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UNIT IGC2
CONTROL OF INTERNATIONAL WORKPLACE
HAZARDS

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IGC2: CONTROL OF INTERNATIONAL WORKPLACE HAZARDS

EXAMPLE LONG QUESTIONS

Question 1
Battery-powered forklift trucks are used in a warehouse to move pallets around.
(a) Describe FOUR hazards arising from the use of battery-powered forklift trucks. (4)
(b) Outline the controls needed to ensure pedestrian safety in locations where the forklift
trucks are in use. (8)
(c) Outline EIGHT rules that must be adhered to when a forklift truck is left unattended by
the driver during a work shift. (8)

Model Answer
(a) There are a number of hazards associated with battery-powered forklift trucks. The
main hazards relate to charging the battery of the forklift truck. They include the
generation of hydrogen gas (which is highly explosive) and the potential release of battery
acid. For this reason battery charging should be completed in a designated area that is
well ventilated. This will prevent any build-up of fumes which could in turn lead to
explosion and/or injury to personnel. There are also hazards associated with the handling
of the batteries including manual handling and contact with battery acids. Contact with
electrical components is another hazard that could result in electric shocks or burns.
Collision with pedestrians might occur due to the near silent running of the truck.

(b) In order to ensure that pedestrians are kept safe in areas where forklift trucks are being
used, there are a number of precautions that must be implemented. Firstly, it is important
to have traffic routes marked out so that it is clear where forklift trucks are allowed. In
addition, pedestrian routes should be clearly marked and forklift trucks must not be
allowed in pedestrian areas. Where possible, pedestrian areas should be physically
segregated from the traffic route the warehouse should have adequate lighting to ensure
good visibility at all times. Fixed wall mirrors may also be necessary for use on corners. In
addition, high visibility clothing and transparent doors will ensure that personnel can be
seen easily at all times. The forklift trucks must be fitted with audible alarms and, in
particularly noisy environments, rotating or flashing lights may also be necessary. It is also
important to ensure that safe systems of work for loading, unloading and stacking are in
use and are being adhered to at all times. In the same way, it is essential that all rules
relating to the safe use of the forklift trucks are enforced, particularly those relating to
speed restrictions and access. In addition to the above, it is vital that drivers and
pedestrians are adequately trained and supervised to ensure that the precautions above
are adhered to.

(c) There are a number of rules that a driver must follow when leaving his/her forklift truck
unattended. The first one relates to leaving the forklift truck on a firm level surface, in a
designated area, to ensure that it cannot roll away. The truck must not be left in a position
where it could obstruct emergency exits, walkways or fire points, and must be parked
away from other vehicles. The truck should be left with the mast tilted slightly forward and
forks resting on the floor to make sure that it is stable and not likely to overturn.
The truck must not be left until the brake has been applied and the power switched off.
Where a start key is used, the key must be removed and returned to a responsible person,
as appropriate. This will prevent unauthorized use of the truck.


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Question 2 New owners are about to move into an existing office building.
(a) The new owners are carrying out an assessment of the suitability of lighting within the
building. Identify the factors that should be considered. (8)
(b) Outline FOUR factors, other than lighting, associated with the physical working
environment that may impact on the health and safety of personnel. (4)
(c) Outline the welfare facilities required in the building. (8)

Model Answer
(a) When assessing the suitability of lighting within the building, the new owners must
consider a number of factors. Firstly, they must consider the tasks to be undertaken and
the equipment to be used. Where close work is to be carried out, then the lighting
requirements will be greater than where general office administration is being completed.
Again, where intricate machinery requiring precise setting is being used, then extra
localized lighting may be required. The new owners must look at the suitability of the
existing lighting in all areas including stairs and corridors. They must also look at the
amount of natural light in the building and make best use of this, as natural light is
preferable to artificial light. In addition, they must also consider significant contrast in
lighting between different areas. For this, they must look at the layout of the office
including the positioning of screen dividers in relation to overhead lighting, and other areas
that may be in shadow. It may be possible to move screens and/or furniture around to
improve existing lighting levels, or to reduce/remove glare from computer screens. The
condition and appropriateness of the artificial lighting must be considered. Flickering
fluorescent tubes can be annoying, as can excessive glare caused by spotlights in the
wrong place. The maintenance and the cleaning procedures may also require
consideration. Emergency lighting must also be considered, as people are especially
exposed to danger in the event of a lighting failure.

