulnerablegroupssuchastheyoung.
n Donotforgetvisitors,maintenancestaffandmembersofthepublic.
Step 3 Evaluate the risks arising from the hazards and take the necessary remedial action
n Askwhetherexistingprecautionsareenoughtoprotectpeopleand,iftheyarenot,whatmoreneedstobedone.Donotassumepeoplecanconcentrateallofthetime.Checkexistingsafeguardsdowhatthey’reintendedtodo.Remember,badlydesignedguardscanbedefeatedand,ifnotproperlymaintained,willfail.(SeeChapter5formoredetail.)
n Userecognisedindustrystandards,suchaspublicationsfromtheHealthandSafetyExecutive(HSE),PIAC,theBritishPrintingIndustriesFederation(BPIF)orothertradeassociationsasabenchmark.
n ForchemicalsrefertoCOSHHessentials for printersandmanufacturers’datasheets.Forfurtheradvice,seeChapter4.Youneedtokeepuptodatewithdevelopmentssuchassafersolventsornewtypesofmachineryguarding.Refertosuppliers’instructionsanddatasheets.Askyourselfwhethertheprecautionsyouhaveinplacecomplywiththelaw,representgoodpracticeandreducerisksofarasisreasonablypracticable.
n Prioritiseyouractions.n Allocatenecessaryresources.n Implementprocedurestoensurethenecessaryworkwillbedone.
Step 4 Record your findings
n Ifyouhavefiveormoreemployeesyoumustrecordthesignificantfindingsofyourassessment.(AnexampleriskassessmentformisgiveninAppendix2.AschematicdiagramofhazardstoconsiderinanoverallassessmentofasmallprintingpremisesisgiveninAppendix3.)
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Step 5 Review your assessment
n Youwillalsoneedtoreviseyourassessmentwhennecessary.Youmayfindthatyouneedtomakechangestoyourarrangementsafteryouhaveinvestigatedthecausesofanaccident.Onceimprovementshavebeenmade,rememberthatthingschangeandyouneedtocheckregularlythatprecautionsremaininplaceandareeffective.
Monitoring
Monitoringisamanagementresponsibilityandshouldtakeplaceatalllevels.YoursafetypolicyshouldincludearrangementsformonitoringanditisarequirementundertheManagementofHealthandSafetyatWorkRegulations1999.Monitoringshouldincludespotchecksandmoredetailedinspections.Reportsofallaccidents,nearmissesandillhealthcausedbyworkshouldbestudiedtoidentifyemergingtrendsorpatterns.Informationfrommonitoringhelpsyoutodecide:
n whatneedsimprovement;n whatprogressisnecessaryandreasonableinthecircumstances;n howthatprogressmightbeachievedagainstparticularrestraints(egresources
ortime).
Inspection and checksMonitoringcanbecarriedoutbyseveraldifferentmethods,eg:
n routinechecksbymanagers,supervisorsandmaintenancestaff,egtoursofinspection;
n statutorytestsandexaminationsbycompetentpersons,egoflifttruckchains,liftingequipment,andpressuresystemsbyengineeringsurveyors;
n reportingofdefectsbyemployees,egoperatordaily/weeklyinspectionofmachinerysafeguards;
n healthsurveillancebyaresponsibleperson,eginspectinghandsofprinterswhoworkwithUV-curedinksforsignsofdermatitis;
n investigationofincidentsandmonitoringofreportstoidentifyreasonsforfailuresincontrolsandthestepsneededtopreventarecurrence.
Evaluation of accidents, ill health and near missesAneffectivesystemforrecordingallrelevantincidentsisimportant.Recordsofaccidents/illhealthandnearmissescanbeusedtoidentifyproblemareasandtakerelevantaction.Alackofaccidentsdoesnotnecessarilymeanalliswell-goodluckmayhavebeenplayingarole.
Detailedinvestigationofincidentswillhelpyouidentifytheunderlyingcausesofallincidents.Itwillhelpyouhighlightweaknessesoromissionsinyourpolicyormanagementsystems.Thefindingscanbeusedtohelppreventrecurrenceandinitiatethenecessaryremedialaction(whichshouldbecarriedoutpromptly).See‘Accidentsandemergencies’.
Auditing and review
Healthandsafetyauditingaimstoprovideacomprehensive,independentcheckofworkactivities.Itwillreviewexistingarrangementsformanagingandmonitoringhealthandsafetyandidentifyanyshortcomings.Itprovidesfeedbacktomanagersonhowwellrisksarebeingcontrolled.Auditingisusuallymosteffectivewhenitiscarriedoutbypeopleindependentoftheareasbeingaudited,egfromanotherdepartmentorsite.
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Auditingschemescanbedevelopedin-houseorcommerciallyavailableschemescanbeused.Anumberofconsultantsoperateschemesbutprintingfirmsneedtosatisfythemselvesthataconsultantisappropriate,sufficientlyqualifiedandcompetenttohelpintheirparticularoperation.
Theinformationobtainedfrommeasuringsafetyperformanceandauditingcanbeusedtoreviewhowwellyouaredoingandwhatmightneedimprovement.
Home working
Healthandsafetylegislationalsoappliestothoseemployeeswhoworkathome.Ifyouhaveemployeeswhodothis,youstillneedtoensuretheyarenotexposedtorisksfromtheworktheydo.SeetheleafletHomeworking: Guidance for employers and employees on health and safety(INDG226)forfurtheradvice.
Lone working
Solitaryworkersmayfaceparticularproblems.Withoutsupervisorsorco-workerspresent,theyarevulnerabletothenormalworkplacehazardsanddonothaveaccesstotheassistancetheycannormallycallon.Incertaincircumstancestheymaybemoreexposed.Forexample,staffleavinglaterthannormalmaybeunabletogethelpifthreatenedinthecarpark.Solitaryworkersshouldnotbeexposedtosignificantlymoreriskthanemployeeswhoworktogether.Precautionsshouldtakeaccountofnormalworkingconditionsandforeseeableemergenciesincluding,fire,illnessandaccident.ForfurtheradviceseetheleafletWorking alone in safety: Controlling the risks of solitary work(INDG73).
Accidents and emergencies
Asanemployeryouneedtoputinplacesuitablearrangementsforidentifying,recordingandinvestigatingallrelevantaccidentsandincidents.Certainaccidents,dangerousoccurrencesandincidencesofillhealtharealsoreportable.
The law and reporting accidentsTheReportingofInjuries,DiseasesandDangerousOccurrencesRegulations1995(RIDDOR)requireyoutoreportcertainaccidents,incidentsandoccupationaldiseasestoyourenforcingauthority.From1April2001therehasbeenanIncidentContactCentre(ICC)torecordthedetailsyousupply.ReportsnolongerneedtobemadetoyourHSEorlocalauthorityoffice.
RIDDORrequiresyoutodothefollowing:
n Keepdetailsoftheincident(eginyouraccidentbook).n Notifytheenforcingauthorityimmediately(viatheICC)ifanyofthefollowing
happenasaresultofwork:
– anybodydies;– anemployeereceivesamajorinjury(suchasabrokenarmorlegoran
amputationinjury)oranyotherpersonistakentohospitalimmediatelyasaresultofaninjurycausedbyyourworkactivities;
– anyoneisseriouslyaffectedbyanelectricshockorpoisoning;– ifthereisadangerousoccurrence,egafireorexplosionwhichstopswork
formorethan24hours,oracraneoverturns.
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n Reportwithintendaysaccidentsatworkwhichresultinanemployeebeingabsentfromwork(orunabletodotheirnormaljob)formorethanthreedays.
n Reportcertaindiseasessufferedbyworkerswhodospecifiedtypesofworkassoonaspossibleonreceivingawrittendiagnosisabouttheillnessfromamedicalpractitioner.
Youcanreportincidentsbytelephone(08453009923),fax(08453009924),e-mail([email protected])orbyposttoICC,CaerphillyBusinessPark,CaerphillyCF833GG.
Investigating accidents and emergenciesAtthetimeofwriting,theHealthandSafetyCommissionwasconsultingonanewlegaldutytoinvestigateaccidents.Whatevertheoutcome,investigationofaccidentsandincidentsin-houseisimportanttoestablishthecausesandpreventivemeasuresneededtominimisetheriskoffurtheraccidents.Youshouldalsolookatnearmisses,minoraccidentsandpropertydamage.Itisoftenonlybygoodfortunethatsomeoneisnotinjured.Employersneedtoputproceduresinplacetoensurethefollowingstagesarefollowedifthereisanaccidentordangerousoccurrence:
n Takeanyactionrequiredtodealwiththeimmediaterisks,egprovidefirstaid,putoutthefire,isolateanydanger,fenceoffthearea,calltheemergencyservices.
n Iftheincidentisonethatmustbeimmediatelynotifiedtoyourenforcingauthority,consultthembeforedisturbingthesite.Eveniftheincidentisnotreportable,itissensibletotakephotographsandmeasurementsbeforedisturbingthesite.
n Obtainbasicfacts,egwitnessnames,plantcondition,substancesinuse,place,time,extentofinjury.
n Establishthecircumstances,egwhatwasbeingdoneatthetime.n Trytounderstandthesequenceofeventsleadingupto,duringand
immediatelyfollowingtheaccident.n Fromtheaccidentsequencewritedowntheimmediatecausesoftheaccident.n Fromthislistidentifytheunderlyingcausesoftheaccident.(Youmayhaveto
repeatthisstepseveraltimestogettotherootcausesoftheaccident.)Forexampleifanindividualdidnotfollowaprocedure,trytoidentifywhytheydidnot-itcouldbeduetolackoftraining,anunrealisticprocedureorlackofsupervision.
n Foreachoftheunderlyingcausesidentifiedconsiderwhatstepsneedtobetakentopreventarecurrence.AtthispointconsulttheguidanceissuedbyPIACandHSEforspecificinformationonhowtocontrolhazards.
n Thinkalsoiftheinitialresponsetotheaccidentwasadequate,egwhethertherewasaneffectivefirst-aidresponseorwhethercorrectspillagearrangementswereused.
n Considerifanyofthelessonslearnedapplyelsewherewithintheorganisation.n Consideriftheriskassessmentsneedtobereviewedinthelightofyour
findings.n Throughouttheinvestigation,itisimportantnottojumptoconclusions,and
involveyourtradeunionappointedsafetyrepresentativesoremployeesasappropriate.Thinkabouteachstep,andifnecessaryplanwhatyouaregoingtodoBEFOREithappens.Thefollowinginvestigationchecklistmaybeuseful.Althoughitisnotanexhaustivelist,itgivesexamplesofquestionsthatmightberelevant.
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Investigation checklist
As a result of this assessment you should then take action to stop the accident happening in future
Factors involved in the accident
Why this occurred Action to be taken
Machineryorequipmentfailure,eglackofguards,interlocksormaintenance
Workingpracticeorprocedure,eglackofsupervision,customandpracticeornoprocedure
Theworkingenvironment,egstateofthefloor,fumesornoise
Theindividual,eglackoftraining,poorinstructionsorbadlylabelledcontrols
Substancesused,egsolventsorinkshavechanged
Do you need to: Yes No
Improvephysicalsafeguards,egprovideaninterlockedguard?
Provideanduselocalexhaustventilation?
Usemechanicalhandlingaids,egpileturnersormobilelifts?
Introducebettertestandmaintenancearrangements?
Improveworkmethods?
Provideandusepersonalprotectiveequipment?
Makechangestosupervisionandtrainingarrangements?
Reviewsimilarrisksinotherdepartments?
Setupsystemstoriskassessnewplantandchemicalsbeforeuse?
Reviewproceduresforcontractors?
Updatestandardsandpolicies?
Introducemonitoringandauditingsystems?
Givetraininginmanualhandlingtechniques?
Substitutechemicalswithsomethinglesshazardous?
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Dealing with emergenciesWhenthingsgowrongpeoplemaybeexposedtoseriousandimmediatedanger.Specialproceduresarenecessarytodealwithemergenciessuchasseriousinjuries,explosion,fire,electrocution,powerfailuresandchemicalspills.
Youshouldprepareanemergencyplanespeciallyifamajorincidentatyourworkplacecouldinvolveriskstothepublic,theneedtorescueemployeesorco-ordinationoftheemergencyservices.
Todothisyoushouldcarryoutariskassessmentandconsider:
n theworstthatcouldhappen;n howpeople-thoseinchargeandothers-areinstructedandequippedtodeal
withtheproblems;n howtheemergencyservicesshouldgetaccessontothesite;n howthealarmwillberaised(don’tforgetnightandshiftworking,weekends
andholidays);n howandwhentocalltheemergencyservicesandhowtohelpthemwith
informationwhentheyarrive;n thatyouwillneedtonotifythefireauthorityifyouhaveover25tonnesof
certaindangeroussubstancesonsite;n wheretogotoreachaplaceofsafetyortogetrescueequipment;n providingemergencylighting;n whetheryouhaveenoughemergencyexitstoalloweveryonetoescapequickly
(andsuitablearrangementstoensurethatemergencydoorsandescaperoutesarekeptunobstructedandclearlymarked);
n nominatingcompetentemployeestotakecontrol;n pre-planningandpractisingemergencyplantshutdownsormakingprocesses
safe.Importantitemssuchasshut-offvalves,electricalisolatorsetcshouldbeclearlylabelledtoavoidconfusion;
n ensuringyouhaveadequatefirst-aidprovisionandfirstaiders;n trainingpeopleinemergencyandevacuationproceduresandrememberingthe
needsofpeoplewithdisabilities.
First aidTheHealthandSafety(First-Aid)Regulations1981requireyoutohaveadequatearrangementsforfirstaid.Theminimumfirst-aidprovisionforeachworksiteis:
n apersonappointedtotakechargeoffirst-aidarrangementsincludinglookingaftertheequipmentandfacilitiesandcallingtheemergencyserviceswhenrequired.Anappointedpersonwillneedtobeavailablewheneverpeopleareatwork;
n asuitablystockedfirst-aidcontainer(easilyaccessibleincasesofemergency);
n informationforemployeesonfirst-aidarrangements(includingnoticestellingpeoplewherethefirst-aidequipment,facilitiesandpersonnelcanbefound).
Do you need to: Yes No
Changemake-readyproceduresorothersystemsofwork?
Institutehealthsurveillance,egforUVinkusers?
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Additionalprovisionwillbeappropriateinmanycases,forexample:
n Iftherisksofinjuryandillhealtharisingfromtheworkasidentifiedinyourriskassessmentaresignificant,trainedfirstaidersmaybeneeded.Theymayalsobeneededwherelargenumbersofpeopleareemployed.Theymustbegiventherighttrainingandholdacertificate(whichwillbevalidforthreeyears).Refreshercoursesandre-examinationwillberequiredwhenoldcertificatesexpire.InformationontrainingcoursesandorganisationscanbeobtainedfromyourlocalEmploymentMedicalAdvisoryService(whocanbecontactedviayourlocalHSEoffice).
n Wheretherearespecificrisksfromworkingwithhazardoussubstances,dangerousmachineryandloads,considerspecifictrainingforfirstaiders,extrafirst-aidequipment,sitingoffirst-aidequipment,informingemergencyservicesandfirst-aidrooms.
n Whereworkplacesareremotefromemergencymedicalservices,informlocalmedicalservicesofyourlocationandconsiderspecialarrangementswiththem.
n Whereyouhaveinexperiencedworkers,disabledworkersorpersonnelwithspecialhealthproblems,considertheneedsforspecialequipmentandlocalsitingofequipment.
n Formobilepeople,egsalesstaff,afirst-aidkitneedstobeprovided.
Ifyouhaveasmallcompanywithfewemployeesitmaybemoreappropriatetohaveapersontrainedinemergencyfirstaid.Asyourcompanygrowsyouwillneedtomakesureyourfirst-aidprovisionremainsadequate.
Permits to work
Somehigh-riskactivitiessuchasentryintoconfinedspacesorworkinglargemachinerywillrequireapermittowork.Thisisaformalwrittensystemusedtocontrolcertaintypesofpotentiallyhazardouswork.Thepermitdetailstheworktobedoneandthenecessaryprecautionstobetaken,andformsanessentialpartofmanysafesystemsofworkformaintenanceactivities.SeeChapter8formoredetails.
Working time
ThemainaimoftheWorkingTimeRegulations(WTR)istoensurethatworkersareprotectedagainstadverseeffectsontheirhealthandsafetycausedbyworkingexcessivelylonghoursorhavinginadequaterest.Atthetimeofpublication,proposalsforchangeswereunderconsideration,howeverfurtherguidancecanbefoundinthebookletYour guide to the Working Time RegulationsandA short guide to the Working Time Regulations(availablefromDTI,Tel:08456000925orfromtheDTIwebsite:www.dti.gov.uk).
The problemWorkinglonghourscanhaveamajoreffectonthehealthandsafetyofemployees-thosewhoaretiredaremorepronetomakemistakes,whichcouldresultinaccidents-ortheycoulddeveloplong-termadversehealtheffects.Forhistoricalorproductionreasonsthereisacultureoflonghoursinsomepartsoftheprintingindustry,butinmanycompaniescarefulmanagementofproductionpressuresandplannedpreventivemaintenanceprogrammescanresolvemostoftheproblemsthatcanarise.
Application of WTRIfyouemployworkers,nightworkersoryoungpeopleyouarecoveredbythe
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WorkingTimeRegulations.Youneedtotakeparticularcaretoknowtherulesaboutyoungpeople(betweenschoolleavingageand18yearsold)andpeoplewhoworkatnight,sincespecialrequirementsapplytothem.Mostpeopleworkinginprintingarecoveredbythelaw.
Working time limitsForadultworkersthelimitis48hoursperweekaveragedovera17week‘referenceperiod’.Theaveragecanbecalculatedoverdifferentperiodsdependingonthecircumstances.Whereatradeunionisrecognised,employerswhowanttoextendthereferenceperiodwillneedtomakeanagreementwiththattradeunion.Workforceagreementsapplyintheabsenceofarecognisedtradeunion.
Currentprovisionswhichallowforindividual‘opt-out’fromtheaverage48hourslimitareexpectedtoendwithinthenexttwoyears.Companieswillneedtotakeaccountoftheendingofthe‘opt-out’andmakearrangementstocoverthis.
Nobodyshouldworkforlongperiodswithoutabreak.Theseareneededtobreakupmonotonousorcontinuousprocessesandtherearespecialentitlementsforyoungworkers.
Health assessmentWorkinglonghours,especiallyatnight,candisruptthe‘bodyclock’.Workerswhoaretoworkatnightmustbeofferedafreehealthassessmentbytheircompanybeforetheystartnightworkandthenatsuitableintervals,forexamplebeforetheintroductionofanewshiftpattern.Takeadvicefromanoccupationalhealthprofessionalwhenyoudesigntheassessment.
Night shift risk assessmentTheWTRrequireariskassessmentforthespecialrisksassociatedwithnightworkwhichisinadditiontotherequirementslaiddownbytheManagementofHealthandSafetyatWorkRegulationsforageneralriskassessmentandtheControlofSubstancesHazardoustoHealthRegulations(COSHH)forariskassessmentforharmfulsubstances.ForadviceonmakingtheseassessmentsseeearlierinthischapterandCOSHH essentials for printers.
AWTRriskassessmentisneededbecausetasksmaybecomemoredifficult:
n whenperformedatnightindarkness;n whenthefullrangeofdaytimeservicesmaynotbeavailable;n whereworkersfinddifficultyadjustingtodifferentworkingpatterns;n wherethereisincreasedriskofviolencetostaff;n whereworkersaresubjecttoincreasedstressbecauseofreducedsupervision
ormanagement.
Theassessmentmay,forexample,identifytheneedforemergencyorsupplementarylightingtobeinstalled.Actontheassessmentandprovidewhatevercontrolmeasuresmightbeneededsuchasmorelighting,additionaltraininginfirstaid,additionalsecuritymeasures,orperhapsadjustthefrequencyofbreaks.
RecordsYoudonotneedtokeepspecialrecords.Mostcompaniesfindthattherecordstheyalreadykeepofhoursworkedforotherpurposes,likepay,aremorethanadequateforWTR.However,ifyouhavenotpreviouslykeptrecordsofanysortthenWTRdoesrequireyoutokeepsufficientrecordsofthehoursyouremployeeswork.
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People with more than one jobSomepeoplehavetwooreventhreejobs,forexampleworkingatnightinapub.Wherethisisthecasethenthetotalhoursworkedshouldbeaddedtogetherwhencalculatingworkingtime.Itisuptoyoutomakereasonableenquiriesaboutanysecondjobsdonebyyourstaffandtoco-operatewithotheremployerstocalculatetotalworkingtime.
Good time management is good businessPromotionofgoodtimemanagementresultsinbetterhealthandsafetymanagement.Itallowsemployerstoplanproperlyforpeaksandtroughs,workerstoplanaproperregimeofworkandfamilylifeandresultsinaworkforcethatis‘happy,healthyandhere’,increasingproductionefficiencies.
Figure 1 Contractedworkcanbesmall-orlarge-scale
Control of contractors
Contractorsareemployedtoworkintheprintingindustryformachineryorbuildingsmaintenanceandmodifications,installationofplantandotherequipment.However,nowadayscontractorscanalsobefoundthroughouttheindustry,asfreelancedesigners,cleaners,caterersandinlogistics,doingarangeoftasksthatwerepreviouslydonebyemployees.Everyoneworkingonyourpremisesorforyouneedstoknowwhathealthandsafetystandardstheyhavetoachieve,includingnotionallyself-employedlabour-onlycontractors.
The law and managing contractorsTheHSWActplacesdutiesonyouandyourcontractortoprotect,sofarasisreasonablypracticable,thehealthandsafetyofemployeesandotherpeoplewhomaybeaffectedbyyourworkactivities.Allpartieswillneedtoco-operatewitheachotherandco-ordinatetheirworktoensureeveryoneiscomplyingwiththeirlegalduties.
InadditiontotheHSWActandtheManagementofHealthandSafetyatWorkRegulations1999,youshouldbeawareoftheConstruction(DesignandManagement)Regulations1994.TheseRegulationsplacedutiesonclients,clients’agents,designersandcontractorstoplantheirapproachandtakehealthandsafetyintoaccount.Healthandsafetyneedstobeco-ordinatedandmanagedeffectivelythroughoutallstagesofaconstructionproject,fromconceptionthroughtosubsequentmaintenanceandrepairarrangements.
Clientsmustbereasonablysatisfiedthattheyonlyusecompetentpeopleasplanningsupervisors,designersandprincipalcontractors.Theyneedtobesatisfiedthatenoughresources,includingtime,havebeenorwillbeallocatedtoenabletheprojecttobecarriedout.Theyalsorequireclientstoproviderelevantinformation-goodexamplesarethelocationofservicesandasbestos-containingproductswithinbuildings.(SeeChapters3and4forfurtherinformationonmanagingasbestosinworkplacebuildings.)
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TheConstructionDesignandManagementRegulationsapplywhereconstructionworkisexpectedtolastmorethan30daysorinvolvefiveormorepeopleon-siteatanyonetime.Thiswillincludetheinstallationoffixedplantwherepeopleareliabletofallmorethan2m,suchasinstallationoflargerweb-fedpresses.Wheredemolitionordismantlingofastructureistakingplace,theRegulationsapplyregardlessofthelengthoftimeorthenumberofpeoplecarryingoutthework.
ForfurtherinformationseeA guide to the Construction (Health, Safety and Welfare) Regulations 1996(INDG220)andtheApprovedCodeofPracticeontheConstruction(DesignandManagement)Regulations1994(HSG224).
Ifyouhavepeopleworkingunderyourcontrolanddirectionwhoareself-employedfortaxand/orNIpurposes,theyarelikelytobetreatedasyouremployeesforhealthandsafetypurposes.Youmaythereforeneedtotakeappropriateactiontoprotectthem.Ifyouareinanydoubtaboutwhoisresponsibleforthehealthandsafetyofapersonworkingforyouthiscouldbeclarifiedandincludedinthetermsofthecontract.However,remember,youcannotpassonalegaldutythatfallstoyouundertheHSWActbymeansofacontractandyouwillstillretaindutiestowardsothersbyvirtueofsection3oftheAct.
n Makecontractorsawareofyourcompanysafetyculture.
Stage 2: Choosing a contractor
Contractorsshouldbechosencarefully.Beforeyouchooseacontractor:
n DecidewhatareyourcriteriaforselectingcontractorsandplacingthemonanApprovedList?Assesstheircompetenceinhealthandsafetymatters.Thisappliestoseniorpeopleaswellasthosewhowillbeworkingonyoursite.
n Decidewhatsafetyandtechnicalcompetenceisneeded.Hasthecontractorgotit?n Askquestionsabouttheirsafetyperformance.Howdotheymanagetheirperformance?Asktoseethe
writtenproceduresforsimilarpreviouswork-theiraccidentrecordmaybeagoodplacetostart.n Getevidence.Examinetheirtrainingandrelevantcertificates.Safetypassportschemesareagoodway
ofdemonstratingthetrainingofindividualworkers.
Five practical stages for working with contractors
As with all things a few simple precautions will save time and prevent accidents in the future. Just like managing your own employees, working with contractors will be made so much easier (and safer) if you follow these five practical stages:
Stage 1: Plan before you start
Decideafewgroundrulesbeforeyouevenstarttousecontractors.Ifthecontractorsaregoingtobeworkingwithyouforalongtimeitisespeciallyimportanttomakeplansaboutwhatyouareaskingthemtodoandhowyourownstaffwillbeworkingwiththem.
n Ensurethatyouhaveagoodplanningframeworktopulltogetheralltheseparateelementsofwhatyouareaskingthecontractortodo.Writeplansdown,meetandconsulteveryoneinvolved.
n Definethejob.n Identifythehazards.Considertheindividualelementsofthejobandtheeffectofeachpieceof
contractedworkonthewholeproject.n Assesstherisks.n Eliminateandreducetherisksthatyoucontrol.n Specifythehealthandsafetyconditionsthatyouwantthecontractortofollow.n Discussthesewiththecontractor/s.
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n Gothroughinformationaboutthejobandthesite,includingsiterulesandemergencyprocedures.n Agreerespectiveresponsibilitiesforriskassessmentsandprecautions.n Askforasafetymethodstatement,riskassessmentorsafetypolicy.n Decidewhethersubcontractingisacceptableandusetheinformationgatheredtohelpyoumakeyour
decision.Ifitis,howwillhealthandsafetybeensured?n Ifyouhaven’tusedthecontractorbefore,asktotalktosomeoftheirpreviousclients.n Considerhowyouwillmonitortheirhealthandsafetyperformance.
Stage 3: Contractors working on site
Whentheyarriveonsiteyouneedtohavethegroundrulesinplace.TheseshouldbeagreedBEFOREthecontractorstartswork.Theycanincludethefollowing:
n Howdoyoucontrolaccesstoyoursite?Doeseveryonesigninandout?n Nameasitecontactforday-to-daycommunication-don’tjustwaitforsitemeetingstodiscussand
resolveproblems.Makesurethepersonappointediscompetentandtrained.n Reinforcehealthandsafetyinformationandsiteruleswithasimpleinductioncourseorasafetycheck
cardsettingoutyourrulesforeveryvisitor.Makesureemergencyproceduresarecovered.n Implementsafesystemsofwork,suchasforhotworkorworkonfragileroofs.n Howwillyourownoperationsaffectthecontractor’swork?n Whattools,plant,substancesandequipmentwillbeused?n Whatwillthearrangementsforpropersupervisionbe?n Checkthateveryoneunderstandsthejobbeforeyouallowworktobegin.n Don’tforgettoprovidefacilitiesforcontractors,iewashroom,toilets,canteenetc.
Stage 4: Keeping a check
Don’tjustleavethecontractortoit.Notonlycancostsspiraloutofcontrol,butsafetycantoo.
n Decidehowoftenyouoryourmanagersneedtomakecontactwithyourcontractors.n Isthejobgoingasplanned?Isthecontractorworkingsafelyandinthewaythattheyagreed?Checkif
therehavebeenanyincidentsorchangesinpersonnel?n Areanychangesorspecialarrangementsrequired?
Stage 5: Reviewing the work
Learnlessonsfromcontractingsothateveryone,includingyouremployeesandthecontractorcanimprovethewaytheywork.Beforeyoustart,plantoreview.
n Howdoyouplantoreviewthejobandthecontractor’sperformancewithallthoseinvolved,includingthecontractor?
n Duringthereview,askyourselfhoweffectiveyourplanningwas,howthecontractorperformed,andhowthejobwent.
n Recordthelessons,reviewandlinkthesetoyourselectionprocedures.
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Contractors and your employeesAttimessuchasmajorrebuildingworkstheremaybelargenumbersofcontractorsonsite,oftenworkinginproximitytoyourownemployeesandeachotherandtoatightdeadline.Youneedtothinkabouthowtheirworkmayaffecteachotherandhowtheyinteractwithyourownmaintenanceorproductionactivities.Themoreactivitiesthataregoingon,thegreaterthechancethereisofsomethingbeingoverlooked.Thekeyisgoodcommunication,planningandcontrol.Withoutthese,chaoscanresultandaccidentswillhappen.
Consulting employees on health and safety
Employersmustconsultalloftheiremployeesonhealthandsafetymatters.Whereemployershaverecognisedunions,theSafetyRepresentativesandSafetyCommitteesRegulations1977willapply.Whereemployeesarenotmembersofaunion,ortheunionisnotrecognised,theHealthandSafety(ConsultationwithEmployees)Regulations1996(HSCER)willapply.
Consultationshouldinclude:n anychangethatmaysubstantiallyaffecttheirhealthandsafetyatwork,egin
procedures,equipmentorwaysofworkingsuchassafesystemsofworkforcleaningprintingcylinders;
n theemployer’sarrangementsforgettingcompetentpeopletohelphimorhersatisfyhealthandsafetylaws;
n theinformationthatemployeesmustbegivenonthelikelyrisksanddangersarisingfromtheirwork.Thiswouldincludefireandexplosionhazardswhenusinghighlyflammableinksandmeasurestoreduceorgetridoftheserisks;
n theplanningofhealthandsafetytraining;n thehealthandsafetyconsequencesofintroducingnewtechnology,for
exampleuseofUVinks.
FurtherinformationonconsultingemployeesisavailableinthefreeleafletConsulting employees on health and safety: A guide to the law(INDG232).
UndertheSafetyRepresentativesandSafetyCommitteesRegulations1977,tradeunionappointedsafetyrepresentativeshavetherightto:
n investigatepotentialhazardsanddangerousoccurrences;n examinethecausesofaccidents;n investigatecomplaintsbyemployeesrelatingtohealthandsafety;n makerepresentationstotheiremployeronhealthandsafetymatters;n carryoutinspectionsoftheworkplace;n receivetimeoffwithpaytoperformthesefunctionsandundergotraining.
Employershaveageneraldutytoconsultsafetyrepresentativesonallaspectsofhealthandsafetyintheworkplace,andprovidethemwiththenecessaryinformation,facilitiesandhelptoallowthemtocarryouttheirfunctions.Thisiswithaviewtomakingandmaintainingarrangementsfortheirjointco-operationinthepromotionanddevelopmentofmeasurestoensureemployees’healthandsafetyatwork,andtochecktheeffectivenessofsuchmeasures.
Asafetycommitteemustbeestablishedifrequestedinwritingbytwosafetyrepresentatives.Theemployershouldthenconsultwiththesafetyrepresentativesandestablishthesafetycommitteenolaterthanthreemonthsaftertherequestwasmade.Anoticeshouldbepostedforemployeesstatingthecompositionofthecommittee.
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FurtherinformationcanbefoundinthepricedpublicationSafety representatives and safety committees(L87),knownasthe‘BrownBook’.
Inspectors and enforcement
EnforcementforhealthandsafetyatworklieswitheitherinspectorsfromHSEorfromyourlocalauthority.HealthandsafetyinprintingandmanyalliedtradesisnormallyenforcedbyHSEinspectors.Aninspector’sprimaryfunctionistoensurerelevantlegalstandardsofhealthandsafetyintheworkplacehavebeenachieved.Tohelpenforcingauthoritiescarryouttheirduties,youarerequiredbylawtonotifyyourenforcingauthority(normallyyourlocalHSEoffice)thatyouareoccupyingafactoryoroffice.
Powers of inspectorsFollowingavisit,inspectorswillprovideadviceandmayconfirmthisinwriting.Inspectorshavepowersofenforcementwhichmightinclude:
n servingimprovementnoticesthatrequireimprovementstobemadewithinacertaintime;
n servingprohibitionnoticesthatstopaprocessortheuseofapieceofequipmentwhereariskofseriouspersonalinjuryexists;
n prosecutionofabusiness,orundercertaincircumstancesanindividual,forbreachesofhealthandsafetylaw.
Theymayvisittoinspecttheworkplaceortoinvestigateaccidentsorcomplaints.Theyoftenvisitworkplaceswithoutgivingnoticebutyouareentitledtoseetheiridentificationbeforelettingthemin.Theirpowersincluderightofentryintoyourpremises,therighttotalktoemployeesandsafetyrepresentativesandtotakephotographsandsamples.Theyareentitledtoyourco-operationandanswerstoquestions.
Inspectorswillenforcethelawwhentheyjudgeitnecessary,buttheyareconcernedtohelpyoudowhatisreasonableandpracticabletocontrolriskstohealthandsafety.Theywillgiveadviceandyoumayturntothemforguidance.Theyarehappytoanswerquestionsandgiveyouinformation,muchofwhichisfree.YoucanalsocontactyourlocalHSEofficeorHSE’swebsite:www.hse.gov.ukorHSEBooks:www.hsebooks.co.ukor,forgeneralenquiries,contactHSE’sInfoLine Tel:08701545500.
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Chapter 2 TrainingSee the ‘References’ section at the back of the book for details of publications which relate to Training
Relevant legislation
TrainingrequirementsareidentifiedinseveralActsandregulationsincludingthefollowing:
n HealthandSafetyatWorketcAct1974(HSWAct)n ManagementofHealthandSafetyatWorkRegulations1999n ProvisionandUseofWorkEquipmentRegulations1998(PUWER98)n ControlofSubstancesHazardoustoHealthRegulations1999(COSHH)n ElectricityatWorkRegulations1989
Itiscrucialthatallemployees,includingsupervisorsandmanagers,haveadequatehealthandsafetytraining.
Training methods
Thesewillvaryfordifferentpeopleandjobsdependingonexistingabilitiesandtherisksofthejob.Anytrainingproviderneedstobecompetent.
Trainingcanbecarriedoutbyoneormoreofthefollowing:
n in-housetrainingpersonnel(thismightincludesupervisors);n externaltrainers(thiscanbedoneonthepremisesorbysendingemployees
awayonshortcoursesorday-releasecourses);n distanceandopen-learningtechniques;n trainingprovidedbysuppliersandmanufacturersfollowinginstallationofnewor
refurbishedmachinery,ortheintroductionofnewconsumablessuchasblanketwashes;
n ‘sittingwithNellie’-youshouldbeconfidentthatthepersongivingthetrainingiscompetentbothinthejobanditshealthandsafetyaspectstoavoidpassingonbadhabits.
TrainingmaterialsareavailablefromanumberofsourcesincludingthePrintingIndustryAdvisoryCommittee(PIAC),tradeorganisations,safetyorganisationssuchastheBritishSafetyCouncil(BSC)andtheRoyalSocietyforthePreventionofAccidents(RoSPA),andindependenttrainingandhealthandsafetyconsultants.
ThePIACPrinting industry:Health and safety training packagepublishedbyHSEisacomprehensiveopen-learningcoursedesignedforuseinmediumandlargerprintemployersandprintingcolleges.Itcontainstargetedmodulescoveringarangeofsubjectsincludingnoiseandriskassessments,assessingmachineryguardingandconductingaccidentinvestigation.
Foreachactivityastructuredtrainingsessionisprovidedincludingsubjectsfordiscussionandcasestudies,supportedbyhand-outsandvisualaids.Thepackagehasbeendesignedtobeusedanddeliveredbycompetentin-housestaff.
SectorSkillsCouncils(SSCs)(UK-wide),LearningandSkillsCouncils(LSCs)inEngland,EducationandLearningWales(ELWa)inWalesandLocalEnterpriseCompanies(LECs)inScotlandareabletoprovidepracticalhelpontraining.They
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canalsoprovideinformationonNationalandScottishVocationalQualifications(NVQsandSVQs)whichmeetstandardsofcompetencelaiddownforparticularjobs.Manyofthesequalificationscanbeobtainedbyattendanceatvariousprintingcollegesaroundthecountry.
TheInstituteofOccupationalSafetyandHealth(IOSH)providestrainingandexaminationintechnical,legalandhealthandsafetymanagement.
OrganisationssuchastheBritishPrintingIndustriesFederation(BPIF)andtheGraphical,PaperandMediaUnion(GPMU)alsoprovidearangeofprint-specifichealthandsafetytrainingcoursesforalllevelswithincompanies.
Seethe‘Furtherinformation’sectionforthefullcontactdetailsoftheseorganisations.
Induction training
Inductiontrainingfornewemployeeswillhelpthemsettleintotheirwork.Thistypeoftrainingusuallyincludesinformationaboutthecompany,theorganisationformanaginghealthandsafety,thehazardsoftheworkplace,theprinciplesofsafeworkingpracticeandthesafetyresponsibilitiesofindividuals.
Managersandsupervisorshavealegalresponsibilitytomaintainasafeworkingenvironment.Theyareaccountableforthesafetyofthoseundertheircontrol.Theyareresponsibleforspottinghazardsorpoorworkingpracticesandcorrectingthem.Theyarealsoresponsibleforinvestigatingaccidentsandnearmissesandmayhavefurtherspecificdutiesallocatedtothemunderthesafetypolicy.
Seniormanagersneedtoknowenoughabouthealthandsafetytodetermineprioritiesandtoassesstheperformanceofpeoplefurtherdownthemanagementline.Theyshouldexaminethehealthandsafetytrainingneedsofindividualsatregularintervals.Thecommitmenttotrainingshouldbespeltoutinthecompanysafetypolicy.
Afterinduction,thehealthandsafetytrainingneedsforeachindividualshouldbeidentifiedandtrainingprovidedsothatnooneisaskedtoperformataskforwhichtheyhavenotbeentrained.
Thefollowingareexamplesofthetopicsappropriateforinclusionininductiontrainingatdifferentlevelswithinacompany:
Thefollowingareexamplesofthetopicsappropriateforinclusionininductiontrainingatdifferentlevelswithinacompany:
Training for all employees - example topics
n Companystructuren Companysafetypolicyn Safetycommitteesn Safetyrepresentativesn Occupationalhealtharrangementsn Responsibilitiesofindividualsn Companyrulesn Hazardsandsafeworkingstandards,including:
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– Safesystemsofwork– Housekeeping– Machinerysafety– Visualdisplayunits(VDUs)– Fire– Chemicalsandsolvents– Materialshandling– Electricity– Noise– Firstaid
Training for all supervisors/managers - example topics
n Responsibilities-includingtheirownresponsibilitiesandthoseofothersinthecompany
n Monitoringofhealthandsafetystandardsn Hazardidentificationn Accidentinvestigationandreportingn Riskassessmentn Relevantlegalrequirementsn Safesystemsofworkandothermethodsusedtocontrolriskn Sourcesofinformationn Controlofcontractors
Training for senior managers - example topics
n Purposeofcompanyhealthandsafetypolicyn Causesofaccidents/illhealthandtheircostsn Planningforhealthandsafetyn Monitoringaccidents,reportsandstatisticsn Personalresponsibilityandaccountabilityn Functionsofsafetycommitteesandsafetyrepresentativesn Developingasafetyculturen Useofsafetyauditsn Relevantlegalrequirementsn Roleofsafetyadvisern KnowledgeoftheworkofHSEandotherauthoritiesn RoleoftheOccupationalHealthServicen Existenceofrelevantstandardsandguidance
Remembertherearemanyhazardousactivitiesintheprintingindustrywherespecificjobtraininginsafesystemsofworketcisessential,egpresscleaning,webbing-up,guillotineoperating,maintenancework,lifttrucks,andmanualhandling.
Evenexperiencedemployeesmayneedtrainingwhentheyaremovedtonewareasofworkoraskedtooperatenewtypesofmachines.Retrainingshouldbecarriedoutregularly,toreinforceparticularsafetyissues,orwhentherearechangesintheprocessandequipment.Sometimesaccidentinvestigationscanrevealtheneedforretraining.
Trainingneedsshouldberegularlyreviewedtocheckthatthetrainingdeliveredisadequate.Trainingneedscanalsobereviewedwheninvestigatingaccidents,investigatingnearmissesandasaresultofcarryingoutriskassessment.Fromtimetotimeitpaystodorefreshertraining.Everyonecangetstaleandthisavoidsslippingintobadhabits.
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Training safety representativesTradeunionappointedsafetyrepresentativeshavetwodistincttrainingneeds.Firstly,theyneedtounderstandtheirfunctionsasatradeunionofficialandtodothistheyareentitledtotimeoffwithpaytoattendaTUCorotherapprovedtradeunioncourse.
Secondly,theymayneedadditionaltrainingintheparticularhazardsoftheindustry-notonlythehazardsintheirownjobsbutalsothehazardsofworkdonebythepeopletheyrepresent.Theemployerhasdutiestowardssafetyrepresentatives(see‘Consultingemployeesonhealthandsafety’inChapter1).Companiesshouldco-operatesothattradeunionappointedsafetyrepresentativesintheircompanycanreceiveadequatetrainingonindustryhazards,rulesandprocedures.
Accidents
Job specific
Theoperatorofanoffsetlithoprintingmachinewasstrangledwhenhispulloverwascaughtbytheinkingrollers.Hewastryingtoretrievemisfedpaperviathegapbeneaththeductkeysbelowtheinkingrollersguard.Theguardwasdeficientandtheoperatordidnotturnthemachineoffbeforetryingtoretrievethepaper.Trainingshouldhavebeengiveninthesafemethodofworkingandtherequiredstandardofmachineryguarding.Proceduresshouldhavebeeninplacetochecktheconditionofguardsregularly.
Amachineoperatorinaprintingworksdamagedhisspinewhenhefellfromaladderwhilecarryingoutmaintenanceworkathigh-levelmachinery.Theladderwasnottiedorfooted.Operatorsregularlycarriedoutminormaintenanceworkbutnoonehadbeentrainedtouseladders.
Training for those moving jobs
Anexperiencedprinterhadpartofhisrightindexfingeramputatedwhilechangingthebladeofaguillotinehehadnotoperatedbeforeandhadnotbeentrainedtouse.
Refresher training
Aprintingshopsupervisortrappedtwofingersinafoldingmachinewhileclearingacreasedpieceofpaperwithoutstoppingthemachine.Hehadbeenfullytrainedsomeyearspreviouslybuthadshort-circuitedthesafeworkproceduressofrequentlywithoutincidentthathenolongerrecognisedtheobviousrisk.
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Chapter 3 Workplace and transport safetySee the ‘References’ section at the back of the book for details of publications which relate to Workplace and transport safety
Relevant legislation
GeneralrequirementsforworkplaceandtransportsafetyarecontainedinanumberofActsandregulationssuchastheHealthandSafetyatWorketcAct1974(HSWAct)andtheManagementofHealthandSafetyatWorkRegulations1999.
TheWorkplace(Health,SafetyandWelfare)Regulations1992arespecificallyaimedatprotectingthehealthandsafetyofeveryoneintheworkplace,andensuringthatadequatewelfarefacilitiesareprovidedforpeopleatwork.EmployershavedutiestoensurethatworkplacesundertheircontrolcomplywiththeseRegulations.MoredetailedinformationcanbefoundinthepublicationWorkplace health, safety and welfare. Workplace (Health, Safety and Welfare) Regulations 1992. Approved Code of Practice(L24).
TheDisabilityDiscriminationAct1995createsarightofnon-discriminationagainstdisabledpeopleinthefieldofemployment,includingadutyonemployerstoprovide‘reasonableadjustment’toworkingconditionsortheworkingenvironmenttoovercomethepracticaleffectsofdisability.Employersarenotexpectedtomakeanychangeswhichwouldbreakhealthandsafetylaws.
TheemploymentpartoftheDisabilityDiscriminationActdoesnotapplytoemployerswhoemployfewerthan20people.However,theyareencouragedtofollowgoodpracticeguidelines.FurtherinformationontheDisabilityDiscriminationActshouldbeobtainedfromtheDepartmentforEducationandSkills.
Fundamentals of workplace health and safety
Someofthebasicrequirementsforemployersare:
Safe place of workYoumusthave:
n buildingsingoodrepair;n precautionsthatstoppeopleormaterialsfallingfromopenedges,eg
mezzaninefloors,rackingareasandrunningboards;n spaceforsafemovementandaccess,egaroundreelstandsandonmezzanine
floors;n floors,corridorsandstairsetcfreefromobstructions,egtrailingcablesand
pallets;n gooddrainageinwetprocesses,egscreencleaninginscreenprintingor
flexographicprintingusingwater-basedinks;n windowsthatcanbeopenedandcleanedsafelyincludingrooflights.Youmay
needtofitanchorpointsifwindowcleanersneedtouseharnesses;n weatherprotectionforthoseworkingoutdoors,eglifttruckdrivers,security
guards,trafficcontrollers(banksmen)anddeliveryworkers;n outdoorrouteskeptsafeduringicyconditions,egsalted,sandedandswept.
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Alsothinkabout:
n machineryandfurniturebeingsitedsothatprojectingpartsdonotcauseariskofinjury,egatbuckle-folders;
n notoverloadingfloors-presses,particularlyoldones,areveryheavy;n spaceforstoringtoolsandmaterials.
LightingYoumustprovide:
n enoughlight.Usenaturallightwherepossiblebuttrytoavoidglare;n agoodleveloflocallightingatworkstations;n suitableformsoflighting.Somefluorescenttubesflickerandcanbe
dangerous,givingsomerotatingmachinerytheappearanceofbeingstationary;n well-litoutsideareas-thiswillhelpsecurity.
Youwillneedspecialfittingsforflammableorexplosiveatmospheres,egatheat-setovens,flexographicandgravurepresses(see‘Explosionrisksinflexographicandgravure’inChapter7).
Light-colouredwallshelptomakethemostofnaturalandartificiallight.FurtherguidanceaboutlightingisgiveninthebookletLighting at work(HSG38).
Moving around the premisesYoumusthave:
n safepassageforpedestriansandvehicles.Youmayneedclearlymarkedseparateroutes(see‘Safemovementofvehicles’laterinthischapter);
n level,evensurfaceswithoutholesorbrokenboards;n hand-railsonstairsandrampswherenecessary;n safedoors,egvisionpanelsinswingdoorsandsensitiveedgesonpower
doors;n surfaceswhicharenotslippery.
Thinkaboutmarkingsteps,kerbsandfixedobstacles,egbyblackandyellowdiagonalstripes.
Designing workstationsWhendesigningworkstationsandseatingarrangements,considercomfortandsafety.ErgonomicprinciplesshouldbefollowedandadequateaccounttakenofresponsibilitiesundertheManualHandlingOperationsRegulations1992andtheHealthandSafety(DisplayScreenEquipment)Regulations1992.Thisadviceappliestothehand-workingandinsertionsectorsinparticular.
Workstationsandseatingmustsuittheworkerandthework.Seatingmustbeprovidedwheretheworkoperations(orsubstantialpartsoftheoperations)canormustbedonesitting.Seatingshouldalsobeprovidedforemployeeswhoseworknecessitatesthemhavingtostandforlongperiods.
Insomecircumstancesmanualhandlingrisksmaybebettercontrolledbypeoplestandinguptocarryoutatask.Othermeasurestoreducetherisksandproviderelieffromstanding,suchasregularjobrotation,canalsobetaken.FurtherinformationisgiveninthebookletSeating at work(HSG57).
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Figure 2 Modernguillotineandhandlingsystem
CleanlinessYoumust:
n providecleanfloorsandstairswhicharenotslippery;n providecleanpremises,furnitureandfittings(eglights);n providecontainersforwastematerials,egmetal-liddedbinsforwash-upcloths;n removedirt,refuseandtradewasteregularly-remembertonotifylaundriesif
theyarereceivingsolventoruncuredUVink-ladencloths/wipes;n clearupspillagespromptlyandarrangeproperdisposal,egthroughalicensed
contractor;n keepinternalwallsorceilingsclean.Theymayneedpaintingtohelpeasy
cleaning.
Hygiene and welfareYoumustprovide:
n clean,well-ventilatedtoilets(separateformenandwomenunlesseachtoilethasitsownlockabledoor);
n washbasinswithhotandcold(orwarm)runningwater;n soapandtowels(orahanddryer);n skincleansers,withnailbrusheswherenecessary;n pre-orafter-workcreamsandskinconditioningormoisturisingcreamswhere
necessary;n dryingfacilitiesforwetclothes;n facilitiesforworkersworkingawayfrombase;n lockersorhangingspaceforclothing;n changingfacilitieswherespecialclothingisworn;n acleandrinkingwatersupply(markedifnecessarytodistinguishitfromthe
non-drinkablesupply);n restfacilities,suchasrestroomsorrestareas,includingsuitablefacilities
toeatmealswherefoodeatenintheworkplacewouldotherwisebecomecontaminated.TheWorkplace (Health, Safety and Welfare) Regulations 1992. Approved Code of Practice(L24)outlinesadditionalarrangements,egforheatingfood;
n arrangementstoprotectnon-smokersfromdiscomfortcausedbytobaccosmoke,egprovideseparateareasorroomsforsmokersandnon-smokersorprohibitsmokinginrestareasandrestrooms;
n restfacilitiesforpregnantwomenandnursingmothers;
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n acomfortabletemperatureandadequateventilationincludingfreshair.TheWorkplace (Health, Safety and Welfare) Regulations 1992. Approved Code of Practice(L24)referstoaminimumtemperatureof16°Cunlesstheworkinvolvesalotofseverephysicaleffort,inwhichcasethetemperatureshouldbeatleast13°C.
Safe movement of vehicles
Manyaccidentseachyearinvolvepoweredvehiclesincludinglorries,vansandlifttrucks.Injuriesmaybesevere,andevenfatal.Transportmovementsinandaroundtheworkplaceneedtobecontrolledtoprotectpedestrians,andtopreventdamagetoplantandequipmentsuchasrackingsystems.Riskassessmentsneedtotakeaccountofanycontractorswhomayworkon,orvisitthesite,suchascontractloadersinthenewspaperindustry.