(b) The physical working environment can be affected by a great many factors which can
affect the health and safety of the employees working in that environment. One such factor
is noise, which can have a stressful effect on employees. Another factor is temperature.
Extremes of temperature can affect an individuals ability to concentrate and can make
them feel physically unwell. For an office environment, a temperature of 16 degrees
Celsius is reasonable. Space constraints may also affect employee health and safety.
Cramped conditions may make individuals feel claustrophobic. Additionally, though,
inadequate space may result in accidents. Ventilation is another important factor.
Enclosed workplaces must be ventilated by a sufficient quantity of fresh or purified air.
Poor ventilation may make employees feel ill with symptoms such as headaches and
nausea (Sick Building Syndrome).

(c) There are a number of welfare facilities that are required in the building. An adequate
number of well-ventilated and well-lit sanitary conveniences in relation to the number of
male and female employees are essential. In addition, washing facilities with hot and cold
running water and a means of drying must be available. A source of drinking water must
be present, and this must be clearly marked, where appropriate. There must also be some
facilities for taking rest and refreshment away from the working area. Additionally pregnant
women and nursing mothers must have rest facilities. The building must protect non-
smokers from the effects of inhaling tobacco smoke. Many buildings will have a
designated area for smoking or smokers may be obliged to go outside. Accommodation
must be available for clothing not worn during working hours, e.g. coats, etc. This
accommodation may take the form of lockers or merely a hook. First-aid facilities must be
available. The number of people employed in the building will determine whether a first-aid
kit is adequate, or whether a fully equipped first-aid room is required.

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EXAMPLE SHORT QUESTIONS

Question 1

Outline the principal health effects of the following agents and, for EACH ONE, identify
the work situation in which a person may be exposed:
(a) Carbon monoxide. (2)
(b) Asbestos. (2)
(c) Legionella bacteria. (2)
(d) Hepatitis virus. (2)

Model Answer
(a) The principal health effects of carbon monoxide are headaches, drowsiness and
possible suffocation. Exposure could occur when working near a vehicle exhaust in an
unventilated area, e.g. vehicle repair premises.

(b) Exposure to asbestos may cause asbestosis (a fibrotic disease of the lung), lung
cancer or mesothelioma (cancer of the lining of the lung). Workers engaged in
maintenance or demolition work where asbestos is contained in the fabric of the building
are at risk.

(c) Exposure to Legionella bacteria may cause legionellosis, which is characterised by flu-
like symptoms, pneumonia and in about 15% of cases, death. Any workplace that has
untreated water tanks and systems from which water droplets may be released into the
atmosphere (e.g. from air-conditioning systems or cooling towers) poses a risk to those in
the vicinity.

(d) The principal health effects of the hepatitis virus include jaundice, fever, abdominal
pain and, ultimately, liver failure. Any workplace situation that exposes people to infected
persons or used hypodermic needles presents a risk, e.g. hospitals. The Hepatitis A virus,
which is normally less serious, is transmitted via the mouth; Hepatitis B and C via the
blood.


Question 2
Outline the requirements necessary to evacuate people safely from a building on fire. (8)

Model Answer
In order to ensure the safe evacuation of people from a building, it is important that the
following requirements are in place. Firstly, there must be a means for raising the alarm
(e.g. fire alarm, hand bell), and the distance to the nearest available exit must be
acceptable. Escape routes must be of sufficient width and have clear signage to indicate
the escape route. In addition, escape routes must be kept clear of obstructions, with fire
doors closed to prevent the spread of smoke. Appropriate fire-fighting equipment must be
provided and be in full working order. Emergency lighting must be provided where
necessary.
In order to ensure that the evacuation process itself runs smoothly, fire marshals must be
appointed. These marshals will ensure that the building is evacuated fully and that nobody
is left inside. There must also be procedures to evacuate people with a physical disability,
e.g. in relation to hearing, sight or mobility. It is important to practice the evacuation plan at
regular intervals.

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Question 3
(a) Consider a piece of machinery with moving parts and identify:
(i) TWO mechanical hazards (associated with the moving parts). (2)
(ii) TWO non-mechanical hazards that the operator of the machine may be exposed to. (2)
(b) In order to reduce the risk of injury from dangerous parts of the machinery, outline a
hierarchy of control measures that may be used.(4)

Model Answer

(a) (i) Mechanical hazards are those from the moving parts of the machinery and/or the
material being worked and include impact and entanglement.
(ii) Non-mechanical hazards that could affect the machine operator include noise and
vibration.