Lookatthemovementofgoodsaround,intoandoffthesite.Forexample,checkthat:
n vehiclesandpedestriansareseparatedasmuchaspossible.Trafficroutesusedbybothneedtobewideenoughtoenablevehiclestopasspedestrianssafely.Barriersorrailsmaybeneededinparticularlyvulnerableplaces,suchasdoorways,gateways,tunnels,bridgesorotherenclosedroutes;
n pedestrianaccesstoloadingbaysanddeliverypointsiscontrolled;n theneedforvehiclestoreverseiskepttoaminimumandthat,wherepossible,
reversingisrestrictedtodesignatedareas;n areasinwhichvehiclesaremovedarewelllit;n workstations,vulnerableplant,gascontainersandchemicalstoragefacilities
arenotlikelytobestruckduringvehiclemovements;n trafficroutes,roadwaysandpedestrianroutesareclearlymarked;n sitespeedlimitsaremarkedandobserved;n speedcontrolmeasures,suchashumps,areprovidedwhereappropriate
(gapsmaybeneededtoallowlifttruckstopasssafely);n safecrossingpointsforpedestriansaremarked;n actionistakentocontroldangeratblindspots,includingopeningswithstrip
curtainswhichvehiclestravelthroughorpast;n visitingdriversknowandfollowyourrules;n ifnecessary,vehiclemovementsaredirectlysupervisedbyproperlytrained
signallers(banksmen),particularlywhenreversingandnearblindcorners;n banksmenarevisibletodriversatalltimes,andareabletostandinasafe
positionwhileguidingthereversingvehicle;n ifnecessary,high-visibilityclothingisprovidedforandwornbybanksmen;n trainingintheuseofrecognisedsignalsisgiventodriversandanyonewho
controlsvehiclemovements;n floorsandroadwaysarekeptingoodcondition.n ForfurtherinformationseethefreeleafletManaging vehicle safety at the
workplace(INDG199).
Loading and unloading of vehicles
Accidentsfrequentlyhappenwhenpeoplefallfromvehicles,ortheloadmovesunexpectedlyandtheyarestruckbyit.Particulardangersexistwherereelsofpaperarebeingunloadedastheyareheavyandgainmomentumoncetheystarttomove.
Unloadingofreelsneedstobedonewithsuitableequipmentsuchasaclamp,boomorpoleattachmentonalifttruck,andinaccordancewithasafesystemofwork.Tiltingclampdevicesareparticularlyuseful,astheypermitreelstobepickedupfromthehorizontalandplacedvertically,orviceversa.
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Areputablesupplieroflifttruckattachmentswillbeabletogiveadviceaboutsuitableequipmentforyourjob,andtheeffecttheuseofthedevicewillhaveontheratedcapacityofyourtruck.
Points to check:
n avoidtheneedtoclimbonloadsbyusingcurtain-sidedvehicles,orproprietarysheetingsystems;
n providesafeaccessifworkmustbedoneataheight;n provideanduseagantrysystem,safetylinesandharnessesifworkonhigh
loadscannotbeavoided;n eliminatemanualhandlingofreels;n loadandunloadinasafeplaceandkeepeveryone,includingmembersof
thepublic,wellclearoftheareaduringloadingandunloadingoperations;n avoidmanualhandlingbyusingpallets,alifttruckoraporter’strolley;n deviseasafesystemtodealwithmishaps,suchasstuckloads.Acommon
mistakeistoattempttofreeastuckloadbytyingaropetoitandpullingwiththelifttruck-injuriesoccurwhentheropeoritsfixingbreaksanditrecoilsviolently;
n makesureinstructionsexistfordealingwithanyvehiclethatmightarriveon-sitewithanunsafeload,forexamplepalletisednewspaperbundleswhichhaveshiftedduringtransit,andthattheinstructionsarefollowed;
n makearrangementstosecureloadsbeforevehiclesleavethesite,forexampleusingloadbindersinsidecurtain-sidedvehicles,topreventdangerousmovementoftheloadintransit.
Figure 3 Rackingshouldbesecurelyfixedandhaveaisleswideenoughtoallowmanoeuvring
Safe stacking and storing
General principles
n Storageareasshouldbespecificallydesignated,clearlymarkedandunderthecontrolofaresponsibleperson.
n Considerpermissiblefloorloadings.n Placematerialshandledbycraneorlifttruckonbattensorothersuitable
materialtoensurethataslingorforkscanbeinsertedunderthem.n Goodhousekeepingisessentialatalltimes.n Providesufficientlighting.n Maintainadequateclearancebetweenrowstoensuresafestackingand
withdrawal.
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n Maintainadequateheadroomforlifttrucks.Remembertocheckthatlighting,cablingandheatersaremountedhighenoughtopreventthembeingaccidentallystruckbythemast.
n Positionloadscapableofbeingstackeddirectlyontopofeachotheronafirm,levelbase.
n Checkstacksperiodicallyforstabilityandtakecorrectivemeasureswherenecessary.
n Considerfireprecautionsatanearlystage-stackswhicharetoohighmaypreventsprinklersystemsfromworkingcorrectly.
Don’t:
n exceedthesafeloadofracks,shelvesorfloors;n allowitemstostickoutfromstacksintogangways;n climbrackstoreachuppershelves-usealadderorsteps;n leanheavystacksagainstwalls;n de-stackbythrowingdownfromthetoporpullingoutfromthebottom.
Racking installationsRackingshould:
n beinstalledandmaintainedinaccordancewiththemanufacturer’sinstructions;n beerectedonsound,levelfloorscapableofwithstandingthepointloadingof
eachbaseplate;n besecurelyfixedtothefloorwherelifttrucksandmechanicalhandling
equipmentareused.Ifrackshavetobesecuredtothebuilding,calculationsshouldconfirmthebuildingisfitforthispurpose;
n haveaisleswideenoughtoensurethatmechanicalhandlingequipmentcanbeeasilymanoeuvred;
n havethemaximumloadclearlystatedonthem;n neverbealteredwithoutconsultingthemanufacturerfirst;n makekeycomponentshighlyvisibletohelplifttruckdriverspositiontheirforks
correctly.
Use of palletsOperatorsshouldreceiveinstructiononthesafeuseofpallets.Accidentsinvolvingpalletsarecausedby:
n poordesign;n poorconstruction;n usingpalletsunsuitableforparticularloads/rackingsystems(rememberyou
mayreceiveconsignmentswithdifferent-sizedpallets);n continueduseofdamagedpallets;n badhandling.
Precautions to reduce the risk of accidents when working with pallets
n Establishaneffectivepalletdamageinspectionschemeatthegoods-instage.Ifpalletsareregularlyinadamagedcondition,takeactionwiththesupplier.
n Inspectallpalletsagaineachtimebeforere-use(damagedonesshouldbewithdrawn).
n Handleemptypalletscarefullyandmakesuretheyarenotdraggedorthrownabout.
n Toavoiddamagetopallets,andtolifttheloadssafely,makesuretheforksofanyhandlingdeviceextendintothepallettoatleastthree-quartersofitsdepth.
n Forksshouldnotextendbeyondthepalletbeinglifted(egtheycouldoverturnanadjacentload).
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n Asageneralguide,theheightoftheloadshouldnotexceedthelongestbasedimensionofthepallet.
n Avoidstackingofpalletisedloadscapableofbeingcrushed.
Reel storage and stackingIdeally,pedestriansshouldbeexcludedfromreelstorageareasinwhichlifttrucksareused.Thisisespeciallyimportantwhenstackingorde-stackingoperationsaretakingplace.
Stackingreelsonendusuallyrequirestheuseofclamptrucksorsimilarequipment.Themaximumheightforanystackwilldependonthereelsizeandwillbelimitedbystability,drivervisionandoverheadobstructions.Thereshouldbegoodlightingwithminimumshadow.Reelsshouldbestackedsafely.Pillarsshouldbeclearlymarked,egwithyellowbanding.
Whereclamptrucksorothersafemeansofstackingonendarenotavailable,reelswillprobablybestoredhorizontally.Itissafesttostorereelswithoutstackingbutiftheyarestackedmorethanonetierhighduetolackofspace,itisvitaltouseproperwedgestopreventaccidentalbreakingdownofthestack.Ifwedgesaretoosmallorincorrectlyshaped,notonlywilltheybeliabletomove,butthepaperwillalsobedamaged.Atleastonewedgeshouldbeplacedateachsideofeveryreelatfloorlevel-largewedgeswithhandlesmaybebest.
Stackingaislesshouldbewideenoughforanyvehiclesdoingthework.
Figure 4 Correctpositioningofwedgesandsafestackingofreels
Reels must be stacked true and vertical and be of equal diameter in any one stack, except that a reel with diameter slightly less than the other may be used as the top reel of a stack
Reels with dished ends or protruding centres must not be stacked on end
Reels must not be placed horizontally against a vertical reel
Correct positioning of wedges
WRONG RIGHT
Height limitedfor this method
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Manual breaking down of pyramid stacksReelsmaybedeliveredonlorriesinpyramidstacks,orbestoredthatwayinthewarehouse.Wherepossible,considerchangingthedeliveryandstoragearrangementssoreelsarestoredanddeliveredonend.Itisbesttousemechanicalmethodsofhandlingreelsstackedlikethis,egbyusingalifttruckwithtiltingclamp,liftingboomortinedevices-askaspecialistsupplieroflifttruckattachmentsforadvice.Mechanicalhandlingdeviceswillhelpprotectyouremployeesandalsohelppreventdamagetothereels.
Ifmanualbreakingdownofsuchstackscannotbeeliminated,asafesystemofworkmustbesetdownandimplemented.Thesystemneedstotakeaccountof:
n theneedtode-stackreelsinapredeterminedorder;n theneedtoensurethatpeopleonlyworkfromthesideofthestack,where
theywillnotbehitbyareelifitmovessuddenly;n theneedtoadequatelyandfirmlychockallreelsonthebottomrowofthe
stackuntilitisnecessarytomovethem(chockdesignisimportant-theheightofthechockshouldbeatleastoneeighthofthediameterofthereel);
n theuseofproperlydesignedbatsorpaddlestocontrolunchockedreels.Brakingchocksmaybeused,togetherwithachockpaddleandaleverbat;
n theneedtoprovideenoughpeopleforthejob-unloadingshouldbeconductedbyateamofatleastthreeadequatelytrainedandsupervisedpeople,andthismayincludethedriverofthedeliverylorry.Onepersonwilldrivethelifttruck,whiletheothertwoworkatthesideofthestack,barringdownthereels;
n theneedtoprovideasafesystemofworkfordealingwithreelsdeliveredincontainerswheresideaccessmaynotbepossible.
Therehavebeenfatalaccidentswhenreelsbeingmanuallyde-stackedhaverunoutofcontrol-mechanicalmethodsshouldbeusedifatallpossible.
SeeChapter7forfireprecautionsrelatingtostackedreels.
Lift and clamp trucks
Liftandclamptruckscanbeusedformanymaterialhandlingoperationsintheprintingindustry,particularlyinthemovementofpalletsofpaper,paperreels,chemicalsandwastematerials.Lifttruckaccidentscausemanyseriousinjuriesincludingfatalitieseveryyear-suitableoperatortraining,vehiclemaintenanceandworkingconditionsareessential.
The law and lift trucksInadditiontothegeneralrequirementsoftheHSWAct,thoroughexaminationandtestingofthechainsofalifttruckbyacompetentpersonisrequired.Youwillneedtoobtainandkeepacopyofthesereportsandrectifyanysafetydeficienciesidentifiedinthem.
ThepublicationRider-operated lift trucks: Operator training. Approved Code of Practice and guidance(L117)givespracticalguidanceoncomplyingwiththerequirementsofsection2oftheHSWActinrelationtothebasictrainingofoperatorsofrider-operatedlifttrucks.
TheApprovedCodeofPracticerequires:
n employerstoprovidebasictrainingforoperatorsbyrecognisedinstructors(suchinstructorsmaybeemployeeswhoarecompetenttocarryoutthisrole);
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n competencetestingoflifttruckoperators;n authorisationof,andappropriaterecordsfor,allemployeespermittedtodrive
lifttrucks.
Inadditiontotheabove,driver-operatedlifttrucksusedregularlyontheroadforlongperiods,andtheirdrivers,mustbelicensedbytheDrivingStandardsAgency.
Health problemsLifttruckscancreatehealthproblemswhichwillneedtobeconsidered.Thesecaninclude:
n breathingproblemsfromusingdieseltrucksinconfinedworkingenvironments(goodmaintenance,egoffuelinjectors,canreducefumeproblems);
n backandupperlimbdisordersduetopoorseatingand/orcontrols.n Poorroadwayscancauseexcessivetruckvibrationandbackproblems.
Common accidents
Somecommoncausesoflifttruckaccidentsinclude:
n unsafereversing;n speeding;n overloading;n passengercarrying;n untraineddrivers;n poororinadequatevisibility;n poorworkingenvironment,egunevenroadsurfacesorobstacles;n inadequateseparationofpedestriansandlifttrucks;n inadequateseparationofhighwayvehiclesandlifttrucks;n poortruckmaintenanceincludingmaintenanceofchainsandbrakes.
Safety guidelines for lift trucks
n Ensurealloperatorshavereceivedadequatetraining.n Ensureenoughpeoplehavebeentrainedtocoverholidays,weekends,
overtimeandsickness.n Ensuretraininginstructorsarecompetentininstructionaltechniquesandskills
assessment.n Restrictuseoflifttruckstoauthorisedoperatorsonly(authorisationshouldonly
begiventoadequatelytrainedandexperiencedoperators).Itmayhelptopostalistofauthoriseddriversonthetruck.
n Providesuitablerefreshertrainingforoperators.n Ensuremanagersandsupervisorsaretrainedinsafetyaspectsofliftandclamp
trucks.n Managersshouldhaveanappreciationoftherisksandthewaystominimise
them.n Supervisorsshouldhaveenoughknowledgetobeabletorecognise
inadequaciesintheoperationoflifttrucksandthetrainingneedsofoperators.n Screenoperatorsforfitness,egeyesighttesting.n Keepfloorsandroadwaysingoodcondition,freefromobstacles,obstructions
andpotholes.n Allowenoughroomforlifttruckmanoeuvres.n Maintainalllifttrucksonaregularbasistoensuretheyareingoodcondition
(includingexaminationofthemastchains,tyres,brakesandhorns).Introducedailydriverchecksofthesafetyequipment.
n Ensurethatthoroughexaminationandtestingofliftingchainsarebeingcarriedoutbyacompetentpersonasrequired.
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n Segregatelifttruckroutesfrompedestrianandworkingareasasmuchaspossibleandmarkthemwithbarriersorlinesonthefloor.
n Ensuregradientsarenottoosteep.n Keepkeyssafewhenthelifttrucksarenotbeingusedbyauthoriseddrivers.n Ensurethatoperatorsuseseatbelts.n Ensuregoodvisibilitywhenmovingloads-wherenecessaryuseabanksman
todirecttrafficsafely.n Rememberthatthefittingofcranejibattachmentsissubjecttoadditionallegal
requirements.
Don’t:
n allowanyonetodrivealifttruckunlesstheyhavebeenselected,trainedandauthorisedtodoso;
n carryreelsstackedontopofeachother(asthetopreelswillbeunsupportedandliabletofall);
n uselifttrucksinareaswhereflammableconcentrationsofvapoursmaybepresent,egclosetogravureorflexographicpressesusinghighlyflammableliquidsorininkstoresunlessthetruckshavebeenspeciallydesignedandprotected;
n leavekeysintheignitionwhentrucksareparkedorleftunsupervised;n allowanyoperatorstoconsumeanyalcoholwhileatwork;n useforks,palletsorbinstoliftpeopletoworkatheights(useproperlydesigned
mobileworkplatforms);n pickuploadsifsomeoneisstandingclosetotheload;n allowpeopletowalkunderraisedloads;n moveunstableloads;n leavealifttruckunattendedonagradientexceptinanemergency(ifyoudo
havetoleavethetruckonaslopeinanemergencyusewheelchocks);n carrypassengersunlessthelifttruckisdesignedtodoso;n runoverelectricalcablesorflexiblepipesonthefloorunlesstheyaresuitably
protected;n operatewiththeloadraisedexceptforstackingandde-stackingmanoeuvres;n allowspeedingorunsafereversingpractices;n fitattachmentstolifttruckswhichcouldaffecttheirliftingcapacitywithout
consultingthemanufacturer,authorisedsupplierorqualifiedlifttruckengineer;n forgettoconsidertheneedforbeacons,mirrors,hornsetc,theprotectionof
driversfromfallingobjectsandlightingwherenecessary;n allowotherpeople,suchasdeliverydrivers,touseyourlifttrucksunlessyou
arecertainthattheyhavereceivedappropriatetrainingetc.
Accident
Aprintworkerwascrushedbetweentwofullpalletsofpaperweighinghalfatonneeachwhenalifttruckreversedandinadvertentlypushedapalletintoherbackasshestoodatherworkstation.Despitehavingaconsultants’reportwarningthattheriskofcollisionbetweenpedestriansandlifttrucksinthecrampedpremiseswashigh,noattempthadbeenmadetosegregatetheactivitiesorprovideaone-waytrafficmanagementsystem.
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Safety guidelines for automatic guided vehicles (AGVs)Theseinclude:
n ensuringthatallsafetyfeaturesareoperatingcorrectly;n ensuringthatstoppingperformancesareappropriatetotheriskandload.
Vehicleswillneedtocometoacontrolledstopsotheydonotreleasetheirloadsuddenly;
n ensuringthatappropriatemaximumspeedsareset;n ensuringthatadequateclearanceshavebeenlefttopreventtrappingpeople
betweenmovingvehiclesandfixedstructures.
Figure 6 SafetyfeaturesofanAGV
Asbestos in buildings
Asbestos-relateddiseaseskillanestimated3000peopleeachyearintheUKandthisfigureisexpectedtorise.Manyofthepeoplenowsufferingfromthesediseasesworkedinthebuildingandmaintenancetrades-joiners,plumbers,electricians,engineersetc.
Asaroughguide,ifyourbuildingwasbuiltbeforethe1980sandyoucarryoutanytypeofmaintenance,repairorrefurbishmentwork,youcouldbeexposingpeopletoasbestosdustwithoutrealisingit.Anyindividualexposuremaybesmall-butthesecanbuildupandmayresultinanasbestos-relateddiseaselateroninlife.Thisisparticularlyrelevanttomaintenancepersonnel.Atthetimeofwriting(January2002)theHealthandSafetyCommissionproposestointroduceanewdutytomanageasbestosinbuildings.
Warninglight
Beacon
Emergencystop
Tripbumpers
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Theintentionofthe‘dutytomanage’,ascurrentlydrafted,istorequireemployersto:
n takereasonablestepstodeterminethelocationofmaterialslikelytocontainasbestos;
n presumethatmaterialscontainasbestosunlessthereisareasontosupposetheydonot;
n makeawrittenrecordofthelocationofasbestosandpresumedasbestosmaterial,andkeepituptodate;
n keepacheckontheconditionofasbestosandpresumedasbestosmaterials;and
n assesstheriskofexposurefromasbestosandpresumedasbestosmaterialsandrecordtheactionnecessarytoensurethat:
– ifthematerialmaycreateariskofexposurebecauseofitsstateandlocationitisrepairedorifnecessaryremoved;
– anysuchmaterialismaintainedinagoodstateofrepair;– informationaboutthelocationandconditionofthematerialisgivento
anyonelikelytodisturbit,includingmaintenancecontractorsaswellasthosenormallypresentinthebuilding.
AnewApprovedCodeofPracticewillbeproducedfortheduty,togetherwithsupportingguidance.Rememberyourownemployeesmayalsobeexposediftheyworkinofficeorstorageareaswhereasbestosinsulationboardproductshavebeenusedwhichhavebeendamagedbyalterationsorthemovementofmaterials.
Where is asbestos found in buildings?Thefollowingareareaswhereasbestosmightbefoundinolderbuildings:
n inspraycoatingforfireprotectionandinsulationonsteelwork,concretewallsandceilings;
n ininsulationlagging,onpipework,andforboilersandducts;n inasbestosinsulatingboardusedaswallpartitions,firedoors,ceilingtiles
etc;n inasbestoscementproductssuchassheetingonwallsandroofs,tiles,cold
watertanks,gutters,pipesandindecorativeplasterfinishes.
What should you do?
n Identifyanyasbestosmaterialonsite(ifyouareunsure,haveittested).Keeparecordofitslocation.
n Ensureanyrelevantemployeesorcontractorsknowifandwhereasbestosmaybepresentwithinyourworks.
n Ensureanyasbestosyoudofindisinasafecondition,egundamagedand/orsealed(andwillnotaffectexistingemployeesworkinginyourfactory).Carryoutregularcheckstomakesurethatitremainssafe.
n Ifworkisrequiredonorneartheasbestosyoumayneedtocallinlicensedcontractors.Youwillneedtoinformanyonecarryingouttheworkofthedangersandensuretheycarryouttheworksafely.
n Askyourlocalenforcingauthorityforfurtherinformation.Freeandpricedpublicationsareavailable,egManaging asbestos in premises(INDG223rev2).
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Chapter 4 Health risksSee the ‘References’ section at the back of the book for details of publications which relate to Health risks
Nationally,over2millionpeopleayearsufferfromillhealthcausedormadeworsebywork.Thirteenmillionworkingdaysarelostaspeopletaketimeoffbecauseworkhasmadethemill.Theprintingindustryisnoexception.Ill-healthproblemsincludemusculoskeletaldisorders,occupationalasthma,deafness,eyedamageanddermatitis.Dermatitisisaparticularprobleminprinting-Europeanreportshaveindicatedthatitaccountsfor65%ofallcasesofillhealthintheindustry.
Themanagementofhealthriskswithintheworkplaceisoftenneglectedorfailsbecause,unlikesafetyissues,healthriskstendtobebothlessobviousandlesswellunderstood.Becausetheonsetofillhealthisoftendelayed,theriskscanbeunderestimateduntilitistoolateandpermanentdamagehasoccurred.
Employershavejustasmuchresponsibilityforsafeguardingthehealthasthesafetyoftheiremployees.Riskassessmentsneedtocoverhealthaswellassafetyhazards(seethegeneraladvicegivenonriskassessmentinChapter1).
Relevant legislation
n HealthandSafetyatWorketcAct1974(HSWAct)n ControlofSubstancesHazardoustoHealth(COSHH)Regulations1999n ManagementofHealthandSafetyatWorkRegulations1999n Workplace(Health,SafetyandWelfare)Regulations1992n NoiseatWorkRegulations1989n ControlofLeadatWorkRegulations1980(CLAW)n ManualHandlingOperationsRegulations1992n ControlofAsbestosatWorkRegulations1987(ConsolidatedRegulations
areduetobemadein2002)n IonisingRadiationsRegulations1999
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Table 1 Examplesofhealthhazardsinprinting
Occupational health and rehabilitation
Inanybusiness,workersarethemostvaluableassetsanditisimportanttolookafterthemproperly.Employersneedtoactivelymanagehealth.Witheffectiveoccupationalhealthsupportandadvice,healthrisksatworkcanbemanagedinwaysthatarenotcostlyordifficult.Manyworkerswhohavealreadybeenmadeill,fromwhatevercause,canbehelpedtoremaininorreturntowork.
Therearelegaldutiestopreventillhealthcausedbywork.ThemainlegalframeworkistheHSWAct,supplementedbyregulationswhichcoverparticularactivities,suchasmanualhandlingandexposuretoharmfulsubstances.Theserequireyoutomakeassessmentsofthehealthriskstoworkersarisingfromworkactivitiesandtotakeactiontopreventorreducethoserisks.
Hazard Health effects Typical processes
Inhalationofsolventvapour(healtheffectsdependonthesolvent,itsconcentrationinairandthelengthofexposure)
Headaches,nausea
Effectsonthecentralnervoussystem
Cleaninglithoandletterpressrollersandcylinders
Screen,flexoandgravureprinting
Contactwithandabsorptionofsolventthroughtheskin
Dermatitis
Inhalationofvapoursandmistsfromisocyanatesorreactiveacrylates
Occupationalasthma Useoflacquers,adhesives,inksetccontainingisocyanatesorreactiveacrylates
Skincontactwithreactivechemicals(healtheffectsdependonthechemical,itsconcentrationandthelengthofexposure)
Dermatitisincludingsensitisation(skinallergy)
UseofUV-curedproducts
Etching,engraving
Platemaking
Screenreclamation
Stereorollerpreparation
Gravurecylinderpreparation
Skincontactwithandinhalationofpotentiallytoxic,verytoxicadditives(egthosewithriskphasesR40‘Possibleirreversibleeffects’,R45‘Maycausecancer’,R46‘Maycauseheritablegeneticdamage’,R61‘Maycauseharmtotheunbornchild’)
Carcinogenic(cancer)
Mutagenic(harmtotheunbornchild)
Screenprintingwithspecialistinksandcoatings
Screenreclamation
Generalprintingandcleaningactivityinvolvingtheuseof,egfontsolutions,biocides,formaldehyde,dichloromethane,N-vinylpyrrolidone(NVP)
Exposuretohighlevelsofnoise Noise-induceddeafness
Tinnitus
Webprinting
Printfinishing
Unsafemanualhandling Backinjuries Handlingofpaperreels,sheetsandbundles
Awkwardorrepetitivemovements Upperlimbdisorders,egtenosynovitisandcarpaltunnelsyndrome
Typesetting
Printfinishing
Exposuretomicro-organismsfromcontaminatedwater
Humidifierfever
Legionnaires’disease
Paperstorageorprintingwherehumidifiersareused
Anyprintingprocessinbuildingswithcoolingtowersorotherwatersystemsthatcanbecomecontaminated
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Occupational health servicesEmployersmayneedexpertandspecialistadviceonhowtohelpthemwithissuessuchas:
n identifyinghealthhazards,assessingrisksandchoosingthenecessarycontrolmeasures;
n checkingtheeffectivenessofthecontrolmeasuresand,whererequired,measuringtheexposureofemployees,forexamplebyatmosphericsampling;
n advisingonplacementandrehabilitationofemployees;n provisionofappropriateon-sitefirst-aidandtreatmentfacilities;n identificationofcausesofillhealthwithintheworkforce;n promotionofgoodgeneralhealthamongemployees.
Occupationalhealthservicesmaybeabletohelpwiththesematters.HSE’sEmploymentMedicalAdvisoryServicecanadviseyouandtheleafletNeed help on health and safety?(INDG322)providesmoreinformation.(SeealsoNHSPlus:www.nhsplus.nhs.uk)Health surveillanceHealthsurveillanceisonecomponentoftheoverallmanagementofhealthrisks.Itinvolvesobtaininginformationaboutanemployee’shealthandhelpstoprotectthatemployeefromhealthrisksatwork.Itmaybenecessary:
n undertheControlofSubstancesHazardoustoHealth(COSHH)Regulations1999,forexampletoprotectagainstdermatitisoroccupationalasthma;
n undertheManagementofHealthandSafetyatWorkRegulations1999,wherepeopleworkinnoisyprocesses;
n wherethereissignificantexposuretoleadinpremisessuchastraditionalcraftprintersandtheControlofLeadatWorkRegulations1980apply.
TheneedforhealthsurveillanceshouldbedecidedaspartoftheassessmentsrequiredbytheseRegulations.Healthsurveillancecannotreplacepropercontrolmeasuresbutisanessentialpartofahealthconservationprogramme.
Healthsurveillanceisrequiredwhere:
n anidentifiablediseaseoradverseeffectmayberelatedtoexposure;n thereisareasonablelikelihoodofthatdiseaseoreffectoccurringunderthe
particularworkconditions;n therearevalidtechniquesfordetectingsignsofthediseaseoradverseeffect
andsurveillanceislikelytoimprovetheprotectionofemployees’health.
Themainobjectiveofhealthsurveillanceistoprotectthehealthofindividualemployeesbycheckingforearlysignsofwork-relatedillness.Italsoprovidesinformationaboutandearlydetectionofadversechanges,whichmaybecaused,forexample,byexposuretonoiseorasubstancehazardoustohealth.
FurtherguidanceabouthealthsurveillanceisgivenintheHSEbookletHealth surveillance at work(HSG61).
Allemployeeswillneedtobegiveninformation,instructionandtrainingaboutanyriskstotheirhealththatmightarisefromtheirwork.Wherehealthsurveillanceisappropriatetheyalsoneedtoknow:
n whatsymptomsandsignstolookoutfor,andwhereappropriate,howtoself-examine(egfordermatitis);
n howthehealthsurveillanceschemeworksandwhotoreporttoiftheyareconcerned;
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n whatthearrangementsareforseeingtheirownhealthrecordsandcollectiveresultsofthehealthsurveillanceprogramme.
RecordsmustbekeptwherehealthsurveillanceiscarriedouttocomplywiththeCOSHHRegulations.TheinformationthatshouldbeheldintherecordsisdetailedintheAppendixoftheCOSHHGeneralApprovedCodeofPractice(L5).Recordsshouldberetainedfor40years.
RehabilitationEarlydetectionofillnessgivesyouachancetodealwiththeproblempromptly,andprovidestheopportunityforyoutohelpworkersremainatwork,perhapsbyarrangingforlightdutiesormodifyingworkforalimitedperiod.Ifaworkerexperiencesdifficultiesinreturningtotheirnormaldutieswithinafewweeksthenyoushouldspeaktoahealthprofessionalaboutsettingupanactiverehabilitationprogramme.
Largerorganisationsmayhavetheirownspecialistsandanoccupationalhealthservice,butallbusinessescanobtainaccesstotreatmentandrehabilitation.Somemakearrangementsthroughtheiremployer’sliabilityinsurer,somehave‘goodneighbours’(largercompaniesthatoffersmallbusinessesintheirsupplychainaccesstotheirsupportservices),andothersgoitalone.Somesmallbusinessesfinditworthwhiletomakelocalpartnershiparrangementswithhealthprofessionals.
Anumberofpeoplecanadviseyouaboutwhatisavailabletoyoulocally.Atradeassociation,chamberofcommerceortradeunionrepresentative,ifyouhaveone,willprobablyknowifthereareany‘goodneighbour’businessesyoucouldcontact.YourlocalHealthandSafetyExecutiveofficemightalsobeabletoadvise.
Hazardous substances
Manychemicalsubstancescancauseharmiftheyareinhaledorabsorbedthroughtheskin.Manyalsocausedermatitisordamagetotheeyes.Exposurecanhaveanimmediateeffectormaybedelayed.Repeatedexposuretosomesubstancesmaycausedamagetothelungs,liverorotherorgans.Theycanbetakenintothebodybybreathingthemin,passingthroughtheskinorbyeatingfoodwhichhasbeentouchedbycontaminatedhands.
Somesubstancescancausebothlocalandinternaleffects,forexampletheymightdamagetheskinandcauseliverdamage.Themosteffectivewaytoprotectemployeesfromanyharmfulsubstanceistoseeiftheuseofthesubstancecanbeavoidedcompletely,perhapsbyfindingasafersubstituteorbychangingtheprocessinsomeway.
ManyofthehealthhazardslistedinTable1relatetotheuseofhazardoussubstances.Withtheexceptionsofasbestosandlead(forwhichtherearespecialisedregulations),theuseofhazardoussubstancesatworkissubjecttotheControlofSubstancesHazardoustoHealth(COSHH)Regulations1999.ThissectionsummarisestherequirementsofthoseRegulationsandgivesadviceonthecontrolmeasuresforparticularprintingprocesses.
Foreverydaytasksinvolvingcommonlyusedprintingchemicals,thePrintingIndustryAdvisoryCommittee(PIAC)hasproducedCOSHH essentials for printers.ThisguidancegivesyouagoodheadstartwithyourCOSHHassessments,andcomprisesaseriesofsummarysheetscoveringtypicaltasks,whichexplainthestepsyouneedtotaketocontrolemployees’exposure.Thefirststagesoftheassessmentprocesshavebeendoneforyouusinginformationfromsuppliers.UndertheCOSHHRegulationsyoumust:
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n assesstheriskstohealtharisingfromtheuseofhazardoussubstancesatwork(andreviewyourassessmentifchangesoccur);
n preventorcontroltherisk,egbyusingasafersubstitute,orbysuitablecontrolmeasures;
n ensurethatcontrolmeasuresareusedandmaintained;n monitorexposureandcarryouthealthsurveillancewhennecessary;n inform,instructandtrainyouremployeesabouttherisksandtheprecautions
needed;n keeprecordswhererequired.
Figure 7 TheuseofhazardoussubstancesatworkissubjectedtotheCOSHHRegulations
Exposure limitsForcertainsubstances,wherethereisariskofinhalation,occupationalexposurelimitshavebeenset.Therearetwokinds-maximumexposurelimits(MELs)andoccupationalexposurestandards(OESs).Youmayneedtorefertothesewhenassessingtherisksinyourworkplace.Furtherinformation,includinganexplanationofthedifferencebetweenthetypesofexposurelimits,isgivenintheguidancebookletOccupational exposure limits(EH40),whichispublishedyearly.
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Assessment under COSHH
Firstgatherinformationonthesubstancesusedinyourworkplace.Usemanufacturers’labelsandsafetydatasheetstohelpyoudecidewhichonesarehazardous.Anysubstancewhichcarriestheclassification‘verytoxic’,‘toxic’,‘harmful’,‘corrosive’,or‘irritant’,orwhichhasbeenassignedamaximumexposurelimitoroccupationalexposurestandardbecauseofrisksfollowinginhalation,issubjecttotheCOSHHRegulations.Thisalsoappliestobiologicalagents,substantialquantitiesofdusts,andothersubstanceswhichpresentcomparablehazards.
Suppliersofchemicalsforuseatworkarelegallyobligedtoprovidesafetydatasheetscontaininginformationunder16headings,specifiedintheChemicals(HazardInformationandPackagingforSupply)Regulations.ThisinformationwillhelpyoutocarryoutyourCOSHHassessment,butsimplycollectinginformationisnotenough-youneedtousetheinformationtodecidewhetherornotthereisarisk,andwhetherornotyourowncontrolsandworkingproceduresaresufficient.Contactyoursupplierforadviceifyouareinanydoubtabouttheinformationprovidedinsafetydatasheets.
Consider:
n howthesubstanceisused,handledorstored;n whomightbeaffected;n thelikelyroutesofexposure-inhalation,ingestion,skinabsorption;n thelikelihoodandeffectsofspillsorleaks;n whatcontrolmeasuresarecurrentlyused;n anyrisksduringcleaningormaintenanceactivities.
Itisimportanttofindouthowsubstancesareactuallyusedintheworkplace,andwhoisexposedtothem-don’tforgetcontractorsandmaintenanceworkers.Thinkaboutthehandlingofsubstancesfromdelivery,touseanddisposal.Thinkalsoaboutwhatcangowrong,forexamplehowyouwoulddealwithspillageorleakingcontainersofsolvent,orcarryoutrepairsonmachineswherethereisuncuredUVink.Drawconclusionsabouttherisksanddecideifyouneedtotakeactiontoreducethem.Specialisthelpmayberequiredtohelpyoumakethesedecisions,forexamplefromanoccupationalhealthprofessional.Recordyourconclusions.
Prevention or control of exposureIfyourassessmentconcludesthatthereareriskstohealth,thenyouneedtodecidewhatelseyouneedtodotocomplywiththeCOSHHRegulations.
Ifpossible,preventexposurebyusingalesshazardoussubstanceoradifferentprocess.AgoodexampleofthisisthePrintingSolventSubstitutionSchemefortheoffsetandUV-curablesectorintroducedinthiscountryinOctober2000.Thisisavoluntaryscheme,basedonaverysuccessfulapproachinGermany,toreducevolatileorganiccompounds(VOCs)intheprocess,byreplacingrollerandblanket
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washeswithahighboilingpointsolvent/vegetablecleaningagent(VCA)andtakingstepstoreduceoreliminateisopropylalcohol(IPA)fromthefountsolution.Theprinciplesoftheschemeareshownintheboxinsertlaterinthischapter.Anotherexampleistheuseofwater-basedinksforflexiblepackaging.Askyoursupplierforalternativeproductsthatmaybesafertouse.RememberifyouchangeyourproductyouwillstillneedtocarryoutaCOSHHassessmentforthenewsubstanceandensurethatyouprovideappropriatecontrols.
Wherepreventionofexposureisnotpossible,youneedtoconsidercontrolmeasures.Thisusuallymeansacombinationofsomeofthefollowing:
n Enclosingtheprocess.n Partialenclosureand/orlocalexhaustventilation(LEV).n Generalventilation.n Asystemofworkandhandlingprocedurestominimiseleaksandspills.n If,andonlyif,youcannotadequatelycontrolexposurebyacombinationofthe
measuresabove,thenyoushouldalsoprovidepersonalprotectiveequipment(PPE)suchasrespiratoryprotectiveequipment,glovesandeyeprotection.See‘Personalprotectiveequipment(PPE)’towardstheendofthischapterforfurtherinformation.
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Chemical hazards in printing
Table 2 Printingprocesseswhichmaygiverisetoskinoreyecontacthazards
Note: The examples here are only illustrative and are not exhaustive
Process or activity Type/name of substance Potential health hazard
Etching,engraving,platemaking,certainphotographicreproductionsystems,correctionoflithoplates(hydrofluoricacid)
Corrosiveacids,egconcentratednitricandsulphuricacids,hydrofluoricacid
Skinburnsandblisters
Burnswithconcentratedhydrofluoricacidareverysevere
Eyedamage
Cleaningofscreensinscreenprinting Strongalkalis,egconcentratedsodiumorpotassiumhydroxide
Corrosivetoskin,eyesandmucousmembrane
Concentratedphotographicdevelopersolutions
Hydroquinone Irritanttoeyesbutmaycausepermanentdamage
Irritantandsensitisingtotheskin,maycausedermatitis
UVandelectronbeamcurableinks,varnishesandlacquers
Reactiveacrylatesormethacrylates Corrosivetoskin,eyesandmucousmembranes
Potentialforskinsensitisation
Photographicfixersolutions Aceticacid,acidicsaltsolutions(egsodiumthiosulphate)
Irritant
Hardeneraddedtophotographicfixersolutions
Diluteformaldehydesolution Irritant
Frequentcontactmayleadtoskinsensitisation
Lithoplatemaking,gravurecylinderpreparation,photoengraving,photographicbleaches
Dichromates,egammonium,potassiumandsodiumdichromates
Verycorrosive
Inhighconcentrationscancausedeepulcers
Potentialforskinsensitisation
Lithoprinting:fountsolution,blanketrestorers,cleaningsolvents
Isopropylalcohol(IPA),methylethylketone(MEK),whitespirit
Dermatitis
Gravureandflexographicprinting:variousinks
MEK
Alcohols,egindustrialmethylatedspirits(IMS),IPA
Esters,egethylacetate
Aromatichydrocarbons,egtoluene,xylene
Dermatitis
Screenprinting:UV-curedinks N-vinylpyrrolidone(NVP)andMichler’sKetone
Cancer,harmtotheunbornchild
Screenprinting:inks Ketones,egcyclohexanone
Aromatichydrocarbons,egtoluene,xylene
Dermatitis
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Table 3 Printingprocesseswhichmaygiverisetoinhalationhazards
Examples of processes or activity Type/name of substance Potential health hazard
Makingflexographicandletterpressplates
Perchloroethylene Dizziness,drowsinessandothereffectsonthecentralnervoussystem
Cleaningrollers,cylindersandblanketrestoring
Chlorinatedhydrocarbons,egdichloromethane
Ketones,egmethylethylketone(MEK)
Dizziness,drowsinessandothereffectsonthecentralnervoussystem
Cardiacarrhythmia(highconcentration)
Affectsliverandkidneysonlong-termexposure
Lithoprinting-fountsolution Alcoholssuchasisopropylalcohol(IPA) Dizziness,drowsinessandothereffectsonthecentralnervoussystem
Gravureandflexographicprinting Inkscontainingketones(egcyclohexanone),alcohols(asinIMS),esters(egethylacetate,isopropylacetate)oraromatichydrocarbons,egtoluene,xylene
Asabove
Screenprinting Inkscontainingketonesoraromatichydrocarbons
Asabove
Screenprinting:UV-curedinks N-vinylpyrrolidone(NVP)andMichler’sKetone
Cancerandharmtotheunbornchild
Adhesivelaminating
Useofpolyurethanelacquers
Isocyanateprepolymers Irritationofrespiratorytract(highconcentration)
Occupationalasthmacouldoccurevenatlowlevels
Handling,cutting,grindingleadtype,hotmetalwork
Leaddust/fume Leadabsorbedinbloodstreamleadstoheadaches,tiredness,stomachpains,constipationandlossofweight
Dyelineprinting Ammoniumhydroxide Irritationofrespiratorytract(asammoniavapour)
High-speedprintingusingUVink-leadingtoinkmisting
ReactiveacrylatescontainedinUVinksetc Irritationofrespiratorytract
Potentialforoccupationalasthma
Laserengraving(gravurecylinders)
Maintenanceinvolvingwelding
Metalfume Irritationofrespiratorytract,‘flu-like’illness(metalfumefeverdependingonthemetal)
Poisoningfromsubstancesinthefume
UseofUVlampsforphotoprocessing,UVcuring,coronadischarge
Ozone Irritationoftheupperrespiratorytract
Headachesandnausea
Digital(ink-jet)printing Methylethylketone
Propanol
Cardiacarrhythmia(highconcentration)
Affectsliverandkidneysonlong-termexposure
Dizziness,drowsinessandothereffectsonthecentralnervoussystem
Dusts
Saw/knifemillinginbindery Paper
Dustofanykindcanirritatetherespiratorytractandblockthenose
Useofanti-set-offpowder Sugar/starch
Thermography Plasticisers
Bronzingmachines,mixingaluminiumpastes
Metal
Manufactureofformes Softwooddust Respiratorydisordersincludingoccupationalasthma
Maintenanceinvolvingcutting,sawing,drillingetc
Hardwood Occupationalasthmaandcancers
Maintenancework,particularlytobuildings
Asbestos Cancersandasbestosis
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Specific process health hazards
Design and artworkRiskstohealthfromdesignandartworkcanbereducedby:
n usingnon-flammableadhesives-preferablywax;n removingwaxfromglasssurfacesbyscrapingratherthanusingsolvent;n usingalternativestoaerosolswheretheseareavailableandonlyusingaerosols
ifthereisgoodventilation;n notsmokingwhereaerosolsareused-manywillbeflammable.
Graphic reproductionDarkroomswithautomaticfilmprocessorsneedmechanicalventilationtoensurehealthyandcomfortableworkingconditions.Tentofifteenairchangesperhouristhestandardnormallyachievedintheindustry.Asuitableextractorfanmountedinanoutsidewallwilldo,butitisimportanttoprovideanairinlet.Carefullydesignedlouvrecoverswillensurethatunwantedlightdoesnotentertheroom.
PlatemakingAutomaticprocessingeffectivelyreducesthelikelihoodofskincontactwithchemicalsduringnormaloperation.Somedeveloperscancauseaggressiveskinreactions,sonitrileorbutylrubbergauntletsandprotectiveclothingareneededwhenmanipulatingthechemicalcontainers.Suitablegogglesorfaceshieldsshouldbeprovidedandwornifthereisariskofsplashing.
Keepdrumsofreplenishersolutionfeedingprocessequipmentinshallowtrays,soastocontainspillage(andprotectthefloor).
Deletion fluidsDeletionfluidscontaininghydrofluoricacidintoxicandcorrosiveconcentrationsmaybeusedtomakeminoralterationstoprintingplates.Theseproductsareparticularlyharmfulifskinoreyecontactoccurs-theaffectedareashouldbewashedimmediatelyunderrunningwater,andmedicaladviceobtained.
Checkthesafetydatasheetsfortheseproductstoensurethatappropriatefirstaidisavailable.Antidotecream(calciumgluconategel)willpreventseriousburnsrightdowntothebone.Ifitisneeded,keepfreshstockonthepremises.Makesurepeopleknowwhyitisneededandhowtouseit.
Wherepossible,usedeletionpensasanalternativetosmalljarsorpotsofdeletionfluidtoreducethedangerofskincontact.Iflarge-scaledeletionworkisessential,keepthecontainersofdeletionfluidsinsecurestoragewhennotinuse.
Lithographic printingWash-upsolventshavecommonlyincludedwhitespiritandsimilarmixturesofpetroleumdistillates.Vegetableoilderivativesandhighboilingpointsolventsarenowavailableforuseasrollerandblanketcleaners,andtheseproductsusuallyreducerisktohealthbyinhalation.Skincontactmayremainahazardsothataskincareregimemaybenecessary.TryusingtheseproductsaspartofthesubstitutionapproachunderCOSHH.SeetheboxinsertoverleaffordetailsoftheUKPrintingSolventSubstitutionScheme.
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Figure 8 Usedriptraysandautomaticpumpingtoreduceskincontactwithchemicals
UK Printing Solvent Substitution Scheme
Principles of the scheme:
n All‘new’machines(suppliedafter11October2000)willbecapableofbeingusedthroughouttheirnormalworkinglifeandacrossthenormalrangeofproductioncapabilitieswithcleaningsolventshavingaflashpointof55°Cormore(‘AIIIsolvents’).
n Cleaningsolventswithaflashpointoflessthan21°Cwillnotbesuppliedorusedforroutinerollerandblanketwashing(‘AIsolvents’).
n Cleaningsolventswithaflashpointofbetween21°Cand55°Cwillexceptionallyberestrictedtomachinesinusebeforethedateofthisagreementwhere,fortechnicalreasons,thereisnootherpossibleoption.Theywillnotbeusedonnewmachines(‘AIIsolvents’).
n Manufacturers,suppliers,printersandemployeesandtheauthoritieswillworktogethertopromotetheuseofalternativestotheabovesolvents,includinghighboilingpointsolvents(flashpoint>100°C)andvegetablecleaningagents.
n Solventsinblanketreviverandinkstripperproductswhichhavebeenintentionallyformulatedtoincludehalogenatedhydrocarbons,terpenes(assignedtheriskphrasesR38‘Irritatingtotheskin’,R43‘Maycausesensitisationbyskincontact’),n-hexaneandsecondaryaminesoramideswillnotbesuppliedorused.
n Thebenzenecontentofsolventssuppliedorusedwillbelessthan0.1%.n Thetolueneandxylenecontentofsolventssuppliedorusedwillbelessthan
1%.n Thearomaticcontent(C9)ofsolventssuppliedorusedwillbelessthan10%.n Thepercentageofisopropylalcoholoralternativelowboilingorganic
substancesusedinfountsolutionswillbereduced(immediatelyto5-10%)andprogressivelyto5%orless.
n Smallamountsoflowboilingpointmaterialsthatareinfrequentlyused-suchasblanketreviversordriedinkremoverscontainingmethylethylketone-maycontinuetobeusedprovidedappropriatespecialprecautionsareobservedandtraininggiventothoseusingthem.
SupplierswillindicateconformancewiththeschemebyinsertionofthePIACsymbol(availablefromthePIACSecretariat)withthephrase‘UKPrintingSolventSubstitutionScheme’-andtheAI,AIIorAIIIdesignationontheproductlabel.Thephrase‘ConformstoUKPrintingSolventSubstitutionScheme’,theAI/AII/AIII
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designationtogetherwiththewords‘ItistheaimoftheschemetoreducetheuseoflowboilingpointorganicsolventsintheprintingindustryinaccordancewiththeprinciplesoftheControlofSubstancesHazardoustoHealth(COSHH)Regulations1999andpromoteimprovedcontrolofsolventexposureinlinewiththeguidancegiveninthebooklet COSHH essentials for printers’shallbeinsertedintoSection16‘Otherinformation’ofthematerialsafetydatasheet(MSDS).
Press,presscomponentandconsumablesuppliersanduserswillworktogetherthroughPICON,theAssociationofPrintingMachineryImporters,theScreenPrintersAssociation,theFlexiblePackagingAssociation,theCorrugatedPackagingAssociation,theNewspaperPublishersAssociation,theNewspaperSociety,theBritishPrintingIndustriesFederation,theScottishPrintEmployersFederationandtheGraphical,PaperandMediaUniontoprovidetechnicalsupportandtrainingonnewcleaningmethodstouserswhomakethechangetohigherboilingpointsolventsandwho,wherenecessary,replaceblanketsandinkingrollers.
Morevolatileandaggressiveorganicsolventsaresometimesusedforremovalofdriedinkortoswelllowareasoftheblanket.Checkwiththesupplierstomakesurethattheleasthazardousproducthasbeenchosen.Whateversolventisselected,useasafesystemofworktocontrolitandreduceexposure.Useoftheseproductsshouldbekepttoaminimum.
Isopropylalcohol(IPA)isamajorcontributortothetotalsolventcontentofpressroomair.Makesurethatthepercentageconcentrationinthefountdoesnotexceed5%andconsidersuitablealternatives.
Humidifiersmaybeusedtomaintainsuitableenvironmentalconditionsforlithoprinting.(Seeunder‘Humidifierfever’inthe‘Otherhealthissues’sectionlaterinthischapter.Thisneedstobeconsideredifhumidifierswithwaterreservoirsareused.)
Ultraviolet (UV) curable materialsParticularcareisneededwhenhandlingultraviolet(UV)andelectronbeamcurablematerials(inks,varnishesandlacquers).Theyareusedinalltypesofprintingandpackagingapplicationswheretheirfastdryinganddurablefilm-formingpropertiesallowimmediateprocessingoftheprint,suchascartonprinting,labels,plasticsubstrates,pharmaceuticalpackaging,printingoftheoutersurfaceoffoodandconfectionerywrappersandmetaldecorating.ClearUV-curablevarnishesandlacquersgiveaprotectiveandhighglossfinishandareusedforgeneraloverprintingwork.
UVlightcuresfreshlyprintedmaterialalmostinstantaneouslybyinitiatingarapidpolymerisationprocess.Beforetheinkorvarnishiscuredtheapplicationviscosityisdependentonthemixtureofreactiveacrylateschosen.MostUV-curableinkscanbeconsideredsolventfree.
However,thehandlinganduseofuncuredmaterialandassociatedwash-upsolventsgiverisetoanumberofrisks.
BurnsTheinitiatorsandsomeconsituentsincludedinUV-curableinksarepowerfulUVabsorbersandcancausesevereburningifinkorvanishcontaminatestheskinandisthenexposedtosunlight.Itisimportanttoensurethatinkandvarnishdoesnotgetontotheskin.Youshouldensurethatappropriatepersonalprotectiveequipmentisprovidedandused.
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Skin irritancyPolyfunctionalacrylatesandmethacrylatescancauseskinirritationandsomecanalsocauseskinsensitisation.Thefirstsignsofirritation-reddeningoftheskinandappearanceofarash-maynotdevelopuntiladayafterexposure,andmayworsenoverthefollowingtwotothreedays.Itisgenerallyatemporaryeffectanddisappearsonceexposurestops.
TheUKPrintingIndustryhasagreedaschemeknownasAcrylatePreferenceCriteria,summarisedintheboxinsert,tocontroltheuseofacrylateswithahighpotentialtoirritate.Reactiveacrylatesmeetingthepreferencecriteriastillhavethepotentialforirritancyandsensitisation,buttoalesserextent,andtheirpreferreduseshouldbeconsideredundertheCOSHHsubstitutionduty.