(b) A hierarchy of control measures that could be used to reduce the risk of injury from the
dangerous parts of the machine commences with the fitting of fixed guard(s). These
enclose the dangerous parts and must be fixed in place. Where fixed guards are not
practical, then other types of guards, e.g. interlock guards (where the machine cannot start
before the guard is closed), or protective devices, e.g. trip systems or pressure sensitive
mats, should be considered. Where guards cannot give full protection, safety aids such as
jigs, push sticks or holders can be used. In addition to the above, the provision of
information, training and supervision are important to ensure that operators use the
machines safely.

Question 4
Consider an individual lifting a load. Outline the factors that may affect the risk from
manual handling in relation to:
(a) The load. (4)
(b) The individual. (4)

Model Answer

(a) The nature of the load may present a risk of injury during manual handling activities.
Important factors to consider are the size and the weight of the load. In addition,
consideration should be given to whether the contents of the load may move and the load
become unbalanced. The position of the centre of gravity is important too. If the centre of
gravity is not in the centre then this can make the manual handling activity more difficult.
Consideration must also be given as to how easy it is to secure a firm grasp of the load
and whether sharp edges are present.

(b) The individual carrying out the task may affect the level of risk of a manual handling
activity. Firstly, one should consider the body size and strength of the individual in relation
to the task. The age and gender of the individual must also be considered. Other factors
such as physical handicaps or restrictions due to illness, disability or pregnancy should be
taken into account. Note that individual lack of training in manual handling will increase the
level of risk associated with the task. Finally, inappropriate clothing or footwear will also
increase the level of risk associated with the manual handling activity.





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ELEMENT 1: MOVEMENT OF PEOPLE AND VEHICLES HAZARDS AND CONTROL

Short Questions

1. State the primary hazards associated with the movement of people and vehicles. (8
marks)

The primary hazards associated with the movement of people and vehicles are:

Slips, trips and falls on the same level and from height
Collision with moving vehicles
Collision with or being struck by a falling object, e.g. part of a load
Striking against fixed or stationary objects
Environmental conditions

2. Outline the precautions that might be needed to ensure the safety of pedestrians in
areas where vehicles are in use. (8 marks)

To ensure the safety of pedestrians and vehicles and to prevent them coming into contact
with each other, the following precautions should be used:

Segregation of pedestrians and vehicles
Separate pedestrian and vehicle routes
Speed limits for vehicles
Signage; audio and/or visual alarms
Road marking
Training of drivers
Guarding and barriers
Maintenance of floor and traffic routes
Employee awareness

3. Identify FOUR factors to consider when selecting potential drivers for workplace
transport and equipment. (8 marks)

When selecting potential drivers for workplace transport and equipment, the following
factors should be taken into consideration:

Competence
Training in use of any special features or requirements
Age generally at least 17 years old
Reliable
Able to perform task in a responsible manner
Reasonable fitness
Reasonable intelligence
(Only four factors are required.)




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4. State FOUR reasons why a forklift truck may overturn in the workplace. (8 marks)

A forklift truck may overturn due to:

Loss of control
Speed of travel
Steepness of a slope
Travelling with a raised load
Uneven tire pressure
Poorly-maintained road surfaces
Environmental conditions
Wind

5. Outline the means by which the risk of accidents from reversing vehicles within a
workplace can be reduced. (8 marks)

Accidents from reversing vehicles can be reduced by:

Avoiding the need for vehicles to reverse one-way or drive through systems,
turning circles, etc.
Separation of vehicles and pedestrians use of barriers and signs
Suitable vehicle and workplace design audible alarms, mirrors on vehicles and at
blind corners, refuges, adequate lighting, etc.
Procedural measures use of banks men, good site rules, driver training, etc

6. A high percentage of the many fatal accidents which occur every year are caused by
workers being struck by vehicles. Outline the necessary precautions to reduce risks of
vehicle accidents. (20)

The precautions which can be used to reduce the risk of vehicle accidents will include the
following:

Road systems clearly lit and one-way traffic clearly marked.
Space for parking, reversing, loading and unloading
Use of crossings and white and yellow lines
Vehicles not allowed to reverse unless necessary and then only with a banks man
and controls, like alarms.
Avoiding sharp bends
Protection of vulnerable plant
Barriers
Segregation of pedestrians and vehicles
Parking areas
Maintenance of roadways
Speed limits and restrictors
Signage