Acrylate Preference Criteria
Preferreduseofacrylatesfulfillingthefollowingcriteria:
n Skinirritancyrating(OECDtest404)lessthan2.n Organicsolventcontentlessthan0.2%.n Acrylicacidcontentlessthan0.1%.n MembersoftheacrylatesuppliersCEFICUV-curableacrylatessectorgroup
willprovideinformationinsafetydatasheetsandskinirritationratingstoinkmanufacturers.
n PrintinginkmembersoftheBCFwillpreferentiallyformulateproductswithacrylatesmeetingthecriteriaandindicatethisonsafetydatasheets.
n Printersadvisedtouseproductsconformingwiththecriteria.n GPMUmembersadvisedingeneralonlytouseproductsconformingwith
thecriteria.n DetailedCOSHHassessmentandadditionalcontrolmeasuresneededif
non-conformingacrylatesused.n Thephrase‘ThisproductconformstotheBCFguidelinesonAcrylatePreference
Criteria’tobeaddedtoSection16oftheproductsafetydatasheet.ThefollowinginformationonglovestobeaddedtoSection8oftheproductsafetydatasheet:
‘Glovesofalengthtooverlapthesleevesofoverallsshouldbeused.Thefollowingisrecommended:
n Single-usedisposableunpowderednitrilegloves(short-durationexposurenotexceeding30minutesorwhereonlysplashesarelikely).Nottobeusedwheremechanicalresistanceisrequired,orwherepunchingortearingoftheglovesislikelytooccur.Nottobereusedwhenremoved.
n Minimum0.45mmthickness,unlined,unpowdered,naturalrubber,latex-free,nitrilegloves(longerdurationexposure,upto4hours,ormechanicalhandlingactivities).Tobereplacedimmediatelywhenpuncturedordegradedorwhenachangeofappearance(colour,elasticity,shape)occurs.
n Heavyduty,unlined,naturalrubber,latex-free,nitrilegloves(whenusingsolvents).Notethatcontactwithketonesorchlorinatedsolventsmayaccelerateglovedeterioration.Tobereplacedimmediatelywhenpuncturedordegradedorwhenachangeofappearance(colour,elasticity,shape)occurs.’
Someacrylatesthatarelesswellused,butmayberequiredtomeetthedemandsofparticularapplications,donotcurrentlyconformtotheAcrylatePreferenceCriteria.Typically,commercialgradesoftheseacrylateshaveskinirritationratingsof2ormore.Particularcareshouldbetakenintherareexceptionswhereitisnecessarytousesuchproducts.
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Skin sensitisationSkinsensitisationisapowerfulallergicreactionthatcanoccuratanytime,causingsensitivitytofurthercontact,evenatlowlevels-wellbelowthoseassociatedwithirritancy.Theskincanbecomeredandswollen,notalwaysatthesiteofcontact,forexample,aroundtheeyes.Sensitisationisnormallyirreversibleandmaybecausedbybothnaturalandsyntheticproducts.
HavingselectedtheleasthazardousUV-curableproductpossible,thefollowingfactorsshouldbetakenintoaccounttoreducetheriskofinjuryfromhandlinginksandcoatingsandfromcleaningpresses:
Handling inks and coatings
n Automaticinkdispensersreducetheneedtohandleink,andwherethequantityhandledislarge,considerpumpapplicationfromadrumorstoragearea.Wherethisisnotpossibleandinksareappliedtoductsbyhand,appropriateglovesshouldbeworn.
n Poweredmixingandstirringetcwhichgivesrisetoairborneemissionsshouldtakeplaceindesignatedareaswithsuitableandeffectiveexhaustventilation.
n Keepcontainersforuncuredmaterialsclosedwhennotinuse.n IdentifyprocedurestodealwithwebbreaksorrandomfailureofaUVsource
whichcanproducelargequantitiesofwebcoatedwithuncuredmaterial,alongwithsuitabledisposalarrangements(seeunder‘Cleaningandspillages’).
n Personalprotectiveequipmentshouldbecleanedordisposedofasspecialwasteafteranyobviouscontaminationasitmayotherwisebeamethodoftransferringuncuredmaterial.Sendcontaminatedclothingforspecialistlaunderinginlabelledbags.Suchclothingshouldneverbetakenhomebyemployeesforlaundering.
n Ifuncuredmaterialenterstheeye,rinsewithplentyofcleanwaterandseekmedicalassistance.Dealwithskincontactbywashingwithsoapandwater.Adequatefacilitiesarebestlocatedclosetothepointofuse.
Cleaning and spillages
n Cleaningofmachineryandassociatedequipment,inkducts,rollersetcwillbeneededregularly,forexampleatchangeofcolour,endofshiftortheworkingday,orchangetootherinks.
n Provideimperviousaprons(includingabib),longgauntletglovesandeyeprotectionsuchasaclearplasticfaceshield.SeeAcrylatePreferenceCriteriaforadviceonglovetype.
n Makesureallthelocalexhaustventilationandpersonalprotectiveequipmentprovidedisused.Rememberthatmaintenancepersonnelarealsoatriskfromcontactwithuncuredmaterialsthatcaninadvertentlyaccumulateinnormallyinaccessiblepartsofplantandmachinery.
n Providesuitableliddedcontainerslabelledtoindicatethatskincontactshouldbeavoidedforthesafedisposalofcontaminatedclothsetc.Theseshouldberemovedfromtheworkroomattheendoftheshift.
n Ifcleaningsolventsareintendedtobeusedseveraltimesbeforeeventualdisposal,keepthemonlyforcleaningmachinesusingUV-curablematerials,andstoreinclosedcontainersthatareclearlyidentifiedandlabelled.
n Clothsdampenedwithsolventforcleaningwillbecomecontaminatedwithuncuredmaterial.Skincontactwiththeseclothsislikelytobeaseriouscauseofskinirritationowingtothe‘defatting’actionofthesolventandthedepositionofuncuredmaterialontheunprotectedskin.Disposeofcleaningclothsimmediatelyanddonotputtheminoverallpocketsorleaveonbencheswhereothersmayhandlethem.
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n Removepermeableclothingthatbecomesaccidentallysplashedwithcleaningsolventsand/oruncuredmaterialsatonce.Cleanordisposeofsuchclothingasspecialwaste.Sendcontaminatedclothingforspecialistlaunderinginlabelledbags.
Ink mistInkmistorflycanbesignificantaspressspeedsincrease,particularlyinoffsetandletterpressprocesses,andthemistformedcanirritatetheskinandrespiratorytract,withthepotentialforrespiratorysensitisation.
n Whereinkmistgenerationisidentified,androller/plate/blanketpressuresarecorrectandproperlymaintained,trytoreduceexposurebyinkreformulation.Coolingofrollersandcylinderswillhelptoreduceflybymaintainingthecorrectinkviscosity.Otherfactors,apartfrompressspeed,thatmayhaveabearingincludetheamountofmaterialontherollers,thesizeoftheroller,airtemperatureandtherelativehumidity.Askforadvicefromyoursuppliers.
n Ifinkflypersists,considerfittingshroudsatrelevantrollersonthepressandtheprovisionoflocalexhaustventilation.Inallcasesworkroomsshouldbewellventilated,forexamplebymechanicalventilationsystems.
OzoneUVcuringlampsgiveoffconsiderableheatandconvertsomeoftheoxygenpresentintheairintoozone.Mechanicalextractioncoolstheair,butalsoleadstocontinuousgenerationofozonebytheconversionofoxygenpresentinthefreshlysuppliedairaroundtheUVlamp.Ozonegasisharmfulevenatrelativelylowconcentrations.Levelsabouttheoccupationalexposurestandard(currently0.2ppm,15minutetime-weightedaverage(TWA))canleadtoeye,noseandthroatirritation.Higherlevelsofexposuresometimescauseheadacheandnausea.Atlevelsabout15timestheoccupationalexposurestandard,chestpainandcoughingmayoccur.
n Provideextractiontocontrolozoneandductthisoutsidethebuildingtoasafeplacewhereitcannotreturntotheworkroom.Monitortoensurethatthesystemisworkingsatisfactorilyandmakearrangementsfor14-monthlyexaminationbyacompetentperson.
n Unitsusingwatercooling,fedthroughspeciallydesignedquartztubes,allowcuringand,aswellasremovingheat,blockorfiltersomeofthehigherenergy(UV-C)lightresponsibleforozonegeneration.Thesewater-cooledor‘cold-cure’UVlampsdonotrequireair-coolingandthereforethereisnobulkairmovementaroundtheUVlampandozoneisnotlikelytobecontinuouslygeneratedinsignificantamounts.Thisshouldbeconfirmedduringinstallation.
FurtherinformationisgiveninGuidanceNoteEH38Ozone: Health hazards and precautionary measures.
UV lightExposuretoUVlightfromcuringunitscancauseparticularlyacuteeffectsastheyaremuchmorepowerfulthanthoseusedinplatemaking.See‘Radiation’laterinthischapter.
ProvidefixedorinterlockingscreenstopreventdirectorreflectedUVlightbeingemittedintotheworkroom.ThereflectivesubstratescommoninlabelandscreenprintingcreateagreaterhazardiftheUVlampcowlingisnotkeptproperlyadjustedtominimiseescapeoflight.Insomecases,atunnelextensionmayberequired.Noattemptshouldbemadetoinspectprintedsheetsunderthelampbecauseofthehighlevelsofreflectedlight;sheetsshouldberemovedfromthepressforinspection.Screensshouldberegularlychecked,andbrokenordamagedscreensorfilterglassesshouldbereplaced.
AsummaryofthepotentialhealthhazardsandtheprecautionstobetakenintheuseofUV-curablematerialsisgiveninTable4.
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Table 4 UV-curablematerials-healthhazardsandprecautions
Health surveillanceHealthsurveillanceofthoseusingUV-curablematerialisrequiredandshouldincludeinspectionofallexposedareasofskinbyaresponsiblepersonwhohasbeeninstructedtorecognisetheskindisordersdescribed.Anypersoncanbenominatedandtrainedastheresponsiblepersonbutoftenafirst-aiderorsupervisorisbest.Thereshouldbeinspectionsatleastonceamonthandemployeesshouldbeencouragedtocheckthemselvesforsignsofskindisease.Casesofsuspecteddermatitisshouldbereferredtoadoctorornurseforfurtherinvestigation.
Wherethemainriskisfrominkfly,promoteawarenessofpossiblerespiratoryproblemsusingpre-employmentenquiriesandinformationaboutsymptoms,andencourageemployeestoreportsymptomstotheresponsibleperson.Wherepre-employmentenquiriesandinformationaboutexistingrespiratoryconditionsandsymptomsoftightnessandpainsinthechest,breathlessnessetcareused,rememberthattheyaresimplyabaselineagainstwhichanyfuturehealthproblemscanbeassessed.Suchenquiriesarenotasubstituteforpropercontrolofexposure.
Healthrecordsforeachemployeesubjecttohealthsurveillanceshouldbekept.Thefirstsignsofharmfuleffect-reddeningoftheskinandarash-maynotappearuntil24hoursafterexposure,andmaygetworseovertwoorthreedays.Asystemofskininspectionwillidentifyanyprinterswhodevelopproblems.
Wash-upsolventswithtracesofUV-curablematerialsareaparticulardanger.Organicsolventsde-fatanddamagetheskin,makingiteasierforallorganicmaterialstopenetratethesurfaceoftheskinandreachthevulnerablelayersbeneath.Keepsuchsolventsoffskinandclothing.
Ifcontactdoesoccur,washoffimmediatelywithplentyofsoapandwater.Removecontaminatedclothingimmediately.Senditforlaundering,butmakesureitisproperlypackagedtopreventinadvertentcontactandlabelled,indicatingthehazard,toprotectotherpeoplewhomayhandleit.Ifeyesareaffected,cleanwithplentyofwaterandgetmedicalhelp.
Screen printing and cleaningScreenprintingisaprocessusinginksandauxiliaryproducts(includingsurfacecoatings)thataresolvent-orwater-based,orcuredbyultra-violetlight(UV).Printing
Type of exposure Health hazards Precautionary measures
ContactwithUV-curablematerials Skinirritation
Skinsensitisation
Considerpossibilitiesforlessirritantsubstitutes,andenclosedhandlingsystemsorautomaticdispensers.Useimperviousaprons,glovesandeyeprotection
InhalationofUVinkmistorinkfly
Upperandlowerrespiratorytractirritation
Potentialforsensitisation
Reformulationofinks,cylindercoolingetc
Shroudingofrollers,andlocalexhaustventilation
Contactwithwash-upsolvents Skinirritation
Upperandlowerrespiratorytractirritation
Consideruseoflocalexhaustventilation.DeviseandusesafesystemsofworkincludinguseofPPEwherenecessary(egspillageandleakage)
Inhalationofozone Eye,noseandthroatirritation
Headachesandnausea
Localexhaustventilation
UVlight Occularirritationtovaryingdegreeswhichmaytemporarilycausedifficultywithvision
Skinburns(ieerythema)
Fixedorinterlockingscreening
Suitablegogglesandskinprotectionduringcertainmaintenancework
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maybedonemanuallyorbyusingmachinerywithvaryingdegreesofautomation.Screenprintinginksandsolventsmaycontainglycolethersandtheiresters.Likemanyothersolvents,glycoletherscancausedizziness,headaches,lossofco-ordinationandnausea.Somearemorehazardousthanothers,astheycanalsoaffectthebonemarrowandcauseaplasticanaemiaandoughtnottobeused.ParticularcareandaveryhighstandardofcontrolarerequiredwhereinkscontainingN-vinylpyrrolidone(NVP)andMichler’sKetoneareused.Checkwithyoursupplierifindoubtandsubstitutesaferalternatives.
Screen preparationAdhesivesusedtoattachthemeshtothescreenframeoftencontainisocyanates(seethesectionontheuseofisocyanateslaterinthischapter).Useimperviousprotectiveglovesandafacevisorwhendegreasingorpreparingthemeshbeforeapplyingthestencil,especiallywhenusingcorrosivedegreasants.
UVlampsusedtopreparethestencilscangiverisetoanumberofrisks(seethesectiononUV-curablematerialsearlierinthischapter).Imperviousglovesshouldbewornduringthepreparationofdirectandindirectstencils,andfortheuseoffillerstoblankouttheremainderofascreennotcoveredbyanindirectstencil.Thepreparationshouldbecarriedoutinawell-ventilatedarea.
Printing and dryingScreenprintingareasneedlocalexhaustventilationorextractionthatpreventsoradequatelycontrolstheriskofinhalation.Asaminimumtheventilationsystemshouldcomplywiththeoccupationalexposurelevelsforthesubstancesused.Positionmechanicalventilationsothatitdrawsfumesawayfromtheprinters.Arrangetheworkflowsothatdryingracksarepositionedinanareaofforcedventilation,sotheairflowacrossthemdrawsthefumeawayfromtheworkingarea.Ventdryingtunnelsandovenstoasafeplaceoutside.
Screen cleaning and reclamationAfterprintingalwaysremoveasmuchwetinkaspossiblefromthescreen,wearingsuitableimperviousglovestopreventskincontact(seekadvicefromyourglovesupplierifindoubt).Cleanscreensinamechanicallyventilatedareasuchasabooth.Donotusehigh-pressurewaterjetstocleanscreensdousedwithsolvents,asthiswillresultinunnecessarilyhighlevelsofairbornesolvent.Jetthemwhentheyarefreefrominkandsolvent.
Ifthequantityofworkallows,enclosedautomaticsystemsprovidethebestmethodofscreencleaningandreclamation.
Figure 9 Screenprintingareasneedverygoodventilationtokeeptheairclearoffumes
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Operatorsshouldweareyeprotection(gogglesorvisors),aprons,glovesorgauntletsandwaterproofbootswhenusinghigh-pressurewater/steamcleaners.Ventilation,electricalsafety,hearingprotectionanddrainageneedtobeplannedwhenthewetcleaningareaissetout.FurtherinformationisavailableinGuidanceNotePM29Electrical risks from steam/water pressure cleaners.
Use of isocyanateslsocyanatesmaybefoundinadhesivesusedinlaminating,polyurethanelacquers,primersandcertainspecialisedinks.Theyarerespiratorysensitisersandhavethepotentialtocauseasthmaticattacks,whichmayoccurimmediatelyonexposureorafteradelayofseveralhours.Healthsurveillancewillbenecessaryinmostcircumstances-seekspecialistadvicefromanoccupationalhealthprofessionalaboutthis.
Trytochooseproductsthatdonotcontainisocyanatesifpossible,butiftheyareunavoidable,choosethosethathavetheminimumisocyanatecontentnecessaryandaretheleastvolatiletofulfilproductionrequirements.Rememberthereisalwaysariskofrespiratorysensitisationwhenisocyanatesareused,eveniftheyarepresentinproductsatverylowlevelsandappropriatecontrolsshouldbeprovided.
Careisneededtoensurethatcontrolmeasuresareselectedandimplementedtopreventinhalationofisocyanates.Localexhaustventilationthatpreventstheriskofinhalationwillbeappropriateinmanysituations.Asaminimumtheventilationsystemshouldensurecompliancewiththerelevantoccupationalexposurelevelforthesubstancebeingused.Riskislikelytobegreaterinsituationsinwhichthesubstanceisheated,orwhenmistingoraerosolformationmayoccur(theoperatingspeedofthemachinewillaffectthis).
Figure 10 Providefacilitiesfordealingwithspillagessuchasaspillkit
Airmonitoringshouldbecarriedout.Therecanbeseriousriskstohealthifthelocalexhaustventilationorothercontrolmeasuresfail,deteriorateordonotworkproperly.Youshouldkeeparecordofanyexposuremonitoringyoucarryoutforatleastfiveyears.YoucanfindmoreinformationonmonitoringintheguidancebookletMonitoring strategies for toxic substances(HSG173)andMethods for the determination of hazardous substances: Organic isocyanates in air(MDHS25/3).
Generalprotectiveclothing,includingglovesandeyeprotection,willbenecessaryandincertainsituationsrespiratoryprotectiveequipmentwillbeneeded-thiswillbedeterminedbytheCOSHHassessment.
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Providefacilitiesforfirstaidandfordealingwithspillages,skinandeyecontaminationandotheremergencies.SeethebookletSafe use of isocyanates in printing and laminatingforfurtherguidance.
Disposal of wasteRememberthatthedisposalofwastematerialsandnominallyemptycontainersaresubjecttoenvironmentalregulations.Takeadvicefromyourwastemanagementcontractorandthewasteregulatoryauthority(EnvironmentAgencyetc).
Noise
Loudnoiseatworkcancauseirreversiblehearingdamage.Itacceleratesthenormalhearinglossthatoccursaswegrowolder.Itcancauseotherproblemssuchastinnitus(troublesomenoisesintheear),interferencewithcommunication,andstress.
Civilclaimsagainstemployersarecommon,andmanyaresuccessfulbecausenotenoughhasbeendoneinthepasttoprotectthehearingofpeopleatwork.
Do you have a noise problem?Asaruleofthumb,ifyoucannothearanormalconversationinyourworkplaceclearlywhenyouare2mawayfromthespeaker,thenoiselevelislikelytobearound85dB(A)orhigher.Ifyoucannothearsomeoneclearlywhenyouareabout1maway,thelevelislikelytobearound90dB(A)orhigher.
Ifyouthinkyoumayhaveaproblem,findoutwhatthenoiselevelsareinyourworkplacebytakingmeasurements.
Measuring noise levelsNoiseismeasuredindecibels-youwillusuallyseeitwrittenasdB(A).Thenoiselevel(soundpressure)ismeasuredlogarithmicallysothatevery3dB(A)increasemeansadoublingofthenoiseenergy,forexample93dB(A)istwiceashazardousas90dB(A).
Inmostjobs,theriskdependsnotjustonthenoiselevels,butalsohowlongpeopleareexposed,includinganyovertime.FormoreinformationseethebookletReducing noise at work(L108).
Noise and the lawTheNoiseatWorkRegulations1989areintendedtoreducehearingdamagecausedbyloudnoiseandtheylaydownthreeactionlevels.TheRegulationsrequireemployerstoassesstherisksandtakeactionwhenworkers’dailyexposuretonoisereachesthe85dB(A)(LEP,d)*‘firstactionlevel’andfurtheractionifitreachesthe90dB(A)(LEP,d)secondor140dB(A)‘peak’actionlevels.Whenmeasuringnoiseexposurenoaccountistakenoftheeffectofanypersonalearprotectorsworn.
* Dailypersonalnoiseexposure:theworker’snoiseexposureaveragedoveraneight-hourworking
period
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Figure 11 Doyouhaveanoiseproblem?Loudnoiseatworkcancauseirreversiblehearingdamage
Ifyoufindthatthenoiselevelisatthefirstactionleveloraboveyoumust:
n havetheriskassessedbyacompetentperson;n tellyourworkersabouttherisksandprecautions;n makehearingprotectionfreelyavailabletothosewhowantitwherelevels
exceed85dB(A).
Ifyoufindthatthenoiselevelsareatthesecondactionlevelorabove,inadditiontotheaboveactions,youmustalso:
n doallthatisreasonablypracticabletoreduceexposurewithoutrelyingonhearingprotection,eguseengineeringcontrols;
n userecognisedsafetysignstoidentifyandrestrictentrytozoneswherenoisereaches(orexceeds)thesecondorpeakactionlevels.Employees,includingmanagersandsupervisors,mustnotenterthesezonesunlesswearingsuitableandeffectivehearingprotection.
Noise reductionConsider:
n choosingquietmachinesorprocessesfornewwork.Makersmustreducenoisebygooddesignandconstructionandalsoprovidenoisedatawiththeirequipmentiflevelsarelikelytoreachorexceedthefirstactionlevel.Ifyouarebuyingmachinery,insistonthisinformation.Oncethemachineryisinstalled,checkthenoiselevelsandtakeanystepsnecessarytoreducenoise.Noiseemissionlevelscanbelimitedaspartofthecontractwithsuppliersandcheckedafterinstallation;
n changingthemachineandprocesstoproducelessnoise.Don’tforgetthatotherchangesyoumakemightaffectnoiselevels;
n enclosingnoisymachinesbyprovidingacousticenclosures.Thesehavetobemadeofappropriatenoise-reducingmaterialsandbecorrectlyinstalled.Iftheyarenotproperlydesigned,noiseescapingfromholes,feedopeningsorpoorlyfittingpanelsmaysignificantlyreduceperformance.Specialistadvicewillprobablybenecessary;
n puttingnoisymachinesandprocessesinseparaterooms,awayfromemployees’workareas;
n fittingsilencerstoallexhaustsandmakingsuretheyarekeptinplaceandmaintained.
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Reducing exposureThinkaboutreducingthelengthofexposurebyrotatingjobsorprovidinganoiserefuge,egatmachinecontrolpoints.
Remember-hearingdamageiscumulative.Makesurethatyoungpeopleinparticulargetintothehabitofavoidingnoiseexposure,beforetheirhearingispermanentlydamaged.
Providing hearing protectionEnsurethatworkerswearhearingprotectionwheredailypersonalnoiselevelsexceed90dB(A).Rememberthisisnotasubstitutefornoisereductionatsource.
Donotrelytooheavilyonhearingprotectors.Inpracticetheyreducenoiseexposurelessthanisclaimedbecausethey:
n havenotbeencorrectlyselected;n arenotfittedandworncorrectly;n arenotproperlymaintained;n areuncomfortableorinconvenienttowear.
Plasticfoamormineralfibre/waxedplugs,ifproperlychosenandcorrectlyworn,canbeasgoodasearmuffs.Towork,hearingprotectorsneedtobewornallthetimethatpeopleareinnoisyareas.Iftheyareleftoffforevenshortperiods,eventhebestprotectorscannotgreatlyreducenoiseexposure.Supervisorsshouldcheckthis.
Protectorsshould:
n besuitablefortheconditionsinwhichtheyaretobeused;n provideenoughattenuationtoreducethenoiseexposureleveltobelow
90dB(A)andpreferablytobelow85dB(A);
n onlybeissuedonapersonalbasis;n neverberemovedinanoisyenvironment;n becompatiblewithotherformsofnecessaryPPE;n preferablybemarkedtoindicateconformitywithBSEN352:1993Hearing
protectors - safety requirements and testingPart1:Ear-muffs.Part2:Ear-plugs.Part3:1997Ear-muffs attached to an industrial safety helmet.
Itwillbebeneficialforemployeestohaveachoiceofhearingprotectionfromarangeoftypesidentifiedassuitable.SeethefreeleafletsNoise at work: A guide for employees(INDG99),Ear protection: Employers’ duties explained(INDG298),andProtect your hearing!(INDG299)pocketcard.
Workersneedtobeadequatelytrainedintheproperfitting,useandcareofhearingprotection.Thiswillhelptoensurethatprotectorsmaintaintheirefficiencyandarecorrectlyworn.
Common problems and solutions for printersExperiencehasshownthattherearecertainareasthatcanusefullybetargetedtoreducenoiseinaprintingworkplace.
Sheet-fedbuckle-foldingmachinesinthefinishingdepartmentcreatehighnoiselevels.Thesemachinesshouldbefittedwithacoustichoodsatallbuckleplatestoreducethenoise.GuidanceisgiveninthepublicationNoise reduction at buckle-folding machines.
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n Web-fedpresseshaveseveralnoisesources(inparticularthefolder),andvariousnoisecontrolmeasuresmaybeappropriate.GuidanceisgiveninthebookletNoisereductionatweb-fedpresses.
n Vacuumpumpsandcompressors,suchasthoseassociatedwithsheet-fedprintingmachines,gatherer-stitcher-trimmersandbuckle-foldingmachines,canproducehighnoiselevelsanditisimportanttositesuchequipmentawayfromtheworkroomorshielditinasuitableenclosure,asthesecanmakealargecontributiontotheoverallnoiselevel.
n Sheet-fedprintingmachines(ingeneral)donotcreateexcessivelevelsofnoiseiftheyareproperlyspacedandhoused,aslongasnoisefromvacuumpumpsandcompressorsiscontrolled.
n Regularpreventivemaintenanceofmachinescanbeimportantinavoidingthegenerationofexcessivelevelsofnoise.Wornbearingsinbuckle-foldingmachinesarefrequentlyfoundtobeasignificantsourceofnoise.
n Itisgoodpracticetocarryoutregularhearingchecksonallemployeeswhosedailypersonalnoiseexposuresequalorexceed90dB(A),andsuchchecksshouldbecarriedoutwhennoiselevelsreachorexceed95dB(A).RefertotheleafletHealth surveillance in noisy industries(INDG193)andtheparagraphsunder‘Hearingprotection’inthe‘Personalprotectiveequipment(PPE)’sectionattheendofthischapter.
Hearing lossUndertheManagementofHealthandSafetyatWorkRegulations1999,employeesexposedtocertaintypesofrisk,suchashighnoiselevels,shouldbeprovidedwithappropriatehealthsurveillance.Suchconditionsarelikely,forexample,atlargeweb-fedpressesandassociatedfolders.Healthsurveillanceforhearinglossusuallyinvolveshearingcheckscalledaudiometry.
Thereisnosimpleformulatoshowwhenaudiometryisnecessary.Thestartingpointistoassesstheriskofemployeesbecomingdeafbecausetheyarebeingexposedtoloudnoise.
Thisriskdependsonthenoiselevelandthelengthofexposure.Employersshouldarrangeforacompetentpersontocarryoutanassessmentoftheiremployees’noiseexposures,asrequiredbytheNoiseatWorkRegulations1989.
Programmesforhearingchecksneedtobeunderthecontrolofsomeonewhocanmakesenseofaudiometricdataandadviseindividualsonthestateoftheirhearingandonfollow-upaction.Thismightbeanoccupationalphysician,anursewithappropriatetrainingandexperience,anaudiologicalscientistoratrainedaudiometricianabletoreferemployeestoamorequalifiedpersonwhentheyneedmoreadvice.
Healthsurveillanceforemployeesinnoisyjobsnormallymeans:
n regularhearingchecksincontrolledconditionstomeasurethesensitivityofhearingoverarangeofsoundfrequencies;
n informingthemabouttheresultsoftheirhearingchecks;n keepingrecords;andn encouragingthemtoseekfurtheradvicefromadoctorwherehearing
damageissuspected.
Formoreinformation,seeGuidanceNoteMS26A guide to audiometric testing programmes.
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Manual handling
The law and manual handlingTheManualHandlingOperationsRegulations1992requireallemployersto:
n avoidtheneedforhazardousmanualliftingandhandlingifitisreasonablypracticabletodoso,egbyredesigningthetaskand/orworkplacelayout,eliminatingtheneedtomoveloadsmanually,usingmechanicalhandlingequipmentetc;
n assesstheriskofinjuryfromanyhazardousmanualliftingandhandlingwhichcannotbeavoided;
n takestepstoreducetheriskofinjuryfrommanualhandling,egbyprovidingmechanicalassistance,improvementstothetask,loadorworkingenvironment;
n provideemployeeswithinformationontheweightoftheloadandanindicationoftheheaviestsidewherealoadhasacentreofgravitythatisnotcentrallypositioned.
Risk assessment filterAdetailedassessmentofeveryriskcouldbeamajorundertakingandinvolvewastedeffort,soHSEhasdevelopedafiltertoscreenoutstraightforwardcases.Thefilterisbasedonasetofnumericalguidelinesdevelopedfrompublishedscientificliterature,anditsapplicationwillprovideareasonablelevelofprotectiontoaround95%ofworkingmenandwomenalthoughitshouldnotbeseenasprovidingsafeweightlimitsforlifting.
Theguidelinesassumethattheloadiseasytograspwithbothhandswiththehandlerinastablebodyposition,andtakeintoaccounttheverticalandhorizontalpositionofthehandsastheymovetheloadduringthehandlingoperation,aswellastheheightandreachofthehandler.
Figure12givesaboundarymappedoutbytheguidelines.Ifthehandler’shandsentermorethanoneoftheboxzonesduringtheoperation,thesmallestweightfiguresapply.Ifthetaskrequiresliftingorloweringofthehandsoutsidetheboxzones,amoredetailedassessmentshouldbemade.
Figure 12 Liftingandlowering
3 kg 7 kg
7 kg 13 kg
10 kg 16 kg
7 kg 13 kg
3 kg 7 kg
10 kg 5 kgshoulder height
elbow height
knuckle height
mid lower leg height
shoulder height
elbow height
knuckle height
mid lower leg height
20 kg 10 kg
25 kg 15 kg
20 kg 10 kg
10 kg 5 kg
women men
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What are the risks?Althoughsomepeoplearemoreatrisk,everyonecansufferinjuriesasaresultofmanualhandling-thisiswhyhazardousmanualhandlingactivitiesshouldbeavoidedifpossible.Ifitisimpossibletoavoidsuchactivitythenitshouldbeassessedandriskreductionmeasuresconsidered.Whenmakinganassessment,youmayhavetogiveparticularattentiontothefollowinggroupsofpeople:
n younger,moreinexperiencedemployees;n olderand/orlessphysicallyfitemployees;n thosewithexistinginjuriesorconditionssuchasasthma;n pregnantemployees.
Manual/materialshandlingcanleadtoinjuriesandmusculoskeletaldisordersinvariouspartsofthebodyincludingtheback,abdomen,neck,upperlimbsandevenlowerlimbs.
Thecumulativeeffectsofevenminorinjuriescanbecomemorepronouncedoveraperiodoftime.Seriousandlastingdamagetothespineandotherpartsofthebodycanresult.Carefuljobdesigncanavoidtheproblemsofrestrictingparticulartaskstoparticularworkersorthedisruptionthatcanfollowifpeopleareinjured.
Poorliftingandcarrying,pushingandpullingcausesmorethan25%ofthework-relatedinjuriesreportedintheprintingindustryeachyear.
Figure 13 Reelandcylindertrolleysreducetheamountofmanualliftingandcarrying
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Reducing the risksWhenmanualhandlingisunavoidable,lookatthejobandthinkaboutreducingtheriskbyprovidingmechanicalhelp,forexample:
n scissorliftsandelevatingtablesatfoldersandguillotines;n pileturnersandjoggerstoreducetheneedforhandturningand‘knockingup’;n mechanicalorfree-runningconveyorstoreduceliftingandcarrying;n hoistsandslingsatreelstandstoreducemanualliftingofpaperreels,especially
thosemountedonswingarms;n reelconveyortrolleysforlocalisedmovementofpaperreelsintoandoutof
reelstands;n cylinderandrollertrolleys;n reelshafttrolley;n sacktrucks.
Otherwaysofreducingtheriskinclude:
n makingtheloadsmaller/lighteroreasiertograsp,egbybuyinginsmallerpaperbundlesorchemicalcontainers;
n reorganisingorredesigningthetaskstoreducetheeffortrequired;n alteringworkstationheightstosuittheworker;n improvingthelayoutoftheworkplacetomaketheworkmoreefficient;n ensuringreasonableworkingtemperatures;n ensuringadequatemanoeuvringspacehasbeenprovided.
Handling newspaper and magazine bundlesSpecificguidanceisavailableonthecontrolofriskfromhandlingbundles,comprisingtwofreeleaflets(IACL105Handling the news: Advice for employers on manual handling of bundlesandIACL106Handling the news: Advice for newsagents and employees on safe handling of bundles)andatrainingvideoWhatthepapersweigh.Theindustryhasagreedamaximumbundleweightof18kg,withatargettoreducethisfurtherto17kgtohelpreducetheriskstoallthoseinvolvedinthedistributionchain-includingdeliveryboysandgirls,andnewsagents.
TrainingConsiderprovidingeveryemployeewithbasictraininginmanualhandlingtechniquesappropriatetothetypeofworktheydo.Youwillalsohavetoconsiderothermoredirectwaystoreducerisk.
Trainingshouldcover:
n howmanualhandlingcancauseinjury;n theessentialsoftheManualHandlingOperationsRegulations1992;n howtorecognisepotentiallyharmfulmanualhandlingtasks/operations;n appropriatesystemsofwork;n correctuseofmechanicalaids;n appropriatehandlingtechniques.
FurtherinformationonmanualhandlingcanbefoundinthebookletManual handling.Manual Handling Operations Regulations 1992.Guidance on Regulations(L23)andtheleafletBack in work: Managing back pain in the workplace(INDG333).
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Accidents
Aprinterliftingamagazinebundleweighing12kgontoapalletinjuredhislowerback.Hehadnotbeengivenanyhandlingaidsortrainingincorrectliftingtechniques.
Anemployeeattemptingtoclearajammednewspaperbundleonaconveyorinjuredherback.Shehadnotbeengivenanytrainingorinformationonmanualhandlingtechniquesorbundleclearingtechniques.
Amaintenancefittersufferedbackpainafterliftingpressinkingrollersweighing23kg.Hehadreceivednotrainingorinformationonmanualhandling.Useofmechanicalliftingequipmentorassistancefromasecondpersonwouldhavereducedtheriskofinjury.
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Assessing and reducing risks
JobDoesthejobrequire:
n liftingorloweringtoofar?n rushing?n carryingoverlongdistances?n lotsofrepetitions?n twistingandturning?
Work areaIstheworkarea:
n toodark?n tooslippery?n toocongested/obstructed?
LoadIstheload:
n tooheavy?n toolarge?n toounstable?n toosharp?n toodifficulttograsp?
IndividualsAreindividuals:
n fit?n inneedofspecialconsideration?n trained?
Example tasks
Loadingandunloadingdeliveriesbyhand
Movingmaterialstoandfrommachines
Loadingandunloadingmachines
Assemblingandpacking
Preparing,maintaining,movingandrepairingpressesandotherequipment
Short-term action
Providehelpforheavyloads.Reducetheloadsize.
Breakdowntheloadsintoeasilyhandledunits.Foldorwrapoverlargesheetsofpaper.
Raisepalletsetctotherightheightandposition.
Useappropriate,fit,trainedpersonnel.Rotatetheworktoreducerepetition.
Useappropriate,fit,trainedpersonnel.Ensureadequateworkingspace.
Long-term solution
Palletiseloads.Uselifttrucks,pallettrucks,boomconveyors,vehicleswithtailliftsetc.
Useconveyors/hoists/lifttrucks/pallettrucksetc.Useairtables,egatguillotines.
Automateloading/unloadingoperations.Usemechanicalaids,egscissorliftsandpilehoists.
Provideawell-litworkingenvironmentwithsuitableseatingwhereappropriate.Automate.Providemechanicalaids.
Providemechanicalaids,eghoistsforremovingcylindersetc.
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Repetitive handlingRepetitivehandlingcanpresentparticularproblemsandgiverisetoconditionscalledwork-relatedupperlimbdisorders(WRULDs)orupperlimbdisorders(ULDs).Sometimestheconditioniscalledrepetitivestraininjury(RSI).
Themusculoskeletalsystem(iethemuscles,bones,ligaments,tendons)inourhands,arms,shouldersandneckcanbeharmedbystaticorawkwardpostures,excessiveforcelevelsandrepeatedexertions.Thisisespeciallysowhenthesearecombinedwithlittleopportunityforvarietyorothermeansofrecovery.
Work-relatedupperlimbdisorders(WRULD)cancauseallofthefollowing:
n pain;n softtissueswelling;n restrictionofjointmovement;n reducedsenseoftouchandmanualdexterity;n permanentdisabilityifothersymptomsgountreated.
Failuretotakepromptactioncanresultin:
n seriousillhealth.Well-motivatedandproductivepeoplehavehadtogiveupworkbecauseofpainanddisablementfromWRULDs;othershavebeensobadlyaffectedthatsimplehouseholdtasksbecomedifficult;
n lostproductionduetoemployeestakingsickleave;n compensationclaimsfromemployeesthathavehadtostopworkingbecause
ofWRULDs;n employeescomplainingof,orseekingmedicalattentionfor,persistentpainor
actualinjury;n hiddencosts,egtrainingnewstafforprovidingextrastaffwheresickness
absenceishigh.Substantialcostsavingscanoccurwhenapreventivestrategyisadopted.
AdditionalinformationaboutupperlimbdisordersisgiveninWork-related upper limb disorders in the printing industry(IACL91).
Toprotectyouremployeesfromupperlimbdisordersyouneedtobeabletoidentifytheoperationsthatgiverisetotheriskandtakestepstoreducethatrisk.
How to assess and tackle ULDsIdentify the hazardsThefollowingareexamplesofoperationswhichcangiverisetoupperlimbdisorders(ULDs):
n Usingpoweredhandtools.n Usingpliersorscissors.n Sealingboxeswithtape.n Handfeeding/unloadingofmachines.n Assemblywork.n Counting,sorting,checking.n Stripping,breaking,knocking-out,knocking-up.n Flatpackwrapping.n Manualhandlingofbundles.n Handinsertionwork.n Jacketingofcasedbooks.
Hazardsmayalsoexistiftheworkinvolvesfrequent,forcefulorawkwardgripping,squeezing,twisting,andrepitition,pulling,pushingorlifting.
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Warningsignsofupperlimbdisorderscanincludecomplaintsbyworkersandimprovisedchangestoworkstationsortools.
Ifanyoftheabovearecharacteristicofyourworkplaceyoushoulddoafullergonomicriskassessment.Don’tforgettoconsidertherisksarisingfromtheuseofdisplayscreenequipment(seeChapter3forfurtheradvice).Asystematicandergonomicapproachwillhelptoassessrisksandprovidesolutions.
Reduce the riskApplyergonomicprinciplestomachines,workstationsandworkmethodssothatthejobfitstheperson.Forexample:
n reducehighforcelevels(maintainequipmentproperly,spreadforcelevels,usetoolswithappropriatelydesignedhandles);
n reducehighlyrepetitivemovements(balancefrequentrepetitionwithnon-repetitivework,carryouttaskswiththeotherhand,introducehandlingaids,useautomation,providemorevariedtasks);
n providerest/recoverytimebybreaksoractivitychangesbeforefatiguestarts;n changepostures(modifyoperation,redesignworksothewristcanbestraight);n changetheoperator’spositioninrelationtowork;n wherepeopleremaininthesameposition,provideamixofworkrequiring
movement.
Otherstepsinclude:
n makingsureoperatorsreceiveadequateinformation,instructionandtraining;n beingawareofthemaincauses/symptomsandpreventivemeasures;n reportingproblemsearlybeforetheybecomeserious;n ensuringnewemployeesstartatslowerworkratesbeforegradualupgrading;n rotatingjobs(variationoftasks);n ensuringthatanyincentiveschemesdonotadverselyaffecthowtheworkis
done(egensuresufficientbreaksaretaken).
Future control measures
n Examinerisksfromupperlimbdisorderswhenplanningchangestoworkmethodsorpurchasingnewmachinery.Checkthatergonomicprincipleshavebeenincorporatedinthedesign.
n Considerhealthsurveillance,egrecordkeepingandpromptmedicalassessmentwhenproblemsarereported.
n Thinkaboutwaystoencourageearlyreportingofsymptoms.n Lookatsicknessrecordsandstaffturnover.n Considerthepossibilityofalternativeworkifapersoncannotcontinueina
particularjoborwhereitwillassistareturntowork.n Introduceasystemtomonitortheeffectivenessofcurrentcontrolmeasures.n BealerttoanyincreaseinULDsintheworkplace,egafterachangein
process,andtakeappropriateaction.n Ensurethattherearearrangementsforeffectiverehabilitation(see
‘Occupationalhealthandrehabilitation’earlierinthischapter).
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Radiation
LasersLaseruseintheprintingindustryisincreasing.Applicationsincludelaserprintersandcopiers,scanners,platemakers,engravers(inprintingcylindermanufacture),packagedatemarking,diecuttingandtypesetting.
Radiation hazardsAlaserisasourceofintenselight.Laseremissionscanbedangerouswhenviewedeitherdirectlyorwhenreflectedfromasmoothsurface.Thegreatesthazardistotheeye,becauseitfocusesvisiblelaseremissionstoformaverysmallimageontheretina.Powerintensitiescanbeincreasedbyafactorof100000sothatevenafewmilliwattsoflaseremissioncancauseseriousandpermanentdamagetotheretina,andthereforevisionintheaffectedeye.
Itisimportanttogetaneyeexaminationimmediatelyfollowinghazardouspersonalexposure,butroutineeyeexaminationaspartofhealthsurveillanceisnotrecommended.Sometypesoflaserproduceinvisiblebeamsthatmaystillbefocusedbytheeyetoproduceaharmfulimageontheretina.Skinburnsmayalsobeariskthatneedsassessment.
Fume hazardsLasercopiersandcomputerprintersmaygiveoffozone,dustandfume-thisisseldomexcessiveandnotnormallyaproblemiftheequipmentisbothwellmaintainedandsitedinaplacethatiseffectivelyventilated.Othertypesofequipmentmayneedlocalexhaustventilation(LEV)-yourCOSHHassessmentwillhelpyoutodecidetheneedforthis,andyoursuppliershouldbeabletoadvise.
Mechanical and electrical hazardsAswithanymachinery,dangersfrommovingpartsandfromelectricalinstallationsexist-thesehazardsshouldbeevaluatedaspartofyourriskassessment.
Safeguarding standardsLaserproductsareclassifiedinaccordancewiththeirlevelofhazard.BSEN60825-1:1994Safety of laser products Part 1: Equipment classification, requirements and user’s guidegivesinformationonclassdefinitions.LaserproductsusedintheprintingindustrywillgenerallybeClass1(safebyengineeringdesign).Thismeansthelaserandworkpiecewillbefullyenclosedduringnormaluse.
Lasersaregenerallyclassifiedaccordingtotheiroutputpower,butrememberthataClass1laserproductmaycontainahigh-poweredClass4laserinsideitscasing.TamperingwithorremovalofshieldingorenclosurefromaClass1productmayresultinexposuretoahigh-poweredlaseremission.Alsorememberthatharmfulexposurecanresultfromreflectedlaserbeamsaswellasthosethatarevieweddirectly.Avoiduseofmirrorsorreflectiveglassnearlasersources.
Whenyouacquirelaserequipmentthesupplierhasadutytoprovideadequateinformationtoyou(see‘Acquiringmachineryandotherworkequipment’inChapter5).Theinformationprovidedbythesupplierwillhelpyoudevelopsuitablesystemsofworkforthesafeoperationofyourequipment.
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Onlyacompetentperson(usuallyaserviceengineer)shouldcarryoutanyservicingorotherworkonyourlaserequipment.Acompetentpersonissomeonewhoisproperlytrainedinlasersafetyandwhoisabletofollowasafesystemofworkwhichinmanycaseswillincludewearingsuitableeyeprotection.Itisyourresponsibilitytoassesseyeprotectionneedsandtoensureyourworkerswearit(see‘Personalprotectiveequipment(PPE)’laterinthischapter).
ForfurtherinformationonlasersseethebookletLaser safety in printing.
Ultraviolet (UV) lightUVlightisusedinphotoengravingandlithographicplatemakingandtocurecertaininks,vanishesandlacquers,eginlithographic,flexographicandlabelprinting(see‘Hazardoussubstances’earlierinthischapterforhazardsofUV-curableinksetc).
UVlightistypicallygeneratedbyacarbonarc,xenondischargetubeormercuryvapourdischargetube.Nowadays,carbonarcsareseldomusedbecauseofthefumetheygenerate(primarilycarbonmonoxideandtoxicoxidesofnitrogen).
Accidents
Anemployeewasdealingwithafilmmisfeedonanimagesetter.Heturnedoffthecomputerbutforgotabouttherasterimageprocessor(RIP).Heopenedthecovertothefilmandlaser,andusedanoverridekeytorunthefilmthroughmanuallysothathecouldfindthemisfeed.ButstoredinformationintheRIPcausedthelasertostartupunexpectedly,andtheemployeesufferedeyedamagefromthereflectedlaseremission.
Radiation hazardsExcessiveUVexposurecancauseacuteeffectssuchasrednessandburningoftheskinanddamagetotheeyes(possiblycausingpainfulconjunctivitis).Theonsetofsymptomsmaybedelayedforseveralhoursafterexposure.Peoplewhohavehadthelensoftheeyeremoved(aphakes)maysufferretinaldamagefromexposuretoUVlight.
SomepeoplemayhaveanabnormallyincreasedsensitivitytotheeffectsofUVlightwhichmaybeaconsequenceofoneofanumberofuncommonmedicalconditionsormayresultfromexposuretoasensitisingchemicalsuchasaprescribeddrug,forexamplesomeantibioticsincludingtetracyclinesandsulphonamides,thiazidediuretics,tricyclicantidepressants,phenothiazinesandsomeothercategoriesofdrugs.Suchsensitisationmayresultinanexaggeratedsunburnresponseorinmorevariedandlesswelllocalisedskinchanges.Anyonewhodevelopsanabnormalconditionaffectingmainlythelight-exposedareasofthebodymayhavebecomephotosensitised.FurtheroccupationalexposuretoUVlightshouldstopandtheindividualshouldbereferredtoadoctor.
UVexposurealsoincreasestheriskofdevelopingvarioustypesofskincancerandisassociatedwithacceleratedskinageingandcataracts.Skincancerriskincreaseswithexposurelevelandwithexposuretimeandisnotthoughttohaveanexposurethresholdbelowwhichthereisnorisk.
Whenconsideringacuteeffects,asageneralrule,UVBsources(thoseemittingatwavelengthsbetween280and320nm(nanometres))aremorehazardousthanUVAsources(thoseemittingatwavelengthsbetween320and400nm).UVCsourcesemitbelow280nmandarepotentiallythemostharmful.UVCradiation
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is,however,easytoremoveasevenglassisaheavyabsorber.Thisisatechnicallycomplexarea,andusersmayneedtotakeadvicefromtheirsuppliersabouttheadequacyoftheirprecautions.
Fume hazardsUVlightsourcesusedforcuringareusuallymuchmorepowerfulthanthoseusedinplatemaking.Itisimportanttoensurethatwheretheselampsareaircooledtheyarewellventilatedsothatfumeandozoneisremoved.
Safeguarding standardsFixedorinterlockedscreeningatUVlightunitspreventsdirectorreflectedUVemissionfrombeingemittedtotheworkroomwhereitwouldpresentarisktotheskinandeyes.Itisimportantthatthescreens,shuttersandsealingbrushesonprint-downframesarewellmaintained,sothatemissionleakageisprevented.ItisparticularlyimportanttocheckthatlampcowlingsareadjustedsothatUVescape,especiallywherereflectivesubstratesareinuse,isminimised.Acommonfailureisthesplittingofinfillcanvasscreens.Theseshouldberegularlyinspectedandreplacedasnecessary.
Figure 14 ScreenallUVlightsourcesadequately,preferablywithautomaticcurtainsorblinds
PrintedsheetsshouldnotbevisuallyinspectedunderaUVlampbecauselevelsofreflectedradiationmaybehigh:removesheetsfromthepressbeforeinspection.
ForsomeunusualmaintenanceworkitmaybenecessarytorunaUVlampwithoutscreening.Insuchcases,suitableeyeprotectionagainstUVemissionwillbenecessary,togetherwithclothingtocoverexposedareasofskin.
Forfurtherinformationsee‘Screenprinting’and‘Basicrulesofmachinerysafety’inChapter5.
Infrared sourcesInfraredunitsareusedtypicallyfordryingprintedmaterialatoffsetlithopresses,asanalternativetotheuseofanti-set-offpowderandforaccelerateddrying.Theequipmentmaybefittedretrospectivelytoexistingmachines.
Radiation hazardsInfraredlightmaycauseeyeinjury(especiallytothelensoftheeye).Intheprintingindustry,however,itisunlikelythatsourceswillbeofsufficientoutputforthisrisktobeaseriousproblem.Exposuremayalsocausereddeningandburnstotheskin.
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Fume hazardsTheinksusedonlithopresseshavealowsolventcontent.Therearegenerallynofire,explosionorfumehazardsarisingfromtheirevaporation,howeveryouwillneedtoassessthefumehazardsandintroducecontrolmeasuresifnecessary.
Safeguarding standardsInterlockingoflampunitswithpressespreventstheriskoffirewhenmachinesarestoppedduringaprintrun,orwhenthereisamisfeed.
Dryersshouldbeelectricallyisolatedduringwash-upatmachinesandusingflammablesolventsshouldbeavoidedontheinfraredunititself.Lampenclosuremaybenecessarytoshieldoperatorsfromexcessiveexposureandtoreducelevelsofglarethatmightotherwiseinterferewithwork.
Static eliminatorsStaticelectricitymaybeaprobleminsomeplants.Aswellasthepossibilityofoperatorsexperiencingpainfulstaticshocks,thereisalsotheriskofstaticignitionofflammablevapours,forexamplewherevolatile,flammablesolventsareusedinprocessessuchasweb-fedgravureandflexographicprinting.Polythene,PVCandotherinsulatingsubstratesareparticularlylikelytogeneratestatic.
Staticeliminatorsareusedtopreventthebuild-upofunwantedelectrostaticchargesandsoavoidthepotentialforstaticignitionofflammablevapours.Staticeliminatorsneedtobedesignedsothattheycannotproduceincendiarysparks,andwhererelevantneedtobeconstructedtoasuitableexplosionprotectionstandard.Staticeliminatorsmaybeusedinconjunctionwith‘staticassist’devices,ormaybeusedtocontrolstaticgeneratedbythemovementoftheweb.
Somestaticeliminatorscontainsmallamountsofsealedradioactivematerial,whichionisestheair.Itisalsopossibletousestaticeliminatorssuchascarbonfibrebrushes,andhighvoltagetypes,whichdonotcontainradioactivematerial.
Itisimportantthatstaticeliminatorsarekeptcleanandproperlymaintained.
Thecorrectfittingofanystaticeliminatorsisaskilledtaskanditisrecommendedthatadvicebetakenfromthesuppliers.Staticeliminatorscontainingradioactivematerialshouldnotbetamperedwithordismantled.Ifyoususpecttheyarenotworkingcorrectly,callthesupplier.
Skin disease (dermatitis)
Adetailedstudyintheprintingindustryhasidentifiedthatabout40%ofprintingworkersarelikelytohavesufferedfromaskincomplaintatsomestageandover10%arelikelytohaveacurrentproblem.Thishighlightsthefactthatskinproblemsareanimportantproblemintheprintingindustry,whichwerepreviouslyunderestimated.Peopleworkingintheprintingareaandinvolvedincleaningprintingmachineryshowedthegreatesttendencytowardsskinproblems,buttheevidencesuggeststhatsomeproblemscanexistinallareasofprinting.
What is dermatitis?Dermatitisisacommonskincondition,whichisreportedtoaffectbetween15to20%oftheUKpopulation.Thecausesarevaried.Itisoftenquitesimplyaninflammationoftheskin,andcanariseasaresultof:
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n aninheritedsensitivitytoeczema(atopy);n contactwithirritantssuchassoaps,solventsandwetwork;n anallergycausedbycontactwithcertainsubstancessuchasnickelorrubber.
Intheworkplaceallthesefactorsmaybeinvolved.Theprintingindustryusesdevelopers,etchingsolutions,solvents,inks,glues,gums,oilsandgreasesthatcanallcauseskinirritation.
Printingprocesseswithahighoccurrenceofskinproblemsare:
n platemaking;n correctionoflithoplates;n solventuse;n UV-curedinkuse;n materialscontainingisocyanates;n cleaningoflithorollersandcylinders;n guillotining;n handlingpressroomconsumables.
Fiftypercentofworkersinvolvedinthecorrectionoflithoplatesorcleaningoflithorollersandcylindersarelikelytohavehadaskincomplaintatsometime.
Affected areasThemostcommonlyaffectedpartsofthebodyarethefingersandthewebsbetweenthefingers,closelyfollowedbythebackofthehands,particularlythoseofprintingpressworkers.Theseworkersgenerallyalsohavemoreproblemsonthewrist,forearmandelbowsthanotherworkers.Somethinglikethree-quartersofthosewhohaveeverhadaskincomplaintfindtheproblemclearsupawayfromwork.Amajorityofskinproblemsfirstoccuraftertheageof16.
SymptomsThemostfrequentlyreportedsymptomsbyprintworkers,andwhichareconsistentwithirritantcontactdermatitisare:
n itching;n roughskin;n dryskin;n redness.
Work-related substancesThemostcommonwork-relatedsubstanceswhichgenerallyaggravateskinconditionsare:
n wash-upsolutions;n inksandcleaningsolvents;n UVvarnishes;n UVinks;n developers;n thinners;n handcleansers.
Washingpowders,cleaningagentsandpersonalsoapsbothatworkandinthehomecanalsocauseproblems.Handlingofpaper,constantwashingandcontactwithwatercanallleadtodryness,anditchyandsoreskinconditions.
Thedisappearanceofsymptomsawayfromwork,foundinaboutthree-quartersofallprinterswithaskincomplaint,reinforcestheneedforbetterskincareprovisionintheindustryandmoreawareness.
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Why employers should take action TheManagementofHealthandSafetyatWorkRegulations1999andtheControlofSubstancesHazardoustoHealth(COSHH)Regulations1999requireemployerstoassessriskstohealthaswellassafety,suchasdermatitis,andtakeactiontopreventit.Also,dermatitiscostsmoney-fromsicknessabsence,lossofproduction,staffturnover,retrainingetc.
AspartoftheiroverallCOSHHassessmentsemployersneedtoassesstherisksofdermatitisfromthematerialsandprocessestheyuse.Health surveillance should be carried out and employees properly informed, trained and supervised(seeearlierinthischapterunder‘Healthsurveillance’).
Wherethereisexposuretosubstancesthatmaycausedermatitisandthehandsandforearmsarelikelytobeaffected(forexamplewhereUV-curableinks,lacquersandvarnishesareused)thefollowingmeasureswillhelpprotectemployees.
n Arrangeforaresponsiblepersonsuchasasupervisororfirstaidertobegiventrainingbyanoccupationalhealthprofessionalonthesymptomsandsignsofdermatitis,andsetupasystemofperiodicskininspections.Thefrequencyoftheinspectionswilldependontheindividualcircumstances,egthelikelyseverityofthedermatitisthatmightdevelop,butwouldnormallybeatleastmonthly.
n Arrangefornewemployeestohavetheirhandsandforearmsinspectedbeforetheystartworkwiththesubstancethatmightcauseaskinreaction.
n Referanyemployeefoundtohaverelevantsymptomsorsignstoasuitablemedicalpractitioner(normallyanoccupationalhealthphysician)whoisfamiliarwiththerisksoftheprocessandtheprinciplesofhealthsurveillance.
n Trainemployeessotheycanrecogniseandreportrelevantsymptomsandsignsofillnesstotheresponsibleperson.
FurtherguidanceisgiveninthebookletAssessing and managing risks at work from skin exposure to chemical agents(HSG205)andSkin problems in the printing industry(IACL101rev1).
Other health issues
Workplace stressStressisthesecondbiggestoccupationalhealthproblemintheUK,afterbackpain.About5millionworkerssufferfromhighlevelsofstressatwork.Howemployersdesignandmanagejobsaffectsthementalandphysicalhealthoftheiremployees.
What are the effects of stress?Stressispeople’snaturalreactiontoexcessivepressure-itisn’tadisease.Butifthestressisintenseorgoesonforsometime,itcanleadtomentalandphysicalillhealth,suchasdepression,nervousbreakdownorheartdisease.Thesymptomsofstresscanalsoincludeindecision,anxiety,alteredappetite,changesinweight,headaches,backache,skinrashesanddifficultyinsleeping.
What must employers do?Itisthedutyofallemployerstomakesurethattheiremployeesarenotmadeillbytheirwork.Wherestresscausedormadeworsebyworkcouldbe,oris,leadingtoillhealth,employersmustassesstherisk.
Ariskassessmentforstressinvolves:
n lookingforpressuresatworkwhichcouldcausehighandlong-lastinglevelsofstress;
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n decidingwhomightbeharmedbythese;andn decidingwhethertheemployerisdoingenoughtopreventthatharm.
Ifnecessary,employersmustthentakereasonablestepstodealwiththosepressures.Simplyrelyingonemployeestomanagetheirownstress,forexamplebytrainingtheminrelaxationtechniques,orjustprovidingcounsellingwhentheyexperiencehighorsustainedlevelsofstressisnotenough.Referalsotothesectiononoccupationalhealthservicesatthebeginningofthischapter.
Managing stressMostofthe‘thingstodo’onstressboildowntogoodmanagement,includinggoodmanagementofhealthandsafety.Theyareongoingprocessesthatneedtobebuiltintothewayacompanyisrun.
n Takingstressseriously,andbeingunderstandingtowardspeoplewhoadmittobeingundertoomuchpressure.
n Encouragingmanagerstohaveanopenandunderstandingattitudetowhatpeoplesaytothemaboutthepressuresoftheirwork,andlookingforsignsofstressintheirstaff.
n Ensuringthatstaffhavetheskills,trainingandresourcestheyneed,sothattheyknowwhattodo,areconfidentthattheycandoitandreceivecreditforit.
n Ifpossible,providingsomescopeforvaryingworkingconditionsandflexibility,andforpeopletoinfluencethewaytheirjobsaredone.Thiswillincreasetheirinterestandsenseofownership.
n Ensuringthatpeoplearetreatedfairlyandwithconsistencyandthatbullyingandharassmentarenottolerated.
n Ensuringgoodtwo-waycommunication,especiallyattimesofchange,andnotbeingafraidtolisten.
Workplace stress and mental healthWorkplacepressurecankeepstaffmotivatedandbethekeytoasenseofjobsatisfaction,butpeople’sabilitytodealwithpressureisnotlimitless.Excessiveworkplacepressureandresultingstresscanbeharmfulanddamagingtobothyouremployees’healthandtoyourbusinessperformance.
EmployershavearesponsibilityundertheHSWActtotakereasonablecaretoensurethathealthisnotputatriskthroughsustainedlevelsofstressarisingfromthewaytheworkisorganised,thewaypeopledealwitheachotherorfromday-to-daydemands.
Itisknownthattoolittlepersonalcontroloverthework,notbeingallowedtouseskillsfully,beingoverworkedorunderworked,andboringworkcanallcontributetostress.
Learntorecognisesignsofstressandencourageemployeestodiscussproblemsopenly-arepeopledistracted,tenseorworried?
Givehelp,besympatheticand,ifappropriate,adviseemployeestoseetheirdoctor.Delaycanmakemattersmuchworse.
Furtherinformationonstressatworkcanbefoundintheemployer’sguideTackling work-related stress: A manager’s guide to improving and maintaining employee health and well-being(HSG218)andtheleafletWork-related stress: A short guide(INDG281).
New and expectant mothers at workEmployersarerequiredtotakeparticularaccountofriskstonewandexpectantmotherswhencarryingoutriskassessments.Particularattentionshouldbegivento
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liftingandcarrying,hoursofworkincludingnightwork,workrequiringlongperiodsofstandingandworkinvolvingexposuretochemicals,egexposuretolead.Employersneedtoensurethatexposuretocarcinogenic,mutagenicorteratogenicsubstancesisprevented,assuchexposuremaycreatearisktotheunbornchild.
Ifariskisidentifiedthensuitablealternativeworkshouldbeoffered.Ifthisisnotpossibletheworkershouldbegivenpaidleaveforaslongaspossibletoprotectherhealthandsafetyandthatofherchild.
FurtherinformationcanbefoundinthebookletNew and expectant mothers at work. A guide for employers(HSG122).
Drugs and alcoholThemisuseofalcoholanddrugscanaffectworkperformanceandpotentiallyposeathreattohealthandsafety.Employerscanbenefitbydevelopinganalcoholanddrugspolicy.Thispolicyshouldformpartoftheoverallhealthandsafetypolicy.Itshouldhelpemployersidentifyproblemsatanearlystage,encourageaffectedpeopletocomeforwardforhelpandtreatmentandensureappropriatecontrols.
Worksuchasoperatingmachineryordrivingdemandsclearthinkingandsoundjudgement.Whereperformanceisimpaired,peopleshouldnotbeallowedtoundertakesuchduties.Allactivitiesofemployeeswhoareinaplaceofworkwhileundertheinfluenceofdrugsoralcoholshouldbestrictlycontrolled.
HSE’sEmploymentMedicalAdvisoryServicecanadviseonallaspectsofoccupationalillhealthincludingdrugabuse.FurtherinformationforemployersisavailableintheleafletDrug misuse at work(INDG91).
Passive smokingPassivesmokingisthebreathinginofotherpeople’stobaccosmoke.Itcancausedamagetohealth,makeasthmaworseandcauselungcancer.
Thinkaboutagreeingruleswiththeworkforcetoprotectnon-smokersandencouragingandhelpingsmokerstogiveup.AdviceisgiveninthebookletPassive smoking at work(INDG63).
TheWorkplace(Health,SafetyandWelfare)Regulations1992requirethatrestroomsandrestareasincludesuitablearrangementstoprotectnon-smokersfromdiscomfortcausedbytobaccosmoke.Thiscanbeachievedbyprovidingseparaterestareasorroomsforsmokersandnon-smokersorbyprohibitingsmokinginrestareasandrestrooms.
Humidifier feverHumidifierfeverisaflu-likeillnesscausedbyinhalationoffinedropletsofwaterfromhumidifiersthathavebecomecontaminatedbymicro-organisms.ItshouldnotbeconfusedwithLegionnaires’disease(see‘Legionellosis’).
Thesymptomsofhumidifierfevervaryfrommildfeverwithheadache,malaiseandmuscleweakness,toacuteillnesswithhighfever,cough,chesttightnessandbreathlessnessonexertion.Theonsetofsymptomsisdelayed,beginningfourtoeighthoursafterthestartoftheworkingshift.Thesymptomsusuallyoccuronthefirstdaybackatworkafteraweekendorotherbreakandtendtoresolveover12to16hours.
Humidifiersaresometimesusedinprintcompaniestostabilisepapersizeandcondition.Theyarealsopresentinbuildingair-conditioningsystems.
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Contaminationofhumidifiersystemsismostlikelytooccurininternalreservoirswithinthehumidifiersandinholdingtanks,especiallyifthewaterisrecirculated.Paperdustoranti-set-offpowdersmayactasanutrientforthegrowthofmicro-organismsifallowedtoaccumulate.Exposurethenresultsfromsprayemittedfromthecontaminatedsystem.
Sofar,casesofhumidifierfeverintheprintingindustryhavebeenassociatedwithspinningdiscandspray-typehumidifiersincorporatingholdingreservoirs.
Prevention and controlChoosethehumidificationequipmentthatisleastlikelytobecomecontaminated,egsteamhumidifiers,compressedairatomisersthattakewaterdirectlyfromthemains,orevaporativetypehumidifiersthatdonotcreatewaterspray.
Maintaincleanliness-weeklycleaningmaybenecessaryinprocessenvironments,everytwotothreemonthsmaybeacceptableforoffices.Ensurethathumidifiersaredrainedandkeptdryduringperiodswhentheyarenotinuse,andarethoroughlycleanedanddisinfectedbeforetheyareusedagain.
Ifhumidifierfeverissuspected,turnoffthehumidifiersandseekadvicefrombothamedicalpractitionerandacompetentventilationengineerwiththenecessaryspecialisedknowledgeofhumidifiers.
LegionellosisLegionnaires’diseaseisapneumoniathatprincipallyaffectsthosewhoaresusceptibleduetoage,illness,immunosuppression,smokingetcandmaybefatal.Legionellaecanalsocauselessseriousillnessesthatarenotfatalorpermanentlydebilitatingbutwhichcanaffectalltypesofpeople.
Infectionisattributedtoinhalinglegionellae.Thesebacteriaarewidespreadinnaturalwatersourcesbutmaymultiplyundercertainconditionsiftheyenterman-madesystemsorwaterservices.Mostcasesandoutbreaksoflegionellosishavebeenattributedtowaterservicesinbuildingsandcoolingtowers;othersourcesmayincludehumidificationsystemsandindustrialcoolants.Plantandsystemscontainingwaterwhichislikelytohaveatemperatureintherange20-45°C,andwhichmayreleaseasprayoraerosolduringoperationorwhenbeingmaintained,mayalsopresentarisk.
The lawTheNotificationofCoolingTowersandEvaporativeCondensersRegulations1992requirethenotificationtolocalauthoritiesofwetcoolingtowersandevaporativecondensers.Legionnaires’ disease: Control of legionella in water systems. Approved Code of Practice(L8)givesguidanceoncomplyingwiththerequirementsoftheHealthandSafetyatWorketcAct1974andtheControlofSubstancesHazardoustoHealthRegulations1999inrespectofthisrisk.
AsbestosAsaroughguide,ifyourbuildingwasbuiltbeforethe1980sandyoucarryoutanytypeofmaintenance,repairorrefurbishmentwork,eveninstallationofnewcablinginanoffice,youcouldbeexposingpeopletoasbestosdustwithoutrealisingit.Anyindividualexposuremaybesmall-butthesecanbuildupandmayresultinanasbestos-relateddiseaselateroninlife.Thisisparticularlyrelevanttomaintenancepersonnelandcontractorswhocouldunknowinglydisturbasbestosinpremisesbuiltbefore1985iftherearenorecordsofwhatmaterialisinthebuilding.
SeethesectioninChapter1dealingwiththecontrolofcontractorsandChapter3aboutthemanagementofasbestosinworkplacebuildings.
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Local exhaust ventilation (LEV)
Maintenance, examination, testing and the lawUnderregulation9oftheControlofSubstancesHazardoustoHealthRegulations1999,controlmeasuresmustbemaintainedinanefficientstate,inefficientworkingorderandingoodrepair.Regularmaintenancewillensurethisisachieved.EmployersmustalsoensurethatthoroughexaminationsandtestsofLEVarecarriedoutevery14months,andappropriaterecordsmustbekeptforatleastfiveyears.
Someonewhohasthenecessarytraining,knowledge,skillsandexperienceshouldcarryoutmaintenance,examinationandtestingofLEV.Yourinsurancecompanymayhavethecompetencerequired.
Selection and useLEVisfrequentlyusedandcanbeaneffectivewayofcontrollingexposuretohazardoussubstances.Itworksbydrawinghazardousemissionsawayfromthebreathingzonesofworkersintoahoodorboothandductworkconnectedtoanextractorfan.LEVmayalsobeusedonmachinesforcontrollinghazardoussubstancesatthepointatwhichtheyaregenerated.
ExamplesofsituationswhereLEVmightbenecessaryinclude:
n screenprintingandscreencleaningwork;n gravureprintingusingvolatilesolvents;n UVunitswhereozoneorinkflyisgenerated;n hotmeltgluestationsandpapermillingatadhesivebinders.
InmanycircumstancesLEVmaybecheaperandmoreeffectivethangeneralventilation.(Generaldilutionventilationworksbyintroducingfreshairintotheworkplacetolowerthegenerallevelofhazardoussubstancesintheair.)
HeatlossesfromLEVmaybeminimisedbyheatrecoverysystemsorrecirculationoffilteredair.Recirculationshouldonlybeemployedafterspecialistadvicetopreventtherecirculationofhazardousmaterialsinharmfulquantities.
Making the most of LEVGetanexperttodesignandinstallthemostappropriatesystem,withtherighthoods/enclosures,ductwork,airvelocitiesandcleaningandfiltrationsystems.Itissensibletoinvolveemployeesindiscussionsaboutthedesignofthesystems,astheyhavetousetheplantandwillhaveviewsaboutwhatisworkable.Ingeneral:
n Keeptheextractionasclosetothesourceofcontaminationaspossible.n Makesurethefandrawsairawayfromtheoperator.n Extractatthesamelevelorbelowthesourceofcontaminantunlessthereis
needtocontrolfumerisingfromaheatedsource.Extractionpositionedabovetheoperator’sheadwilldrawharmfulsubstancesintotheirbreathingzone.
Check,cleanoutandmaintainthesystemregularly,particularlyflexibleductwork.Ifnecessary,provideenoughheatingandlighting(suitablyprotected)withintheenclosuretoencourageworktobedoneinsidetheextractedarea.
Common causes of LEV failureThefollowingarecommoncausesofLEVfailureandareeasilycheckedbyyou.Ithelpstokeeparecordofthesechecks:
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n physicaldamagetoandpoorpositioningofhoodsandbooths;n damagedand/orblockedductwork;n blocked,damaged,unsuitableorincorrectlyinstalledfilters;n toohigh/lowwaterlevelsinwetcollectors;n wear,corrosionorbuild-upofcontaminantonfanblades;n slippingorbrokendrivebeltstofans;n poorlubricationoffanbearings;n poorfitmentoftheductwork.
Figure 15 Makesurefansdrawairawayfromtheoperator
Personal protective equipment (PPE)
Ifyouarethinkingofusingpersonalprotectiveequipment(PPE)tocontrolemployees’exposuretosubstanceshazardoustohealth,rememberthatCOSHHlimitsitsusetosituationswhereitisnotreasonablypracticabletouseothercontrolmeasuressuchaslocalexhaustventilation.
PPE and the lawThePersonalProtectiveEquipmentatWorkRegulations1992requireemployersto:
n assessriskstohealthandsafetywhichhavenotbeenavoidedbeforeprovidingPPE;
n providesuitablePPEfreeofchargetoprotectemployeesagainstriskswhichhavenotbeencontrolledbyothermeans;
n takeallreasonablestepstoensureitisproperlyused;n maintainPPEprovidedincleanandefficientworkingorderwithappropriatestorage
accommodationforitwhenitisnotinuse;n giveinformation,instructionandtraininginitsuse.
EmployeesmustusethePPEprovidedandreportanylossorobviousdefecttotheemployer.
GoodBad
GoodBad
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Figure 16 Someprinciplesofgoodductingdesign
Respiratory protective equipment (RPE)ChoosingWhenchoosingrespiratoryprotectionconsiderthejobtobedoneindetail.Identifythecontaminantandthelikelylevelofexposureagainstwhichprotectionisrequiredandtakeintoaccounttheworkingenvironmentinwhichitwillbeworn.
DifferenttypesofRPEofferdifferentlevelsofprotectionandthecorrecttypehastobematchedagainstthejob,includingthepotentiallevelsofexposure,andthewearer.Assesstheworkcarefullyandconsultthesuppliersofthesubstanceinuseandtheprotectiveequipment.British(BS)andEuropean(EN)Standardssetoutthespecificationsforrespiratoryprotectivedevicesandfilters.Checkthatequipmentismarkedtoindicateconformitywithastandard.Unlessitisagoodfitandproperlyworn,RPEwillnotoffereffectiveprotectionandwillnotperformasdesigned.
MaintainingThoroughlyexamineand,whereappropriate,testRPEatleastonceamonthandmorefrequentlywhereconditionsaresevere.(Thisdoesnotapplytoone-shiftdisposablerespirators.)Half-maskrespiratorsusedonlyoccasionallyagainstdustorfumesofrelativelylowtoxicitymaybeexaminedatlongerintervals,butnotlessthanonceeverythreemonths.Makesureemployeeshavefacilitiestocleanrespiratorsandknowhowtodothiswithoutdamagingthem.
Ensurethatbreathingairsuppliedtoair-fedequipmentissatisfactory;proprietaryequipmenttodothisiswidelyavailable.
BAD GOOD
BAD GOOD GOOD
BAD GOODBAD
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Figure 17 EmployersneedtoprovidesuitablePPEandinformation
Figure 18 Examplesofrespiratoryprotectiveequipment
Eye protectionEyeprotectionwillhavetobeprovidedandused(sometimesthroughoutthewholeworkshop)whereworkthatputseyesatriskiscarriedout,eg:
n theuseofpressure-cleaningapplianceswhichleadstotheprojectionofsprayandparticles;
n theuseofhazardoussubstances,suchassolventswhichmaysplashintotheeye;
n inmaintenancedepartments,grindingandothermachiningprocesses,whichleadtotheuncontrolledejectionofmetallicparticles.
BSEN166:1996Personal eye-protection. Specificationssetsoutthestandardforeyeprotectionforindustrialandnon-industrialuses.Specialarrangementsareappropriateforpeoplewhonormallywearglassessuchastheuseofgogglesorsafetyglasses.
Skin protectionTheselectionofsuitableprotectiveglovescanbeacomplicatedprocedure.Seekexperthelpfrommanufacturersordistributors.Fortheglovetobesuitableitmust:
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n beappropriatefortherisk(s)andtheconditionswhereitisused;n takeintoaccounttheergonomicrequirementsandstateofhealthoftheperson
wearingit;n fitthewearercorrectly,ifnecessary,afteradjustments;n eitherpreventorcontroltheriskinvolvedwithoutincreasingtheoverallrisk.
Furtherinformation,includingatablewithasimpleguidetoselection,isgivenintheleafletSelecting protective gloves for work with chemicals(INDG330),thebookletCost and effectiveness of chemical protective gloves for the workplace(HSG206)andtheleafletSkin problems in the printing industry(IACL101rev1).
Forotherprotectiveclothingrequirementssee‘WorkwithUV-curablematerials’earlierinthechapter.
Storage of PPESuitableaccommodationshouldbeprovidedforPPEwhenitisnotinuse.ThestorageshouldbeadequatetoprotectthePPEfromcontamination,loss,ordamageby,forexample,harmfulsubstances,damporsunlight.WherePPEbecomescontaminatedduringuse,theaccommodationshouldbeseparatefromanyprovidedforordinaryclothing,andwherenecessarybesuitablylabelled.SpecialarrangementsmayhavetobemadetocleanPPE.Makesureyouinformyourcleanersaboutanyhazards.
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Chapter 5 Process safetySee the ‘References’ section at the back of the book for details of publications which relate to PROCESS SAFETY and also see Appendix 1 ‘Safeguarding terms’
Relevant legislation
TheHealthandSafetyatWorketcAct1974(HSWAct)requiresemployerstoensure,sofarasisreasonablypracticable,thehealth,safetyandwelfareatworkoftheiremployees.Thisdutyextendstotheprovisionandmaintenanceofplantandmachinerythatissafeandwithoutriskstohealth.
TheProvisionandUseofWorkEquipmentRegulations1998(PUWER98)placegeneraldutiesonemployerstoensurethattheworkequipmenttheyprovideissuitableandsafeforuse.
ManufacturersandsuppliershavedutiesundertheSupplyofMachinery(Safety)Regulations1992(amended1994)toprovidenewequipmentthatmeetscertainessentialhealthandsafetyrequirementsandissafe.Employers,however,shouldstillassessallequipmenttoensureitissafeandfreefrompatentdefectsbeforebringingitintouse.ThefactthatamachineisCEmarkeddoesnotnecessarilymeanthatitissafeforuseinyourprintworks-youmayhaveproceduresandancillaryprocessesthatwerenotconsideredbythemanufacturersoyouwillstillneedtodoyourownriskassessment.
Provision and Use of Work Equipment Regulations 1998 (PUWER 98)
ThemainrequirementsoftheRegulationswhichwillneedtobemetbyemployersintheprintingindustryaretoensurethat:
n equipmentissuitablefortheusethatwillbemadeofitandisnotusedforunsuitableapplications(egunprotectedelectricalequipmentinpotentiallyexplosiveatmospheres);
n equipmentisadequatelymaintained;n guardsandprotectivedevicesarekeptingoodworkingorder,egby
performingdaily/weeklychecksonthesatisfactoryoperationofphotoelectricorinterlockedguards;
n equipmentwhosesafeoperationiscriticallydependentonitsconditioninuseandwheredeteriorationwouldleadtosignificantrisk,suchaspower-operatedguillotinesandhand-fedplatenpresses,areinspectedatsuitableintervalsbyacompetentperson;
n adequateinformation,instructionandtrainingisgiventooperators,eglifttruckoperators;
n newequipment(includingsecond-handequipmentfromoutsidetheEuropeanEconomicArea)conformswithproductsafetylegislation,egtheSupplyofMachinery(Safety)Regulations1992andamendments;
n hazardouspartsofmachineryareguarded,egin-runningnipsatcylindersandrollers;
n thereisprotectionagainstspecifichazards,egdisintegrationandejectionofslittingdiscs;
n controldevicesareclearlyvisible,properlymarked,unambiguous,reliableandperformallthetasksnecessaryforsafeoperation,egprovisionofemergencystopandothercontrolswhereappropriate;
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n equipmentcanbeisolatedfromtheelectricalsupplyandothersourcesofenergy,egusingaproperlyearthedelectricalsupplyisolatoradjacenttothemachine,orisolatinggasvalvesatheat-setovens;
n adequatelightingisprovided,egatthetestsheetremovalareaofasheet-fedpress;
n maintenancecanbecarriedoutsafely,egprovisionofladderwaysandworkingplatformsonlargewebpressesformaintenanceoffreerunningrollers;
n equipmentisstable,egboltedtothefloor.
Basic rules of machinery safety
Everyyearseriousaccidentsoccurintheprintingindustryasadirectresultofunguardedorinadequatelymaintainedmachinery.Justbecauseyouhaven’thadanaccidentataparticularmachine,don’tassumethatthemachineissafe.Machinerymayneedupgradingtomeettherightsafetystandards.Doariskassessmenttocheckwhetheryourguardingissuitable,thentakeanynecessaryactiontoreducerisks.(See‘Planningandriskassessment’inChapter1.)
Thefollowingareexamplesofbasicstepsyoucantaketoreducetheriskofmachineryaccidentsatwork:
1 Choosetherightmachineforthejob.
2 Checkthatitisadequatelyguarded,egisthereprotectionfromin-runningnip hazardsatinkingrollersandprintingcylinders,istransmissionmachinery enclosed,areallinterlocksworkingcorrectly,aregapcoversprovidedand usedwherenecessary?
3 Ensureoperatorsandsupervisorsareadequatelyinformed,instructedand trainedsotheyknowhowtoworksafelyandhowtousetheguardsandsafety devicesprovided.Somemachines,includingguillotinesandplatenprinting machines,areextremelyhazardous.Youngpeopleinparticulararelikelyto needadditionaltrainingandahighlevelofsupervision.
4 Checkadequatelightinghasbeenprovidedforworkatallmachines.
5 Provideclearworkingspacearoundmachinery.
6 Testandcheckmachineryregularlytoensuresafeguardsareworking.
7 Carryoutmaintenanceworkonaproactiveratherthanreactivebasis.
Machinery guardingAllmachinerymustbeguardedsothataccessisnotpossibletohazardousparts.Whereverpossible,fixedguardsshouldbeused.However,ifregularaccessisneededtohazardousparts,egprintingcylinders,theninterlockingguards,tripnipbars,fixednipbars,anelectrosensitivesafetysystemoracombinationoftheabovewillbemoreappropriate.
EuropeanNorm(EN)Standardsgivespecificationsfornewmachines.However,someofthesestandardsmayalsoberelevanttoexistingmachines.
Guardsshouldbecarefullydesigned,constructedandfittedtoensurethattheyare:
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n inaccordancewiththesafetyreachdistanceslaidoutinBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbssothatopeningsinoraroundguardsdonotallowaccesstothehazardousparts;
n sufficientlyrobust,egnipbarsdonotbecomedeflected;n notheavyorawkwardtouse(egsomegapcoversandlift-offinterlocked
guardsprovidedforflexopresses);n designedtoallowoperatorstoseecertainmachinefunctions(eggluinguniton
anadhesivebinder);n designedtobecompatiblewithmachineryoperation(egfittingofwash-up
trays);n ofadequateelectrical/electronicintegrity(egsuitableforusewithin
flammableatmospheresatgravurepresses),andreliableenoughforasafetyapplication;
n arelocatedcloseenoughtorollersiftheyarenipbars(ienomorethan6mmfromthecylindersurface);
n designedsothattheydonotcauseahazardthemselves.
Figure 19(a) Identifyingbasicmachineryhazards
Thefollowingareexamplesofmachineryhazards-someorallofthesemayberelevanttoyourworkplace.
Partsofthebody,clothingandcleaningclothscanbecomeentangledinrotatingandin-runningpartssuchasinkinganddampingrollers,printingcylinders,nippingrollersortransmissionmachinery.
Transmissionmachinery Conveyors
Gears Inkrollers Nippingrollers Printingcylinders
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Figure 19(b) Identifyingbasicmachineryhazards
Interlocking guardsOpeninganinterlockedguardshouldstopmovementofhazardouspartsbeforetheycanbereached.Alternatively,guardlockingcanbeusedtopreventtheopeningofguardsuntilhazardousmovementhasstopped(thisisparticularlyappropriateformachineswithlongrundowntimes).Interlockedguardsshouldbeusedwherethereisaneedforfrequentaccess.
Figure 19(c) Identifyingbasicmachineryhazards
Shearingcanoccurbetweenpartsmovingpastoneanother.
(a) (b)
When a cylinder has a gap in it as shown in (a), a gap cover which completes the periphery of the cylinder as shown in (b) can be fitted. This eliminates the shear trap which arises when the cylinder rotates past the fixtures.
Crushingcanoccurbetweenpartsmovingtowardseachotherorbetweenfixedandmovingparts,egthetrapsbetweengripperbarsandmachinebodyoncertainlithopresses,trapscreatedbyclosingscissorliftsortrapscreatedbetweenmovingpartsofmachinesandfixedstructures,eglithoproofingpresses.
Cuttingandseveringcanoccuratsharpedgesorsurfaces,egweb-severers,slittersandguillotineblades.
Materialscanbeejectedfrommachinery,egreelsfromreelstandsandhotgluesfromadhesivebindingmachines.
Electricitycanalsocauseaccidentsatmachines(seeChapter6).
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Figure 20 Integrityofguardinterlocks
Machine controlsControlswitchesshouldbeclearlymarkedtoshowwhattheydo.Emergencystopcontrolsshouldbeprovidedwherenecessary,egredmushroom-headedbuttonsonayellowbackground,withineasyreachofoperatorpositionsthatstopallhazardousmotionandrequirepositiveresetting.
Operationalcontrolsshouldbedesignedandplacedtoavoidaccidentaloperation,egbytheuseofshroudsonstartbuttonsandpedals.Presseswithreversefacilitiesshouldhavethereversecontrolsdistinguishablebytouch.Thisisusuallydonebytheuseofdeepshrouds.Hingedflapscanalsobeused.
Multi-operator equipmentMulti-operatorpressesshouldhavepre-startwarningdeviceswhichautomaticallygiveanaudiblewarningwhenaninch,crawlorrunbuttonisdepressed.Anacousticsignalofonetothreesecondsdurationshouldbegiven.Fromthemomentthesignalisactivated,atleastthreesecondsshouldelapse(waitingtime)beforethemachinecanbestartedbyrepeatedactivationofthesameordifferentcontrolelement.
Afterthewaitingtimeorafteraprecedingoperationintheinchmode(notcontinuousrunmode)themachinecanbestartedwithin0to12seconds(releasetime)withoutanotheraudiblewarning.
Afterthereleasetimeoractivationofastopcontrol,ortheemergencystop,itshouldonlybepossibletooperatethemachineafterrepeatingthewholeoftheabovesequence(seeFigure21).
Zoningofcontrolsshouldbeusedonmulti-operatorpressesorotherequipmentwherethevisionofasecondoperatormaybeobscured.Azonedcontrolwillonlyallowlimitedmovement(slowcrawlorinch)ofaspecificpressareawithaguardopen,suchasonesideofaprintunit,orasinglesectionofagatherer-stitcher-trimmer,whenallotherguardsareintheclosedposition.
Wherehazardouspartshavelongrundowntimes,interlockingmethodsincorporatingbrakingand/orguardlockingshouldbeused.Systemsshouldbedesignedtoincorporateadevicetoeithercausethehazardtobeeliminatedastheguardisopened(byapplyingabrake),orpreventtheguardfrombeingopeneduntiltheriskofinjuryfromthehazardhaspassed(guardlocking).TheStandardprEN1010Safety of machinery. Safety requirements for the design and construction of printing and paper converting machineryrequiresguardlockingtobeprovidedonnewpresseswithrundowntimesinexcessoftenseconds.
Guardinterlockscanfailasaresultofageorroughtreatment.Theyshouldbedesignedtoworkinthepositivemodesothatundernormalcircumstancesafailureoftheinterlockswitchpreventsmachineoperation.
Switch A is installed in the positive mode, ie the contacts have been opened by the positive mechanical action of the cam. Switch B is installed in the negative mode, ie the contacts are opened by spring pressure when the cam is rotated. When switches are used singly, the positive mode should be used. Failure should prevent operation of the machine. Positive switches are also more difficult to defeat. The use of two cam-operated switches positioned next to each other but operating in opposite modes provides an even better standard.
Guardoverlap
SwitchAPositivemode
SwitchBNegativemode
6
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Figure 21 Audiblepre-startwarningsignalsequences
Control definitions for press movementTrue inch-asingledepressionofthecontrolbuttoncausingamovementof25mmmeasuredcircumferentially.Itshouldnotbepossibletocauseuninterruptedmovementofthecylindersbyrepeateddepressionoftheinchbutton.
Limited inch-asingledepressionofthecontrolbuttoncausingamovementgreaterthan25mmbutlessthan75mmcircumferentially.Itshouldnotbepossibletocauseuninterruptedmovementofthecylindersbyrepeateddepressionoftheinchbutton.
Hold-to-run slow crawl-uninterruptedmovementofthecylindersat1m/min(5m/minforweb-fedmachines)causedbycontinueddepressionofthecontrolbutton.Crawlspeedmaybeincreasedtoamaximumof5m/min(10m/minforweb-fedmachines)onlyifthereisnosubstantialincreaseinhazard.
Continuous slow crawl-uninterruptedmovementofthecylindersat1m/min(5m/minforweb-fedmachines)whichdoesnotrequirecontinueddepressionofthecontrolbutton.Crawlspeedmaybeincreasedtoamaximumof5m/min(10m/minforweb-fedmachines)onlyifthereisnosubstantialincreaseinhazard.
Note:Certain other types of machines, eg gatherer-stitcher-trimmers, folders, have increased slow crawl speeds necessary for setting purposes. These are referred to where relevant later in this chapter.
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To measure crawl speed -countthenumberofrevolutionsperminuteandmultiplybythecylindercircumference.
Trip nip bar performance standard-aftertrippingthestopfunction,thelengthofmovementofthetripbarshouldbegreaterthanthestoppingdistanceofthecylinder,iecylindermovementshouldceasewithinthedeflectiontraveldistanceofthetripbar.(SeeboxinsertbelowTable6fortestingprocedure.)
Safe systems of work
Asafesystemofworkisanagreed,documented,safejobmethodbasedonriskassessmentthatisdesignedtoreducetheriskofaccidentsorillhealth.Examplesarethe‘inch-stop-clean’or‘inch-stop-lock-clean’safesystemsofworkwhichminimisetheriskoffingersbeingdrawnintoin-runningnips.Itisessentialthatthecorrectsystemofworkisusedforthetask-forpresscleaning,seethetablesunderthesectionsdealingwitheachpresstype.
Safe systems of work for press cleaningTherearethreemainsafesystems:
n Inch-stop-lock-clean.Inthissystem,thepressissubjecttolimitedmovementusingtheinchbutton,stoppedandthepowerisolatedusingtheemergencystopbuttonbeforeapplyingthesolvent-soakedcloth.Inmulti-operatoroperation,eachpersonmustretaincontroloverthere-settingoftheirownemergencystopbuttonsothatitisnotpossibleforanotherpersontocausethepresstomoveunexpectedly.
n Inch-stop-clean.Inthissystemthecylindersarerotatedenoughtoexposethenextsectionofcylindersurfacetobecleaned.Thehandwiththecleaningclothisheldclearofthecylinderwhileitisrotating.Thecylindershouldbestationarybeforethesolvent-soakedclothisapplied.Formachineswithatrueorlimitedinchcontrol,severaldepressionsofthebuttonmayberequiredtoexposeenoughofthecylindersurfacetoclean.Multi-operatorcleaningisacceptableusingthissystemonlywherezonedprintunitcontrolsareprovided,iecylindermovementateachprintunitcanoccurandbecontrolledindependentlyoftherest.
Figure 22 Emergencystopcontrolsshouldbeprovidedwithinreachofalloperatingpositions
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Avariationofthissystemcanbeusedonsheet-fedpresseswithsemi-automaticplatechange.Bymakinguseoftheplatechangecycle,andpre-cockingthecylinderposition,thereisalmostacompleterevolutionatslowspeedwhichissufficienttoallowcleaningofthewholecylindersurfacewithoutallowingexposuretothecylindergap.
n Slow crawl cleaning.Inthismethod,thecleaningclothisappliedtothecylinderasitrotatesatveryslowspeed.Movementiscontrolledusinghold-to-runslowcrawlcontrolsornon-hold-to-runcontrols(continuousslowcrawl).Note:This method isonlyacceptable where the defined trip nip performance is met and
rigorous guard checking is done. See box insert below Table 6 for the definition of trip nip
performance.
Accident
Anoperatorwascleaningtheblanketcylinderofapressoncontinuousslowcrawl.Theraghewasusingwasdrawnintothenipbetweentheplateandblanketcylinder.Thepresswasfittedwithatrip-nipbarwhichstoppedthemachinebutonlyaftertheprinter’shandhadbeentakeninuptothewrist.Theaccidentcouldhavebeenpreventedbyusingtheappropriatesafesystemofworkandcheckingtheperformanceofthetripbar.
Other essential safeguards
n Operatorsshouldknowhowtostopamachinebeforetheystartit.n Allguardsshouldbeinpositionandallprotectivedevicesworking.n Cylindergapcoversshouldbeusedwhereprovidedbythemanufacturer.n Hickeys(fluff)shouldonlyberemovedfrommovingcylindersusingaproper
hickeypicker(suchasarubberblademountedonawoodenhandle).n Ragsshouldneverbeappliedtomovingrollersorotherpartssuchasduct
rollersoroilytransmissionmachinery.
Machinery maintenance
n Allguardsandothersafetydevicesshouldbekeptingoodworkingorderandcheckedregularly,egdailychecksonguillotinesandhand-fedplatens,andweeklychecksonpresses.
n Machineryshouldbeisolatedfromallpowersourcesbeforemaintenancework,includinglubrication,iscarriedout,especiallyiftheworkinvolvestheremovalofguards.
n Safeguardsshouldbecheckedafteranymodificationstomachinery.n Maintenanceneedsshouldbeconsideredbeforeinstallingnewmachines.n Preventive,ratherthanbreakdown,maintenanceproceduresshouldbe
implemented.
Safety hazards by process
Pre-pressManual design and art workAlthoughthisisgenerallyalow-riskarea,takecarewithscalpelswhichshouldbesheathedwhennotinuse.Provideinclinedlay-upboardswithahighlipatthebasetopreventscalpelsfallingfromthem.Disposeofusedscalpelbladessafely-don’tjustputthemintowastebins.
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Electronic/digital image preparationTypesettingandelectronicpre-pressinvolvelargeamountsofworkatvisualdisplayunits(VDUs).TheuseofVDUsbytheemployedandself-employediscoveredbytheHealthandSafety(DisplayScreenEquipment)Regulations1992.Employershaveadutytomakesurethatthedisplayscreenequipmentissafeanddoesnotaffecttheuser’shealth.Experiencehasshownthatrepeateduseofinputdeviceslikeamousecanleadtoupperlimbdisorderssoitisimportanttoconsideralltherisks.
WorkersusingVDUsneedwell-designedworkareaswithsuitablelightingandcomfortable,adjustableseating.Thishelpstopreventunduetiredness,reduceeyestrain,andpreventpainsinthehands,arms,neck,shouldersandback.PlaceVDUsinapositionwherelightingwillnotcausereflectionsorglareonthescreen.Nospecialprecautionsarenecessaryagainstradiation-thelevelsemittedfromVDUequipmentarewellbelowtherecommendedsafelevels.
Employersmust:
n analysetheworkstationsofemployeescoveredbytheRegulationsandassessandreducetherisks;
n ensuretheworkstationsmeetminimumrequirements;n plansotherearebreaksorchangesofactivity;n trainandinformdisplayscreenusersaboutthehealthandsafetyaspectsof
theirwork;n provideeyeexaminationsandtestsforusersonrequestandspecialspectacles
whererequired-foradefinitionofusersandfurtheradviceseeVDUs: An easy guide to the Regulations(HSG90).
Trailingelectricalanddigitaldatacablescancauseaccidents.Runcablesinducts,underthefloor,aroundthewallsorinapendantdroppedfromtheceiling.
Computeranddigitaldatahandlingequipmentoftengenerateslargeamountsofheat.Goodgeneralventilationand/orairconditioningshouldcopewiththis.Automaticgas-floodingfire-protectionsystemsmaybeusedtoprotectmajorsystems.Setupprocedurestoensurethatwhenpersonnelentertheprotectedspacetheautomaticfireprotectionsystemisswitchedtomanualandilluminatedindicatorsareprovidedtoshowthesystem’soperatingmode.
Graphic reproduction and platemakingScreenallUVlightsourcesadequately.Screeningonprintdownframescantaketheformofcurtains(preferablyautomaticorinterlocked),automaticshuttersorautomaticrollerblinds.Blindsshouldbemaintainedingoodcondition.BrushesshouldbeusedtoreduceleakageofUVlightaroundtheperipheryoftheframeonprintdownboxes.
Onlargeformatprintdownframes,asfoundinscreenprinting,theUVsourcesshouldbepositionedsothatlightisdirectedawayfromdoors,windowsandpassageways,andscreenedfromotherworkareas,egbyusingcurtains.Timerswitches(orotheron/offcontrols)shouldbelocatedoutsidethescreenedarea.
ProvidelasercontainingequipmentsuchasscannersandimagesetterswithinterlockedcoversaspartofthelaserbeamscreeningtoensurethatClass1conditionsaremet(ietheoutputofthelaserlightisinherentlysafe)andtopreventaccesstorotatingpartsofmachinery.
Seethe‘Radiation’sectioninChapter4formoreinformation.
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Rollersonautomaticfilmandlithoplatedevelopersneedperiodiccleaning.Thebestmethodistoremovetherollersbeforecleaning.In-runningnipsneedtobeguarded(thisisusuallyachievedbyusinginterlockedguards)exceptwheretherollersareheldinpositionbytheirownweightandthemaximumforcethatcouldresultis50newtons.Rollersshouldnotbecleanedwhilethemachinesarerunningasfingersmaybedrawnintoin-runningnips.
Makesuredriptrayshavebeenprovidedbeneathautofilmandplateprocessors.Hotsurfacesonplatedeveloperpre-heatandbakingovensshouldbeshieldedtopreventcontact.
Assesstheergonomicrisksarisingfromhandlingandloadingofplatesandfilmintocomputer-to-plateunits(see‘Manualhandling’inChapter4).
Platebendingmachinesneedtoeitherbeadequatelysafeguardedorprovidedwithasimultaneoustwo-handcontrol.Onplatepunchingdevicesthemovementofthepunchingtoolshouldbesafeguardedeitherbydesignorbyprovidingguards.
Duringflexographicplatemaking,mouldingpressesarefrequentlyusedtoimposeheatand/orpressuretorubberorsyntheticcompounds.Theclosingmovementofthesepressesshouldbesafeguarded.Localexhaustventilationshouldbeprovidedfortheheatandfumegenerated.Alsoconsiderextractionforsolventwash-offfromphotopolymerplatesandpersonalprotectiveequipmentsuchassuitablegloveswherethereisapossibilityofskincontactwithuncuredphotopolymers.(See‘Personalprotectiveequipment’inChapter4.)
Conventional litho proofing pressesThedangerofhandsbeingtrappedinthesheartrapscreatedbythemovingcarriageoflithoproofingpressesshouldbeeliminated.Tripdevicesshouldbeprovidedateachendofthecarriagewhichactuateafail-safestopdevicetoarrestmovementofthecarriage.
Wherehazardousin-runningnipsexistatthestationarydampingandinkingrollerunits,theyshouldbeguarded,egbyfixednipbars.Manylithoproofingpressesavoidthishazardbyhaving‘liftout’rollersorstoppingtheserollerswhenthecarriagemovesaway.
Theinkinganddampingrollersonthemoveablecarriageshouldbesafeguardedeitherbyinterlockingguards,fixednipbarsorothereffectivemeans.Theactionof‘sheetingoff’isahazardousoperationwhichshouldbeprohibited.
Regularlymaintainandchecksafetyfeaturesonallproofingpresses.
Digital printing and copying
Manyofthehealthandsafetyconsiderationsrequiredfortraditionalprintingarealsorelevanttodigitalprintingandcopying.Themainrisksinclude:
n Manualhandling-paperisheavyanditisimportanttokeeptheareaaroundmachinescleartoalloweasyaccesstoclearpaperjamsetc(seeChapter4).
n Electrical-maintainelectricalequipmentandensurecablesandconnectorsdonotbecomedamaged(seeChapter6).
n Fire-maintainaclearairflowtoallowpropercoolingofthemachineandremoverubbishregularly(seeChapter7).
n UVlight-takeprecautionstoensurethatstronglightsourcesinphotocopiersandlargereprographicsinstallationsareadequatelyshrouded(seeChapter4).
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n Hazardousmovingparts-feedertrays,staplersandotherattachmentshavethepotentialtotrapfingers.Remembertoisolatethemachinebeforeclearingblockagesandtoreplaceguardsandcoversbeforeoperating.Associatedfinishingmachinery,suchasguillotines,shouldbeproperlyguardedandthoseguardsmaintained.
n Chemicalsandozone-alwayshandleandchangetonerorcleaningagentsinaccordancewiththemanufacturer’sinstructions.Provideadequateventilationtopreventbuild-upofheatandozone(seeChapter4).
n Brokenglass-thetopglassofcopierscanbreakifabused.
PrintingLitho sheet-fedWhereaccesstomovingpartsisneeded,egforcleaningandmake-readyoperationsonprintingmachines,theguardcontrolcircuitsshouldbeinterlockedsothatwithguardsopenthemachinecanbeoperatedbyhold-to-runcontrols(oronslowcrawlonlywhereatripnipdevicemeetingtheperformancestandarddetailedlaterinthischapterisachieved).Thehold-to-runcontroldevicesshouldbedesignedtoallow:
n machinemovementlimitedto25mm(trueinch)oneachdepressionofthecontroloramaximumoperatingspeedof1m/min;or
n wherethemeasuresdefinedabovewouldreducetheabilityofthemachinetoperformitsfunctionandwheretherewouldbenosubstantialincreaseinrisk,machinemovementlimitedtoamaximumof75mm(limitedinch)oramaximumoperatingspeedof5m/min.
Whereinterlockedguardsallowhold-to-runslowcrawlorinching,cylindertripnipbarswithin6mmofthecylindersurfacewhichstopprintingcylindermovementwithinthedeflectiontraveldistanceofthebarshouldbeprovidedtopreventtheriskofentanglementincontra-rotatingrollersorcylinders,especiallywheregapcoversarenotprovided.Fixednipbarsareonlyacceptableinconjunctionwithcylindergapcoverswherethereisaslowcrawlfunction.Theprintunitguardingoptionsforsheet-fedpressesaresummarisedinTable5.
Figure 23 Two-colourpressfittedwithslotted,interlocked,all-enclosingguards
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Figure 24 Inmulti-operatorpressesanaudiblepre-startwarningdeviceshouldbefitted
Table 5 Safeguardingsheet-fedoffsetpresses
Safeguarding other parts of litho pressesGuardingisrequiredforthehazardouspartsoffeedtables,including:
n in-runningnipsassociatedwithchainsandsprockets;n rotatingshafts;n swingarmgrippers.
Transfercylindersanddeliverymechanismsneedhighstandardsofguardingduetotheseverityofinjurytheycause.Interlockedand/orfixedguardsareessential.Theinterlockarrangementshouldonlyallowthepresstobe‘inched’(trueorlimited)duetotheseverityofthehazardandusuallackofnipbars.Thedeliverymechanismguardingshouldpermitthesaferemovaloftestsheets.
Hazard Safeguard
Sheet-fed offset
In-runningnipsbetweeninkinganddampingrollerassemblies
All-enclosinginterlockedguardswitheithernopoweredmovementortrueinchonlywhentheguardisraised.
In-runningnipsbetweentheplate,blanketandimpressioncylinders
Anenclosinginterlockedguardwhichallowslimitedpoweredmovementwhenraisedbymeansoftrueorlimitedinch,orhold-to-runorcontinuousslowcrawl;andatripnipbaradjustedtowithin6mmofthecylindersurfacewhicheithermeetstheperformancestandarddetailedintheboxinsertunderTable6,orissupplementedbycylindergapcoversforbothplateandblanketcylinders,orthereisnofacilityforcontinuousslowcrawl;oranenclosinginterlockedguardasabovesupplementedbyfixednipbarsadjustedtowithin6mmofthecylindersurfaceandgapcoversforbothplateandblanketcylinders.Fixednipbarsarenotadequateintheabsenceofcylindergapcoversunlessthereisnofacilityforcontinuousslowcrawl;oroncertainoldmachines,tripnipbarswhichdonotmeettheperformancestandard(seetheboxinsertunderTable6)orfixednipbars,ineithercaseadjustedtowithin6mmofthecylindersurfaceandclose-fittinggapcoversforbothplateandblanketcylinders.Thereshouldbenofacilityforcontinuousslowcrawl.Usersshouldplantoupgradesuchpressesbytheadditionofenclosinginterlockedguards.
In-runningnipsbetweenimpression/transfercylinders
Anenclosinginterlockedguardwhichallowslimitedpoweredmovementwhenraisedbymeansoftrueorlimitedinch.Anemergencystop(or‘stop-lock’)controlshouldbeprovidedateachprintunit.
Unexpectedstart-upduringmulti-operatorcleaning
Pre-startaudiblewarningdevice.