7. Diesel powered fork lift trucks are used in wide range of organisation and can introduce
additional hazards into the working environment
1. Identify four hazards associated with such vehicles that may pose a risk to the
health of drivers.
2. Describe the various circumstances that may cause such a vehicle to overturn

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3. Outline the precaution may be needed to ensure the safety of pedestrians in areas
where fork lift trucks are operating
1. Hazards particularly relevant to drivers such as:

Fumes
Fire and explosion
Collision with buildings
Manual handling
Falling object
Noise
Vibration
Ergonomics

2. A forklift truck may overturn due to:

Loss of control
Speed of travel
Steepness of a slope
Travelling with a raised load
Uneven tire pressure
Poorly-maintained road surfaces
Environmental conditions
Wind
3.
Segregation of pedestrians and vehicles
Separate pedestrian and vehicle routes
Speed limits for vehicles
Signage; audio and/or visual alarms
Road marking
Training of drivers
Guarding and barriers
Maintenance of floor and traffic routes
Employee awareness

8. Outline the hazards and corresponding precautions to be taken when charging batteries
for fork lift trucks.

Hazards of battery charging

Release of hydrogen gas during charging (fire and explosion)
Electrical short circuits
Corrosive and burning effect of battery acid
Manual handling of batteries, etc

Precaution for charging batteries should be:

Well ventilated area to prevent build up of hydrogen
No sources of ignition near refuelling/recharging points
Suitable PPE (acid resistant gloves, eye protection etc.)
Insulated tools / procedures for connecting charger.
Lifting equipment for removing batteries.


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9. Outline the factors that should be taken into account when planning traffic routes for
internal transport

When organising traffic routes the precaution should be:

Keep pedestrians and vehicles apart
Separate routes, designated crossing places and suitable barriers at recognised
danger spots.
High visibility clothing if necessary
Clearly marked and signed traffic routes
Roads, gangways and aisles should have sufficient width and overhead clearances
for the largest vehicle
Speed limits are established and enforced
Adequate lighting should be provided
Good all round visibility
Clear direction signs and marking of doors
Sharp/blind bends and overhead obstructions should be avoided
The floor surface should be in god condition
Any gradient should be kept as gently as possible
Sufficient and suitable parking areas should be provided
Avoid reversing if possible
Making people aware of the moving of vehicles

10. List the ways in which a dumper truck may overturn

Overloading or uneven loading of the bucket
Cornering at excessive speed
Hitting obstructions
Driving too close to the edges of embankments or excavations
Mechanical defects
Inappropriate tyre pressure
Driving across slopes.

11. List items to be included on a checklist for the routine inspection of a fork lift truck at
the beginning of a shift

Condition and pressure of tyres
Functioning of lights, horns, brakes
Warning devices working
Suitable mirrors
Engine for oil leaks
Water leaks
Seat securely fixed and suitable restraints where fitted
Signs of damage to bodywork and lifting mechanism
Security of equipment fitted i.e. LPG tank

12. Outlines how slip and trip hazards in the workplace might be controlled

The precautions that should be taken to prevent slips and trips should include
Designated walking routes where possible
Ensure walkways are level
Ensure walkways are non slip

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Well lit and clearly marked walkways
Procedures to quickly identify and remove spillages and obstacles
Eliminate need to carry loads
Make employees aware of the hazards

13. List 8 design features or safe practices intended to reduce the risk of accidents on
staircase used as internal pedestrian routes within work premises.

Adequate width
The provision of handrails
The dimension of treads and risers
The provision of landings
Special provisions for disabled persons
Possibility of using a lift as an alternative
Avoid the need to carry large or heavy items up or down stairs.
Appropriate footwear low heels
The provision of non-slip surfaces together with reflective edging.
The adequate lighting and effective maintenance
The removal of obstructions, with particular attention to escape route

14. Outline the factors to consider when assessing the risk to a long distance delivery
driver.

The job

Duration of journey
Road condition
Means of communication
Security

The driver

Physical and psychological capabilities
The level of training

The vehicle

Suitability for the load
Design and layout of cab
Vehicle maintenance

The load

Properly labelled if hazardous
Spillage procedures if hazardous
Weight
Value



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15. Outline the precaution that should be considered when parking a fork lift