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Clearlymarkallpresscontrols.Emergencystopcontrolsshouldnormallybeprovidedatalloperatingconsolesandwithineasyreachofallotheroperatingpositionsandprintstations,andshouldstopallhazardousmovement.Oncertainsmallerexistingpresseswithoutpoweredinching/crawling,additionalemergencystopcontrolswillnotbenecessaryastheywillnotenhancetheoverallsafetyofthemachine.Controlstationsonunitsshouldpreferablybelaidoutsothathold-to-runcontrolsareabove,orimmediatelyadjacentto,theemergencystopcontrols.
Onmulti-operatorpresses,orthoseonwhichitisnotpossibletoclearlyseealloverthepressfromanycontrolstation,anaudiblepre-startwarningdeviceshouldbefitted(seeunder‘Machinecontrols’inthe‘Basicrulesofmachinerysafety’sectionearlierinthischapter).Guardsandotherprotectivedevicesneedtoberegularlymaintainedandchecked(seeChapter8).Aweeklycheckoftheguards,theiroperation,thehold-to-runcontrolsandtheemergencystopcontrolshouldensurethatpressesremainproperlyguarded.
Hickeys(fluff)shouldneverberemovedfromamovingcylinderexceptwithaproperhickeypicker.Ragsshouldneverbeappliedtomovinginkingordampingrollersincludingductrollers,evenifadjacentrollersarewellguarded,becauseoftheriskofentanglement.
Figure 25 Hickeysshouldnotberemovedfrommovingcylindersexceptwithaproperhickeypicking
stick
Safe systems of work for sheet-fed press cleaningAveryhighproportionoftheaccidentstoprintersresultfromcleaningtasks(seeChapter1).UseTable6toselecttheappropriatesafesystemofwork.
Figure 26 Basicguardsforasingle-colourpress
Inking roller guards
Cylinder trip nip bar
Plate and blanket cylinder guard
Cylinder gap covers
Delivery mechanism guards
Inking and damping roller guard
Paper feed mechanism guards
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Table 6 Safesystemsofworkforpresscleaning
Trip nip performance standard-ontripping,thelengthofmovementofthetripbarshouldbegreaterthanthestoppingdistanceofthecylinder,iecylindermovementceaseswithinthedeflectiontraveldistanceofthebar.Totest:
n Withthepressstationary,measurethetotaldeflectionofthetripnipbar(t).n Markthecylinderandmachineframe.n Operatethecrawlcontrol.n Pushthetripnipwithacardboardtubewhenthetworeferencepointsare
inline.n Measurethedistancemovedbythecylinder(c)andcomparemeasurements
(t)and(c);(t)shouldbegreater.
Web offset pressesWebbing-upOneofthemainadditionalhazardsassociatedwithweb-fedpressesarisesfromtheneedtoweb-upfollowingawebbreakand/oraformatchange.Itisextremelyimportanttoensurethatasafesystemofworkisdevisedandawrittenprocedurelaiddownandadopted.Onnewpressesthiswillbesuppliedbythemanufacturer.Onolderpressesmanagementmayneedtodevelopasafesystemofworkinconjunctionwithpresscrewsandsafetyrepresentatives.
Thesafesystemofworkshouldtakeaccountofthedifferentwebpathconfigurations(includingpathsthroughcoloursatelliteunitsinnewspaperprinting)andthroughthefolder,involvingcross-associationifappropriate.Itshouldalsodealwiththeuseof
Task Risk factors System of work
Sheet-fed offset
Cleaninginkingrollers,multi-orsingle-operatorcleaning
Itshouldnotbepossibletoaccessrollerswheninmotion
n Useofdemountablewash-up
tray.
Cleaningplateandblanketcylinders,single-operatorcleaning
Frequentlackofgapcoverswithresultantaccessibilitybehindtripnip/nipbars
n Autowash-up.
n Inch-stop-clean,forward
motion.
n Forwardslowcrawlcleaning
onlyifthereissafeguard
checkingandatripniptothe
definedperformancestandard.
Cleaningplateandblanketcylinders,multi-operatorcleaning
Frequentlackofgapcoverswithresultantaccessibilitybehindtripnip/nipbars
Unexpectedstart-up
n Inchstop-lock-clean.
n Ifpresshaszonedcontrols
allowingindependent
movementofprintunit
cylinders,inch-stop-clean,
forwardmotion.
n Forwardslowcrawlcleaning
onlyifthereissafeguard
checkingandtripnipstothe
definedperformancestandard.
Cleaningimpressionandtransfercylinders,multi-orsingle-operatorcleaning
Relativeinaccessibility;absenceofnipbarsandhazardfromgrippers
n Inch-stop-lock-clean.
n Forpresseswithdedicated,
zonedtrueinchcontrols
beneaththefootboardonly,
inch-stop-clean.
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part-widthwebswhereweblead-indevicesmaynotbeusable.Thewrittenprocedureswillneedtoincludeacleardiagramofthepressshowingallpossiblewebpaths.
Manualwebbing-upshouldbecarriedoutwiththepressstationaryandoffimpressionsothatthewebcanbepassedbetween/aroundthecylinders.Weblead-indevicescansignificantlyreducethehazardassociatedwithwebbing-upandshouldtakethewebfromthereelstands,throughtheprintunitsanddryerstothetopofthefolder,butnotincludingturnedorbaywindowwebpathswherethetapesmaybeterminated.
Onolderpresses,ormachinesnotfittedwithweblead-indevices,thepracticeoftuckinginorattachingthewebtothecylinderwithadhesivetapeshouldbeusedsothatalloperatorscanwithdrawcompletelyandstandawayfromthepresswhenthecrawlcontrolsaredepressed.
Trapsassociatedwithdrivenweblead-intapesorchainsshouldbeguardedwherethereisariskofinjury,egbyprovidingdiscguards.
Safeguarding of print unitsInkinganddampingrollersmustbeguarded(seeTable7).Oncertainoldinstallationstheinkinganddampingrollersmaybeguardedbynon-interlockedenclosingguards.Theseshouldbeupgradedbyprovidingnipbarsorbyinterlockingtheenclosingguards.Wherealcoholdampingsystemshaveaseparatedrivewhichcontinuesaftertheinterlockedguardisopened,thein-runningnipsshouldbeguardedbynipbars.
Plate,blanketandimpressioncylindersmustbeguarded.Guardingcantaketheformofrobustfixednipbarsiftheprintingandblanketcylinderguttersarelessthan4mmdeepand8mmwide(orexceptionally19mmwideonnewspaperpresses)andthepress’sthrow-off(cylindermovementgoingonimpressionandoffimpression)stillkeepsthenipbarswithin6mmofthecylindersduringmake-readyandwash-up.
Followingwebbreaks,nipbarsshouldbecheckedbyoperatorstoensuretheyhavenotbeendeflectedawayfromthecylindersleavinggapsinexcessof6mm.
Insomesituations,suchastheblanket-to-blanketnip,thewebpathprecludestheuseofasinglefixednipbar.Inthesecircumstances,adualfixednipbaror‘letterbox’guardmaybeused.Thereneedstobealargeenoughgaptoallowforwebflutter,buttheguardsshouldbepositionedfarenoughawayfromtheniptopreventriskofinjury.
Certaintypesofpressesrequiresomenipbarstoberemovedformake-ready.Ahingednipbarsecuredwhenthepressisintherunmodeisacceptableaslongasmeasuresaretakentoensureitmustbeinpositionwhenthepressisrun,egbyinterlocking.
Onunitarchtypepresses,accessmustbepreventedtoroller/cylinderintakeswithinthearch.Thisguardingcantaketheformofinternalguarding,egnipbarsorfixedguardsorinterlockedunitgates.Withinterlockedgatesopen,movementofrollers/cylinderswithinthearchshouldbevialocalhold-to-runcontrolsonlyallowingcrawlspeedsofnomorethan5m/min(10m/minmaybeacceptableinexceptionalcircumstances,egonsomeolderpresses).
Theprintunitguardingoptionsforweb-fedpressesaresummarisedinTable7.
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Table 7 Safeguardingweb-offsetpresses
Safeguarding other parts of web pressesDraw rollersDrawrollersmaybeincorporatedintothereelstand,betweenthereelstandandthefirstprintunit,orwithintheframeoftheprintingunits.Wheretheintakebetweendrawrollersisaccessible,itshouldbeguardedusinganipbar,asplitbarwithabell-shapedmouthtoassisthandwebbing-up,oranenclosingguard.
Web severersWebsevererswithinunitarchesandelsewhereonthepressneedtobeguardedorbesafebydesign.Tunnelguardsarefrequentlyused.Precautionsneedtobetakentoensurethatthewebseverersdonotautomaticallyfirewhenoperatorsorothersareinthevicinity.Interlockedaccessgatestounitscanbeused.
Guide rollersDuetothehighspeedsofmanyofthesemachinesandtheinertiaofweb-drivenguiderollers,theserollersshouldbesafeguarded.Guardingsuchasnipbarscanbeprovidedortherollerscanbeseparatedfromothercontra-rotatingrollersandthemachine’sframebyagapofatleast120mm.
Drying unitOvensatheat-setoffsetpressesmayhaveopeninghingedtops.Ensurethatthesewillnotcloseinadvertently,trappingtheoperators.Thecontrolstoclosetheovenshouldbeofthehold-to-runtypeandbelocatedsothattheclosingmovementoftheovencanbeseenalongitsentirelength.SeeChapter7‘Explosionrisksinblanketwashsystems’forguidanceonavoidingfireandexplosionrisk.
Chill rollersAgapofatleast120mmshouldbeallowedbetweenaccessiblein-runningchillrollers,oraguardshouldbefitted.Guardsshouldbefittedoveranyaccessiblebalanceweightsattheendsoftherollers.
Propeller rollersPropellerandslitterrollerintakesshouldbeguarded.Thisguardingisoftenassociatedwithdustcollectionhoodsandshouldalsoeliminatethelacerationhazardposedbyslitters.Theguardingshouldcoveratleast300ºoftheroller.
Hazard Safeguard
Web-fed offset
In-runningnipsbetweenadjacentinking(anddamping)rollers
All-enclosinginterlockedguardswitheithernopoweredmovementortrueinchonlywhentheguardisraised;orfixednipbarsadjustedtowithin6mmoftherollersurface.
In-runningnipsbetweenplate,blanket(orimpression)cylinders
Interlockedguardsallowingtrueorlimitedinchorhold-to-runslowcrawlonlywherenipbarsarenotfitted.Alldangerpointsshouldbewithinviewofasingleoperator,orofseveraloperatorseachofwhomneedstooperateahold-to-runcontrol.Nipsoutofviewshouldbesafeguarded;and/orfixednipbarsadjustedtowithin6mmofthecylindersurface;and/orfixedorinterlocked‘letterbox’distanceguards;and/orsweep-onnipbarsinterlockedwithreversecrawlornofacilityforreversecrawl.Wherenipbarsareprovidedandcontinuousslowcrawlisavailable,thisshouldalwaysbesupplementedbyanemergencystop(or‘stop-lock’control)ateachprintunit.
Unexpectedstart-upduringmulti-operatorcleaning
Pre-startaudiblewarningdevice.
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Figure 27 Propellerandslitterrollersshouldbeguarded
ControlsClutchesusedtodisengagethedrivetopressunitsonolderpressesshouldbeprovidedwithinterlockswhichensurethatthecontrolsonadisengagedunitremainineffectivewiththeexceptionoftheemergencystops.
Misinterpretationofindicationlightsonpresseshasresultedinanumberofaccidents.Itisthereforeextremelyimportantthattheindicatorlightsareclearandunambiguous.
Folding unitsGuardallin-runningnipsandothermechanicalhazardsonfolders.In-runningnipsshouldbeprotectedwithnipbarsand/orenclosingguards,egnippingandcross-associationrollers.Guidanceonfoldersisgivenunder‘In-linefolders,sheetersanddiecutters’laterinthischapter.
Incorporatenoisecontrolmeasuresinenclosingguardsand,wherepossible,extendcontrols,lockingnutsandadjustingdevicesthroughtheguard.
Figure 28 Examplesofareasthatneedsafeguardingatweb-offsetprintingpresses
Webs
Idle rollers, web-driven rollers,and contra-rotating rollers
Slitter andpropeller rollers
Kite former
Printing cylindersUnit arch
Reelstands
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Table 8 Safesystemsofworkforweb-fedoffsetpresscleaning
Cleaning and make-readyTofacilitatemake-ready,cleaningoperationsetc,hold-to-runcontrolsshouldbeprovidedwhichmayallowmovementofthepresswiththeinterlockedguardsopen.Onnewandexistinginstallationshold-to-runslowcrawlspeedsshouldbelessthan10m/min.Certainolderinstallationsmaynotbeabletoachievethisspeedandtheslowcrawlspeedattheseshouldbeaslowaspracticable.
Safe systems of work for web-fed offset press cleaningAveryhighproportionoftheaccidentstoprintersresultfromcleaningtasks.UseTable8toselecttheappropriatesafesystemofwork(seeChapter1).
Reel unwinds and rewindsForthepurposesofthisbook,theterm‘reelunwindingandrewindingdevices’appliestosimplesingle-reel,non-automaticequipmentfortheprovisionandcollectionofpaper,polythene,foilorothertypesofweb.Theterm‘reelstands’appliestolargerinstallationscapableofholdingtwoormorepaperreelsandinstallationsassociatedwithautomaticoperationssuchassplicing.
Thefollowingsafeguardsareappropriateforreelunwindingandrewindingdevices:
n Unwindunitsareusuallyoftwotypes,shaftedorshaftless.Onunwindsthein-runningnipsbetweenthereelandpressurerollershouldbeprotectedeitherbyatripdeviceorguards.
n Devicesforbringingthereelsuptospeedshouldbeguardedifdangerpointsareaccessible,egatrunningtensionbelts.
n In-runningnipsassociatedwiththepressure/riderrollersshouldbeguardedovertheentirereeldiameter.Thismaybeachievedbytheprovisionoftripdevices,self-adjustingnipbarsorareainterlockedguards.Atreel-up,thelatterarebestdesignedoncastorswithtongue-operatedinterlockswitchestoallowhold-to-runmovementonlywhenremovedforaccessduringreelchange.
n Ticketstomarkdefectsetcshouldbeself-adhesiveandattachedtothewebatanaccessiblelocationawayfromtheguardednipbetweentheformingreelandlay-onroller.Consideralsoprovidingdeviceswhichwillallowremoteplacingofmarkertickets.
n Anyshearhazardscreatedbymovementofthereelliftingarmsorotherreelliftingdevicesshouldeitherbeguardedorreellifting/loweringshouldonlybepossibleusinghold-to-runcontrolsrestrictedtoaspeedofnomorethan5m/min.
Task Risk factors System of work
Web-fed offset
Cleaninginkingrollers,multi-orsingle-operator
Itshouldnotbepossibletoaccessrollerswheninmotion
n Autotraywash-up.
Cleaningplate,blanket(andimpression)cylinders,multi-orsingle-operator
‘Smooth’cylindersonly(gutternotexceeding4mmradiallyby8mmcircumferentially(exceptionally,4mmx19mmonnewspaperpresses))
n Inch-stop-lock-clean,
forwardmotion.
n Forwardslowcrawl
cleaningonlyifnip
barsandanemergency
stopareprovidedanda
suitableguardchecklistis
completed.
Cleaningtransfer/pathrollers,multi-orsingle-operator
Relativeinaccessibility;absenceofnipbars n Inch-stop-lock-cleanwhere
rollersarepowered,orby
handturningwherefree
running.
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n Whereshaftlessunwindingorrewindingisused,thechuckingconesshouldbedesignedsotheycanonlybeinsertedusingahold-to-runcontrol.Thehold-to-runspeedshouldnotexceed5m/minfornewmachines.Thecontrolsystemofthemachineshouldpreventstart-upuntilthechuckingconeshavebeenfullyinserted.
n Ejectionofareelduetoa‘corechewout’orinadvertentopeningofthechuckingconesmustbeprevented.Thecontrolsshouldnotallowseparationofthechuckingconeswhilethepressisinmotion.
Safeguarding reelstands
n Existingreelstandsshouldhaveaminimum500mmclearancebetweenthesurfaceofthelargestreelthatthestandisdesignedtoacceptandanyobstructionsuchasafullreel,mountedonanadjacentstand,orawall,unlessfixedorinterlockedbarrierspreventwhole-bodyaccess.
n Sinceanyreelbeingloadedwillencroachonthe500mmgapmentionedabove,reelsshouldnotbeleftstandingwithinthereelstandsonthesub-trucks.
n Perimeterfenceguardingshouldalsobeprovidedwherehand/armaccessispossibletoin-runningtraps/nipscreatedbetweenrotatingandstationaryreelsonthesamereelstand,unlessaminimumseparationdistanceof120mmcanbemaintainedbetweenthereels.
n Additionaldangerscreatedbyanadjacentstandindexingduringautomaticsplicingwillneedtobeaddressed,egunexpectedstart-upofthereel,splicingunitmovementandspiderarmmovement.Asafesystemofworkshouldbeimplementedtoaddresssuchhazardsinconjunctionwithsafeguarding.Safeguardingmaybeprovidedbyelectrosensitivedevicesandtripbars.
n Whereturretsorspiderarmsrotateautomatically,pressure-sensitivematsorsimilarshouldbeprovidedtopreventrotationwhenapersonisinthepit.Whererotationismanuallycontrolled,movementshouldbebymeansofahold-to-runcontrol.
n Wherereelsaredrivenbybeltsonthereelcircumference,thedangerpointbetweenthereelandthebeltshouldbesafeguardedbyinterlockedorothereffectiveguards.Guardsshouldalsobeprovidedtoprotectoperatorsfromin-runningnipscreatedatdrive-beltguiderollers.
n Whereflyingsplicingdevicesarefitted,theymusteitherbesafeguardedbyfixedandinterlockedguardsorbe‘safebyposition’(ieoutofreachofanyworkplatform).
n Onpressesfittedwithreelshafts,guardsorloosesleevesneedtobeprovidedforanyexposedendsoftheshafts.Anybrakediscsshouldalsobeguarded.
n Safeguardingfordrawandfestoon/dancerrollersisnecessarytoprotectoperatorsfromin-runningnipsandrollermovement.Thismaybeachievedbyacombinationoffixednipbars,interlockingguards,tunnel-typeguardsorbyensuringaspacingofatleast120mmbetweentherollers.
Figure 29 Reelstandsshouldhaveaminimum500mmclearancebetweenreelsorfixedparts
500mm 500mm 500mm
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Reeler/winder slitters used in paper conversion and flexible packagingThesemachinesvaryinsizefromlessthan1mtoseveralmetreswideandareusedwidelyforconvertingpaperandprintedpaperandflexiblepackagingmaterials.Thediameterofthereelsbeingrewoundcanvaryfromlessthan100mmto1mandabove.Themachinespeedsalsovary.Allmachineshaveincommonasignificantaccidenthistory.
Common issues to all types of machine
n Preventreelejectionbyensuringthatthereisgradualstart-upandspeedcontrolandprovideinterlockedrestraintswherethereelshaftrestsonopen-toppedbearings.
n Preventtheriskoftrappingbetweenthereelloadingarmsandthereelshaftbyensuringtheloadingarmsareoperatedunderhold-to-runcontrol.
n Preventtheriskoftrappingbetweenthechuckingconesandreelbyinsertionofconesunderhold-to-runcontrolandwithintheviewoftheoperator.
n Wherethereareweb-drivencontra-rotatingrolls,nipguardsshouldbeprovidedifthesizeandweightoftherollscouldcauseinjury.Webbing-upshouldonlybeundertakenwhenthemachineisstationary.Power-drivenrollsshouldbeprovidedwithpost-boxtypeguards,or,wherethewebanglemakeswebbing-updifficultbecauseofthedistancebetweentheslotandthenip,acombinationoffixedguardsbelowthewebpathandahingedinterlockedguardabove.
n Makesurethereisagapofatleast120mmtopreventnipsbetweendrivenrollsandfixedpartsorprovidefixedguarding.
n Makesureguardingisprovidedwheretherearerunningnipsbetweenthewebandweb-drivenrollsforflexiblepackagingmaterialandpaperwithahighbreakingstrength.
n Guardthewholeofthesurfaceofslittingknives(exceptthatinimmediatecontactwiththesubstrate)byindividualfixedplatesorinterlockedhingedguardsalongthelengthoftheknifeshaft.Adjustmentsshouldnotbemadeontherununlessthiscanbedoneremotely.
Two-drum reelers
n Preventaccesstothein-runningnipbetweenrewindingreelsandthedrivedrumbyoneormoreof:perimeterfencingwithinterlockeddoors;localisedfixed/interlockedguarding;photoelectricdevices;pressure-sensitivemats.
n Wheretherider(lay-on)rollisheldunderhydraulicorpneumaticpressure,orhasaselfweightatapressuregreaterthan300newtons,interlockedguardingoraself-adjustingnipbarwillberequired.
n Whereatrapunderthedescendingriderrolloccursunderpower,atwo-sectionguardwithatripfunctionwhichdescendsinadvanceoftherollshouldbeprovided.Machineswithoutratchet-operatedriderrollsshouldhaveascotchtopreventgravityfall.
n Whenrepairingapaperbreak,asingleoperatorshouldcontrolthemachineusinghold-to-runslowcrawlatnomorethan5m/min.
Centre winders
n Thenippresentbetweenthecentreandthesurfacedriverolluntiltheformingreelhasreachedadiameterof120mmshouldbesafeguardedbylocalisedfixed/interlockedguarding,photoelectricdevicesorpressure-sensitivemats.
n Automaticallyadjustingnipguardsarenecessarytosafeguardthenipbetweenformingreelsandthesurfacedriveroll,asthepositionofthenipwillchangewiththeincreasingdiameteroftheformingreel.
n Theoperationofcross-cutknivesshouldbeoperatedbyahold-to-runcontrolpositionedoutofreachoftheknifewheretheoperatorcanseetheknifemovement.
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n Interventionbytheoperatortoinserttickets,‘smooth’theweb,checkforbindingbetweenslitreels,feelthesidesoftheformingreeltoidentifytelescopingandtocorrectproblemswithtrimmustnotbedonewiththemachinerunningatproductionspeed.
Accidents
Anoperatorofasmallslittingmachineconvertingapolyesterwebwasinjuredwhenhisfingersweredrawnintothenipbetweenthepatentrollerandanunpoweredrubbercoatedroller.Hehadattemptedtoremoveapieceofadhesivetapeusedtolabelthepatentrollfromanunpoweredtensionroller.
Theoperatorofawindersufferedafracturedfingerwhenitwastakenintothenipbetweenthepolyesterfoilwebandthetake-uproller.Hehadbeensmoothingcreasesinthefoil.
Frictionburnsweresustainedbytheoperatorofawindingmachinewhenhewasfeedingatailofpapertoweb-up.Theinterlockedguardwasopenandthemachinewasbeingoperatedoncrawlusingafootpedalcontrol.Anairfeedwassubsequentlyfitted.
Flexographic press safeguardingSafeguardingofunwindandrewindingunitsisexplainedunder‘Reelunwindsandrewinds’earlierinthissection.
Safewebbing-upproceduresneedtobeimplemented.Muchoftheadviceunder‘Weboffset’earlierinthischapterisapplicable,thoughmanyolderpresseswillnothaveweblead-indevices.
Flexographicprintingunitsonallsizepresses,eglabelpressestoflexiblepackagingpresses,areafrequentsourceofaccidents.Itisparticularlyimportanttoensurethattheyareproperlyguarded.
Removableenclosinginterlockedguardsorgate/barrierinterlockedguardsaregenerallyconsideredacceptable.Theformerareusuallymoresuitableforsmall-tomedium-sizedpresses,andpresseswithwebwidthsupto1m,andthelatterforlargermachines.
Adjustablenipbarshavenotprovedsatisfactoryastheyarefrequentlyremovedorincorrectlyadjusted(duetotheuseofstereocylindersofvariablediameter).Theyareonlylikelytoprovideasatisfactorystandardofprotectiononpresseswhichcarryoutlong-runworkwithfewornocylinderchangeswherestrictcontrolsareinplacetoensuretheyarealwayscorrectlyadjusted.
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Diagramofaflexographicprintingpress
Standards for flexographic presses with removable interlocked guardsThefollowingstandardsshouldbemetonflexographicprintunitsguardedbyremovableenclosinginterlockedguards:
n Aremovableenclosingguardshouldbeprovidedwhichpreventsaccesstointakesbetweenimpression/stereoandstereo/aniloxcylindersasappropriate,fortheentirerangeofstereocylinderdiameters.Thisguardshouldbeelectricallyinterlockedwiththedrivesothat,withtheguardremoved,thepressmayonlyberunatslowcrawlspeed,ienomorethan5m/min.Theoperationoftheslowcrawlshouldbeviaahold-to-runbutton.Onsomesmallpresseswherecylindersmaybeturnedbyhandtheninterlockingshouldbetostop,ienottoslowcrawlorinch.
n Electricalinterlockingshouldbeviaproximityswitchesdesignedforsafetyapplications,andinpressesusinghighlyflammableinksandlacquersshouldbesuitableforpotentiallyexplosiveatmospheres(seeChapter7).
n Inadditiontotheenclosingguard,afixednipbarshouldbeprovidedattheintakebetweenaniloxandductrolleronthedown-runningwebside,astheserollersoftenhaveanauxiliarydrivetopreventtheinkfromdryingwhenthepressisstopped.Thedistancebetweenthisnipbarandthesurfaceofthecylindershouldbenomorethan6mm.Onsomepressesachamberdoctorbladearrangementmaybefitted.Thisdeviceismounteddirectlyontotheaniloxrollerandtheductrollerisremoved.Considerusingplasticdoctorbladestominimisetheriskofcutsduringhandlingandcleaning.
n Gearsdrivingthecylindersshouldbeadequatelyguardedbyeitherfixedsheetmetalenclosingguardsorinterlockedguards(whichoftentaketheformofinterlockedside-openingdoors).
Accident
Anemployeecrushedhisfingersbetweenthecentralimpressioncylinderandstereocylinderwhencleaningthestereoduringmaking-ready.Non-interlockedguardswerefittedandthemachinewasabletorunoncontinuousslowcrawl.Thesafeguardingandthesystemofworkusedforcleaningwereinadequate.
Newandrecentlyinstalledpressesshouldalreadybeguardedbyoneofthemethodsoutlinedinthisbooklet.Manyoldermachineswillnotbeadequatelyguarded,relyingonnon-interlockedlift-offcoversoradjustablenipbars.Youwillneedtoupgradethese.
Standards for flexographic presses with gate/barrier interlocked guardsThefollowingstandardsshouldbemetonflexographicprintunitsguardedby
7
6
5
4
3
2
110
8
9
1Unwindstation 4Drivegears 7Oven 10Rewindstation2Contrarotatingrollers 5Printunits 8Chillroll3Inkpumps 6Accesstoheights 9Web-drivenrollers
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gate/barrierinterlockedguards.Theseguardsusuallytaketheformofdistancinghingedmeshbarrierssituatedatthefrontofeachprintunit:
n Side-openingdoorsshouldbeprovidedonthedriveandoperator’ssideofthepresstoguardthedrivegearsandintakesaccessiblefromthesideofthepress.Anyopeningsaroundand/orbetweenthegateguardanddoorsshouldpreventaccesstohazardousparts(seealsoBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs).Onsomeolderpressesthesidelaycanonlybeadjustedwhenthepressisrunningataspeedgreaterthan5m/minsoprovisionshouldbemadeforthis,egbyextendingtheadjustmentmechanismoutsidetheguardedarea.
n Theguardsshouldbeinterlockedsothatwiththeguardopenthepressmayonlyberunatslowcrawlspeed.
n Thefixednipbarfortheintakebetweenaniloxandductrolleronthedownrunningwebsideshouldbefittedasdetailedforflexographicpresseswithremovableinterlockedguards.
Table9summarisesthesafeguardingoptionsforflexographicandrotaryletterpressmachines.
Table 9 Safeguardingflexographicandrotaryletterpressmachines
Safeguarding other parts of flexographic pressesAswellastheguardingoftheprintingunitsonflexopressesthereareoftenotherhazardousintakesorotherpartsthatwillrequireguarding,egbetweenchillandpressurerollers,betweenothercontra-rotatingbutnon-contactrollers,andatunwind/rewindpoints.Gapsoflessthan120mmbetweencontra-rotatingpoweredrollerswillrequireguardingandthiscannormallybeachievedusingnipbarsorfixedguards.
Wherefixednipbarsareused,theyshouldbepositionedtocomplywiththemaximumpermissiblegapofnomorethan6mmfromthecylinderorrollersurface.Ideally,right-anglednipbarsshouldbeused.
Theremayalsobein-runningnipsonnon-poweredridingorguiderollersdrivenbythemovementoftheweb.Assesswhetherthereisaneedforsafeguarding-thiswilldependonanumberoffactors,suchastypeofmaterial,wrappingangleandwebspeed.
Hazard Safeguard
In-runningnipsbetweeninkingrollers(rotaryletterpress),duct,anilox,stereoandimpressioncylinders
Interlockedguardsallowinglimitedinchandhold-to-runslowcrawlonlywhenremovedoropened;andafixednipbaradjustedtowithin6mmoftheanilox/ductrollerswherethesehaveaseparateauxiliarydrivewhichisnotstoppedbyopeningoftheinterlockedguard.
Unexpectedstart-up
In-runningnipsbetweenduct,anilox,stereoandimpressioncylinders
Pre-startaudiblewarningdevice.
Interlockedguardsallowinglimitedinchandhold-to-runslowcrawlonlywhenremovedoropened;andafixednipbaradjustedtowithin6mmoftheanilox/ductrollerswherethesehaveanauxiliarydrive.
Unexpectedstart-up Pre-startaudiblewarningdevice.
Flexographic and rotary letterpress - small- to medium-size, up to 1 m web
Flexographic - larger format, eg flexible packaging
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Enclosingguardsarebestmadeofweldmeshmaterialonarigidframeasthismakesthemreasonablylightweightandallowsgoodvisibilityofthecylindersandprintedweb.Itislikelythatoperatorswillwantsheetmetalsectionsattheductrollertopreventinksplashing,andinsomecasesameansofreplenishinginkbyhandwithoutremovingtheguard.
n Itisveryimportantthatsafesystemsofworkareimplementedforcleaningandmake-readyoperationswhichcannotbecarriedoutwithoutremovingguards.Table10liststheappropriatesafesystemofworkforvarioustasks.Giveparticularattentiontodevelopingandimplementingsafemeansofaccessandmethodsofworkwhenaccessingtheuppersectionofacommonimpressioncylinderonalargepress.
Table 10 Safesystemsofworkforcleaningflexographicandrotaryletterpressmachines
Standardsofsafegardingattherewindunitshouldmeetthosesetoutunder‘Reelunwindsandrewinds’earlierinthischapter.Seealso‘Reeler/winderslittersusedinpaperconversionandflexiblepackaging’.
Wherehold-to-runcontrolsarebeingusedtosafeguardadangerpoint,startingthemachineinthehold-to-runmodeafteropeninganinterlockingguardshouldonlybepossiblewhenotherinterlockingguardsoutsidetheareaviewablebytheoperatorareclosed.Controlsshouldbezoned-thisisparticularlyrelevanttonewmachines.
Careshouldbetakenwhencleaningsharpdoctorblades.Anti-cutglovesshouldbeprovided,orplasticbladescanbeused.
Safeguarding gravure web-fed pressesReelunwindandrewindunitsongravureprintingpressesmustbeadequatelysafeguarded.Therequirementsforthedifferingtypesofreelstandsaresetoutunder‘Reelunwindsandrewinds’earlierinthischapter.Seealso‘Reeler/winderslittersusedinpaperconversionandflexiblepackaging’.
Gravureprintingcylindersneedtobeguarded.Thiscanbedifficulttoachieveastheprintcylindersandgearsvaryindiametertodeterminethepatternrepeat.Guardingshouldtakeaccountofaccessneedsforsafecleaningofdoctorblades.
Task Risk factors System of work
Flexographic/rotary letterpress
Cleaningduct/aniloxrollers,single-operator
Absenceofnipbarsn Inch-stop-clean.
Cleaningduct/aniloxrollers,multi-operator
Absenceofnipbars n Inch-stop-lock-clean.
n Ifpresshaszonedcontrols
allowingindependent
movementofprintunit
cylinders,inch-stop-clean.
Cleaningstereomid-run,single-operator
Accessibilitytoin-runningnipwheninterlockedguardraised n Inch-stop-clean.
Cleaningstereomid-run,multi-operator
Accessibilitytoin-runningnipwheninterlockedguardraised n Inch-stop-lock-clean.
n Ifpresshaszonedcontrols
allowingindependent
movementofprintunit
cylinders,inch-stop-clean.
Cleaningstereoatendofrun Stereoremovedfrompressn Off-machinemanualor
auto-washing.
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Wherepressesareusedforlong-runwork,adjustablenipbarscanbeusedtoguardthegravure/impressionintakeandimpression/backimpression(boule)rollers.Theseshouldbedesignedsothattheycanbeadjustedtowithinamaximumof6mmfromthesurfaceofthecylindersandareoftenbestmountedoffthedoctorbladecarrier.Safesystemsofworkwillneedtobeimplementedtoensurethenipbarsarealwaysusedcorrectly.
Wherepressesareusedforshorttomediumruns,guardingshouldbeprovidedintheformofinterlockingguards.Thesecaneitherbefittedalongthesideofthepressesoroverindividualprintunits.
Givecarefulconsiderationtotheneedfordoctorbladewiping.Slotscanbecutintheguardswhichallowthedoctorbladetobewipedwithalongpencilbutpreventfingeraccesstothehazardousparts.Alternatively,youmaybeabletoreducetheneedforwipingdoctorbladesbyintroducingreformulatedinks-contactyoursupplier.
Makesureallequipmentissuitableforuseinpotentiallyexplosiveatmospheres(see‘Explosionrisksinflexoandgravure’inChapter7).Table11summarisesthesafeguardingrequirementsfortheprintunitsofgravurepresses.
Table 11 Safeguardinggravurepresses
Asthesepressesareusuallymulti-operator,audiblepre-startwarningdevicesmustbefitted.Usehold-to-runcontrolsformake-ready,cleaningetcanddevelopsafesystemsofworkformake-ready,cleaningandwebbing-upetc.Rememberthatmanyoftheaccidentsthatoccurinprintinghappenwhenitisnecessarytointerveneonamachineintheseways.SafesystemsofworkarelistedinTable12forthevariouscleaningtaskslikelytoberequired.
Gravure - long-run presses
In-runningnipsbetweengravureandimpressioncylinders
Nipbarsadjustedtowithin6mmofthegravure/impressionandimpression/backimpression(boule)cylinderswhicharedesignedtoallowadjustmentforthefullrangeofgravurecylinderdiameters.
Continuousslowcrawlshouldbesupplementedbyanemergencystop(or‘stoplock’)controlateachprintunit.
Ifwipingofthedoctorbladeisrequiredduringtheprintrun,provisionforsafeaccessshouldbemade.Thesafesystemofworkshouldconsiderotheraspectsincludinglightingandprovisionofapurpose-designedtool.
Unexpectedstart-up Pre-startaudiblewarningdevice.
Gravure - short-run presses
In-runningnipsbetweengravureandimpressioncylinders
Interlockingguardsfittedeitherateachprintunitoralongthelengthofthepresswhichallowlimitedinchandhold-to-runslowcrawlonlywhenopen.
Ifwipingofthedoctorbladeisrequiredduringtheprintrun,provisionforsafeaccessshouldbemadeeitherbymeansofaslotintheinterlockedguard,orbymeansofanadjustablenipguard.
Thesafesystemofworkshouldconsiderotheraspectsincludinglightingandprovisionofapurpose-designedtool.
Unexpectedstart-upduringmulti-operatorcleaning
Pre-startaudiblewarningdevice.
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Table 12 Safesystemsofworkforcleaninggravurepresses
Safeguarding screen printing pressesThemainrisksfromscreenprintersarefrom:
n crushrisksfromeitherthescreenriseandfallmechanismorsqueegeemovement;
n in-runningnipsfromfeederanddeliverymechanisms;n shearpointsfromgapsonlowercylindersoncylinder-typepresses;n hazardoussubstances,suchasinksorvarnishes,eitherwheninuse,when
curingorwhencleaningscreens.
Mostscreenprintoperatorsaddinkorvarnishwhilethepressismoving.Althoughthisisnotinherentlydangerous,itpreventsperimeterguardingfrombeingusedtopreventscreencrushinjuries.
Screen crush risksThereareseveralsituationswhichcancreateariskofcrushingtheupperbodyorfingers:
n Whentheframeholdingthescreenisraisedtoallowaccessunderthescreenitmustnotbepossiblefortheframetodescend,crushingtheupperbody.Onsomemachines,lightbeamsareprovided,butthesecansometimesbeineffectiveasitispossibletoreachoverthebeamwithoutinterruptingit.Itisoftennotpracticabletoextendthebeamoverthewholeareaasmachinecomponentsmayinterruptit.Sensitiveedgesmaybeapracticalsolution,orlightcurtainsinfrontofthemachinetodetecttheoperator’slegsratherthantheupperbody.Safesystemsofworkmustbeusedtoisolatethemachinebeforeenteringtheareabelowthescreen.
n Thesqueegeeriseandfallmechanismscanprovidecrushpointsforfingers.Provideafixedguardaroundthem.
Task Risk factors System of work
Gravure
Wipingdoctorblades Approachclosetoin-runningnipsatproductionspeed n Useofpurpose-madetool
andproperlyadjustednip
barorslotininterlocked
guard.
Cleaninggravure/impressioncylindersmid-run,single-operatorcleaning
Accessibilitytoin-runningnipswheninterlockedguardraised n Inch-stop-clean.
n Forwardslowcrawl
cleaningonlyifnipbars
andemergencystops
areprovidedandaguard
checklistcompleted.
Cleaninggravure/impressioncylindersmid-run,multi-operatorcleaning
Accessibilitytoin-runningnipswheninterlockedguardraised n Inch-stop-lock-clean.
n Forwardslowcrawl
cleaningonlyifnipbars
andemergencystops
areprovidedandaguard
checklistcompleted.
Cleaninggravure/impressioncylindersatendofrun
Gravurecylinderremovedfrompress n Off-machinemanualor
auto-washing.
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n Theoscillatingsqueegeecarriagecancreateacrushorshearpointasitmovestotheendofitstravel.Whilethiscouldquiteeasilyhavebeendesignedout,itisgenerallynotpracticabletoshieldthese.
Semi-automatic pressesOnsemi-automaticflat-bedmachines,takeprecautionstominimisethelikelihoodofthereciprocatingtablestrikingtheoperator,byprovidingsensitiveedges,presence-sensingdevicesorchainrailstopreventaccess.Thetrapsbetweentheverticallyreciprocatingframe-holderandthefourmainmachinepillarswillalsoneedtobeguarded.
Cylinder type machinesThesemachinescanposeariskwhenmakingready,thoughthisriskisremovedinnormaloperation.Therisksoccurfrom:
n shearpointsbetweengapsinthecylinder(bythegrippers)andthefixedstructure.Safesystemsofworkmustbeinplacetoaddressthisriskanditshouldneverbenecessaryfortheoperator’sfingerstobeinthisarea;
n in-runningnipsbetweenexposeddrivegearsandthefixedstructure.Thesegearstendtohaveteethlargeenoughtotrapafinger.Itmaybedesirabletoincreasethegapbetweenthegearandthestructuresothatafingerisnotdrawnin.
Hinged presses with power closureHingedorclam-typescreenprocessprintingmachineswithpowerclosureshouldbefittedwithefficienttripguardsaroundthethreeedgesofthescreen(unlesstheclosingforceislessthan300newtonsandtherearenosharpedges).Thesewillstopthescreenormakeitretractifanyonebecomestrapped.Regulartestingofthesafetydevicesshouldbecarriedouttoensuretheycontinuetooperateeffectively.
Safeguardthecrushingpointbetweenthesqueegeeandscreenframebyadjustingthestopgaugetoensureaminimum25mmgap.Ifthedescendingsqueegeecreatesacrushingrisk,makesurethattheliftingpathisasshortaspossible.
Feed and delivery in-running nipsBeltdrivesonmanymachineshaveinadequatenipguardswheretheypassoverrollers.Belttensionstendtobelowwhichreducesthepotentialseverityoftheinjury,butnipguardsshouldbeprovided.
Hazardous substancesWhereUV-curedinksorvarnishesareused,appropriatecontrolsmustbeprovidedtolimitskincontact.Emptyinginkfromscreensattheendoftheruninvolvesmovingasignificantamountofinkandappropriateprecautionsshouldbetakentopreventcontamination.Also,greatcaremustbetakenwhenwashingscreensusingwaterjettingtechniquestoavoidspraysofUV-curedinkshittingtheoperator.Verticalstripcurtains,similartothoseprovidedindoorwaysforfork-lifttrucks,canbeusedtobothpreventthesprayfromhittingtheoperatorandtomakeanylocalexhaustventilationmoreeffective.
Formoreinformationsee‘Screenprintingandcleaning’inthe‘Hazardoussubstances’sectioninChapter4.
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Figure 31 Hingedorclam-typescreenprintingpresseswithpowerclosureshouldbefittedwithsafety
tripbars
Label printing machinesPresseswithtwinsideframesshouldmeetthestandardslaidoutundertheheadings‘Weboffset’and/or‘Flexographic’earlierinthischapter.Labelpressesofthecantilevertypeshouldmeetthefollowingstandards.
Thegearwheelsandin-runningnipsoncylindersandrollersoftheprintunitsoncantileverlabelprintingmachinesshouldbesafeguarded,forexamplewith:
n hingedorriseandfallinterlockedguards;orn removableenclosinginterlockedguards.
Hingedorriseandfallinterlockedguardsareoftendesignedtocoverallprintunitswithoneguard.Thisoftenpreventsoperatorsfrombeingabletomakeadjustmentsoraddinkonthe‘run’soprovisionshouldbemadefortheseadjustmentsbyextendingcontrols/inktroughsthroughtheguard.
Removableenclosinginterlockedguardscanbeusedtosafeguardeachprintunitindividuallyand,ifproperlydesigned,allowadjustmentsandtoppingupofinkwhilethepressisrunning.Detailedinformationontheirdesignisgivenunder‘Flexographic’earlierinthischapter.
Someoldermachinesmaybeprovidedsolelywithadjustablenipbarsasguarding.Theyareusuallyfoundtoberemovedorincorrectlyadjustedandarethereforenotadequate.Pacing/drawrollersshouldbeprovidedwithenclosinginterlockedguardsorsuitablenipbarswhereaccessispossibletoin-runningnipscreatedbycontra-rotatingrollers.
Aswellastheenclosingguardonflexographicprintunits,afixednipbarshouldbeprovidedatanyin-runningintakebetweenaniloxandductrollerastheserollersoftenhaveanauxiliarydrivetopreventtheinkfromdryingwhenthepressisstopped.Thedistancebetweenthisnipbarandthesurfaceofthecylindershouldbenomorethan6mm.Lowpowereddrivesmayalsobeacceptableiftheypreventinjury.Onsomepressesachamberdoctorbladearrangementmaybefitted.Adequateproceduresshouldbelaiddownforthesafehandlingofdoctorblades.
Finishing sectionThehazardouspartsofthefinishingsectionoflabelprintingmachinesmustbesafeguarded.Thesesectionswillcomprisesomeorallthefollowingunits:rotarydie-cuttingunits,flat-beddie-cuttingunits,slittingknives,trimremoval/rewind,punchingunits,perforating(crossandinline)etc.Combinationsoffixednipbarsandinterlockingguardsneedtobeusedtoguardthesefinishing/processingstations.Itisimportantto
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ensurethattheguardingarrangementsareadequateforallwebpathsincludingthedifferenttrim/labelstrippingpaths.Theseareasoftenproducealotofdustandhighnoiselevelssotheguardingarrangementsshouldtakethesehazardsintoaccount.
Tofacilitatemake-readyandcleaning,labelprintingmachinesmaybefittedwithhold-to-runcontrolstoallowoperationofthepressatslowcrawlspeedswithguardsopened.Table6under‘Flexographic’earlierinthischapterdetailsappropriatesafesystemsofworkforcleaning.
In-line folders, sheeters, die-cutters etcAllin-runningnipsandothermechanicalhazardsonfoldersandotherin-lineprocessingequipmentneedtobeguarded.Guarddesignmayneedtotakeaccountofotherhazardssuchasnoiseanddust.
Onnewandrecentlyinstalledfolderinstallations,thefoldershouldbetotallyenclosedwithfixedandinterlockedguards.Guardlockingdevicesshouldbefittedwherethereisahighriskofsevereinjury(iechopperfolder)andthepresshasarundownperiodofmorethan10secondsevenafteractuationoftheemergencystopcontrol.
Totallyenclosedfoldersshouldbeprovidedwitharrangementsfortheremotecontroloffoldersettingseitherbyelectrical/electronicordirectmechanicalmeans.Thebendingrollersanddeliveryareaarelikelytobeoutsidethe‘enclosedarea’.
Thebendingrollersneedtobeprovidedwitha‘nose’guardatthebaseoftheformer(kite)andadjustableguardsfortheportionofthebendingrollersbehindtheformer.Thedeliveryareamustbeadequatelyguarded.However,ahold-to-runguardoverridecontrolbuttonmaybeprovidedforthedeliverytunnelguard.Depressionofthishold-to-runcontrolwillallowoperatorstoopentheguardatspeedsupto8m/mintoallowremovalofthefirstincompleteproductcopies.
All-enclosingguardsmaynotbepracticableonolderfoldersandlocalisedguardingofthehazardouspartsshouldbeprovided.Inthesecircumstancesthefollowingareasneedtobesafeguarded:thenipping/pinchingrollers,cross-associationrollers,foldingdrum,cuttingcylinders,cross-perforatingcylinders,jawcylinder,quarterfolderetc.Hazardousnipsbetweendeliverybeltsandpulleysshouldalsobeguarded.
Onsheetingunitsthemainareasofdangerarethedrawrollersandtherotaryknife.Thedrawrollersshouldbeguardedbyeitherfixednipbarsorenclosinginterlockedguards.Therotaryknifeisahigh-riskareaandonalargeinstallationshouldbeguardedbyahigh-riskinterlockingarrangement(iedual-circuitinterlocking)andwiththeprovisionofguardlockingiftherundowntimeislongenoughtomakeitnecessary.
Makesurethatprecautionshavebeentakentocontrolemployee’sexposuretonoiseanddust(seeChapter4).
Business forms pressesThehazardouspartsoffinishingsectionsofbusinessformspressesmustbesafeguarded.Thesesectionsandthemeansusedtoguardthemarethesameasthoseforlabelprintingmachines.Ifwanderleadsareprovided,allowingaccesstopartswithguardsopen,theyshouldbeofasimultaneoustwo-handcontroltype.Thesemayallowspeedsinexcessof10m/minwherespecifiedbythemanufacturerandwherethereisappropriateguardzoning.
Where,onbusinessformspresses,thewebisdeliveredbyaspiralfolderasinazig-zagfoldedcontinuousstationerypack,thedeliveryguardmaybefittedwithan
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enableguardoverridecontrolbutton.Thisoperatesasahold-to-runcontrolallowingtheguardtobeopenedatslowrunspeedstofacilitateremovalofthefirstincompletecopies.
Aminimumgapof25mmshouldbemaintainedbetweenthespiralsbytheprovisionofadjustmentstops.Wherethespiralsneedtobeclosedtolessthan25mm,alocalguardpreventingaccessintothenipmustbeprovided.Fixedguardsmustbeprovidedforthespiraldrivegears.
Publishing roomsTypesofconveyors,counters,stackers,tyersandstrappersvaryconsiderablysothefollowingguidanceisgeneral.
ConveyorsEffectivemeansforstoppingnewspaperconveyorswhichenterthepublishingroomshouldbeprovidedforuseinemergencies.Wheredumpgatesareprovidedatfolderstodivertcopies,itshouldbepossibletostoptheinsertconveyorleadingtothepublishingroomwithoutstoppingthepress.Wheredumpgatescannotbefitted,itmaybenecessarytoprovidestopbuttonsinthepublishingroomwhichstopthepressaswellastheconveyorswherethesearemechanicallylinked.Normalpressstopsshouldbecarriedoutfromthepressroom,andasignallingsystemprovidedsothatpublishingroomstaffcanrequestthatthepressissloweddownorstopped.
Overheadconveyingmechanismsoutofreach,ie‘safebyposition’willnotnormallyrequireadditionalguarding.However,accessmaybepossibletothesemechanismswhiletheyarerunningsosomelocalisedguardingmayberequired.Operatorshavebeenknowntouseladdersormoveablestepsforcopyorblockageremovaletc.
Hazardouspartsassociatedwithconveyorssuchasbeltandchaindrivesmustbesafeguardedincludingthosesituatedbelowtheconveyors.Lift-upconveyorsontheseunitsshouldbearrangedsothataccesstohazardouspartsisnotpossiblewhentheconveyorsectionisraised,usuallyachievedbyinterlockingtheconveyorsection.
Whereconveyorsenterthepublishingroomfrombelow,adequatebarriersandtoe-boardsshouldbeerectedaroundtheconveyorandflooropening.
Copypick-uppointsshouldbedesignedtopreventaccesstohazardouspartsbyprovidingfixedorinterlockedguards.
Counter stackersCounterstackersshouldbeprovidedwithguardspreventingaccesstohazardousparts,forexamplerotatingcollectionhoppers.Safetyreachdistancestopreventhazardouspartsbeingaccessedwillapply(seeBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs).Whereguardshavetobeopenedbyoperators,theyshouldbeinterlockedtothecounterstackerdrive.Otherwisetheyshouldbefixedinpositionandrequireatoolforremoval.
String-tyers and strappersConveyor-fedautomaticstring-tyersandstrappersmaybedividedintotwogroups:
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n thosewithalow-pressureclampnotcapableofinflictinginjury,eglessthan300newtonsandwhereanelasticbottomplatecoverhasbeenprovided;
n thosewithhigh-pressureclamps.
Machineswhichfallintothesecondcategoryshouldbeprovidedwithacombinationoffixedandinterlockedguardspreventingaccessfromthesides,in-feedanddeliveryends.SafetyreachdistancesinBSEN294:1992apply.Lift-offguardsandguardsthatneedtobeopenedfrequentlyforcleaningjams,replacingstringetcwillneedtobeinterlocked,includinganylift-upconveyorsections.
Somestrappingmachinesmayhaveforce-limitingdevices,egslipclutchesontheclampaswellasaresilientrubberfacing,andmayhavenootherassociatedhazardousparts.Gravity-fallcrucifix-turndevicescanbecomehazardouswhenladen,andscreen-guardingshouldbefitted.Thismayrequireinterlockingifaccesstootherhazardouspartsispossible.Whereyourelyonforce-limitingdevices,theseshouldberegularlytestedusingaload-cellpressuregaugeorothersuitableinstrument.
Figure 32 Conveyors,counters,stackers,tyersandstrappersinpublishingroomsneedtobesafeguarded
Insertion equipment
n Therisksposedbyinsertionequipmentareprimarilythoserelatedtoin-runningnipsorpinchpointsfrommovingequipment.Onmodernequipment,theseareeitherhousedbehindfixedorinterlockedguardsorareabove2mfromthefloor.Equipmentmustnotberunwiththeguardsremovedorinterlocksoverridden.Regularchecksmustberuntotestthecontinuedcorrectoperationoftheinterlocks.
n Whereitisnecessarytoruntheequipmentwiththeguardsopenduringmakeready,thenitmustonlybepossibletorunitusingahold-to-runbuttonandatcrawlspeed.Systemsofworkmustrestrictsuchoperationstoappropriatelytrainedpersonnel.
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n Systemsofworkmustbeinplaceforelevatedwork,egmaintenance,nearinsertionequipmentortheirassociatedconveyors.Suchworkmustonlybecarriedoutwiththisequipmentisolatedandlockedoff.Equipmentisnormallyautonomousandsoyouneedtoisolateinsertionequipmentandconveyorsseparately.
Automatic insertion disc equipmentControlstationsshouldnotbelocatedinthepathofautomaticallymovingdiscsofinsertionmaterial.Makesuretherearenoaccessiblesheartrapsbetweenthemovingdiscsandcontrol/electricalpanelsandseparatemovingdiscsandpersonnel.Ensuretripwire/pressure-sensitiveedgedevicesprovidedonthedisccarriagesgiveadequateprotectiontooperatorsandthatthesearemaintainedinfullworkingorder.Theintegrityoftheinterfacebetweentheguardingdevicesandtheprogrammablecontrolsystemsforthedisccarriagesshouldbeassessed.Disccarriagesshouldstopsafely,withouttrappingoperatorsorejectingtheirload.
Inserting and stitching drumsFrontandendcoversofinsertingandstitchingdrumsshouldbeinterlockedsothatwhentheyareopenonlymovementbyhold-to-runslowcrawlispossible.
Adequatesafeguardingshouldbeprovidedattherearofthedrumstopreventinjurywhenremovingmisfedcopies.
Interlockedorfixedguardsshouldbeprovidedtopreventaccesstohazardouspartsfromsteps,workingplatformsorotherareas.Accidentshaveoccurredwhenoperatorshaveattemptedtoclearblockagesbyreachingoverinterlockedguardsbystandingonpalletsandshortsteps.Overheadchaindrivesshouldbesafebypositionorguarded.Full-lengthguardingmaybemorepracticalthanmultiplelocalisedguards.Stitchingheadsshouldbefittedwithinterlockedhoodguardswhereotherwiseaccessible,egfromworkplatforms.
Figure 33 Newspaperproduction-printingandpublishingoperations
Envelope-making machinesTherearetwobroadcategoriesofenvelope-makingmachine,blank-fedorweb-fed.Bothtypesofmachineusuallyconsistofprintingunits,gummingstation,window-patchingstation,foldingandgluingstation,acollatordrumandatake-offsection.
Webpaths(Webbing-upandsafeguarding)
Folder(noiseandsafeguarding)
Soundhaven(noise)
Vanway(transportsafety)
Loading(manualhandling)
Conveyors(safeguarding)Reels
(manualhandling)Reelstands(safeguarding)
Printunits(safeguardingandzoningofcontrols)
Tying,strappingandconveyors(safeguarding)
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Blank-fedmachineshaveafeedplateorfeedpillar.Web-fedmachineswillhaveareelstand,profilecuttingsystemandrotaryorflyingknifeaswell.
Thehazardouspartsofthesemachinesincludethein-runningrollernips,gummingwheels,knives,reciprocatingfeeddevices,gearwheelsanddrum-relatedsheartraps-thesemustbesafeguarded.Manyofthesehazardouspartscanbeguardedbyfittingsideguardstothemachines.Theseshouldbeinterlockedtothemachine’smovementsothatopeninganyoneoftheseguardsstopsthemachine.Localisedinterlockedorfixedguardingcanalsobeused.In-runningnipsonfoldingrollerswheresafeguardedbytunnel-typeguardsmay,inexceptionalcircumstances,haveopeningsof30mmwherethesafetydistancetothedangerpointis200mm.
Machinesmaybefittedwithtwo-hand,hold-to-runcontrolsforsetup.Thespeedshouldbelimitedto10m/minandguardzoningprovided.Inexceptionalcircumstances,wheretheuseofstroboscopesisneededatproductionspeedsforfault-finding,thefollowingshouldbeprovided:
n hold-to-runcontrol;n guardzoning;n aselectorswitch;n asafesystemofworkwhichincludesusingtheslowestspeedpossible.
Additionallocalfixed,interlockedandadjustableguardsarenecessaryonmanyofthemachine’sindividualunits.Thefeedplateorfeedpillarwillneedlocalprofiledguardsforthedraw,hookrollersandanyscorerollers.Anyhingedgummingunitsshouldbeinterlockedtopreventthembeingleftoutofposition,exposinghazardouspartswhennotinuse.
Standardsforreelstandsonweb-fedmachinesshouldmeetthoseoutlinedunder‘Weboffset’earlierinthischapter.Theprintunitsonbothtypesofmachineshouldbeguardedinaccordancewiththestandardssetoutunder‘Flexographic’earlierinthischapter.
Sealflap,windowandbottomflapgummingunitswillallrequireguardingtopreventaccesstoin-runningnipsorcontactwithhotglues.All-enclosinginterlockedguardingmaynotbefeasibleasaccessmaybeneededtothegluebottles.Acombinationoffixedandinterlockedguardsisoftenmostsuccessful.Thinkaboutthehandlingofthegluebottlesasthismayposeasignificantmanualhandlingrisk.
Theintakesassociatedwiththeglassinetissueknifeandtissueapplicatorin-runningnipsneedtobeguarded.Anysheartrapbetweenthedeliverytableanddryingdrumshouldbesafeguarded.Thismaybeachievedbyprovidingfixedorinterlockedguardingorahingedtableendofatleast25mm.Anybeltorpulleyintakesshouldalsobeguarded.Deliveryguardingcanusuallybeachievedeitherbyfixedtunnelguardingorbyadjustableplates.
Onweb-fedmachines,areasofhighriskincludetheprofilecuttingsystemandseparatingknife.Thesemustbeadequatelyguardedbyprovidingfixedorinterlockedguards.Guardingshouldtakeaccountoftherundowntimesoftheknivesandthefrequencyofaccess.
Noisecancauseseriousproblemsonenvelopemachinessoitisoftenagoodideatocombineguardingandnoise-reductionmeasures.Newmachineswithhighnoiselevelsshouldbesuppliedwithnoisecontrolmeasuresincorporatedasstandard.
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Accident
Anemployeewasfatallyinjuredwhenhisheadwastrappedbetweentherotatingspokesofadryingwheelandthefixedframeoftheenvelope-makingmachine.Theaccessdoorstothewheelwerenotsecured.Fixedorinterlockedguardsshouldbeprovidedatbothsidesofthedryingwheeltopreventaccesstotheshearhazardcreatedbetweentherotatingwheelandfixedmachineframe.
Figure 34 Suitablenoise-hoodsshouldbeprovidedforbuckleplates
Sheet-fed folding machines Thedangerpointsonsheet-fedfoldingmachinesmustbeguarded.Thetwomaintypesofmachine,buckleandcombination,giverisetosimilarrisks.Oneoftheseisnoisewhichcanbeaddressedbyprovidingsuitablenoise-hoodsforthebuckleplates.Onnewmachinesnoise-reductionmeasuresshouldbeprovidedaspartoftheirstandardspecification(see‘Noise’inChapter4).
Themainin-feedrollersshouldbeprovidedwithfixedorinterlockedguardswithanarrowslotforsheetentry.Accesstothefoldingrollersshouldbepreventedbyacombinationofguards,themachine’sframeandthebuckleplates.
In-runningnipsassociatedwithdrivetapesshouldbeguarded.Thiscanbeachievedbydesigningthetransport/feedtablesto‘fit’thepulleys,iereachtoapointnomorethan6mmfromthein-runningbelt/pulleynip,ortheprovisionofnipbars.Giveparticularattentiontothenipsassociatedwithtensioningpulleys.
Thehazardouspartsinvolvedwithfoldingknivesshouldbeguarded.Onnewmachinesthismaybeinconjunctionwiththedeliveryareaofthebuckle-foldingunit,ieanall-enclosinginterlockedguard.Onoldermachinesamorelocalisedfixedorinterlockedguardshouldbeprovided.
Perforators,creasingunitsandslittersareoftenfittedtothistypeofmachine.Theintakesassociatedwiththesedevicesshouldbeguarded,includinganyin-runningnipcreatedbetweenthemandfixedpartsofthefoldingmachine.Precautionsalsoneedtobetakentopreventaccesstotheperipheryofrunningslittersandperforators.
Forsettingpurposes,interlockedguardsmayneedtobeopened.Inthesecircumstances,themachineshouldonlystartunderhold-to-runcontrolwithamaximumspeedof70m/minmeasuredatthefoldingrollers.Guardsinareasoutsidetheoperator’sviewshouldbeclosed,aselectorswitchshouldbeprovidedandtherunspeedshouldbeasslowaspossible.
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GuillotinesPower-operatedpaper-cuttingguillotinesarepotentiallythemosthazardousmachinesintheprintingindustry.Theymustbeadequatelysafeguarded,regularlycheckedbybothoperatorsandcompetentguillotineengineers,andoperatorsmustbeproperlytrained.
Furtherguidanceontheguarding,maintenanceandtestingofguillotinesisavailableinthePrintingIndustryAdvisoryCommitteebookletThe guide to safe use of power-operated paper-cutting guillotines.Thispublicationalsocontainsinformationontrainingandknifechangeprocedures.
Figure 35 Guillotinefittedwithphotoelectriccurtainandsimultaneoustwo-handcontrols
Common accidents
n Amputationsfollowingdoublestrokingoftheknifeduetofaultybrakesandpoormaintenance(includingtopdeadcentrecams).
n Crushandamputationinjuriesbytheclampparticularlywhenthedynamicgaugingforceexceeds500newtons.
n Amputationinjuriescausedbytrappingfingersinthescrewadjustmentholesoftheclampwhentheclampreturns.
n Trappingaccidentsbetweenthemovingbackgaugeandclamp.n Accidentsduetoincorrectguardpositioningorguardsbeingdefeated.n Accidentsduringknifechanging.
Photoelectric (electrosensitive) safety systemsPhotoelectricsafetysystemsforguillotinesshouldmeetcertainminimumstandardswithfullfunctionmonitoring(FFM)asthelowestacceptablelevelforoldmachines.Newermachineswillneedtomeetmorestringentstandards.
Ingeneral,guillotinessuppliedbefore1974withoriginalphotoelectriccurtainswillrequireupgradingtomeetthestandardsinThe guide to safe use of power-operated paper-cutting guillotines.Guillotinessuppliedbetweenapproximately1974and1987shouldhaveelectrosensitivesafetysystemsdesignedandoperatingtofullfunctionmonitoring(FFM)standards.However,onsomeguillotines,certainmodificationswillneedtobecarriedoutsuchastheremovalofthefullyautomaticfacility.Acompetentguillotineengineershouldbeabletoadviseyou.
Guillotinessuppliedafter1987shouldcomplywithBSEN61496-1:1998,IEC61496-1:1997Safety of machinery. Electro-sensitive protective equipment. General requirements and tests.
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Guillotinessuppliedafter1January1995shouldbe‘CE’markedandcomplywiththeSupplyofMachinery(Safety)Regulations1992asamended.
Itisextremelyimportantthatthephotoelectriccurtain(lightcurtain)islocatedcorrectly.Seriousinjurieshaveoccurredwhenthecurtainhasbeenincorrectlymountedandoperatorshaveaccidentallyreachedoverorunderthecurtainwithoutbreakingthebeams.
Asageneralrule,theoutermostbeamshouldbeapproximately635mmfromthecuttingstickandnomorethan185mmabovethetable.
Wherenewmachineshaveausablepileheightofmorethan185mm,theoutermostbeammaybeataposition610mmminimumand700mmmaximumfromthecuttingstickandnomorethan205mmabovethetable.Anelectrosensitiveprotectivedevice(additionalbeam)shouldalsobeprovidedatadistanceofbetween400and550mmfromthecuttingstickandataheightofbetween0and205mmabovethetable.Anadditionalbeamshouldbefittedonallnewmachinesfittedwithfullyautomaticcuttingoperation.Wherethemachinedesignissuchthatthecurtainextendsdowntothemachinetable,theoutermostbeamshouldbeatleast400mmfromthecuttingstickifthebeamislessthan38mmfromthetable.
Theseparationdistanceofthecurtainfromthecuttingstickmustbeconsistentwiththeoverallstoppingperformanceofthemachine.Oldermachineswillgenerallyhaveadistanceofatleast460mmbetweencuttingstickandcurtain.
Sixkeypointstocheckonphotoelectricsafetysystems:
n Thesystemmeetstherequiredstandardsandisupgradedifnecessary.n Thephotoelectriccurtainislocatedcorrectly.n Twofinalswitchingdevicesareprovidedforfullyautomaticmachines.n Simultaneoustwo-handcontrolsarefitted.n Thedynamicgaugingforceoftheclampislessthan500newtons.n Suitablereartableguardingisfitted(see‘Interlockingguards’below).
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Figure 36 Positioningoftheelectrosensitiveprotectivedevices(beams)andcurtainhousing
Not more than 185 mm from the centre of the outermost beam to the machine table
610-635 mm from the centre of theoutermost cell of the light barrierto the cutting plane
610 mm or greater from the cutting plane to theoutermost edge of the light barrier housing orits extensions
Housing to be as low as practicable
610-635 mm
Not more than 185 mm from the centre of theoutermost beamto the machinetable
Housing to be equal to or less than165 mm to the machine table
550 mm betweenthe lowest point of thecutting plane and theoutermost edge of thelight barrier housingor its extensions
At least 635 mm
Cutting plane
205 mm
Front table400 mm
500 mm
At least 850 mm fromthe cutting plane tothe outer edge of theside table
Not more than 185 mmfrom the centre of the outermost beam of themachine table Not more than
150 mm
At least 635 mm
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Body push guardsBodypushguardsfittedtoguillotinesarenolongerconsideredadequatesafetydevices.Guillotinesfittedwithbodypushguardsshouldhavebeenwithdrawnfromservice.
Figure 37 Guillotineswithbodypushguardsshouldnolongerbeinuse
Interlocking guardsFourkeypointstocheekoninterlockingguards:
n Theguardpreventsaccesstothedangerzone(ieyoushouldn’tbeabletoreachover,aroundorbeneaththeguardwhenitisinthedownpositionandliftingoftheguardstopsthemachinebeforeyoucanreachthebladeorclamp).
n Theinterlockingarrangementisoftherequiredstandard(thiswillnormallyneedtobeadual-channelcontrolsystem-yoursuppliershouldbeabletoconfirmthis).
n Simultaneoustwo-handcontrolsarefitted.n Suitablereartableguardingisprovidedwhichpreventsaccesstodangers
createdbythemovingclamp,bladeorbackgauge.
Automatic sweepaway guardsThesearedesignedtopushoperators’handsawayfromthecuttingareabeforetheycanbeinjuredbytheknifeorclamp.
Fivekeypointstocheckforguillotinesfittedwithsweepawayguards:
n Theguardsweepstowardstheoperatortoapoint500mmfromthefaceoftheclampbeforetheclamporknifehavedescended50mm.Youmayfinditusefultoputamarkatthe500mmpointonthetabletohelpyoucheckthis.
n Additionalguardbars/meshareprovidedtopreventaccessover/throughtheguard.
n Sideaccesstothedangerzoneatthefrontofthemachineispreventedwhentheguardisextended,egbyprovidinglargesidetablesorfixedguards.
n Simultaneoustwo-handcontrolsareprovided.n Suitablereartableguardingisprovided.
Guillotineswithsweepawayguardsshouldnotbesuppliedsecond-handorsoldon.Sweepawayguardsshouldnotbechangedforelectrosensitivesystemsifanon-fail-safebrakeisfitted.
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Figure 38 Automaticsweepawayguards
Common requirements for all power-operated paper-cutting guillotinesModificationstoguillotinesafetysystemsshouldonlybecarriedoutbycompetentguillotineengineers,manufacturersorsuppliersbecauseofthecomplexityofthesystemsandthepotentialdangersresultingfrominadequatemodifications.
Simultaneoustwo-handcontrolsshouldbefittedtoallmachinesotherthanthosewithhigh-integrity,all-enclosinginterlockedguards.Thesewouldhavecross-monitoreddual-channelcontrolusingtwoguardpositionswitchesoperatinginoppositemodes.Oldermachinesmayneedtheircontrolsupgrading.Thetwo-handcontrolshouldmeetthefollowingbasicstandards:
n bothbuttonsshouldbeoperatedwithinapproximately0.5secondsofeachotherbeforethemachinewilloperate;
n ifonecontrolisreleased,bothbuttonsshouldhavetobereleasedandre-operatedforre-initiation;
n thecontrolsshouldnotbecapableofbeingspannedbyonehand;n ifoneorbothcontrolsarereleased,themachineshouldstoporreturntotop
deadcentre.
Theaboveguidelinesareverygeneralandthedetailedrequirementsofindividualmachinetypesandmodelsshouldbecheckedwiththemanufacturer/supplierandagainsttheguidelinesinthePrintingIndustryAdvisoryCommitteebookletThe guide to safe use of power-operated paper-cutting guillotines.
Operatorsshouldcarryoutdailytestsandchecksofguillotinesfittedwithelectrosensitive(photoelectric)safetysystemsorinterlockingguards.Thesechecksshouldalsobecarriedoutafterknifechanging.
Sweepawayguardsonguillotinesshouldbecheckedbyoperatorsonamonthlybasis.Alltestsshouldberecorded.Thechecksshouldalsobecarriedoutafterknifechanging.
Six-monthlyexaminationsandtestsshouldbecarriedoutonallguillotinesbycompetentandtrainedengineersandcoversafetycomponents(egbrakeandclutches,interlockswitchesandcams),stoppingperformanceandgaugingpressurestocomplywithregulation6(2)ofPUWER98(seeChapter8).
Sweepawayguardinextendedposition(sideguardsomittedforclarity)
Anunacceptablesweepawayguillotine
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FurtherinformationandexampletestformscanbefoundinthePrintingIndustryAdvisoryCommitteebookletThe guide to safe use of power-operated paper-cutting guillotines.
Theintegrityofguardsandbrakingsystemsonguillotinescanonlybemaintainedbyregulartestingandexamination-failuretomaintainaguillotinecouldresultinaseriousandavoidableincident.
Knife changingSpecialprecautionsarenecessarytopreventinjurywhenknivesarechanged.Theguillotinemanufacturer’sinstructionsshouldbefollowed.Theseusuallyentailproceduresinvolvingdevicessuchasknifehandlesorslidesandsupportsforsaferemoval,mountingboardsforsafetransportandstorage,andtheuseofanassistantwhenchangingknivesonlargermachines.Precautionsshouldalsobetakentokeepothersawayduringknifechanging,egbyusingbarriersandatablenearthefrontoftheguillotine.
Other cutting machinesThree-knife trimmersTheseusuallyconsistsofthreeguillotinebladesorknives(theheadandtailknivesandtheforageknife).Theknivesreciprocateautomaticallythroughouttherun.Guardingforthebladesandotherhazardouspartsisessential.Accesstothebladeswiththeguardsopenwillberequiredforknifechangingandadjustment.Three-knifetrimmersmustbeadequatelyguarded.Thisisusuallyachievedbyprovidingfixedorinterlockedguards.
Manually fed machines
n Provideinterlockedtunnel-typeguardstopreventaccesstotheknivesfromtherearofthemachine.
n Feed-sideguardingshouldincorporatetripdevices,forexampleatrippedflaprunningthelengthofthefeedopeningortrippedsideguardsorboth.Thetripdevicesshouldoperateatminimaldeflectionandshouldinstantlycutpowerandmovementofhazardouspartsifanoperator’shandsarecarriedintothefeedopening.
n Provideadjustablefeed-sideguardswherebooksizesvary.Thesewillneedtobemaintainedinthecorrectpositiontoallowfeedingoftheworkbutpreventoperatoraccesstothedangerarea.Fronttabledimensionsmayneedextendingtogiveoperatorsextraprotectionbykeepingthemfurtherawayfromthefeedopening.
n Simultaneoustwo-handhold-to-runcontrolsshouldbeprovidedonnewmanuallyfedmachines.Similarstandardsshouldbeprovidedonolderexistingequipment.
Automatically fed machinesGuardingusuallytakestheformofaslidingtunnelguardoralargehoodsplitintotwosectionshingedatthemiddle.Theseshouldbeinterlocked.
Common provisionsOpeningsintheguardsshouldcomplywiththesafetyreachdistancesinBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs.
Photoelectriccurtainscanalsobeusedtoprovideprotectionatthefeed-side.
Emergencystopdevices,includinglift-upbardevicesatcertainoldermachines,arenotasubstituteforthetripdevicesreferredtointhepreviousparagraphs.
Youwillneedsafesystemsofworkforknifechangingandsetting,incorporatingtheuseofknifecovers.
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Forsettingpurposes,two-hand-controlsshouldbeprovidedwhichdonotallowrunningorjoggingofthetrimmersectionwiththeguardsopen.Operatingthetwo-handcontrolwiththetrimmerguardsopenshouldallownomorethanasinglestrokebythetrimmerbladeshoweverlongthecontrolsareactuated,ieifthecontrolsareoperatedandheldinforseveralsecondsthetrimmerbladeshoulddonomorethanonestrokeandthencometoacompleterest.
Whereoperationoftheknivesisnotrestrictedtoasinglecutwiththetrimmerguardsopen,machinesshouldbedesignedtoallownecessaryrunningadjustmentswithguardsclosed.
Loose knife punching machinesManuallyoperatedlooseknifepunching/cuttingmachineshavecausedfingerandhandinjurieswhenoperatorshavenotwithdrawnbeforetheplatendescendsorhaveattemptedtorepositionatopplingknife.Accessshouldbepreventedduringthestrokebyacombinationofaslidingfrontfeedtable,simultaneoustwo-handcontrolsandeitherinterlocked/fallingscreenfrontguardsorself-adjustingtunnel/screenfrontguards,togetherwitheitherlocalisedfixedguardingforthesidesandrear,orperimeter-typefencing.Cutterbalancingspringsshouldbeusedtostopsmallcuttersfallingover.
Automaticmachinesneedahigherstandardofsafeguardingasthetwo-handcontrolsonlyofferprotectionfortheoperatorduringtheinitialstrikeon.Thefeed-sideshouldbesafeguardedbyeitherahingedinterlockguardoranelectrosensitivesafetysystem.Youshouldensurethatthesafeguardingarrangementsatthefeed-sidecomplywithBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs.
Locatethephotoelectriccurtainincorporatedinthissystemcorrectlytopreventpeoplereachingthedangerpointsorbeingabletostandbetweenthephotoelectriccurtainandmachine.Thesidesandrearcanbesafeguardedbyacombinationoffixedandinterlockedguards.
Shearandtrappingpointsonthepaperfeedandtake-offsystemsshouldbeeitherdesignedoutorsafeguardedusingtripdevicesorothermethods.
Figure 39 Exampleofguardingalooseknifepunchingmachineusingafallingscreenguard
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Flat-bed cutting and creasing machinesCuttingandcreasingmachinescomeintwoforms:
n purpose-designedmachines;n convertedprintingpresses.TheHeidelbergOriginalCylinderisatypical
exampleofaconvertedmachine.
Themainrisksare:
n movingcomponentswithassociatedcrushorshearpoints.Cuttingandcreasingmachineshaveaninherentoscillatingmotion,andmovementsmaybesudden.Access(includingdirectorindirect,egviathewastechute)tothemovingpartsshouldbepreventedbymeansofguardsorotherdevicesthatstopalldangerousmotionbeforeinjurycanresult;
n weightsofdiesonlargermachines;n noisefromlargermachines,particularlythosefittedwithtrimmingsextraction
systems;n crushpointsattheoutfeedoflargermachines.
Purpose-designed machinesThefeed-endofmachinesissimilartothatofsheet-fedprintingpresses.Footcrushingrisksfromdescendingpallettablesshouldbeavoidedbyhavingamanualsystemforthefinal100mm,oralternatively,hingedflapsthatraisetheoperator’sfootawayfromthetrappingpoint.Transfermechanismsfromtheproductpileneedtobeadequatelyguardedtocoveranyin-runningnipsorshearpointsasin-feeddevicesoscillate.
Thecutting/creasingandstrippingareasmustbeguardedusingeitherfixedorinterlockedguards.Ifyouneedtobeabletoinchthemachinewiththeguardsopen,thenaudiblepre-startwarningsmustsoundbeforethemachineismoved,andthemovementmustbelimited.Itmustnotbepossibletoaccesstheintermittentlymovingtransportchainswiththeguardsopen.
Removetrimmingssothattheydonotaccumulate.Vacuumextractionisoftenused,butthenoisefromtheairflowandtrimmingsmovementcanexceed85dB(A)inmanymachines.Minimisetheleveltowhichtheoperatorsareexposed.
Delivery-endpalletscansometimeshavepooraccess.Itisoftenimpracticaltopreventaccesstothisareabutduringnormaloperationitshouldnotbenecessaryforpersonneltoentertheareawherethepalletdescends.Safesystemsofworkmustbeinplaceforthechangeoverofpalletsortheircarriageplates,statingthatthemachinemustbeisolatedifaccessisrequiredtothepalletdescentarea.Wheremachinepartsorhigherlevelplatformsarepositionedsothattheoperatorsmayhittheirheadsduringunloadingoperations,thenthesepartsmustbeadequatelypadded.Housekeepingandneighbouringequipmentmustnotcauseanobstructionwhenremovingproductonpallettrucks.
Whenchangingdies,appropriateequipmentorsystemsofworkmustbeprovidedtominimisetheriskofinjurythroughmanualhandling.Extendingrailsmaybeprovidedtoenablethedietoberemovedfromthemachineandequipmentorsystemsmustaddressthemovementtoorfromtheserails.
Converted machinesTypicalmachineshavethefeedanddeliveryatthesameend.Guardsmustbeprovidedovertheformeattheotherendandtheseshouldbeinterlockedratherthanfixedtofacilitatechangeoverofdies.Therisksfrominkingrollersareusuallyovercomebyremovingthesewithpressesdedicatedtocuttingandcreasing.Thesheartrapcausedbythegapinthecylinderasitpassesfixedmachinepartsmust
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beguardedbyeitherafixedorinterlockedguard.AcommonmethodoffixingsuchaguardistouseU-boltsorsimilardevicesroundthecrosstiebar.Riskscausedbyoscillatingdeliveryfingersmustbecontrolledbyensuringthatthesearetelescopic.Mostpressesweredesignedthisway,butdamageduringusemayhavejammedthetelescopicaction.
AutoplatensAutomaticsheet-fedplatenswerenotoriginallysuppliedwithguardsforthereciprocatingplatenortheinkingrollers.Attheveryleast,usersneedtoensurethatfixedsideandrearguardsareprovidedandthat,wherestillused,inkingrollersareguarded.Safeguardingbymeansofinterlockedgatesorpressure-sensitivematsatthefrontofthemachineshouldalsobeconsidered.Itisparticularlyimportantthatoperatorsareproperlytrainedandsupervised.
Hand-fed platens used for cutting and creasingHand-fedplatenshaveresultedinmanyseriousaccidents,includinganumberoffatalities.Themaindangersarehandinjuryduetolatefeedingortakingoutwhenthemachineisincontinuous(timercontrolleddwell)operation,andbodytrappingduetoaccidentaloperationoftheplatenwhilemakingreadyorclearingwaste.
Allelectro-magneticandelectro-pneumaticmachinesshouldhave:
n aU-shapedtripguardwhichcloselysurroundstheplatentowithin12mmonthreesides;
n atripbarorpressure-sensitiveedgeonthefrontedgeofthemovingplaten;n additionalsideguardingintheformof1mwidepressure-sensitivemats
extending250mmbeyondthebackedgeofthefixedplatenorfixed/interlockedsidetables;
n acontrolsystemandguardingcircuitssuitableforahigh-riskapplication,egdual-circuitcross-monitored.
Ariseandfallguardmaybeprovidedonthefrontedgeofolderplatenmachinestoensuretheminimumgapismaintainedbetweenthemovingplatenandthetripguard.
Wheretimer-controlledoperationora‘dwell’deviceisfitted,the‘dwell’periodmustnotexceed12seconds.Amaximumof6secondsdwellshouldbeusedformostoperations.
Thesafeoperationofhand-fedplatensiscriticallydependentontheirconditioninuse-deteriorationofthesafeguardswillputtheoperatoratsignificantrisk.Youneedtoensurethatregularinspectionsarecarriedoutbyacompetentpersonatleastannuallytocomplywithregulation6(2)ofPUWER98(seeChapter8).
Machines with mechanical (positive) clutchesThesemachinescannotbeprovidedwithallofthesafeguardsdetailedunder‘Hand-fedplatensusedforcuttingandcreasing’unlesstheyarecompletelyrefurbishedandprovidedwithasuitableelectro-magneticclutch/brakeunit.Youshouldplantoupgradeorreplacetheseoldmachines.
SomemachineswerefittedwithatreadleconversionkittodisconnectthefootpedalfromtheclutchonoperationoftheU-shapedtrip,preventingaccidentaloperation.However,thismeasurewasdifficulttomaintainandwasnotenoughonitsown.
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Maintenance of hand-fed platen guardsThesafeguardsonallhand-fedplatensneedtobecheckedandtestedonadailyorshiftbasis.BothofthetestsoutlinedbelowshouldbecarriedoutbyproperlytrainedoperatorstoensurethatproperperformanceoftheU-shapedtripismaintained.
Testingshouldalsobedoneperiodicallybyamemberofmanagementoranengineer.Alltestsshouldberecordedandallrecordsheld.
Test 1Theactualtrippingpointshouldbetestedbyturningthemachineoverbyhand.(Thismaynotbefeasibleonlargermachines.)Whenoperated,thetripdeviceshouldensureagapofnolessthan175mmismaintainedbetweentheedgeoftheplatenandtheforme.Onmachineswithatraveloflessthan350mm,trippingmustoccurnotlaterthanhalfwayinthetravel.
Test 2Test2shouldbecarriedoutwhenthemachineiscoldaswellaswhenitiswarmedup.Theoperatorshouldcarryoutthetestsbutonlyfollowingproperandcarefulinstruction.Asuitabletestpiecewouldbea12mmcardboardtube.
Thestoppingeffectofthetripdeviceshouldbetestedwiththemachinerunning.Theplatenshouldcometorestnolessthan90mmfromtheforme,oronmachineswherethetrippingdistancemaybelessthan175mm,nolessthan65mm.
Figure 40 Testingahand-fedplaten
Accidents
TheoperatorofaRabolinimechanicalclutchhand-fedplatenhadhisfingersfrombothhandsamputatedwhenhewasclearingoutstops.Heinadvertentlystoodonthefootpedal,causingthemachinetostrokeandoverridetheU-shapedtrip.
TwobrotherswereseriouslyinjuredwhileremovingtheformefromalargeStrumberplaten.TheU-shapedtriphadbeenpushedintotherearpositionbuttheplatenhadnotbeenisolated.Workingoneithersideofthemachine,theformewassupportedwiththeirhandsbetweentheplatenswhilethesecuringscrewswereundone.Anotheremployeetheninadvertentlyoperatedthepartiallyshroudedfootpedal,causingtheplatentostroke.Heimmediatelyoperatedthesensitiveedgebutnotbeforebothbrothersweretrapped.InvestigationrevealedthattheU-shapedtriphadbeenprovidedwithasinglepositivelyoperatingpositionswitchwhichwasineffectivebecausethegrubscrewsecuringthecamwasloose.Nosideguardshadbeenprovidedandnoguardcheckingwasbeingdone.
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Label punching machinesWhereregularaccessisrequiredformanualfeeding,makesurethatthefeedopeningforthematerialtobepunchedissafeguardedbyaninterlockedguardorphotoelectricdevice.
DischargeopeningsshouldbedesignedinaccordancewiththereachdistancesspecifiedinBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs.
Onnewmachines,whenfeedingthematerialrequiresregularandroutineaccesstothedangerpoint,thesafety-relatedpartsofthehydraulic/pneumaticcontrolsystemshouldsatisfyCategory3,andthesafety-relatedpartsoftheelectric/electronicsystemCategory4,ofBSEN954-1Safety of machinery. Safety related parts of control systems.ElectrosensitiveprotectivedevicesshouldsatisfytherequirementsofType4ofBSEN61496-1andBSEN61496-2Safety of machinery. Electro-sensitive protective equipment. General requirements and tests.
Round cornering machinesMakesurethataccesstothetrimmingknifeorsawispreventedbyanadjustabletransparentguardandthatthecuttingoperationcanonlystartoncethematerialhasbeenfedusingapresence-sensingdevice.Operationofthecuttersmustbeunderthecontrolofahold-to-rundevice,whichcanbeeitherhand-orfoot-operated.
Fixedorinterlockedguardsshouldbeprovidedattherearandonbothsidesofthemachine.
Folder gluer machines used in box makingThissectioncoverssmallerfoldergluersusedforcardboardboxmaking;itdoesnotcovercorrugatedcartonmanufacture.Themaindangerpointsonsmallermachinesarerotatingshafts,in-runningnipsandtrapscausedbypartsmovingclosetoeachother.Guardingmaycompriseindividualfixedguardsateachnippoint,enclosinginterlockedguardsorphotoelectricguards.
Power-drivenshaftsshouldbesafeguardedbyself-adjustingtelescopicguards.
Ifautomaticformatsettingispower-driven,hold-to-runcontroloramaximumsettingspeedof0.5m/minshouldbeprovided.
Onmodernmachines,checkwithyoursupplierthatthefollowingstandardshavebeenachieved:
Feeder
n In-runningnipsatthefeed/pullrollsshouldbesafeguardedbyfixedguardssuchas‘cheekplates’.
n Theclearancebetweentheloweredgeofthemoveablesidelayandthefeedingbeltshouldbenomorethan6mm.Furthermovementofthesidelayshouldnotbepossibleunlessresidualpilemonitoringisprovided.
Folding and gluing section
n Safeguardin-runningnipsbetweentheupperandlowerrollertracksorfoldingbeltbyensuringthatthefirstrollerallows25mmdeflectionandtheremainderoftherollershavefixedguardsonbothsides.
n Raisingandloweringofrollertracksunderpowershouldonlybepossibleunderhold-to-runcontrol.
n Guardthetrapscreatedbyfoldinghooksusingfixedorinterlockedguards.
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Makesurethatthein-runningnipbetweentheglueapplicatorandblankissafeguarded;thisisoftenachievedbythepositionofthegluingunititself.
Folding belt
n Thenipsbetweenthisbeltandpulleysshouldbeguardedbyfixedguards.Thenipsbetweenthebeltandhold-downrollsshouldbeguardedbyrollswhichhaveaminimum25mmdeflection,fixedorinterlockingguardsorphotoelectricdevicesatleast850mmfromthetrappingpoint.
Pressing section
n Safeguardthenipbetweentheupperandlowerpressingbeltbylimitingthepressingforceto500newtonsandensuringadeflectionofatleast120mmbyoff-settingtheupperandlowerpulleys.Nipsbetweenthepressurerollersandthebeltitselfshouldbesafeguardedbyfixedguardsortherollersallowinga120mmdeflectionundera100newtonscontactforce.
BinderyHandworkGuardsarerequiredonedge-gummingmachineswithnippingrollersandonthein-feedbeltsofedgestrippingmachines.Somemachinesusedinmetalcomb(spiro)bindingworkcanbehazardous-guardsonthepoweredbarorplatenofthemachineswhichclosethecombmustbeproperlyadjustedandkeptinposition.
Adhesive (perfect) bindingThehazardouspartsassociatedwiththeopening/closingandindexingofbookclampsonadhesivebindingmachinesshouldbeguarded.Thiscanoftenbeachievedbyall-enclosinginterlockedguarding,thoughadditionallocalisedfixedandtripdevicesmaybenecessaryathand-feedingstations.
Themillingcutterneedstobewellguarded,typicallybyaninterlockedall-enclosingguardandaself-adjusting/adjustablelocalguard.Youcandealwithcutterrundowntimebyusingbrakedmotorsorguardlocking.Minimiserisksfromhotmeltadhesivesbyprovidingtemperaturecontrolwithlimitmonitoringtogetherwithsuitablescreensorcoversandremotemethodsforrefillingtheadhesive.Provideextractiontocontrolfume.
Machinesusingpolyurethanehotmeltgluesshouldbeprovidedwithlocalexhaustventilationtocontrolisocyanateexposure(seeChapter4).
Wherethecoverhopperishand-fed,theseparatingelementsshouldbedesignedtopreventtrapsandresidualpilemonitoringprovided.Automaticallyfedmachinesshouldbeprovidedwithtunnelguardsatleast550mmlong.
Accesstotrapscausedbythemovementofbookcarriagesatthedeliveryshouldbepreventedbytunnelguardsatleast550mmlong.
Make-readyoperationsmayrequireinterlockedguardstobeopened.Wherethisisnecessary,ahold-to-runcontrolshouldbeprovidedattheslowestspeedpossible.Also,suchoperationshouldonlybepossibleiftheinterlockedguardsfordangerzonesoutsidetheviewoftheoperatorareclosed.Ifmanualfeedingisneededduringsetup,thehold-to-runspeedofthebindermustbelimitedtoamaximumof10m/minwhenevertheinterlockedguardsareopen.
Stand-alone stitching machinesPower-operatedstitchingmachinesshouldhaveaguardforthestitchingheadtopreventaccesswhentheworkisinplace.Guardsdesignedforflatstitchingarenot
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effectiveduringsaddlestitching.Eithertwoseparateguardsshouldbeprovidedor,alternatively,reversibleguards(oftensuppliedbythemanufacturer)shouldbeused.Reversibleguardsaredesignedtobeturnedandsecuredinpositiondependingonthetypeofstitchingbeingcarriedout.Operatorsshouldbetrainedtouseguardscorrectly.
Figure 41 Guardsforflatandsaddlestitching
Gatherering, stitching and trimmingSeriousaccidentshaveresultedatgatherer-stitcher-trimmers(GSTs),collator-stitcher-trimmersandgang-stitcher-trimmers,particularlythroughcontactwiththetrimmerknivesandtheincorrectoperationofwanderleadcontrols.
GatheringFixedandinterlockedguardsshouldbeprovidedforhazardouspartsofthegatherer/feedstations.Interlockedguardsnormallytaketheformofhingedperspexlift-upguards,eitherforindividualfeedstations,orasasingleguardcoveringallthefeedstations.Interlockingisnormallyachievedthroughtheuseofpositivelyoperatingcamswitches.Usersneedtocarryoutregularguardcheckstoensuresafetyismaintained.Undernocircumstancesshouldinterlockswitchesberemovedordefeated.
Asingleguardcoveringallfeedstationscaneasilyberenderedineffectiveifonlyasinglecamswitchisprovidedandthismovesoutofalignment.Itisthenpossiblethatthemachinecanbeoperatedwiththeguardraised.Insuchcircumstances,upgradingtoprovideasecondcamswitchoperatingintheoppositemode,mountedbythesideoftheoriginalswitch,wouldachieveahigherstandardofsafety.
Accessshouldnotbepossiblethroughoraroundguardstohazardousparts.BSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbsshouldbeapplied.
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Figure 42 FixedandinterlockedguardsshouldbeprovidedforalldangerouspartsofGSTs
StitchingFixedand/orinterlockedguardsshouldbeprovidedforhazardouspartsassociatedwiththestitchersectionincludingthestitchingheadsandcalliperroll.Guardingmaytaketheformofasinglehingedperspexguardfittedwithasinglecam-operatedinterlockswitch.Anyinterlockswitchshouldoperateinthepositivemode.Accessshouldnotbepossiblethroughoraroundguardstohazardousparts.
TrimmingEnclosingguardsshouldbeinterlockedbymeansofpositivelyactinginterlockswitches.Theswitcheswillnormallybecam-operated.Caremustbetakentoensurethatthecamsdonotmoveoutofadjustment-upgradingasoutlinedabovemaybeappropriate.Regularguardcheckingisrecommended.Openingoftheguardswhilethebladesareinmotionmuststophazardousmovementbeforeahandcanreachadangerpoint.
Fixedguardingisusuallynotasuitablealternativetointerlockedguardsbecauseoftheneedforfrequentaccess.
Openingsintheguards,includingfeedanddeliveryopenings,shouldnotallowaccesstohazardousparts.Whereaccessisfoundtobepossiblethroughthedeliveryorotheropenings,guardingshouldbeupgradedtopreventaccess.
Transmissionmachineryshouldbesecurelyfenced.Standardsforfixedorinterlockedguardingshouldtakeaccountofthefrequencyofaccess.Machinesshouldbedesignedsoaccessisnotrequiredtohazardoustransmissionmachineryonafrequentbasis.
Precautionsshouldbetakentopreventrisksfromliftinghingedguardsfallingundergravity.
Setting and adjustment of GSTsLocaltwo-handhold-to-runcontrolsoratwo-handhold-to-runwanderleadcanbeprovidedwhichallowoperationoftheGSTwithoneguardopen.Single-buttoncontrolsarenotacceptable.Two-hand-controlsshouldmeetthefollowingconditions:
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n TheyshouldrequiresimultaneousoperationinlinewithBSEN60204-1:1993Safety of machinery. Electrical equipment of machines. Specification for general requirementsandbesuitablypositionedtopreventspanningbyonehand.Controlsthatfailtomeetthisstandardshouldbeupgraded.
n Withthegatherer/feederstationorthestitcherguardopen(butnotthetrimmerguard)themachinemay,inexceptionalcircumstances,runatspeedsofmorethan10m/minalthoughthespeedshouldbesetaslowaspossible.
n Setting,maintenanceandknifechangeoperationswiththetrimmerguardsopenshouldbeaone-personoperationcarriedoutbyatrainedoperatorwhoshouldbeincontrolofanyinchorpendantcontrols.Accidentshaveoccurredwhentwooperatorshavebeenworkingtogetherandonehasoperatedthewanderleadwhiletheotherhashadtheirhandsinthetrimmersection(see‘Threeknifetrimmers’earlierinthischapter).
Book sewingAutomatic/semi-automaticmachinesshouldbeprovidedwithacombinationoffixedandinterlockedguardstopreventaccesstohazardousparts.Fithand-fedmachineswithadequatetripguardstoguardthesewingheads.Theseguardsshouldbeeffectiveduringthreadingupandnormalrunning.
Signature pressesMakesurethatthetrapbetweenthemovingpressplateandmaterialsupplyandtheintermediateplatearesafeguardedusingahold-to-runcontrol.
Book pressesSafeguardanytrapbetweenthemoveableandfixedpressingplatesortheformingbarwithatripdevice.Themovementofthetripshouldbegreaterthanthestoppingdistanceofthepressingplate.
Onpresseswhereseveralpressingplatescanbemovedindependently,aguardshouldbeprovidedbetweentheplatestopreventasheartrap.
Thegapbetweentheguardandthepressingplateshouldnotexceed6mm.
Backlining and headbandingWherebooksignaturesaretransportedbetweenverticallymountedconveyors,guardfeed-sidein-runningnipswithtunnelguardsofatleast550mm.Gluerollersandanyhotmeltpartsshouldbesafeguardedwithinterlockedguardsandwarningsignsaffixed.Thegauzecuttingknifeshouldbesafeguardedbyfixedguardsandthein-runningnipsofthegauzeunwindingsectionbyfixednipbars.Accesstohazardouspartsattheheadbandingsectionandcounterpressuresectionsshouldbepreventedbyfixedorinterlockingguards.
Book nipping (smashing)Safetyonhand-fedbooknippingorsmashingmachinescanonlybeachievedbyprovidingguardingandsafesystemsofwork.Youneedtofitadjustableaccess-limitingguards.
Onhorizontallymovingplatenswherethebookisfedfromthetop,aspring-loadedguardcanbeusedwherethebackofthebookdisplacestheguardsothatitcoversthegapbetweenthebookandtheplaten.Alternatively,letterbox-typeguardswhichhaveaslotopeningofthesamedimensionsasthebookcanbeused,buttheplatensideoftheguardmustoverlapthefrontedgeoftheplaten.
Onverticallymovingplatenmachines,adjustableplatesshouldbefittedwhichareadjustedtothebooksizeforeachproductionrun.Thesewillpreventoperatorsfromleavingtheirfingersontheuppersurfaceofthebook.Theoutsideedgeoftheplateshouldextendbeyondtheplatenedgetopreventasecondarytrap.
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Rounding and backingAutomaticmachinesshouldbeprovidedwithacombinationoffixedandinterlockedguardstopreventaccesstohazardouspartssuchasin-runningnipsonthefeedanddeliverybelts,trapsonthetippingsection,trapsandhotpartsonthepreheatersection,andtrapsandshearpointsonthepreforming,roundingandbackingsection.
Onhand-fedmachines,accessisrequiredtofeedthebooktothefeed/roundingrollersbutmustbepreventedduringpoweredmovement.Youcanpreventaccesstothesheartrapbyusingsequentialtwo-handcontrolsandinterlockguarding.
Case making and casing-inOnmosttypesofcase-makingandcasing-inmachines,thehazardouspartscanbeadequatelyguardedbyprovidingall-enclosingguardsinterlockedtothemachine’sdrive.Thefeedanddischargepartsofthemachinesshouldbeoutsidetheguardedarea,withopeningsdesignedtomeetthereachdistancerequirementsofBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs.
Accesstoin-runningnipsandtrapsbetweenfixedandmovingpartsneedtobepreventedoncasemakingmachines,especiallythetrapsbetweentherotatingpickerheadandadjacentfixedpartsonoldermachines.Forthesemachines,acombinationoffixedandinterlockedguardsfittedtotheoutsideedgeofthemachineframearesuitable.Wherecoverclothishand-fedtoacylinder,anyin-runningnipsshouldbeguarded.
Oncasing-inmachines,hazardouspartsincludein-runningnipsatthecoverbendingsection,crushingandnippointsandhotmachinepartsattheheatedformingsection,crushingpointsatthecasing-insection,in-runningnipsatthegluingsectionandin-runningnipsatthecounter-pressuresection.Pictogramswarningofhotpartsshouldbeprovidedinthevicinityofheatedbook-covercrease-formingdeviceswhichareaccessibleoncetheinterlockingguardshavebeenopened.
Atthebooksignaturefeedanddeliverypoints,tunnelguardsatleast550mmlongshouldbeprovidedtopreventcontactwithtrapsbetweenthebooktransportfingersandfixedpartsofthemachine.
Trapsonthebookcoverfeedercausedbyseparatingelementsandtransportdevicesshouldbepreventedbydesignorwhereblanksarefedfromthebottomofthepile,safeguardingcanbeachievedbyresidualpilemonitoring.
Blocking machinesThetrapbetweentheclosingplatens(oneofwhichisoftenheated)onfoilblockingmachinesisveryhazardousandmustbeguarded.Onautomaticmachinesthiscanbeachievedbytheprovisionofall-enclosinginterlockedguards.
Onhand-fedup-strokingordown-strokingmachines,therearandsidesoftheplatenscanbeguardedbyfixed/interlockedguards.Thefrontfeedtableshouldbeprovidedwithanadjustable(oftenrodtype)pivotingguard,whichtripsifthebottomoftheguardispushedin,oratripdeviceandsimultaneoustwo-handhold-to-runcontrols.
Book production linesMakesurethatthein-runningnipsonthefeedanddeliveryconveyorbeltsaresafeguardedusingin-fillblocks.
Trapscreatedbyseparatingelementsonthebookcoverfeedershouldbesafeguarded.
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Checkthatfixedorinterlockedguardshavebeenprovidedtopreventaccesstohazardouspartsat:
n thepreheater.Interlockedguardsshouldbesupplementedbysuitablepictogramswarningofhotparts.Onceinterlockedguardsareopened,thepreheatershouldonlyoperateunderhold-to-runcontrol;
n thebackroundingandpressingsections;n thegluesections.Gluereplenishmentshouldbepossibleduringtheproduction
runwithouttheneedtoopenguards.Hotmeltpansshouldhavetemperaturecontrolandlimittemperaturemonitoring;
n theknifeandgauzeclamps.Nipbarsshouldbefittedatanyremainingin-runningnipsatgauzeunwindingrollersoncetheinterlockedguardhasbeenopened;
n theheadbandingandbackliningsection.Nipbarsshouldbefittedatanyremainingin-runningnipsatheadbandingunwindingrollersoncetheinterlockedguardhasbeenopened;
n thecoverbendingandroundingsections;n thecasing-insection.
Afteropeninganyinterlockedguards,itshouldonlybepossibletooperatethelinewithalimitedinchof75mmorahold-to-runmaximumcrawlspeedof5m/min.Ifahighercrawlspeedisrequired,thisshouldonlybepossibleusingacombinationoftwo-handcontrolandensuring:
n allotherinterlockingguardsareclosed;n aselectorswitchforthisoperationhasbeenprovided;andn thehold-to-runspeedistheslowestpossibleanddoesnotexceedamaximum
of20m/min.
Checkthatemergencystopbuttonsareprovidedatleastoneachmaincontrolpanel.Whereoverallvisionoftheproductionlineisrestricted,makesureapre-startwarningdevicehasbeenprovided.
Paper drillsThestrokeofmanuallyfedpaperdrillsshouldbeunderhold-to-runcontrolandaworkpiecesupportprovided.Whenthehold-to-runcontrolisreleased,thedrillorworkpieceshouldreturntoitsstartposition.
Makesuretheshatterandtrappinghazardsondrillsandchuckjawsaresafeguardedbyafixedorinterlockedguard.
Multi-drillmachinesshouldhavefixedorinterlockingguardstopreventcontactwiththerotatingchuckjaws.Makesurethedistancebetweentheworkpiecesupportorguardandchuckjawisatleast25mm.
Accidents
Book sewing
Anexperiencedoperatorcrushedtheirindexfingerbetweenthebottomplatenandthebookasthetopplatencompressedthebook.Noguardinghadbeenprovided.
Anoperatoramputatedthetipsoftwofingerswhilepushingbooksthroughthecontinuouslystrokingpress.
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Accidents
Rounding and backing machines
Anemployeecrushedhishandbetweentheroundingrollersandbackingjawwhenheinadvertentlystartedthemachinecycle.
Anoperatorbruisedandlaceratedhisfingerinthepressingplateofaroundingmachine.Aguardwasprovidedbutnotused.
Finishing machinesCoatersCheck:
n withyoursupplier,whereroutineandregularaccessisrequiredtodangerpoints,thatthesafeguardsareoftherightintegrity(thesafety-relatedpartsofthehydraulic/pneumaticcontrolsystemsatisfyatleastCategory3ofBSEN954-1:1997Safety of machinery. Safety related parts of control systems,andthesafety-relatedpartsoftheelectric/electroniccontrolsystemsatisfyatleastCategory4);
n whereoverallvisionofthecoaterisrestricted,apre-startwarningdevicehasbeenprovided;
n web-threadingdevicesareprovidedforwebbingup.
Reelunwindingandrewindingunitsneedtobesafeguarded(see‘Reelunwindsandrewinds’earlierinthischapter).