The precautions when parking fork lift trucks should include:

Designated parking area
Applying brakes
Controls in neutral position
Switch off engine
Removing key and returning to responsible person
Forks resting on floor
Mast tilted slightly forward
Not obstructing walk ways
Not obstructing fire exits / fire points




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ELEMENT 2: MANUAL AND MECHANICAL HANDLING HAZARDS AND CONTROL

Short Questions

1. Identify FOUR specific types of injury that could be caused by manual handling of
loads. (8 marks)

Specific types of injury caused by incorrect manual handling of loads are:

Back injuries
Muscle strains and sprains
Hernias
Cuts, abrasions and bruises
Bone injuries, particularly to toes and fingers
WRULDs
Musculoskeletal disorders

2. Identify the FOUR main factors to consider when carrying out a manual handling
assessment. Give an example for EACH. (8 marks)

The four main factors to consider in a manual handling assessment are:

The load, e.g. is it heavy
The individual, e.g. does the load require unusual strength
The task, e.g. how far is the load to be carried
The environment, e.g. is the floor even

3. (a) Outline a good lifting technique that could be adopted by a person when lifting a
load from the ground. (4 marks)

The following are important to ensure a safe lifting technique:

Stop and think
Assess the weight of the load
Bend the knees
Keep the back straight
Get a good grip on the load
Use of body weight
Keep the load close to the body
Dont twist the body
Position the feet slightly apart
Keep the shoulders and hips in line (same direction)
Lift steadily using the leg muscles to straighten up

(b) Give TWO examples of how a manual handling task could be avoided. (4 marks)

FLTs
Hoists
Cranes
Conveyors
(Remember that the use of sack trucks and smaller loads does NOT avoid manual
handling in the context of the question.)

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4. When selecting a crane for a lifting operation, outline the steps to take in maintaining a
safe system of work. (8 marks)

Planning the lift
Correct selection of crane
Correct selection of lifting tackle
Ensure the competence of the crane driver and slingers
Ensure there is a valid and current test certificate


5. A store man is engaged in placing boxes of metal components by hand onto shelves.
(i) List FOUR types of injury to which the store man may be at risk while carrying out the
operation. (4 marks)

Types of injury likely to be suffered:

Back injuries and other muscular-skeletal disorders
Muscular problems strains and sprains
Hernias
Cuts, abrasions and bruising to hands and toes
Bone injuries to hands and feet
Work-related upper limb disorder (WRULDs)

(ii) Outline the factors, in relation to the task, that will affect the risk of injury. (4 marks)
Factors relating to THIS task are:

Distance of the load from the body
Movements that include twisting, stooping or reaching upwards
Excessive lifting or lowering
Sudden or jerking movements
Excessive periods of physical effort
Length of rest periods doing other types of work
An imposed rate of doing work

6. (a) Identify the FOUR main factors to be considered when carrying out a manual
handling assessment. (4 marks)

The four main factors to consider in manual handling assessments are:

The task
The load
The individual
The working environment

(b) Outline steps to reduce the risks from manual handling tasks and give an example in
EACH case. (16 marks)
The steps that should be taken to reduce the risks from manual handling tasks are as
follows:

Eliminate the need to carry out manual handling tasks, e.g. redesign the task to
avoid manual handling altogether

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If this is not possible, minimize the risk to as low as is reasonably practicable by
using mechanical aids, e.g. a trolley to take the weight
Give information, instruction and training to employees, e.g. training in correct lifting
technique
Look at environmental conditions, e.g. redesign the workstation to improve access
to the load and any equipment used

7. With respect to manual handling operations
a) Identify ways in which the nature of a load my present a risk of injury (4)
b) State four factors relating to the individual that may increase the risk of injury (4)

a) Load

The factors to consider with the load should include

Weight
Size
Shape
Rigidity
Outside surfaces
Stability of contents
Other hazards e.g. hot, cold, sharp etc.

b) Individual

Factors relating to individual should include:

Sex
Physical strength
Stature
State of health
Level of training
Persons perception of their own ability

8. Outline four hazards and the corresponding control measures to be taken when using
conveyor systems for moving materials within a workplace.