Ensurethatthefollowingin-runningnipsaresafeguarded:
n betweentheguiderollersandguiderollers/fixedmachinepartsbyensuringaminimumseparationof120mm,orwithfixed/interlockedguardsornipbars;
n atthedosinggapwithfixed/interlockedguardsornipbars;n betweenthecoatingrollerandcoolingroller/coatingrollerwithfixed/interlocked
guards;n attheTeflonbelt(wherehotmeltpolyethyleneisbeingused)withfixed/
interlockedguards.
Preventcontactwithpartsassociatedwithhotmeltmaterialusingfixedguards.
Thetraversingmovementofthecoatingrollersorcoatingrollerandcoolingrollershouldbesafeguardedbymeansofahold-to-runspeedof5m/minorinterlockedguards.
Accessiblein-runningnipsbetweenthecoated,tear-resistantwebandguiderollerswherethereisawrappingangleof45oormoreshouldbeprotectedbyfixedguards.
Forprecautionsrelatingtofireriskoncoaters,seeearlierinthischapter.
Continuous flow dryersCheckwithyoursupplierthatthedryermeetstherequirementsofBSEN1539:2000Dryers and ovens in which flammable substances are released.Safetyrequirementsifthecoatingmaterialyouusegeneratesflammablesubstances.
Itisimportantthatthetrapcreatedwhenclosingtheupperandlowerpartsofthedryerissafeguardedusingahold-to-runcontrol.Automaticclosingshouldonlybepossibleforthelast300mmofmovementandsafeguardedbytripbars.
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Ignitionofthewebinthedryershouldbepreventedusinganairwiper/cushionedcurtaintokeepthewebatanadequatedistancefromtheheatsource.
Ifhydraulicorpneumaticcylindersareprovidedforopeningthedryer,makesurethesehavesafety-ratedcheckvalveswhichcanbeoverridden.Inaddition,amechanicalscotchshouldbeinsertedduringinspectionwork.
Ensureemergencystopbuttonsareprovidedateachoperatorposition.
Laminators with adhesive foilReelunwindingandrewindingunitsneedtobesafeguarded(see‘Reelunwindsandrewinds’earlierinthischapter).
Makesurethefollowingin-runningnipsaresafeguarded:
n atfeedanddeliverybeltsbyinfillingbetweenthebeltandroller;n betweenguiderollersandguiderollers/fixedmachinepartsbyensuringa
minimumseparationof120mm,orwithfixed/interlockedguardsornipbars;n accessiblenipsbetweenthelaminated,tear-resistantwebandguiderollers
wherethereisawrappingangleof45°ormorebyfixedorinterlockedguards;n atthelaminatingrollerusingfixedorinterlockedguards.Ifthematerial
thicknessexceeds18mm,theopeningshouldnotbemorethan30mmandthesafetydistanceatleast200mm.
Thetraversingmovementofthelaminatingrollersformake-readyandcleaningshouldbesafeguardedbymeansofahold-to-runspeedof5m/minorinterlockedguards.
Inhotfoilingwork,preventcontactwiththelaminationrollersbyusingfixedguards.
Ensurecuttingdevicesaresafeguardedbyinterlockingguards.
Checkthatemergencystopbuttonsareprovidedatleastoneachmaincontrolpanel.
Laminators with glue applicationWhereisocyanate-containingadhesivesareused,controlofemployees’exposureiscrucial.SeeChapter4‘Useofisocyanates’andthebookletSafeuseofisocyanatesinprintingandlaminating.
Onnewmachines,whereroutineandregularaccessisrequiredtodangerpoints,checkwithyoursupplierthatthesafety-relatedpartsofthehydraulic/pneumaticcontrolsystemsatisfyatleastCategory3ofBSEN954-1:1997Safety of machinery. Safety related parts of control systems,andthesafety-relatedpartsoftheelectric/electroniccontrolsystemsatisfyatleastCategory4.
Whereoverallvisionofthelaminatorisrestricted,makesureapre-startwarningdevicehasbeenprovided.
Web-threadingdevicesshouldbeprovidedforwebbingup.
Reelunwindingandrewindingunitsneedtobesafeguarded(see‘Reelunwindsandrewinds’earlierinthischapter).
Thefeederanddeliveryunitsneedtobeproperlydesignedandsafeguarded(see‘Pileliftingandloweringdevices’earlierinthischapter).
Checkthatthefollowingin-runningnipshavebeensafeguarded:
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n onbeltsusingfixedorinterlockedguards;n betweenguiderollersandguiderollers/fixedmachinepartsbyensuringa
minimumseparationof120mm,orwithfixed/interlockedguardsornipbars;n accessiblenipsbetweenthelaminated,tear-resistantwebandguiderollers
wherethereisawrappingangleof45°ormorebyfixedorinterlockedguards;n onthesheetfeedrollsbyensuringthattherollshaveadisplacementofatleast
25mmorrollercontactisbytheirownweight;n atthegluerollersandonthedosinggapusinginterlockedguards;n betweenthelaminatingrollersusingfixedorinterlockedguards.Ifthematerial
thicknessexceeds18mm,theopeningshouldnotbemorethan30mmandthesafetydistanceatleast200mm;
n betweenpressingrollersandguiderollersandpressingbeltbyfixedguards,orbyensuringrollersareheldinpositionbytheirownweightandhaveadisplacementofatleast120mm;
n betweentheupperandlowerpressingbeltsattheinfeedpoint.Useeitherfixedorinterlockedguardswithasafetydistanceofatleast850mmfromanopeningapertureofatleast120mmtothepointwherethereisatleast10mmbetweenthebelts,orpressingrollerscapableofdisplacementtoacreateagapof120mmandwithamaximumpressingforceof200newtonsatthe850mmpoint.
Makesurerotaryknivesarefullyenclosedusingfixedguardswhichpreferablydonothavetoberemovedfortoolchange.
Checkthattheopeningandclosingmovementofthelaminatingrollersissafeguardedifthetravelpathismorethan6mmbymeansofhold-to-runcontrolnotexceeding5m/minorinterlockingguards.
Checkthatdangerpointsonthesheeterarenotaccessiblebymeansofinterlockedorfixedguards.
Makesurethatthecrushingpointbetweenthepackagestopandtransportbeltissafeguardedwithinterlockedorfixedguardsifthemaximumclosingforceexceeds200newtons.
Ensurethatshearingpointsbetweentheturningbeltandtransportbeltsaresafeguardedwithfixedguards.
SeeChapter7forfireprecautionsrelatingtolaminators.
Baling machinesMachinesusedforbalingwastepaperandboardhavecausedfatalaccidentsandamputationinjuries.Largemachinestypicallyconsistofahorizontalorverticalbalingchamberwhichisconveyorfed.Thesemachineswillhaveanautomaticorsemi-automaticbalewiringmechanism,incorporatingwiringneedlesthatpassthroughslotsinthefaceofthebalingram.
Fatalaccidentshaveoccurredwhenpeoplehavefallenfromtheconveyorintothechamberwhilethebalerisinoperation,forexamplewhenfollowinganunsafesystemofworkforclearingblockages,andwhentheyhavegainedaccesstotheareabehindtheraminitsforwardpositionforrunningrepairs,andtheramhasretracted.
Amputationinjurieshavebeencausedbypeoplegainingaccesstotrapscreatedbymovingpartssuchastheram,wiretyingmechanismorwiringneedles.Onlargemachines,distributorsmayalsoconstituteadanger.
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Atsmallcompactorstheremaynotbeahighriskoffatality,butprecautionswillbeneededtopreventamputations,crushingandsimilarmajorinjuries.
Ahighstandardofinitialsafeguardingisneededatallmachines,combinedwithregularchecksontheoperationofthesafetydevicesandmaintenance.Followsafesystemsofworktodealwithoccurrencessuchasblockages,andmaintenanceactivities.Suchsystemsshouldincludelock-offisolationproceduresforbothconveyorandbaler.
Initialsafeguardswillincludeahighstandardoffixedandinterlockedguarding,emergencystopsandtripwires,fixedladders(withhoopsasappropriate)andworkingplatformsforaccesstohighlevelsofthemachine.
Wasteisusuallyloadedontotheconveyorusingvehicles.Guardtheedgeoftheconveyororpitasfaraspossibleandmaketheexposedareaforloadingclearlyidentifiable,forexamplebyusingrobustoverheadindicators.
Accessontoconveyorsshouldbestrictlycontrolledbyasafesystemofworkincorporatinganeffectiveisolationprocedure.Themeansofelectricalisolationshouldbereadilyaccessibleandlockable.Itmustisolateboththeconveyorandthebalingmachine.
Fitconveyorswithemergencystopdeviceswhichstopboththeconveyorandthebalingmechanism.Emergencystopbuttonsshouldbereadilyaccessiblefromalloperatingstations.Emergencystopbuttonsortripwiresshouldalsobeprovidedontheinclinedsectionoftheconveyor.Theycaneitherbefittedtorunuptheside(preferablyonbothsides)ortheycanbepositionedlikegoal-postshorizontallyacrosstheconveyorandhungwithverticalcordsforeaseofoperation.Personaldetectionsystemscanbeusedaswellasbutnotasanalternativetosafeguards.
Iffrequentblockagesoccurinthehopperabovethebalerthenapermanentplatform(atleast1.1mbelowthetopofthehopper)withafixedaccessladdershouldbeprovided.Ifitisnotpossibletoprovideafixedaccessplatform,harnesseswithanchoragepointsmaybenecessaryinadditiontothesafesystemofworkandisolationproceduredescribedabove.
Figure 43 Anunacceptablebalingpress
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Accidents
Anoperatorwasattemptingtoclearablockageinabaler.Paperwasfedautomaticallyfromtheshreddertothebaler.Whenthepaperlevelreachedamagiceyetheramoperated.Theoperatorhadclimbedintothechuteboltedtothebaler.Whenthebaleroperated,hisfootwasbadlycrushedbytheram.
Anemployeewascrushedtodeathwhenhebecametrappedbythereturningramofalargehorizontalpaperbalingmachine.Hehadgainedaccesstothebalingchamberviatherearoftheejectorramwhentheramwasintheforwardposition.Themachinehadnotbeenisolatedandtheramretracted.
Anemployeewaskilledwhenhefellintothebalingchamberandcoveredthemagiceyewhichactivatedtheram.Theemployeehadbeenclearingablockageatthetopendoftheconveyor.Themachinehadnotbeenisolated.
Effectivelyguardallopenings(evensmallonesallowinghandaccess)inthevicinityofthebalingchamberandthecompactor/ejectorram.Accesspanelsmaybefixedinpositionifinfrequentaccessisrequiredandthisshouldbemadethroughapermit-to-worksystemincorporatinganisolationprocedure.
Whereaccessisrequiredmorefrequently,aninterlockedguardshouldbeprovided.Thestandardoftheinterlockingrequireddependsonthenatureoftherisk.Ifheadorbodyaccessispossibletheninterlockingtoahighstandardwillberequired,forexample,guard-inhibitedpowerinterlockingorakeyexchangesystem.Alternatively,useadual-channelsystemwithinterlocksandcross-monitoring.
Onhydraulicmachines,dual-channelinterlockingcanuseadifferentcontrolmediumforeachchannel,ieonehydraulicandoneelectric.Wherewhole-bodyaccessispossible,provideprotectiontopreventinadvertentclosingoftheguardpanel/doorwhileapersonisinsidethemachine.Keyexchangesystemsprovidethisprotection.Anequivalentstandardofprotectionwillbeneededifothertypesofinterlockingareused.Whereheadorbodyaccessisnotpossible,interlockingbymeansofasinglepositivelyinterlockedswitchmaybeacceptableaslongasitisproperlymaintained.
Accesstothemovingpartsoftheneedlesandwire-tyingmechanismshouldbepreventedbyusingfixedorinterlockedguardingaccordingtotheprinciplesdescribedinthepreviousparagraphs.Needleswilloftenpassverticallythroughthebale,withanaccesspitunderthemachine,buttheymayalsobehorizontal.Ifpeoplehavetoworkundertheneedlesduringmaintenance,mechanicalscotchesshouldbeprovidedtoholdtheneedlesinasafeposition.
Maintenanceisveryimportantbecauseoftheheavydutyenvironment.Notonlyisitessentialtoensurethatsafetyswitches/devicesareregularlychecked,butpreventivemaintenanceontheequipmentisimportanttoreducetheneedforoperatorintervention.
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Figure 44 Simplifieddiagramofabalingmachine
ShreddersMachinescanbehand-fedeitheronverticalorhorizontalplanes.Horizontallyfedmachinesmayhaveshortfeed-sideconveyorstoaidthetransferofmaterialtothecutters.Somemachinesmayhaveasecondconveyortodelivertheshreddingsattheoutrun.
Feed-side access to rotary cuttersAccesstothecuttingrollersshouldbepreventedbysuitabledistanceguardinginlinewithBSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbs.
Forthesmallestoffice-basedmachines,thiscanbedonebyusingnarrowfeedslots(typicallynarrowingtonomorethan4to6mm).Theslotsshouldnotbeinadirectverticallinewiththein-runningnipcreatedbythecontra-rotatingcuttersbecauseofentanglementhazardstooperators’hair,jewelleryorclothing.Whereresidualrisksremain,suitablewarninglabelsshouldbeplacedinprominentpositionstoalertoperatorsofthepotentialhazard.
Wherewastepaperetcisfedintoashredderviaatop-feedchute,thechuteshouldextendfarenoughtopreventtheoperator’shandorarmaccessingtherotatingcuttersthroughthechute.Youcanalsousehingedinterlockedflapsfittedwithsinglepositivelyoperatingcamswitches.Openingoftheflapswhilethecuttersareinmotionshouldstophazardousmovementbeforeahandcanreachthehazardousparts.
Feedchutesshouldbefixedinpositionorinterlockedusingpositivelyoperatingswitcheswhichstopmovementofthecuttersbeforeaccesscanbegained.Thetypeandmethodofinterlockingshouldtakeaccountofcutterrundowntimeswhereapplicable.Considerguardlockingformachineswithlongcutterrundowntimes.
Wheremachinesarefedhorizontallyusingfeedtables(oftenfittedwithsmallintegralfeedconveyors),thefeedtableshouldactasadistanceguard.Suitablesidepanellingand/orfixedorinterlockedtunnelguardingshouldbeprovidedtopreventaccesstohazardouspartsfromthesidesofthefeedtable.SafetyreachdistancesshouldcomplywithBSEN294:1992.Wherehingedsectionsareprovidedintheguardingarrangements,theseshouldbeinterlockedusingpositivelyoperatinginterlockswitches.
Outrun access to rotary cuttersShreddingmachinesareusuallyprovidedwithareversingdrivefortherotarycutters
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toaidblockageremoval.Thereversefacilityresultsintheotherwiseout-runningnipsatthedeliverysideofthecuttersbecominghazardousin-runningnips.Accesstothesehazardouspartswhiletheyareinmotionshouldbepreventedbymeansoflocalisedfixedguarding(foundonsomesmallermachines,particularlyverticallyfedmachines);suitabletunnelguards(fixedorinterlocked);orinterlockedguards.LocalisedfixedguardsortunnelguardsshouldcomplywithBSEN294:1992safetyreachdistances.
Inexceptionalcircumstancesreversalbymeansofatwo-handhold-to-runcontrolplacedoutofreachofhazardouspartsmaybeacceptableforstrictlysolooperatingpractices.Suchcontrolsshouldbedesignedtoprovidelimitedinchmovementonly.ThecontrolsshouldrequiresimultaneousoperationandcomplywithBSEN60204:1993Safety of machinery. Electrical equipment of machines. Specification for general requirements.
Two-hand-controlsarenotconsideredacceptableifthecuttersarecapableofautomaticreverserunning.Somemachinesmaybefittedwithovercurrentsensorswhichautomaticallyreversethedirectionofthecutters(andofthefeedtableconveyor)ifthemachineiselectricallyoverloaded.Afteraboutfivesecondsofreversemotion,themachineswitchesitselfoff.Providefixedorinterlockedguardingwherethereisapossibilityofautomaticreversal.
Wheretherearehazardsafterinterruptionofthepowersupply,considerinterlockingmethodsincorporatingbrakingand/orguardlocking,forexamplewherecuttersorotherhazardouspartshavelongrundowntimes.Systemsshouldbedesignedtoincorporateadevicetoeithercausethehazardtobeeliminatedastheguardisopened(byapplyingabrake),orpreventtheguardfrombeingopeneduntiltheriskofinjuryfromthehazardhaspassed(guardlocking).
Whereshreddersarecombinedwithintegralbalingmechanisms,anyaccessdoorprovidedattherearoftheshredder/topofthebalershouldbeinterlockedusingatleastonepositivelyoperatinginterlockswitchwhichpreventsmovementofboththeshreddingcuttersandthebalingramassoonastheaccessdoorisopened.Hydraulicorpneumaticoperatedbalingramsshouldblockanddumptheirsupplyonoperationoftheinterlock.
Provideatripmechanismintheformoftrippedaccessflapsorafull-lengthtripbaraswellasdistanceguardingwherethereisanypossibilityofanoperatorbecomingentangledanddraggedtowardsthecutterblade.
Accident
Anoperatorwasfeedingapapershredderwitholdnewspaperswhenherfingertouchedbladesthroughanopeninginthemachine.Thefeedopeninghadnotbeenrestricted.
Anoperatorseveredthetipofanindexfingerinthecuttersofapapershredderwhilecheckingforafault.Afixedguardhadbeenremovedfromoverthecuttinghead.Closingtheelectricallyinterlockeddoorofthewastesackbinhadactivatedthecutters.
Anoperatorlostpartsofthreefingerswhentheywereshearedoffbyoneofthecompactingramsonashredderbalermachinewhichmakesshreddednewspaperintobalesforanimalbedding.Blockagesonthemachinewerearegularoccurrenceandwerefrequentlyclearedbyinsertinganarmthroughaslotinthemachineryhousingwhiletheramswereinmotion.Nofixedorinterlockedguardwasinplacebeforetheaccident.
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Acquiring machinery and other work equipment
The lawSupply of Machinery (Safety) Regulations 1992 (amended 1994)TheseRegulationsimposedutiesonthemanufacturers,suppliersandimportersofnewmachineryandareintendedtoprovideprotectionfortheusersoftheequipmentasmachinerywhichcomplieswiththeseRegulationsshouldbesafe.
TherequirementsoftheRegulationswerevoluntaryfornewandsecond-handmachinesfrom1January1993until1January1995(iftheywerenotfollowedthemachinerystillneededtocomplywiththehealthandsafetyprovisionsinforceintheUnitedKingdom).TherequirementsoftheRegulationsbecamecompulsoryfrom1January1995.
Duties on manufacturers or their responsible persons
n Ensuringthatthemachineryorsafetycomponentsatisfiestherelevantessentialhealthandsafetyrequirements(EHSRs).
n EnsuringthatanappropriateconformityassessmentprocedurehasbeencarriedoutinaccordancewiththeRegulations.
n EnsuringthatthemachineryorsafetycomponenthasbeenissuedwitheitheraDeclarationofConformityoraDeclarationofIncorporation.
n Ensuringthatthemachineryorsafetycomponenthasbeen‘CE’markedtoshowthatitsatisfiestheEHSRs(unlessitishasaDeclarationofIncorporationandisgoingtobeincorporatedintoamachineorassemblyofmachinesthatwillbe‘CE’markedasawhole).
n Ensuringthatthemachineryorsafetycomponentissafe.n Carryingoutresearchandtestingtodeterminethatthemachineryiscapableof
beingerectedandputintoservicesafely.
Duties on suppliers (where the supplier is not the manufacturer or the manufacturer’s appointed responsible person)
n Ensuringthattherelevantmachineryorsafetycomponentissafe.
Duties on users
n Ifyoudirectlyimportanymachinery(second-handornew)fromoutsidetheEuropeanEconomicArea,thentheRegulationsregardyouassupplyingthemachinerytoyourselfandimposethedutiesofasupplierundertheRegulations.
Examplesofmatterscoveredbytheessentialhealthandsafetyrequirementsinclude:principlesofsafetyintegrity;lighting;designofmachinerytofacilitatehandling;safetyandreliabilityofcontrolsystems;preventionofrisksrelatedtomovingparts;requirementsforguardsandprotectivedevices;protectionfromhazards(includingtemperature,electricitysupply,staticelectricity,fire,explosion,noise,vibration,radiationanddusts);markings;andinstructions.
Provision and Use of Work Equipment Regulations 1998 (PUWER 98)Duties on users/employersTheseRegulationsapplytobuyingorhiringmachinery.Asanemployeryoumustensurethattheworkequipmentyouprovideissuitableandsafeforuse.
TheseRegulationsalsorequireyoutocheckthatanyequipmentyouacquireconformstotherelevantCommunityDirectives,egtheSupplyofMachineryRegulations.
Forpracticalpurposes,youcanstartbyensuringthat:
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n machinerysuppliedfrom1January1995comeswithacopyofthemanufacturer’sDeclarationofConformitywhichstatesthemanufacturer’snameandaddress,themachinemodelandtypeetc;
n themachinecomplieswiththeessentialhealthandsafetyrequirements(EHSRs);
n themachineisaccompaniedbyinstructionsforuseandis‘CE’marked.Sometimes,ifthemachineryisgoingtobeincorporatedintootherrelevantmachinery,egatnewspaperpresses,itwillcomewithoutCEmarkingandaDeclarationofConformity,inwhichcaseyoushouldasktoseethemanufacturer’sDeclarationofIncorporation.Oncetheequipmentisassembled,theassemblyasawholewillneedtomeettheEHSRstobeCEmarkedandyouorthepersonassemblingtheplantwillneedtodrawupaDeclarationofConformity.
Health and Safety at Work etc Act 1974, section 6ThissectionoftheActplacesdutiesondesigners,manufacturers,importersandsupplierstoensure,sofarasisreasonablypracticable,thatanyarticlesforuseatworkaresafeandwithoutriskstohealthandareaccompaniedbyadequateinformationforuse.
Word of cautionWhenpurchasingorhiringneworsecond-handmachineryandworkequipment,takespecialcaretoensurethatanyassociatedriskshavebeenassessedandthatyouarecomplyingwiththelaw.Youshouldcheckthatanycontractdealswithhealthandsafetyandthatthereisnomisunderstandingabouttheconditionofthemachineanditsguards.Thelawappliesnotonlytoguarding,buttootheraspectswhichmayaffecthealthandsafety,suchasnoisegeneratedbymachinery,solventvapouremission,andprotectionagainstfireandexplosion.
Situationsmayarisewhere‘CE’markedequipmentisnotentirelysafeasthemarkinganddeclarationprocessisaself-certifyingoneandmanufacturersorsuppliersmayhavefailedtofulfiltheirobligationsundertheRegulations.
Itisyourdutyasanemployertomakesurethatmachineryissafebeforeitisbroughtintouse.Employersareobligedbylawtocarryoutandactupontheirownassessmentsofhealthandsafetyrisks(see‘Planningandriskassessment’inChapter1).Assessbothnewandexistingmachineryandbringthemuptorequiredstandards.
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Chapter 6 ElectricitySee the ‘References’ section at the back of the book for details of publications which relate to Electricity
Relevant legislation
TheElectricityatWorkRegulations1989requireprecautionstobetakenagainsttheriskofdeathorinjuryfromelectricityatwork.The memorandum of guidance on the Electricity at Work Regulations 1989(HSR25)hasfurtherinformation.
Electricitycankill,atnormalmainsvoltageof230Vacandevenatvoltagesconsiderablylessthanthis.Eachyearabout1000accidentsatworkinvolvingelectricshockorburnsarereportedtoHSE,around30ofwhicharefatal.Firesstartedbypoorelectricalinstallationscancausedeathsandinjuries.Explosionscanbecausedbyelectricalapparatusorstaticelectricityignitingflammablevapoursordust.
General hazards and precautions
Checkthat:
n allelectricalwiringisinstalledtoasuitablestandardbyacompetentpersonsuchasaqualifiedelectrician.Poorworkmanshipcanbedangerousanddangerousinstallationsareillegal.(Allnewelectricalworkshouldbeinspectedandtestedbeforebeingputintouse.)BS7671:1992Requirements for electrical installationsgivesguidanceonsuitablestandards;
n powercablestomachinesareinsulatedandprotected,egsheathedandarmouredorinstalledinconduit.Allconnectionsshouldbeingoodcondition.Switches,fusesandcircuit-breakersshouldbelabelledtoidentifythecircuitstheyserve;
n thereisaswitchorisolatorneareach(fixed)machinetocutoffpowerinanemergency;
n plugs,socketsandfittingsareadequatelyprotectedandsuitablefortheworkingenvironment;
n wheneverpracticable,flexiblecablesandwiresdonottrailonthefloor.Theyaremoreliabletodamage,andmaycauseatrippinghazard;
n flexiblecableshaveasuitableplugwiththeflexfirmlyclampedtostopthewires(particularlytheearth)pullingoutoftheterminals;
n whereverreasonablypracticable,enoughsocketoutletsshouldbeprovidedforthenumberofappliancestobeusedatanyonetime.Whenthisisnotpossibleafusedextensionleadwithamultiwaysocketblockcanbeusedinappropriatelocations;
n frayedanddamagedcablesarereplacedcompletely.Joinlengthsingoodconditiononlybyusingproperconnectorsorcablecouplers-‘chocolate-block’connectorsdonotprovidethestrengthorprotectionrequiredforajointinacableandarenotsuitableforthispurpose;
n accessispreventedtoelectricaldanger,egbykeepingisolatorandfuseboxcoversclosed,securedand,itisstronglyrecommended,locked,withthekeyheldbyaresponsibleperson;
n fuses,circuit-breakersandotherdevicesarecorrectlyratedforthecircuittheyprotect;
n homeappliancessuchasfires,radiosandkettlesarenotbroughtinforuseatwork;
n therearenooverheadcablesthatcouldbeaccidentallystruckinareaswherelifttrucksoperate.
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Particular hazards and precautions for printing
Someprecautionsrelatetothespecialconditionstobefoundinprinting.Theseinclude:
n notusingportablefanheatersorhairdryersindarkroomsorinwetconditions-theyarenotdesignedforuseinsuchenvironmentsandcancauseelectricshocks;
n makingsurethatthepowertohigh-pressurewater-jetmachinesissuppliedthrougha30mAresidualcurrentcircuit-breakerwhichisregularlytestedbyoperationofitstestbutton.Thisprecautionwillprovideaddedprotectionagainstelectricalshock;
n ensuringelectricalequipmentisofsuitableexplosion-protectedconstructionifitistobeusedinapotentiallyexplosiveatmosphere.Potentiallyexplosiveatmospheresmay,forexample,ariseinsolventstorageareasandinsomeprocessareassuchasinthevicinityofflexographicandgravurepresses,andinkmixingareas.Youmayneedspecialistadvicetochoosethecorrectequipment.Lowvoltageequipment,eg12V,givesnoprotectionagainsttheriskofignitioninsuchenvironments.
Staticelectricitycanalsobeasourceofignitioninsuchenvironments.Thisisaparticularprobleminflexographicandgravureprinting.Importantprecautionsinclude:
n theusebyoperatorsofanti-staticfootweartopreventthebuild-upofelectrostaticchargeswhichmightcauseaspark.Wherethisisahazard,operatorsalsoneedtoavoidwearingclothingmadeofman-madefibre(thiscanhavetheadditionaladvantageofreducingtheseverityofburnsintheeventofafire);
n theuseofclosedmetalcontainerswhencarryingflammableliquidssuchassolvents;
n thebondingandearthingofmetalworkasnecessarytopreventaccumulationofstaticwhereflammableliquidssuchassolventsaretransferredbypipeorpoured.
SeeChapter7forfurtheradviceonfireandexplosion.
Inspection and maintenance
Allelectricalequipment,wiringinstallations(includingbatterysets),theirconnections(includingfixeditemsofmachinery)andportableelectrictoolsmustbemaintainedsofarasisreasonablypracticabletopreventdanger.Youwillneedtocarryoutinspectionandtestingtochecktheconditionoftheequipment,andfollowthisupwithrepairorreplacementwherenecessary.Thefrequencyoftheinspectionandtestingwilldependontheequipmentyouuseandwhereyouuseit.Youmayfindithelpfultokeeprecordsofinspectionandtesting.
Takesuspectorfaultyequipmentoutofuse,labelit‘DONOTUSE’and,whereappropriate,removetheplugandkeeptheequipmentsecureuntilacompetentpersonconfirmsthatitis,orhasbeenmadesafetouse.Makesureyouremployeesknowhowtoreportanydamageordefectstheydiscoverandwhotheyshouldtell.Don’toverlookhiredorborrowedelectricalequipmentorequpmentsuchasfloorpolisherswhichmaybeusedafterthepremiseshaveclosed.Checktoensurethatanyelectricalequipmentthatcontractorsbringontositeissafetouse.
Checkthatresidualcurrentcircuit-breakersworkbyoperatingthetestbuttonregularly,inaccordancewiththemanufacturer’sadvice.
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Anyonecarryingoutelectricalworkmustbecompetenttodoitsafely.Thismaymeanbringinginoutsidecontractors.IfyoudoneedtouseelectricalcontractorsyoushouldusethosewhobelongtoarecognisedtradeorganisationwhichcheckstheirworksuchastheNationalInspectionCouncilforElectricalInstallationContracting(NICEIC).Yourownstaffmustalsobecompetentifyoudotheworkin-house.
Ifyoudouseelectricalequipmentinflammableatmospheres,makesurethatspecialmaintenancerequirementsforexplosion-protectedequipmenthavebeenwrittendownandthatsomeonewithenoughtrainingisresponsibleforcarryingoutthework,andrecordsthattheyhavedoneso.Themanufactureroftheequipmentshouldbeabletogiveyouadviceonthis.
Nooneshouldbeallowedtoworkonornearexposedliveequipment.Inexceptionalcircumstancesliveworkingmaybepermissible,butonlyifthiscanbedoneinfullcompliancewithregulation14oftheElectricityatWorkRegulations1989andthepersondoingtheworkiscompetenttoundertakethespecifictask(s)involved.Ifindoubt,askyourhealthandsafetyinspectororenforcingauthorityforadvice.
Electric shock
Wouldyouknowwhattodoifsomeonereceivedanelectricshock?Knowingwhattodoshouldbepartofyouremergencyproceduresandfirst-aidarrangements.Thinkaboutdisplayingacopyofthe‘Electricshockplacard’whichshowsyouwhattodo.
Accident
Aminderreceivedanelectricshockwhenhetouchedametaltablebesidehismachine.Adamagedcablerunningalongthefloorwasincontactwiththetable,makingitelectricallylive.Themanwasoffworkforoneweek,buttheaccidentcouldhavehadfarmoreseriousconsequences.
Amanagerwaskilledwhileusingapressurewasher.Anelectricalfaultonthewashermadeitsframeandlanceliveat240V.Earthingwasinadequateandnoresidualcurrentdevicewasfittedinthesupply.
A16-year-oldtraineeprinterreceiveda240Velectricshockandburnstohisfingerswhenhetouchedaswitch,thecovertowhichhadbeenremovedandnotreplaced.
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Figure 45 Electricshockplacard
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Chapter 7 Fire and explosionSee the ‘References’ section at the back of the book for details of publications which relate to Fire and explosion
Relevant legislation
Requirementstoassessandcontrolfireandexplosionriskscanbefoundinthefollowingpiecesoflegislation:
n HealthandSafetyatWorketcAct1974(HSWAct)n ManagementofHealthandSafetyatWorkRegulations1999n Workplace(Health,SafetyandWelfare)Regulations1992n ProvisionandUseofWorkEquipmentRegulations1998(PUWER98)n SupplyofMachinery(Safety)Regulations1992(asamended)n Chemicals(HazardInformationandPackagingforSupply)Regulations1994
(CHIP)n HighlyFlammableLiquidsandLiquefiedPetroleumGasesRegulations
1972(HFL&LPG)(tobereplacedbyDangerousSubstancesandExplosiveAtmospheresRegulations(DSEAR))
n EquipmentandProtectiveSystemsforUseinPotentiallyExplosiveAtmospheresRegulations1996
n ElectricityatWorkRegulations1989n Petroleum(Consolidation)Act1928
(tobeamendedbyDSEAR)n FirePrecautions(Workplace)Regulations1997(asamended)(FPWR)n FirePrecautionsAct1971
Severalhundredfiresoccureveryyearintheprintingindustry.Therehavealsobeenanumberofexplosions.Insomeincidentspeoplehavebeenkilledorinjured;inmanyotherstherehasbeenextensivedamagetobuildings,equipmentandmaterials.
Explosionscanoccuratdryersusedinassociationwithflexographicpressesandwhenblanketwashingonheat-setweboffsetpresses(seeBSEN1539:2000Dryers and ovens in which flammable substances are released - Safety requirementsandprEN12753Thermal cleaning systems for exhaust gas from surface treatment equipment - Safety requirements).Theyoccurwhenflammablesubstances,suchassolvents,blanketwashetcareusedorstoredincorrectly,andthevapourformsanexplosivemixturewithair.
Risk assessmentTheManagementofHealthandSafetyatWorkRegulations1999andTheFirePrecautions(Workplace)Regulations1997containexplicitriskassessmentrequirementsinrelationtofiresafetycoveringbothgeneralfireprecautionsandprocessfireprecautions.
Fire risk management
Managementarrangementsareneededtoensurethatfirerisksareadequatelycontrolled.Theseshouldincludearrangementstoensurethat:
n theriskoffireoccurringisreducedtotheabsoluteminimum;n theriskoffirespreadingisminimised;n adequatefire-detectionandwarningsystemsareinplace;n everyoneisabletoescapefromthebuildingquicklyandsafely.
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Itmightbeappropriatetodesignateaseniormemberofthemanagementteamtohavespecificresponsibilityforfire-riskmanagementandstafftraining.
Athoroughfiresurveyislikelytobenecessarytoproperlyassessthefirerisksfrommaterialsandprocesses,theactionsnecessarytoreducetheriskoffireoccurringandarrangementsthatareneededintheeventoffirebreakingout.TheactionplaninFigure47dealswithbothidentificationandfollow-upaction.AnexampleisgiveninFigure46.
Figure 46 Exampleofaplanpreparedduringafireassessment
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Figure 47 Actionplanforfireriskmanagement
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General fire precautions
Theseareintendedtofacilitatetheunaidedevacuationofpremisesintheeventofanescalatingfire,egfire-alarmsystems,signage,meansofescapeandfire-fightingequipment.
TheFirePrecautions(Workplace)Regulations1997(FPWR)requireemployerstotakeaccountofgeneralfireprecautionsincludingfire-fighting,firedetection,emergencyroutesandexitsandtheirmaintenance.TheFPWRalsointroducerequirementsforcompetentassistancetodealwithgeneralfiresafetyrisks,provisionofinformationtoemployees,co-operationandco-ordinationwithothersandprovisionofcomprehensiveinformationonfireprovisionstooutsideemployers(egtheemergencyservices).SeeFire safety: An employer’s guideinthe‘References’section.
Yourlocalfireauthority,ratherthanHSE,willgiveyouadviceonthis.Youmayneedafirecertificateforyourbuilding-thiswilldependonthekindofbusinessyourunandthenumberofpeopleemployedinyourbuilding.ThemainpiecesoflegislationaretheFirePrecautionsAct1971andtheFirePrecautions(Workplace)Regulations1997(asamended).
Afirecertificateissuedbytheappropriateenforcingauthorityisgenerallyrequiredifmorethan20peopleareatworkinthepremisesatanyonetimeorifmorethantenpeopleareatworkatanyonetimeelsewherethanonthegroundfloor.Itdetailsthegeneralfireprecautionsrequiredatthepremises.Afirecertificatemayalsoberequiredifexplosiveorhighlyflammablematerialsarestoredorusedeitherin,onorunderthepremises.
Firecertificatesaretailoredspecificallytoindividualpremises.Theymaydemandrequirementsformaintainingthemeansofescapeandassociatedfireprecautions,trainingtheworkforce,limitingthenumberofpeoplewhomightbeinthepremisesatanyonetimeandotherprecautionsthathavetobeobserved.Normallytheoccupierofthepremisesisresponsibleforensuringallrequirementsofafirecertificatearemet.Thelawstatesthatfirecertificatesarekeptonthepremisestowhichtheyrelateandareavailableforreferenceorinspectionatalltimes.Ifanyofthefollowingareproposed,thefireauthorityshouldbeinformedinadvance:
n youintendtoundertakestructuralalterationstothebuilding;n youintendtoreorganisetheinternalarrangementsofthepremises,egmove
internalwallsand/ordoors;n youintendtostore,useorincreaseexplosiveorhighlyflammablematerialson
site.
Youneedtocheckthat:
n everyoneknowswhattodoincaseoffire.Displayclearinstructionsandhaveafiredrillperiodically;
n peopleknowhowtoraisethealarmandusetheextinguisherswhereappropriate;
n arrangementsareinplaceforcallingandmeetingthefirebrigadefollowinganysuspectedoutbreakoffire;
n enoughexitsareprovidedforeveryonetogetouteasily;n firedoorsandescaperoutesareprovidedwhichareclearlymarkedand
unobstructed;n fireescapedoorscanbeopenedeasilyfromtheinsidewheneveranyoneison
thepremises-don’tforget‘outofhours’working;n firedoorsareneverwedgedopen-theyaretheretostopsmokeandflames
spreading;
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FUEL
OXYGEN IGNITION
n ifawallismeanttobefire-resisting,ithasnoholesorgaps(egaroundpipework)andthewallcontinuesaboveanyfalseceiling;
n firealarmsarecheckedregularlyandwork.Cantheybeheardeverywhereovernormalbackgroundnoise?
n enoughfireextinguishersareprovidedandtheyareoftherighttype(andproperlyserviced)todealpromptlywithsmalloutbreaks.
Process fire precautionsTheseareintendedtopreventafirestarting.Theyrelatetospecialprecautionsinconnectionwithanyworkprocess,includingtheuseandstorageofmaterialconnectedwiththatprocess,topreventorreducethelikelihoodoffirebreakingoutandcontrolitsintensity.
Main fire hazardsThemainfirehazardsare:
n poorhousekeeping/accumulationofwastematerial;n handling/storageofflammableliquids,solidsandgases,egsolventsinlithoand
letterpressprinting;n heatinganddryingequipment,egultravioletcuringunits,gravuredryers;n poorlymaintainedorunsuitableelectricalequipment;n frictionalheat,egfromhotbearings;n frictionalsparks,egfromusingtools;n electrostaticsparks;n weldingandcutting;n smokingmaterials;n arsonandhorseplay
The Fire Triangle
Eachpointofthetrianglerepresentsoneofthethreeelementsessentialforfire:fuel,oxygenandasourceofignition.Firecanbepreventedbyavoidingallthreeoftheseelementsexistingsimultaneously.
Forexample,itisimportanttoensurethatcombustiblematerialssuchaspaper,boardandinksdonotcomeintocontactwithpotentialsourcesofignition,eghotsurfaces,staticelectricity,cigarettes,batterychargers.
Figure 48 Firetriangle
Storage and use of flammable liquidsFlammableliquidsinthiscontextincludethosematerialsdefinedbytheCHIPRegulationsas‘ExtremelyFlammable’,‘HighlyFlammable’and‘Flammable’(seeHSG51The storage of flammable liquids in containersandHSG140Safe use and handling of flammable liquids fordefinitions).
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Themainhazardinthestorageofflammableliquidsisfireinvolvingeitherthebulkliquidorescapingliquidorvapour.Mostvapoursareheavierthanairandcantraveloveralargedistance.Ignitioncanoccurforaslongasthevapourconcentrationexceedsthelowerexplosionlimit(LEL).Thisistheconcentration(percentage,byvolume,ofthematerialinair)belowwhichthemixtureistooleantoundergocombustion.
Figure 49 Flammableliquidstoresshouldbesecureandhavesuitablemarkings,ventilationand
spillageretention
Someflammableliquidscanbeeliminatedorsubstitutedbysubstancesthatarelessflammableornon-flammableanddonotrequirethesamespecialiststoragearrangements.Wherethiscannotbeachieved,flammableliquidsshouldbekeptinsuitablecontainersin:
n asafepositionintheopenair(wherenecessary,protectedfromdirectsunlight);orn astoreroomthatisinasafeposition;orn afire-resistingstore;orn ifthetotalquantityislessthan50litres,intheworkroominasuitablefire-
resistingcupboardorbin.
Allstorerooms,cupboardsorbinsshouldbemarkedtoindicatethenatureoftheircontents,eg‘highlyflammable’.Storeroomsshouldalsohaveadequateventilation.Allstoragefacilitiesshouldhavespillageretention,egbunding.
FurtherguidanceonthestorageofflammableliquidscanbefoundinHSG51Storage of flammable liquids in containersandHSG176Storage of flammable liquid in tanks.
Someofthekeystepsforthesafeuseandcontrolofflammableliquidsareto:
n minimisetheamountkeptattheworkplace;n dispenseandusetheminasafeplacewithadequatenaturalormechanical
ventilation;n keepcontainersclosed,egalwaysreplacethecapafteruseorusesafety
containerswithself-closinglids;n containspillages,egbydispensingoveratrayandhavingabsorbentmaterial
handy;n provideasafeprocedurefordealingwithspillagesshouldtheyoccur;n ensurethatallelectricalequipmentinstalledorbroughtintoareaswhere
flammableliquidsarestoredorusedissuitable,egintrinsicallysafeorflameproofwhereappropriate;
n controlignitionsources,egnakedflamesandsparks,andmakesurethat‘nosmoking’rulesareobeyed;
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n minimisethepotentialforignitionbystaticelectricitybyearthbondingwhereappropriateandintroduceregularbondingefficiencychecks;
n keepcontaminatedmaterial,egragscontainingisopropylalcohol(IPA)inasuitablylabelled,lidded,metalbin.Thisshouldbeemptiedregularlyandthecontentsdisposedofinasafemanner;
n preventtheaccumulationofcombustiblematerialssuchaswastepaperinareasinwhichhighlyflammableandflammableliquidsarekeptorused;
n disposeofwastesafely,usingpreviouslyagreedsafeworkingprocedures,egburnrubbishinasuitablecontainerwellawayfrombuildingsandflammablematerials.Havefireextinguishersonhand.Neverburnaerosolcansor‘brighten’fireswithflammableliquids.
FurtherguidancecanbefoundinHSG140Safe use and handling of flammable liquids.
Storage of paper reelsAsmallfireinapaperreelstorecanrapidlyescalateintoaseriousfireastheverticalreelsareabletounwrapquicklytofuelthegrowingfire.Thechimneyeffectoftheverticalreelscreatesadraughtwhichalsoexacerbatesthefire.
n Ensurethatloosepapersuchaswrappersandendsaredisposedofandthatdamagedreelsarewrappedortapedondelivery.
n Minimisethechimneyeffectbetweenadjacentreelsstackedonendbyreducingstackheightandthespacebetweenstackstolessthan25mm,andstaggeringthereels.
n Wherethiscannotbeachievedwithoutriskofdislodgingreelsinadjacentstacks,increasethespaceto1.1m.
n Ensuresprinklersystemsaredesignedtodealwithfireswithinstackedreels.n Provideameansofautomaticsmokeventing.n Rigorouslycontrolsourcesofignition.n Ensurethatthereisameansofescapefrominnerrooms.Ifpeopleworkinan
innerroom,provideavisionpanelandanalternativemeansofescape(ienotthroughthereelstore)ifnecessary(seeFire safety: An employer’s guide).
n Avoidstoringverticallystackedpaperreelsbeneathanoccupiedfloororbasement.
n Checkthatstackedreelsdonotadverselyaffecttheaudibilityofthefire-alarmsystem.
n Ensureadequatefireseparation(atleast1/2hourfireresistance)betweenstorageandproductionareas.
Charging electrically operated lift trucks
n Topreventaccidentalshortcircuitofthecellterminalsandignitionofhydrogenvapour,alwaysuseinsulatedtoolsandremovemetallicjewelleryfromtheneck,handsandwrist.
n Alwayscarryoutcharginginanareaintendedforthepurposewhichhasahighlevelofventilation(seeBS6133:1995Code of practice for safe operation of lead-acid stationary batterieswhichincludesaformulaforcalculatingventilationratesforbatterychargingrooms).
n Ensurethatlightandotherelectricalfittingsarepositionedawayfromtheimmediatechargingarea.
n Prohibitsmokingandnakedlightsfromthearea.n Alwaysensurethatthechargerisswitchedoffbeforemakingorbreakingthe
plugandsocketconnection.n Maintainallventplugsinpositionduringcharging.
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n Beforedisconnectingbatteryterminalconnections,switchoffallelectricalcircuitsincludingthechargerandensurethattheterminalconnectedtothevehiclebodyisdisconnectedfirstandreconnectedlast.
n Keepsuitablefire-fightingequipmentavailableinthearea.
Lithographic printing
n Observethegeneralprocessfireprecautionsdescribedearlierinthischapter.n Avoidtheuseofblanketwashes,inkstrippers,blanketreviversetcwithlow
flashpoints,egmethylethylketone(MEK).n Substitutelowflashpointproductswithhighflashpointpreparationssuchas
blendscontainingvegetablecleaningagents(VCA).n Whereinfrareddryersandultravioletcuringunitsareused,provideautomatic
systemstoshutofftheheat/lightsourceifpaperremainsunderthedrying/curingunitforanextendedperiod.
Explosion risks in blanket wash systemsSeriousexplosionshaveoccurredatblanketwashsystemsatheat-setweboffsetprinting.Explosionshaveoccurredindryersonweboffsetprintinglineswhenthewebhastransferredblanketwashsolventintothedryerandtheconcentrationofsolventvapourinthedryerhasexceededthelowerexplosionlimit(LEL)(See‘Precautionsfordryers’laterinthischapter).
Thedesignandoperationofheat-setdryersaresuchthatignitionofsolventvapourisalmostinevitableifaconcentrationabovethelowerexplosionlimitisformedwithinthedryers.Standardshavebeendevisedtoensurethesafeoperationofthistypeofplant.Youwillneedtocheckthatyourequipmenthasbeendesignedwithsafetyinmind.
Newdryersandwherefitted,thermaloxidisersshouldbedesignedaccordingtoBSEN1539:2000andprEN12753,whichdetailthemeasurestopreventandmitigatefireandexplosionhazardsindryersandovensinwhichflammablesubstancesarereleased.Youwillneedtoensurethatthesafetyfeaturesareunderstoodandthattheovenandassociatedcoatingequipmentareoperatedandmaintainedinaccordancewiththemanufacturer’sinstructions.
Thelowerexplosionlimitofflammableliquidsistemperaturedependent-animportantfactorwhichneedstobeconsideredwhendeterminingprocessoperatingconditions.Thestandardsalsogiveinformationonhowthelowerexplosionlimitisaffectedbyoperatingtemperature.
FordryersinstalledbeforethepublicationofBSEN1539youwillneedtocheckthattheyhave:
n suitablegassafetyfeaturesongas-fireddryers,includingsafetyshut-offvalves,ignitionsystems,flamefailuredevicesandpurgingarrangements.Equivalentsafetyfeaturesshouldbeincludedonoil-firedsystemswhereappropriate;
n adequateexplosion-reliefdoorsorpanelsonthedryer.Thisprotectioniscriticalifthedamagecausedbyanexplosionistobeminimised.Theareaandweightofexplosionreliefpanelsneedtobecarefullycalculated,sothattheyareeffectiveifthereisanexplosion;
n enoughexhaustventilationfromthedryer,sothatunderalloperatingconditionstheconcentrationofsolventinthedryerdoesnotexceedthelowerexplosionlimit.Toensurethis,dryersshouldbedesignedsothatundernormaloperatingconditionsthesolventlevelsaremaintainedatlessthan25%ofthelowerexplosionlimit.Asfailureoftheexhaustsystemmayhavecriticaleffects,itshouldbemonitoredsothatanyreductionintheairflowbelow
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pre-determinedlevelswillautomaticallyandsafelyshutdownthefuelsupplytothedryer,theblanketwashsystemandtheprintedweb.Itshouldalsoactivateavisibleandaudiblealarm;
n anannualchecktoconfirmthatsolventvapourlevelsinthedryerremainwithindesignparametersforalloperatingconditions.
Checktheautomaticblanketwashsystemsforthefollowing:
n themonitoringandcontroldevicesautomaticallyensurethatinallcircumstancestheoverallsolventconcentrationinthedryerdoesnotexceed25%ofthelowerexplosionlimit;
n thesystemisnotusedforthefirsttimeuntilithasbeencommissionedandsafeoperatinglimitsestablished.Thisshouldincludemeasurementofthemaximumconcentrationofsolventwithinthedryer,bothaboveandbelowtheweb,assolventapplicationisprogressivelyintroducedatadditionalprintunits;
n commissioningtestsusethemaximumwebwidthandallpapertypes.Wherenecessary,tomaintainsolventconcentrationswithinthedryertobelow25%ofthelowerexplosionlimit,anautomatictimedelayoperatesaftercompletionofoneblanketwashcyclebeforeanotherstarts;
n therearemeasurementchecksofsolventlevelsinthedryerannually,andafteranychangetooperatingconditions,plantorblanketwashtoensurethatvapourlevelsinthedryerremainwithindesignparametersforalloperatingconditions;
n thesolventorinkusedinthesystemisthesameasthatwhichwasusedwhenthesystemwascommissioned.Differentsolventsmayhavedifferentexplosionlimits,andachangeofsolventmayresultindangerousconditions.Checkwiththesupplierofthesystembeforemakinganychanges;
n theblanketwashsupplierhasprovidedinformationaboutthelowerexplosionlimitforthesolventused,inrelationtothetypicaldryeroperatingtemperatures(160-260ºC);
n thequantityofsolventappliedtotheblanketcylindersismetered,andistheminimumnecessary.Thisvolumewillhavebeensetduringcommissioning.Checkthatunauthorisedaccesstothecontrollingmechanismisprevented;
n themanualapplicationofadditionalsolventisstrictlyprohibited.Safetywillbecompromisediftheamountofsolventreachingthedryerisgreaterthanthatexpectedbythedesignerofthesystem;
n ifblanketwashdrip-traysareused,careistakensothattheydonotoverflowandallowthewebtotakeexcesssolventintothedryer;
n adequatewritteninformationhasbeenprovidedbythesupplierabouttheconditionsunderwhichthesystemhasbeencommissioned,operationallimitations,thesafetydevices,theresultsofcommissioningandnecessarymaintenancerequirements.Whereapplicable,thesuppliershouldhaveprovidedanECDeclarationofConformity;
n managers,operatorsandassistantsareadequatelytrainedintheexplosionhazardassociatedwithblanketwashingandinthenecessaryprecautionarymeasures.
Inaddition,whenblanketwashingbyhand,rememberthatitisimportantto:removeorbreakthewebbeforethedryer,anddon’tuseitasawiper;keepthequantityofsolventappliedtoaminimum.
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Fires in the printing industry
Fire in reel storeThreeemployeesdiedinafireinthereelstoreofaprintingfactory.Thefirestartedinsomereelsofpaperatoneendofthereelstoreinthesingle-storeyfactory.Therewasnofireseparationbetweenthereelstorageareaandtheproductionarea.Shortlyafterthefirewasfirstdiscoveredtherewasasuddenrapidspreadoffire(flashover)acrossthetopofreelsofpaperandthewholebuildingrapidlyfilledwithsmoke.Theroofcollapsedwithinminutes.
Horseplay with flammable thinnersA17-year-oldapprenticediedofextensiveburnsafteraninitiationceremonyinwhich2litresofflammablethinnerswerepouredonhisclothing.Thevictimwaschanginghissoakedclothinginatoiletcubiclewhensomematcheswerelit.Theapprenticewasengulfedinflamesanddiedthreeweekslaterofburnswhichcovered80%ofhisbody.
ArsonOnarrivingatawarehousejustaftermidnight,thefirebrigadefoundatimberteachestorpalletonfireoutsidedoubletimberdoorsinanalleywayadjacenttotheseven-storeybuilding.Thedoorswereburningandfirewasspreadingunderthedoorsintoastairwell.Thefirstandsecondfloorswerealsoalight.Firespreadwasrapidduetothetypeofstorageandunprotectedstairwaysinthewarehouseareas.Theentireseven-storeywarehousewasseverelydamaged.
Ignition of toluene vapourAprinterwasoffworkforsixweeksafterreceivingsevereburnstohisrighthandwhenastaticdischargeoccurredashewasusingatoluene-soakedragtocleanthedoctorbladeofagravureprintingpress.Itisthoughtthatanearliermodificationtoacoveratthedoctorbladehadreducedtheextractionsystem’sabilitytoremovevapoursgivenoffbytheprintingink.Anti-staticfootwearwasnotinuse.
Smoking near flammable solventAnemployeesustainedburnstohisfaceandhairashecleanedarollerwashingmachinewithflammablesolventwhilesmoking.Aftertheincidentallstaffwereinstructednottosmokeintheroomwherethemachinewaslocatedand‘nosmoking’signswerepostedup.
Explosion risks in flexographic and gravure
Theseprocessesoftenuseflammableinkswhichcreatesignificantfireandexplosionrisks.Considersubstitutionwithwater-basedinks.Wherethiscannotbeachieved:
n segregateprintingareasfromstorageareasandotherpartsofthebuildingwithhalf-hourfire-resistantpartitioning;
n mixinkswithinadedicatedfire-resistingroomprovidedwithspillageretentionandmechanicalventilation,whichisseparatefromthestoragearea;
n drumsandhandlingequipmentshouldbeearthbonded;n providelocalexhaustventilationatprintunitstopreventflammablevapour
enteringtheworkroomandreduceemployees’exposure.SeeHSG37An introduction to local exhaust ventilationandHSG54Maintenance, examination and testing of local exhaust ventilation(Chapter4references);
n ensuretheworkroomitselfisadequatelyventilated;n minimisetheamountofsolventvapourreleasedintotheairbycoveringinkducts
andkeepingsupplycontainersclosedwhennotinuse.Pumpinktopressesandreturntostorageusinganenclosedsystem;
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n whereconnectionsarefrequentlybrokenandre-made,useasealedendcoupling;
n makesurepipeworkandfittingsaretoasuitablestandard(suchasANSIB31.3)andmakearrangementsforplannedpreventivemaintenance;
n useinksandcoatingsataslowatemperatureaspossibletoreducetheamountofvapourproduced;
n ensurethatanyelectricalequipmentonthepressorintheimmediatearea,includingportableequipment,issuitableforuseinpotentiallyexplosiveatmospheres;
n thefanmotorofextractionequipmentshouldnotbelocatedinthepathofthevapour,egwithinthetrunking.Thetrunkingshouldbeoffire-resistingconstructionandfumesshouldbeexpelledtoasafelocation,preferablyathighlevel,andnotlocaltoairintakesforequipmentorventilationsystemsetc;
n providefixedfire-detectionandextinguishingsystemssuchasCO2,designedforbothmanualandautomaticoperation.Furthersolventshouldbepreventedfromenteringdryers/extractductingonoperationofthesystemanddampersshouldshuttostopthelossoftheextinguishingmedium;
n wherethereisasolventrecoveryunit,providetomonitoradampertoisolateitfromanyfireonthepressorintheducting;
n wherevapourdetectionequipmentisnotprovidedtomonitorinsideprintunits,takeregularmeasurementstoensurethattheatmosphereismaintainedbelow25%ofthelowerexplosionlimit;
n cleanrollers,cylindersandancillaryequipmentusinghighlyflammableliquidsonlyinacontainedsolvent-cleaningmachinewithexhaustventilationorinaventilatedpurpose-designedbooth;
n avoidthegenerationofstaticelectricitywhichcanigniteflammablevapourbytakingthefollowingprecautions:
– limittheflowspeedofpipedflammableliquidsto1m/secondwherewatercouldbepresentorto7m/secondwherethereisnopossibilityofthis;
– useanti-staticadditivestoincreasetheconductivityoftheliquid;– useconductive,bondedandearthedcontainers,pipeworkandhoses;– regularlychecktheresistancetoearthofallmetalpartsoffixedplant;
equippersonnelwithanti-staticfootwearandprotectiveclothingmadefromnaturalfibresandinstructthemnottoremoveitemsofouterclothinginareaswhereflammablevapourmaybepresent;
– avoidflooringmaterialsthatarehighlyinsulating;– provideelectrostaticeliminatorsconstructedtoanexplosion-protected
standardwhereinsulatingwebmaterialisbeingprintedon.
Precautions for dryers
NewdryersshouldbedesignedaccordingtoBSEN1539:2000whichdetailsmeasurestopreventormitigatefireandexplosionhazards.Fordryersinstalledbeforethepublicationofthisstandarditisnecessarytocheckthatcertainsafetyfeaturesareincorporated.(See‘Lithographicprinting’and‘Explosionrisksinblanketwashsystems’earlierinthischapter).
Dryersshouldbedesignedwithenoughairflowtokeepthesolventconcentrationbelow25%ofthelowerexplosionlimit-checkatcommissioning.Airflowshouldbemonitoredsothattheprintingprocessandmeansofheatingisstoppediftheairflowisinadequate.
Provideanemergencystopbuttononthedryerwhichshutsdownthemeansofheatingbutnottheexhaustventilation.
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Continuousmonitoringofthesolventconcentrationshouldbeprovidedwhereinexceptionalcircumstancesdryershavebeendesignedtooperatebetween25%and50%ofthelowerexplosionlimitandvapourconcentrationschangeslowlyrelativetodetectionandactivationofshut-downsystems.Suchdetectionequipmentshould:
n besuitableforthesolventtype;n besuitablycalibratedfortheconditionsofuse(egoperatingtemperature),
testedandmaintained;n sampleatthehighestvapourconcentrationpoints;n operateanaudibleandvisualalarm;n havetwoindependentmeansofmeasuringconcentration,eachcapableof
shuttingdowntheprintingprocessandheatsourcebeforethe50%lowerexplosionlimitisreached;
n bearrangedtofullyopendampersifthereisamalfunctioninthemonitoringsystem;
n monitortheprogressionofthesolventvapourconcentration.
Note A detailed risk assessment should be carried out to identify additional control measures which may be necessary to prevent and mitigate hazardous conditions arising, eg explosion relief. Further
information is given in BS EN 1539.
Precautions for coating machines
Makesurethatfansexhaustingpotentiallyexplosiveatmospheresorcombustibledustsareexplosionprotected.Ductingusedforexhaustingthesematerialsshouldbeoffire-resistingconstruction,conductiveandelectrostaticallygrounded.Thefanmotorshouldnotbelocatedwithintheduct,ieinthepathofthevapour.Fumesshouldbeexhaustedtoasafelocation,preferablyathighlevel,awayfromairintakesforotherequipmentorventilationsystems.
Explosion-protectedelectricalequipmentwillonlyberequiredonthecoaterwherethereisariskofgeneratinganexplosiveatmosphere,forexamplewhenusingahighlyflammableliquidorheatingaflammableliquid,suchastheelectricdrivemotorontherecirculationpumpsandswitches(wherethesearemountedonthepump).Makesurethatthedistancebetweenthedrivemotorandtheouterflangeofthelanternagitatorforviscositycontrolisatleast50mmandadiscismountedontheshafttoincreasethepreventiveeffect.
Precautions for laminators with glue application
Asforcoatingmachines,anyfansexhaustingpotentiallyexplosiveatmospheresorcombustibledustsshouldbeexplosion-protected,andtheductingusedforexhaustingthesematerialsshouldbemadeoffire-resistingmaterial,conductiveandelectrostaticallygrounded.Thefanmotorshouldnotbelocatedwithintheduct,ieinthepathofthevapour.Fumesshouldbeexhaustedtoasafelocation,preferablyathighlevel,awayfromairintakesforotherequipmentorventilationsystems.
Explosion-protectedelectricalequipmentwillonlyberequiredonthelaminatorwherethereisariskofgeneratinganexplosiveatmosphere,forexamplewhenusingahighlyflammableliquidorheatingaflammableliquid.
Theelectricdrivemotoronlaminatingmaterialrecirculatingpumpsshouldhaveexplosionprotectioninaccordancewiththerelevantstandard,currentlyBSEN
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50018:2000Electrical apparatus for potentially explosive atmospheres. Flameproof enclosure ‘d’,orBSEN50019:2000Electrical apparatus for potentially explosive atmospheres. Increased safety ‘e’.
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Chapter 8 MaintenanceSee the ‘References’ section at the back of the book for details of publications which relate to Maintenance
Relevant legislation
n ProvisionandUseofWorkEquipmentRegulations1998(PUWER98)n Workplace(Health,SafetyandWelfare)Regulations1992n HealthandSafetyatWorketcAct1974(HSWAct)n ControlofSubstancesHazardoustoHealthRegulations1999(COSHH)n PressureSystemsSafetyRegulations2000n ElectricityatWorkRegulations1989n LiftingOperationsandLiftingEquipmentRegulations1998(LOLER)
What needs maintenance?
Allbuildings,equipmentandplantneedtobemaintainedingoodworkingorderandingoodrepairtopreventanydangeroussituations.
Statutory testing and thorough examination
Thelawcontainssomespecificrequirementsformaintenancesuchasperiodictestingand/orthoroughexamination.Forexample:
n liftingchainsandropes-generallyeverysixmonths(althoughthiswillbedependentonthefindingsofanappropriateriskassessment);
n liftsandhoists-generallyeverysixmonths(althoughthiswillbedependentonthefindingsofanappropriateriskassessment);
n cranes-generallyevery12months(althoughthiswillbedependentonthefindingsofanappropriateriskassessment);
n steamboilers/airreceiversandpressuresystems-inaccordancewithyourcompetentperson’swrittenschemeforexaminationofpressurevessels;
n localexhaustventilation-minimumevery14months(seetheGeneralApprovedCodeofPracticefortheControlofSubstancesHazardoustoHealthRegulations1999,listedinthe‘References’sectionforChapter4).
Periodictestssuchastheseneedtobecarriedoutbyacompetentperson-thismaybeyourinsuranceengineer.
Otherexamplesofrequiredandindustryrecommendedinspectionsandchecksinclude:
n inspectionofpersonalprotectiveequipment,eghearingprotection;n weeklyinspectionofscaffolds;n monthlyexaminationofbreathingapparatus/rescueequipment;n regularvisualinspectionsofelectricalequipmentatappropriateintervals.
Practicalexperience/manufacturer’sguidancewillhelptodeterminethefrequencyatwhichinspectionandtestbyacompetentpersonisnecessary(egquarterly/annually),andthisshouldbebackedupwithmorefrequentchecksbytheusers.Keepingrecordswillhelptodeterminethefrequencies.GuidanceiscontainedinHSG107Maintaining portable and transportable electrical equipment.
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Routinelubrication,serviceandoverhaulactivitiesmightinclude:
n cleaningoffloorsandmachineryaccessplatforms/walkways(egflexographicpresses);
n annualservicingoffireextinguishers.
Beguidedbythemanufacturer’srecommendationswhenworkingoutyourownmaintenanceschedulesforitemssuchasvehicles,lifttrucks,ventilationplant,ladders,portableelectricalequipment,protectiveclothingandequipmentandmachineguards.Checkthelegalrequirements,especiallyforexaminationsbyacompetentperson.
Maintenance and inspection required by PUWER 98Maintenance frequencyEquipmentmayneedtobecheckedfrequentlytomakesurethatsafety-relatedfeaturesareworkingproperly.Somefaultsinsafety-criticalsystemscouldremainundetectedunlessappropriatechecksaremade.Thefrequencyofmaintenancechecksshouldbedeterminedbyfactorssuchastheoperatingenvironment,theintensityofuse,thevarietyofoperationstheequipmentisusedfor,andtherisktohealthandsafetyfrommalfunctionorfailure.
Maintenance managementPoweredequipmentshouldbeaccompaniedbyamaintenancemanual,whichdetailsthemanufacturer’srecommendationseitherforkeepingtheequipmentinworkingorderorforsafetyreasons.Maintenancemanagementtechniquesincludeplannedpreventivemaintenance,condition-basedmaintenanceandbreakdownmaintenance.Whereyouhavesafety-criticalpartswhichcouldfailandrenderguardsorotherprotectiondevicesinoperable,youwillneedaformalsystemofplannedpreventivemaintenanceorcondition-basedmaintenance.
AgoodexampleofthemaintenancechecksrequiredunderPUWER98isthedailycheckofguardsandsafetymechanismsbymachineoperators.Itisrecommendedthatyoukeepamaintenancelogtorecordthesechecks,whichmaycompriseaseriesofcompletedguardchecklists.Thisisparticularlyimportantinthecaseofhigh-riskequipmentsuchaspower-operatedguillotinesandhand-fedplatens,butalsoappliestopressandothermachineryguarding.Whereyouhavealog,youneedtokeepituptodate.
InspectionUnderPUWER98,whereriskassessmentidentifiesthatamajorinjuryorworsecouldoccurbecauseofincorrectinstallationorre-installation,deteriorationorexceptionalcircumstancesaffectingthesafeoperationofworkequipment,inspectionisnecessary.Thepurposeofinspectionistoidentifywhethertheequipmentcanbeusedsafelyandtodetectanydeteriorationbeforeitcausesunacceptablerisk.
Inspectionwillvaryfromsimpleexternalexaminationtocomprehensiveinternalexaminationincludingdismantlingandtesting.Itshouldalwaysincludesafety-relatedparts.Individualscarryingouttheinspectionwilldetermineitsnatureandshouldhavethenecessaryknowledgeandexperience.
Exampleswhereinspectionisneededbecauseequipmentoperationiscriticallydependentonitsconditioninuseanddeteriorationwouldleadtoasignificantrisktotheoperatorinclude:
n daily/monthly/six-monthlytestingofguillotinesafetydevices(seethePIACbookletThe guide to safe use of power-operated paper-cutting guillotines);
n daily/annualtestingofhand-fedplatens(seeChapter5);
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n daily/weeklytestingoftripnipbarsonsheet-fedoffsetpresseswheretheslowcrawlsafesystemofworkforcleaningisbeingused(seeChapter5).
Safety during maintenance work
Duringmaintenancework,conditionsareverydifferentfromthosenormallyencountered,andnewhazardsmaybeintroduced.Itisessentialthateveryoneconcernedisawareofthehazardsandofthecorrectprecautions.
Additionalpersonalprotectiveequipmentmaybeneededduringmaintenanceactivities,egoveralls,protectivefootwearandheadwear.Don’tforgetglovesforhandlinginkymachineparts,egchanginginkrollersonalithopressusingUVinks.
Safetyduringmaintenanceactivitiescanbeachievedbyusingisolation,lock-offandpermit-to-workprocedures.Generallyspeaking,simpleisolationproceduresmaybesuitableforminormaintenanceworkandformallock-offproceduresformoremajormaintenancework.
Permits to workApermit-to-worksystemisaformalwrittensystemusedtocontrolcertaintypesofpotentiallyhazardouswork.Thepermitdetailstheworktobedoneandthenecessaryprecautionstobetaken,andformsanessentialpartofmanysafesystemsofworkformaintenanceactivities,forexampleallowingworktostartonlyaftereffectiveisolationhasbeenachieved.Permitswillalwaysbeneededwhennormalsafeguardscannotbeusedorwhennewhazardsareintroducedbythework,forexamplehotworkorworkwheresomeonehastoenteraconfinedspace.
Itisessentialthatthoseaskedtodotheworkunderstandthattheycannotstartuntilthepersonincontrolofissuingapermithasfullyexplainedtheprecautionstobetakenandissatisfiedthattheyhavebeencompliedwith.Thismayincludeprovisionofeffectiveisolationandlock-off.Permitsshouldbeformalisedbymeansofawrittenhandoverprocedure,whichincludesthesignaturesofthosepeopleissuingapermitandthosedoingthework.
Permitsshouldcontainthefollowing:
n clearandunambiguousinformationandinstruction;n exactdetailsoftheitemofplantonwhichtheworkisrequired,thenatureof
thework,andtheprecautionsneededtoensurethesafetyofallpersonnel;n thestartandexpirytimeandanyconditionsunderwhichworkshouldcease
shouldbedetailed;n aplaceforthepermitissuertosignthattheyhavesatisfiedthemselvesby
personalinspectionthatallthenecessaryactionforworktocommencehasbeentakenbeforeastartismade;
n aplaceforthepermitissuertosignthattheyhavecheckedcompletionoftheworkbeforesigningthepermitoff.
Makesurethattheissuerhasenoughtechnicalknowledgeofthehazardsandprecautionstobetakenaswellastheauthoritytorequireotherresponsiblepeopletomakerecommendationswheretheyhavespecialknowledge,andtoco-ordinatethedutiesofallconcerned.
Permit-to-workprocedureswillnormallybeneededforactivitiessuchasthefollowing:
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n entryintovessels,confinedspacesormachines;n hotworkwhichcouldcauseexplosionorfire;n building,maintenanceorinstallationworkbycontractors,especiallywherethis
interfaceswithnormalactivities;n mechanicalorelectricalworkrequiringisolationofthepowersource,egbefore
workinginsidelargemachines;n workonplant,mixers,boilersetcwhichmustbecutofffromthepossibleentry
offumes,gas,liquidsorsteam.
Isolation and lock-off procedures
Isolationproceduresusuallycomprisethefollowing:
n switchoff;n disconnectplugorswitchoffatisolator;n tagisolator.
Inadditiontotheabove,lock-offproceduresusuallyinvolvethefollowingsteps:
n isolatethemachinefromthemainsupplybylockingoffthepower;n useasafetylockwithonlyonekeywhichiskeptbythepersondoingthe
work;n useamultiplehaspwhereseveralpeopleareworkingsoeachcanfittheirown
lock;n putawarningnoticeontheisolator.
Accidents
Anexperiencedguillotineoperatorlostfourfingersononehandwhenarepeatstrokeoccurred.Themachinehadnotbeenmaintained,itsbrakewaswornandoilyandtheautomaticsweepawayguarddidnotoperatetoitsfullextent.PIAC-recommendedexaminationswouldhaveidentifiedthesefaultsearlyenoughtopreventanaccident.
Amachineoperatorhadhisrightindexfingerseverelycrushedwhilecleaningtheinkrollersofabagprintingmachine.Theinterlockforthehingedguardhadworkedlooseandheinadvertentlydepressedthestartbutton.Dailycheckingandmaintenanceofthesafetydevicewouldhavepreventedtheaccident.Shroudingofthestartbuttonwouldhavepreventedaccidentaloperationofthebutton.
Theoperatorofathree-knifetrimmerreceivedanelectricshockwhilepickingupaknifefromthefloorandrestingonehandonthemachine.Investigationbyanelectricianrevealedafaultyearthconnection.Regularplannedmaintenancewouldhaveidentifiedthisdefect.
Anexperiencedfitterwaskilledwhileworkingatthefeedendofapapercuttingandcreasingmachinewhentheoperator,whodidnotseehim,startedupthemachine.Therewasnosafesystemformaintenanceworkandthemachinehadnotbeenisolated.
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Appendix 1 Safeguarding termsAudible pre-start warning device-adevice(normallyautomaticondepressionofastartorslowcrawlcontrolonlargermachinery)thatdeliversaclearlyaudiblesignalbeforestart-upofthemachine.(Seeguidanceanddiagramsunder‘Machinecontrols’inthe‘Safetyhazardsbyprocesssection’ofChapter5.)
Contra-rotating rollers/cylinders-rollers/cylindersthatrotatetowardseachother.
Crawl-slowspeed,wheremachinescanrunatcrawlspeedswithguardsopentheyshouldbecapableofrunningatslowcrawlonly(see‘Slowcrawl’).Wheremachinesrunatcrawlspeedswithguardsinposition/closed,thecrawlspeedscanbeinexcessofthosesetoutforslowcrawlasthecrawlinthiscontextisnotdesignedtobeasafetyfeature.
Electrosensitive safety system-electrosensitiveprotectiveequipment,egphotoelectricsafetysystem.
Emergency stop device-readilyaccessiblestopcontrolsintendedtoeffectarapidresponsetoapotentiallydangeroussituation.Notdesignedforuseasastopduringnormalday-to-dayoperation.Commontypesincludemushroom-headedbuttons,pushbars,pullwireandkickplates.
Fail to danger-anyfailureofthemachinery,itsassociatedsafeguards,controlsorpowersupplythatleavesamachineinadangerousorunsafecondition.
Fail to safety/fail-safe-anyfailureofthemachinery,itsassociatedsafeguards,controlsorpowersupplythatleavesthemachineinasafecondition.
Fixed guard-guardsthatrequireatoolforremoval,eganAllenkeyorspanner.Wingnutsorsimilararenotacceptable.OpeningsinfixedguardsarepermissibleprovidedsafetyreachdistancesaremaintainedinaccordancewithBSEN294(see‘Machinerystandards’intheReferencessection).
Gap covers-usuallycurvedmetalsectionsdesignedtobefittedinthegapsofplateandblanketcylinderstocreateacylinderofsmoothcircumference.
Guard-aphysicalbarrierthatpreventsorreducesaccesstoadangerpointorarea.
Guard locking-anadditionalsafetyfeatureofcertaininterlockedguardingformachineswithlongrundowntimeswhichpreventstheguardsfrombeingopeneduntildangerousmovementwithintheguardedareahasstopped.
Hickey picking-removalofhickeys(piecesofflufforotherforeignbodies),usuallyfromthesurfaceofprintingcylinders.
Hold-to-run controls(deadman’scontrol)-permitmovementofamachineonlyoncontinuedactivationofacontrol.Hold-to-runcontroldevicesshouldbedesignedtoallowmovementlimitedtoamaximumof25mmorwithamaximumoperatingspeedof1m/minorwherethiswouldreducetheabilityofthemachinetoperformitsfunctionandtherewouldbenosubstantialincreaseinhazardmovementlimitedtoamaximumof75mmorwithamaximumoperatingspeedof5m/min.
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Inch-limitedmovement.Movementshouldbelimitedto25mm,or75mmwherethisisnotpossibleanddoesnotincreasethehazardssubstantially.Inchingisnotcontinuousmotionunderhold-to-runcontrol.
In-running nip-trappinganddrawing-inhazardcreatedbyrotatingrollersorcylinders.Canoccurbetweentwocontra-rotatingrollers(poweredornon-powered);onerotatingrollerandastationaryrolleroradjacentfixedpartofthemachine;rollersrotatinginthesamedirectionbutwithdifferentperipheralspeedsorsurfaceproperties(friction);guiderollersanddrivingbelts,conveyorbeltsandpossiblytheweb.
Integrity-theabilityofdevices,systemsandprocedurestoperformtheirfunctionwithoutfailureordefeat.
Interlock-asafetydevicethatinterconnectsaguardwiththecontrolsystemorthepowersystemofthemachine.
Interlocked guard-aguardthatwhenopenedoperatesaninterlocktostopmovementofdangerouspartsbeforetheycanbereachedbyanoperatororotherperson.
Isolate-theremovalofallsourcesofenergyinasecuremanner,iebyensuringthatinadvertentreconnectionisnotpossible.
Lift out/pop out rollers-rollersthatarenotfixedinpositionandarelightenoughtoliftoutofpositionifablockageorentanglementoccurswithoutcausinginjury.
Multi-operator presses-pressesdesignedtobeoperatedbymorethanoneperson.
Nip bar-fixedsection,normallymetal,eitherroundorangled,runningalongthelengthofrollersorcylinderssituatednomorethan6mmfromthecylinderorrollersurfacedesignedtominimisetheriskofentanglementbythenipcreatedbycontra-rotatingrollers.
Safe by position-outofreach.SeealsosafetyreachdistancesinBSEN294(see‘Machinerystandards’intheReferencessection).
Safe system of work or safe working practice-amethodofworkingthateliminatesorreducestheriskofinjury.
Safety device/protective device-adeviceotherthanaguardthateliminatesorreducesdanger.
Safety reach distance-safetydistancethatshouldpreventdangerouspartsfrombeingreachedbyoperatorsorothers.
Slow crawl-safety-relatedrestrictedoperatingspeed.Asarule,theslowcrawlspeedshouldbesetatamaximumoperatingspeedof1m/min,or5m/minwherethisisnotpossiblebecauseitwouldreducetheabilityofthemachinetoperformitsfunctionandwheretherewouldbenosubstantialincreaseinhazard.
Slow speed-productioncrawl(withguardsinposition)-seealso‘Crawl’.
Trip devices-deviceswhichbringdangerouspartsofmachinerytorestwhenactivated(egknocked)byoperatorsorotherpeople.
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Trip nip bar-similartoafixednipbarbutwhendeflectedactstocutthepowersupplytothemotor,causingthepresstocometoarapidbutcontrolledstop.Thewithdrawalpath/deflectionofthetripbarshouldbelongerthanthestoppingpathofthehazardousmovement.
Tunnel guard-fixedorinterlockedguardthatpreventsaccesstodangerouspartsusingtheprinciplesofsafetyreachdistancesinconstructionoftheguard,oftenusingatunnelshape.
Two-hand control-controlsdesignedsothatsimultaneousoperationofthecontrols(withinapproximately0.5seconds)isrequiredbeforethemachinewilloperate.Operationofthemachinebysuchcontrolsshouldusuallyallowlimitedmovement,egasinglestrokeofaguillotine,ormovementatslowcrawlspeedsonly.Hazardousmovementshouldstopwheneitheractuator/controlisreleased.
Wander lead control/pendant control-portablecontrolpanelusuallyonflexiblearmouredcableleadallowingoperationofthemachinefromdifferentpositions.Ifthecontrolallowsoperationofthemachinewithguardsopenitshouldoperateasatwo-handcontrol(see‘Two-handcontrol’).
Web-driven rollers-non-poweredrollersthatactasifpoweredduetothedrivingforceoftheweb.
Zoning-eachcontrolonlyallowsoperationofalimitedpressorassociatedareawithaguardopenwhenguardselsewherethatarenotclearlyvisibleareclosed,egatprintunitsoflargerpresses.
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Appendix 2 Example risk assessment form
Thisisasuggestedriskassessmentform.Youdonothavetousethis-itismerelyanexampleofthe
sortofformyoumayuse
RISK ASSESSMENT NO
Site Area
Operationscoveredbytheassessment
Maximumnumberofpeopleexposed:
Frequencyanddurationofexposure:
Hazards
Actiontakentoreducerisk Residual risk
Likelihood Severity
Hazardsstilloutstanding
Assessmentofresidualrisk:low/medium/high
Furtheractionsrequired: Person Dateresponsible completed
Signed: Date Reviewdate
Position:
DateResponsibleDirector’sapproval
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Appendix 3 Assessing hazards in a small print works
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ReferencesChapter 1 Managing health and safety
Management of health and safety at work. Management of Health and Safety at Work Regulations 1999. Approved Code of Practice and guidanceL21(Secondedition)HSEBooks2000ISBN0717624889
Homeworking: Guidance for employers and employees on health and safetyLeafletINDG226HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN071761204X)
Working alone in safety: Controlling the risks of solitary workLeafletINDG73(rev)HSEBooks1998(singlecopyfreeorpricedpacksof15ISBN0717615073)
RIDDOR explained: Reporting of Injuries, Diseases and Dangerous Occurrences RegulationsLeafletHSE31(rev1)HSEBooks1999(singlecopyfreeorpricedpacksof10ISBN0717624412)
A guide to the Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1995L73(Secondedition)HSEBooks1999ISBN0717624315
RIDDOR reporting: Information about the new incident centreLeafletMISC310HSEBooks2001
First aid at work. The Health and Safety (First Aid) Regulations 1981. Approved Code of Practice and guidanceL74HSEBooks1997ISBN0717610500
First aid at work: Your questions answeredLeafletINDG214HSEBooks1997(singlecopyfreeorpricedpacksof15ISBN0717610748)
Basic advice on first aid at workLeafletINDG215(rev2)HSEBooks1999(singlecopyfreeorpricedpacksof20ISBN0717624234)
Health and safety in construction. Construction (Design and Management) Regulations 1994. Approved Code of PracticeHSG150HSEBooks2001ISBN0717621065
Having construction work done? Duties of clients under the Construction (Design and Management) Regulations1994LeafletMISC193HSEBooks1999
A guide to the Construction (Health, Safety and Welfare) Regulations1996LeafletINDG220HSEBooks1996(singlecopyfreeorpricedpacksof10ISBN0717611612)
Consulting employees on health and safety: A guide to the lawLeafletINDG232HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN0717616150)
A guide to the Health and Safety (Consultation with Employees) Regulations 1996. Guidance on RegulationsL95HSEBooks1996ISBN0717612341
Safety representatives and safety committeesL87(Thirdedition)HSEBooks1996ISBN0717612201
Essentials of health and safety at workHSEBooks1994ISBN071760716X
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Health and safety law: What you should knowLeafletHSEBooks1999(pricedpacksof25ISBN0717617025)
Successful health and safety managementHSG65(Secondedition)HSEBooks1997ISBN0717612767
Five steps to risk assessmentLeafletINDG163(rev1)HSEBooks1998(singlecopyfreeorpricedpacksof10ISBN0717615650)
A guide to risk assessment requirements: Common provisions in health and safety lawLeafletINDG218HSEBooks1996(singlecopyfreeorpricedpacksof5ISBN0717612112)
Working together: Guidance on health and safety for contractors and suppliersLeafletINDG268HSEBooks1998(singlecopyfreeorpricedpacksof10ISBN0717615480)
Managing health and safety: Five steps to successLeafletINDG275HSEBooks1998
Chapter 2 Training
PUWER 1998: Provision and Use of Work Equipment Regulations 1998. Open learning guidanceHSEBooks1999ISBN0717624595
LOLER 1998: Lifting Operations and Lifting Equipment Regulations 1998. Open learning guidanceHSEBooks1999ISBN0717624641Managing health and safety: An open learning workbook for managers and trainersHSEBooks1997ISBN0717611531
The training of first aid at work: A guide to gaining and maintaining HSE approvalHSG212(Secondedition)HSEBooks2000ISBN071761896X
Five steps to information, instruction and trainingLeafletINDG213HSEBooks1996(singlecopyfreeorpricedpacksof10ISBN071761235X)
Printing industry: Health and safety training package. An open learning packagePIAC/HSEBooks1998ISBN0717614816
Chapter 3 Workplace and transport safety
Workplace health and safety
Workplace health, safety and welfare. Workplace (Health, Safety and Welfare) Regulations 1992. Approved Code of PracticeL24HSEBooks1992ISBN0717604136
Workplace health, safety and welfare: A short guide for managersLeafletINDG244HSEBooks1997(singlecopyfreeorpricedpacksof10ISBN0717613283)
Lighting at workHSG38(Secondedition)HSEBooks1997ISBN0717612325
Display screen equipment work. Health and Safety (Display Screen Equipment) Regulations 1992. Guidance on RegulationsL26HSEBooks1992ISBN0717604101
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Working with VDUsLeafletINDG36(rev1)HSEBooks1998(singlecopyfreeorpricedpacksof10ISBN0717615049)
Seating at workHSG57(Secondedition)HSEBooks1997ISBN0717612317
Young people at work: A guide for employersHSG165(Secondedition)HSEBooks2000ISBN0717618897
Thermal comfort in the workplace: Guidance for employersHSG194HSEBooks1999ISBN0717624684
Slips and trips: Guidance for employers on identifying hazards and controlling risksHSG155HSEBooks1996ISBN0717611450
Preventing slips, trips and falls at workLeafletINDG225HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN0717611833)
Safe movement of vehicles
Managing vehicle safety at the workplace: A short guide for employersLeafletINDG199HSEBooks1995(singlecopyfreeorpricedpacksof10ISBN0717609820)
Rider-operated lift trucks. Operator training. Approved Code of Practice and guidanceL117HSEBooks1999ISBN0717624552
Safety in working with lift trucksHSG6(Thirdedition)HSEBooks2000ISBN0717617815
Safe use of lifting equipment. Lifting Operations and Lifting Equipment Regulations 1998. Approved Code of Practice and guidanceL113HSEBooks1998ISBN0717616282
Workplace transport safety: Guidance for employersHSG136HSEBooks1995ISBN0717609359Reversing vehiclesLeafletINDG148HSEBooks1993(singlecopyfreeorpricedpacksof15ISBN0717610632)
Asbestos
Managing asbestos in premisesLeafletINDG223(rev2)HSEBooks2001(singlecopyfreeorpricedpacksof10ISBN0717620921)
Chapter 4 Health risks
Need help on health and safety? Guidance for employers on when and how to get advice on health and safetyLeafletINDG322HSEBooks2000(singlecopyfreeorpricedpacksof10ISBN0717617904)
Health surveillance at workHSG61(Secondedition)HSEBooks1999ISBN071761705X
Understanding health surveillance at work: An introduction for employersLeafletINDG304HSEBooks1999(singlecopyfreeorpricedpacksof15ISBN0717617122)
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Hazardous substances
General COSHH ACOP (Control of substances hazardous to health) and Carcinogens ACOP (Control of carcinogenic substances) and Biological agents ACOP (Control of biological agents). Control of Substances Hazardous to Health Regulations 1999. Approved Codes of PracticeL5(Thirdedition)HSEBooks1999ISBN0717616703
COSHH a brief guide to the regulations: What you need to know about the Control of Substances Hazardous to Health Regulations 1999 (COSHH)LeafletINDG136(rev1)HSEBooks1999(singlecopyfreeorpricedpacksof10ISBN0717624447)
Control of chemicals in printing: COSHH essentials for printersPIAC/HSEBooks2000ISBN0717618358
COSHH essentials: Easy steps to control chemicals. Control of Substances Hazardous to Health RegulationsHSG193HSEBooks1999ISBN0717624218
Safe use of printing chemicals: COSHH and substitutionVideoHSEBooks1998ISBN0717618587
A step by step guide to COSHH assessmentHSG97HSEBooks1993ISBN0717614468
Seven steps to successful substitution of hazardous substancesHSG110HSEBooks1994ISBN0717606953
Why do I need a safety data sheet?LeafletINDG182HSEBooks1994(singlecopyfreeorpricedpacksof10ISBN0717608956)
Working safely with solvents: A guide to safe working practicesLeafletINDG273HSEBooks1998
Health risk management: A guide to working with solventsHSG188HSEBooks1998ISBN0717616649
Occupational exposure limits 2002GuidanceNoteEH40HSEBooks2002ISBN0717620832
Specific process health hazards
Safety in the use of inks, varnishes and lacquers cured by ultraviolet light or electron beam techniquesPIAC/HSEBooks1993ISBN0118820451
Ozone: Health hazards and precautionary measuresGuidanceNoteEH38(rev)HSEBooks1996ISBN0717612066
Electrical risks from steam/water pressure cleanersGuidanceNotePM29(Secondedition)HSEBooks1995ISBN0717608131
Monitoring strategies for toxic substancesHSG173HSEBooks1997ISBN0717614115
Organic isocyanates in airMDHS25/3HSEBooks1999ISBN0717616681
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Isocyanates: Health hazards and precautionary measuresGuidanceNoteEH16(Fourthedition)HSEBooks1999ISBN0717617017
Safe use of isocyanates in printing and laminatingPIAC/HSEBooks1997ISBN0717613127
Noise
Reducing noise at work. Guidance on the Noise at Work Regulations 1989L108HSEBooks1998ISBN0717615111
Noise at work: A guide for employeesLeafletINDG99(rev)HSEBooks1991(singlecopyfreeorpricedpacksof20ISBN0717609626)
Ear protection: Employers’ duties explainedLeafletINDG298HSEBooks1999(singlecopyfreeorpricedpacksof5plus5postersMISC185and30pocketcardsINDG299ISBN0717624846)
Protect your hearingPocketcardINDG299HSEBooks1999(singlecopyfreeorpricedpacksof25ISBN0717619249orpricedpackof30plus5postersMISC185and5leafletsINDG298ISBN0717624846)
Noise reduction at buckle folding machinesPIAC/HSEBooks1986ISBN0118838490
Noise reduction at web-fed pressesPIAC/HSEBooks1988ISBN0118839721
Health surveillance in noisy industries: Advice for employersLeafletINDG193HSEBooks1995(singlecopyfreeorpricedpacksof10ISBN0717609332)
A guide to audiometric testing programmesGuidanceNoteMS26HSEBooks1995ISBN0717609421
Introducing the Noise at Work Regulations: A brief guide to the requirements for controlling noise at workLeafletINDG75(rev)HSEBooks1989(singlecopyfreeorpricedpacksof15ISBN0717609618)
Keep the noise down: Advice for purchasers of workplace machineryLeafletINDG263HSEBooks1997(singlecopyfreeorpricedpacksof15ISBN0717614808)
Manual handling
Manual handling. Manual Handling Operations Regulations 1992. Guidance on RegulationsL23(Secondedition)HSEBooks1998ISBN0717624153
Handling the news: Advice for employers on manual handling of bundlesPIACLeafletIACL105HSEBooks1999
Handling the news: Advice for newsagents and employees on safe handling of bundlesPIACLeafletIACL106HSEBooks1999
What the papers weigh: Safe handling of bundlesVideoHSEBooks1999ISBN0717619486
Back in work: Managing back pain in the workplace - A leaflet for employers and workers in small businessesLeafletINDG333HSEBooks2000
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Work-related upper limb disorders in the printing industryLeafletIACL91HSEBooks1994
Work related upper limb disorders: A guide to preventionHSG60HSEBooks1990ISBN0717604756
Manual handling: Solutions you can handleHSG115HSEBooks1994ISBN0717606937
Getting to grips with manual handling: A short guide for employersLeafletINDG143(rev1)HSEBooks2000(singlecopyfreeorpricedpacksof15ISBN0717617548)
Radiation
Laser safety in printingHSEBooks1990ISBN0118854364
BSEN60825-1:1994,IEC60825-1:1993Safety of laser products. Equipment classification, requirements and user’s guideBritishStandardsInstitution
Skin disease
Assessing and managing risks at work from skin exposure to chemical agents: Guidance for employers and health and safety specialistsHSG205HSEBooks2001ISBN0717618269Choice of skin care products for the workplace: Guidance for employers and health and safety specialistsHSG207HSEBooks2001ISBN0717618250
Preventing dermatitis at work: Advice for employers and employeesLeafletINDG233HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN0717612465)
Skin problems in the printing industryPIACLeafletIACL101(rev1)HSEBooks2002
Other health issues
Tackling work-related stress: A managers’ guide to improving and maintaining employee health and well-beingHSG218HSEBooks2001ISBN0717620506
Work-related stress: A short guideLeafletINDG281(rev1)HSEBooks2001(singlecopyfreeorpricedpacksof10ISBN071762112X)
Stress at work: A guide for employersHSG116HSEBooks1995ISBN071760733X
New and expectant mothers at work: A guide for employersHSG122HSEBooks1994ISBN0717608263
Drug misuse at work: A guide for employersLeafletINDG91(rev2)HSEBooks1998(singlecopyfreeorpricedpacksof10ISBN0717624021)
Don’t mix it: A guide for employers on alcohol at workLeafletINDG240HSEBooks1996(singlecopyfreeorpricedpacksof10ISBN0717612910)
Passive smoking at workLeafletINDG63(rev1)HSEBooks1992(singlecopyfreeorpricedpacksof10ISBN0717608824)
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Legionnaires’ disease. The control of legionella bacteria in water systems.Approved Code of Practice and guidanceL8(Secondedition)HSEBooks2000ISBN0717617726
Legionnaires’ disease: A guide for employersLeafletIAC27(rev2)HSEBooks2001(singlecopyfreeorpricedpacksof15ISBN0717617734)
A guide to the Asbestos (Licensing) Regulations 1983 as amended. The Asbestos (Licensing) Regulations 1983. Guidance on Regulations L11(Secondedition)HSEBooks1999ISBN0717624358
The control of asbestos at work. Control of Asbestos at Work Regulations 1987. Approved Code of PracticeL27(Thirdedition)HSEBooks1999ISBN0717616738
Work with asbestos insulation, asbestos coating and asbestos insulating board. Control of Asbestos at Work Regulations 1987. Approved Code of PracticeL28(Thirdedition)HSEBooks1999ISBN0717616746
Local exhaust ventilation
An introduction to local exhaust ventilationHSG37(Secondedition)HSEBooks1993ISBN0717610012
Maintenance, examination and testing of local exhaust ventilationHSG54(Secondedition)HSEBooks1998ISBN0717614859
Personal protective equipment
Personal protective equipment at work. Personal Protective Equipment at Work Regulations 1992. Guidance on RegulationsL25HSEBooks1992ISBN0717604152
Cost and effectiveness of chemical protective gloves for the workplace: Guidance for employers and health and safety specialistsHSG206HSEBooks2001ISBN0717618285
Selecting protective gloves for work with chemicals: Guidance for employers and health and safety specialistsLeafletINDG330HSEBooks2000(singlecopyfreeorpricedpacksof15ISBN0717618277)
Preventing asthma at work. How to control respiratory sensitisersL55HSEBooks1994ISBN0717606619
Respiratory sensitisers and COSHH: Breathe freely - An employers’ leaflet on preventing occupational asthmaLeafletINDG95(rev2)HSEBooks1995(singlecopyfreeorpricedpacksof15ISBN0717609146)
BSEN166:1996Personal eye-protection. SpecificationsBritishStandardsInstitution
BSEN345-1:1993Safety footwear for professional use.SpecificationBritishStandardsInstitution
BSEN345-2:1997Safety footwear for professional use. Additional specificationsBritishStandardsInstitution
BSEN346-1:1993Protective footwear for professional use. SpecificationBritishStandardsInstitution
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BSEN346-2:1997Protective footwear for professional use. Additional specificationsBritishStandardsInstitution
BSEN352-1:1993Hearing protectors. Safety requirements and testing. Ear-muffsBritishStandardsInstitution
BSEN352-2:1993 Hearing protectors. Safety requirements and testing. Ear-plugsBritishStandardsInstitution
BSEN352-3:1997Hearing protectors. Safety requirements and testing. Ear-muffs attached to an industrial safety helmetBritishStandardsInstitution
Chapter 5 Process safety
Safe use of work equipment. Provision and Use of Work Equipment Regulations 1998. Approved Code of Practice and guidanceL22(Secondedition)HSEBooks1998ISBN0717616266
The Supply of Machinery (Safety) Regulations 1992SI1992/3073TheStationeryOffice1992ISBN0110257197
The Supply of Machinery (Safety) (Amendment) Regulations 1994SI1994/2063TheStationeryOffice1994ISBN0110450639
VDUs: An easy guide to the regulationsHSG90HSEBooks1994ISBN0717607356
The guide to safe use of power-operated paper-cutting guillotines(Secondedition)PIAC/HSEBooks1999ISBN0717617076
Application of electro-sensitive protective equipment using light curtains and light beam devices to machineryHSG180HSEBooks1999ISBN0717615502
Pressure systems: Safety and youLeafletINDG261(rev1)HSEBooks2001(singlecopyfreeorpricedpacksof15ISBN0717615626)
Supplying new machinery: A short guide to the law and some information on what to do for anyone supplying machinery for use at workLeafletINDG270HSEBooks1998(singlecopyfreeorpricedpacksof15ISBN071761560X)
Buying new machinery: A short guide to the law and some information on what to do for anyone buying new machinery for use at workLeafletINDG271HSEBooks1998(singlecopyfreeorpricedpacksof15ISBN0717615596)
Using work equipment safelyLeafletINDG229HSEBooks1997(singlecopyfreeorpricedpacksof5ISBN0717613267)
Safe systems of work for cleaning sheet-fed offset lithographic printing pressesPrintingInformationSheetPIS1HSEBooks2000
Safe systems of work for cleaning web-fed offset lithographic printing pressesPrintingInformationSheetPIS2HSEBooks2000
Safe systems of work for cleaning flexographic, rotary letterpress and gravure printing presses PrintingInformationSheetPIS3HSEBooks2000
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Safety at power-operated paper cutting guillotines: Your responsibilitiesPIACLeafletINDG282HSEBooks1998
Machinery standards
ThecurrentENStandardsgivespecificationsfornewmachines.However,someoftheprecautionsmayberelevanttoexistingmachineswhenitisreasonablypracticabletofitthem.
BSEN292-1:1991Safety of machinery. Basic concepts, general principles for design. Basic terminology, methodologyBritishStandardsInstitution
BSEN292-2:1991Safety of machinery. Basic concepts, general principles for design. Technical principles and specificationsBritishStandardsInstitution
BSEN294:1992Safety of machinery. Safety distances to prevent danger zones being reached by the upper limbsBritishStandardsInstitution
BSEN349:1993Safety of machinery. Minimum gaps to avoid crushing of parts of the human bodyBritishStandardsInstitution
BSEN811:1997Safety of machinery. Safety distances to prevent danger zones being reached by the lower limbsBritishStandardsInstitution
BSEN953:1998Safety of machinery. Guards. General requirements for the design and construction of fixed and movable guardsBritishStandardsInstitution
BSEN954-1:1997Safety of machinery. Safety related parts of control systems. General principles for designBritishStandardsInstitution
prEN1010:1998 (Draft) Safety of machinery: Safety requirements for the design and construction of printing and paper converting machinery
BSEN1050:1997Safety of machinery. Principles for risk assessmentBritishStandardsInstitution
BSEN1088:1996Safety of machinery. Interlocking devices associated with guards. Principles for design and selectionBritishStandardsInstitution
BSEN1539:2000Dryers and ovens in which flammable substances are released. Safety requirementsBritishStandardsInstitution
BSEN60204-1:1993Safety of machinery. Electrical equipment of machines.Specification for general requirements British Standards Institution
BSEN61496-1:1998,IEC61496-1:1997Safety of machinery. Electro-sensitive protective equipment. General requirements and testsBritishStandardsInstitution
Chapter 6 Electricity
Memorandum of guidance on the Electricity at Work Regulations 1989. Guidance on RegulationsHSR25HSEBooks1989ISBN0717616029
Your guide to the essentials of electrical safetyCDROMHSEBooks2000ISBN0717617149
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Do you use a steam/water pressure cleaner? You could be in for a shock!LeafletINDG68(rev)HSEBooks1997
Electricity at work: Safe working practicesHSG85HSEBooks1993ISBN071760442X
Electric storage batteries: Safe charging and useLeafletINDG139HSEBooks1993
Electrical safety and youLeafletINDG231HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN0717612074)
Maintaining portable electrical equipment in offices and other low-risk environmentsLeafletINDG236HSEBooks1996(singlecopyfreeorpricedpacksof10ISBN0717612724)BS7671:1992Requirements for electrical installations. IEE Wiring Regulations. Sixteenth editionBritishStandardsInstitution
Chapter 7 Fire and explosion
Fire safety: An employer’s guideHSEBooks1999ISBN0113412290
The storage of flammable liquids in containersHSG51(Secondedition)HSEBooks1998ISBN0717614719
Safe use and handling of flammable liquidsHSG140HSEBooks1996ISBN0717609677
Safe working with flammable substancesLeafletINDG227HSEBooks1996(singlecopyfreeorpricedpacksof15ISBN071761154X)
The storage of flammable liquids in tanksHSG176HSEBooks1998ISBN0717614700
Control of fire in the printing industryPIAC/HSEBooks1992ISBN0118863754BSEN1539:2000Dryers and ovens in which flammable substances are released. Safety requirementsBritishStandardsInstitution
BS6133:1995Code of practice for safe operation of lead-acid stationary batteriesBritishStandardsInstitution
PrEN12753(Draft) Thermal cleaning systems for exhaust gas from surface treatment equipment - Safety requirementsBritishStandardsInstitution
BSEN50018:2000Electrical apparatus for potentially explosive atmospheres. Flameproof enclosure ‘d’BritishStandardsInstitution
BSEN50019:2000Electrical apparatus for potentially explosive atmospheres. Increased safety ‘e’BritishStandardsInstitution
BSEN50021:1999Electrical apparatus for potentially explosive atmospheres. Type of protection ‘n’BritishStandardsInstitution
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Chapter 8 MaintenanceMaintaining portable and transportable electrical equipmentHSG107HSEBooks1994ISBN0717607151
Improving maintenance: A guide to reducing human errorHSEBooks2000ISBN0717618188
Permit-to-work systems LeafletINDG98(rev3)HSEBooks1997(singlecopyfreeorpricedpacksof15ISBN0717613313)
Whileeveryefforthasbeenmadetoensuretheaccuracyofthereferenceslistedinthispublication,theirfutureavailabilitycannotbeguaranteed.
Seethe‘FurtherInformation’sectionfordetailsofhowtoobtainpublications.
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Further informationHSE publications
Printing Industry Advisory Committee (PIAC)
TheSecretaryPIACHealthandSafetyExecutive3EastGrinsteadHouseLondonRoadEastGrinsteadWestSussexRH191RRTel:01342334200Fax:01342334222
Graphical, Paper and Media Union
Graphical,PaperandMediaUnionKeysHouse63/67BromhamRoadBedfordMK402AGTel:01234351521Fax:01234270580Website:www.gpmu.org.uk
British Printing Industries Federation
BritishPrintingIndustriesFederationFarringdonPoint29-35FarringdonRoadLondonEC1M3JFTel:02079158300Fax:02074057784Website:www.bpif.org.uk
Institute of Occupational Health and Safety (IOSH)
IOSHTheGrangeHighfieldDriveWigstonLeicestershireLE181NNTel:01162573100Fax:01162573101Website:www.iosh.co.uk
Royal Society for the Prevention of Accidents (RoSPA)
RoSPAEdgbastonPark353BristolRoadEdgbastonBirminghamB57STTel:01212482000Fax:01212482001Website:www.rospa.co.uk
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Health and Safety Executive
British Safety Council
BritishSafetyCouncil70ChancellorsRoadLondonW69RSTel:02087411231Fax:02087414555Website:www.britishsafetycouncil.org
ForinformationabouthealthandsafetyringHSE’sInfolineTel:08453450055Fax:08454089566Textphone:08454089577e-mail:[email protected],CaerphillyBusinessPark,CaerphillyCF833GG.
HSEpricedandfreepublicationscanbeviewedonlineororderedfromwww.hse.gov.ukorcontactHSEBooks,POBox1999,Sudbury,SuffolkCO102WATel:01787881165Fax:01787313995.HSEpricedpublicationsarealsoavailablefrombookshops.
BritishStandardscanbeobtainedinPDForhardcopyformatsfromtheBSIonlineshop:www.bsigroup.com/ShoporbycontactingBSICustomerServicesforhardcopiesonlyTel:02089969001e-mail:[email protected].
TheStationeryOfficepublicationsareavailablefromTheStationeryOffice,POBox29,NorwichNR31GNTel:08706005522Fax:08706005533e-mail:[email protected]:www.tso.co.uk(Theyarealsoavailablefrombookshops.)StatutoryInstrumentscanbeviewedfreeofchargeatwww.opsi.gov.uk.
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Health and Safety Executive