Hazards of conveyors

Trapping, limbs can be drawn into in-running nips
Contact with moving parts, for example drive elements, screw conveyors
Entanglement with roller, drive mechanisms
Striking, materials falling from heights, incorrectly handled
Impact, e.g. striking head
Items falling off
Slips, fall into rollers
Manual handling
Noise



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Hazards control measures

Fixed guard on drums
Side guards, enclosing conveyed items
Trip wires, if necessary, along the full length of the conveyor
Emergency stop buttons
Safe access at regular intervals
Avoid loose clothing
Restrict access
Wear head protection
Regular maintenance by competent people

9. Outline the practical measures to avoid manual handling injuries

The practical measure can include
Avoid manual handling
Risk reduction
Automation and mechanisation
Team handling
Training
Smaller lighter loads
Selection
Good environmental working conditions.

10. Outline the precaution when using
1. Hoist
2. Lifting accessories.

Hoist
Controls only operated from one position
Clear visibility of landings
Clear signals
Secure objects being carried on goods hoist
Do not overfill items being carried on goods lifts
Do not carry loose items of goods lifts
No passengers on goods lift
Safe working load clearly marked
Hoist properly examined and tested.
Suitable fencing and gates at all levels
Training in use of hoists

Lifting accessories

All accessories properly certificated and tested
Properly inspected by a competent person at regular intervals
Safe working load clearly marked
Inspection prior to use
No repair to accessories on site
Not be used for purposes not intended
Packing between accessory and load
Properly stored after use
Training provided for staff in safe use

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11. Outline the precaution to be taken when using a mobile elevating work platform
(MEWP) to reach a high point such as the streetlight
Inspect the equipment before use and to ensure it is in good state of repair
Using only competent workers
Using outriggers and brakes
Erecting warning signs and barriers to avoid collisions
Ensuring the platform is not overloaded
Wearing a harness



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ELEMENT 3: WORK EQUIPMENT HAZARDS AND CONTROL

Short Questions

1. Outline the factors that would ensure piece of work equipment is suitable for use. (8
marks)

To ensure that an item of work equipment is suitable for use, it must:
Be capable of being maintained.
Be provided with information and instructions for use.
Have an appropriate control system with start, stop and emergency controls.
In the EU it must meet requirements of EU standards and be CE marked.
Have appropriate lighting.
Have appropriate warning signs.
Be stable.

2. Outline precautions for the safe use of hand-held tools. (8 marks)

A control strategy for the safe use of hand-held tools consists of:

Appropriate training
Correct maintenance.
Visual checks
Appropriate PPE

3. Identify, using an example in EACH case, FOUR mechanical hazards associated with
machinery. (8 marks)

Mechanical hazards associated with machinery are:

Crushing, e.g. trapping a finger between moving parts when opening a photocopier.
Shearing, e.g. trapping a finger while using an office guillotine.
Cutting or severing, e.g. coming into contact with the blade of a handsaw.
Entanglement, e.g. a loose cuff getting caught in an abrasive wheel
Drawing-in, e.g. a finger being drawn in while using a document shredder
Impact, e.g. with a robot making unanticipated movements
Stabbing or puncture, e.g. by a sewing machine needle
Friction or abrasion, e.g. coming into contact with a sander

4. Outline FOUR non-mechanical hazards found in using machinery, and in EACH case
give an example. (8 marks)

Non-mechanical hazards associated with machinery are:

Noise, e.g. from a cylinder mower, leading to temporary hearing loss
Vibration, e.g. from a chainsaw, leading to vascular disorders
Electricity, e.g. a faulty drill, causing electric shock or burns
Temperature, e.g. burns from a cutting torch
Radiation, e.g. from an X-ray machine, leading to the development of cancer
Substances, e.g. inhaling sawdust from the working process
Ergonomics, e.g. stress from the need to keep pace with a conveyor system

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5. Outline FOUR guarding methods for machinery and, in EACH case give an example.
(8 marks)

The following are guarding methods for machinery:

Fixed guard, e.g. to enclose a belt-drive mechanism
Distance guard, e.g. a fixed perimeter fence round a machine
Interlocking guard, e.g. to protect from the cutting operation of a lathe
Trip device, e.g. a trip bar guard fitted to a pillar drill
Adjustable guard, e.g. for the cutter on a milling machine
Self-adjusting guard, e.g. on a metal-cutting saw
Two-handed control, e.g. on a power press

6. A bench-mounted circular-saw is being used in a workshop to cut wood in the
manufacture of wooden pallets.
(a) Identify FOUR risks to the health of the saw operators. (4 marks) Risks to health
would include:

Hearing damage
Hand-arm vibration
Respiratory problems (e.g. asthma, nasal cancer, lung cancer)
Dermatitis

(b) Identify FOUR risks to the safety of the operators. (4 marks)

Risks to safety (i.e. and resulting in injuries) would include:

Injuries caused by entanglement on rotating parts such as the spindle of the blade
and transmission (gear-driven parts).
Flying particles of wood and ejection of wood (and any metal fragments of blade)
causing injury.
Manual handling injuries
Electrocution or electrical burns
Injuries due to slips, trips and falls

(c) Outline FIVE non-mechanical hazards associated with machinery, and in EACH case
describe how the associated risks can be minimized. (12 marks)
The remedial measures and non-mechanical hazards would be:

Completion of a risk assessment for the activity
Provide an adjustable guard for the top of the saw; expose as little blade as
possible.
A fixed guard for the blade running below the bench
Protection at the rear of the blade
Availability of jigs and push-sticks to keep the operators hands away from the
blade at the end of the cut
Provision of emergency stop buttons; means of machine isolation
Adequate space around the machine with the floor kept in sound condition free
from debris and loose material.
Fitting and regular maintenance of properly designed LEV system
Adequate level of lighting and heating

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Provision of appropriate personal protective equipment such as goggles, ear
defenders and gloves

7. Outline practical precautions to be taken prior to the maintenance of machinery. (8)

The practical precautions when undertaking machinery maintenance could be:

Isolate electrical power
Permit-to-work system
Isolation of any services or pipelines to the machine
Allow hot machinery to cool
Release loads
Segregation by providing barriers and warning signs
Provision of safe means of access, Provide adequate lighting, means of access, etc
Ensuring availability and suitability of PPE
Ventilate work area
Adequate supervision
Ensuring only skilled and competent staffs are used.

8. Identify the specific hazards associated with routine maintenance of machinery (4)
Outline the hazards identified in (a) may be controlled (4)

Whilst undertaking routine maintenance of machinery the hazards could be:
Unintentional starting of machinery
Release of stored energy e.g. pressure, electricity.
Movements due to gravity
Residual high or low pressure
Restricted access/egress
Residues e.g. chemicals, flammables, corrosives
Mechanical hazards
Heat or cold
Biological hazards
Confined spaces
Working at height

9. Outline the issues that should be addressed in assessing the appropriateness and
suitability of a guard to protect dangerous parts of a machine.

Is compatible with the process, e.g. resistant to dust, chemical, etc.;
Is of good construction
Has adequate strength
Is maintained in an efficient state
Allows maintenance without removing the guard, e.g. by provision of lubrication /
greasing points outside the guard
Is situated a safe distance from the danger zone
Does not increase the risk
Does not restrict the operators view of the hazard
Is not easy to bypass



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10. Identify four mechanical hazards presented by pedestal drill and in each case, how
injury may occur (8)

Entanglement (hair / clothing)
Contact (stabbing / puncture), hand under drill
Impact from an unsecured work piece
Cutting from swarf
Ejection of a broken bit or of materials

11. Outline a hierarchy of control measures that may be used to reduce the risk of injury
from dangerous parts of machinery. (8)

To select the appropriate guard the following hierarchy of measures should be considered:
Fixed guard enclosing every dangerous part
Other guards or protection devices (interlocks, etc)
Protective appliances (jigs, holders, push sticks, etc.)
The provision of information, instruction, training and supervision as is necessary in
each case.

12. A public services worker uses a petrol-driven strimmer to maintain roadside grass
verges.
1) Describe the possible hazards faced by the worker in carrying out this work (10)
2) List 5 items of PPE that should be provided to , and used by , the worker (5)
3) Outline measures other than the use of PPE (5)

1.
Contact with the moving parts of the strimmer
The possibility of being struck by flying stones or other material
Slips/trips/falls
Manual handling hazards
The danger posed by moving traffic, noise, vibration, dust, and fumes
The hazards associated with the storage and transfer of petrol.
2.

Ear defenders
Eye protection
Respiratory protection (dust mask)
Gloves
Safety foot wear
Gaiters
High visibility clothing that also afforded protection against the weather

3.

The use of traffic control or barriers
The selection and maintenance of equipment to reduce to a minimum the levels of
noise and vibration
The provision of information, instruction, training and supervision, and health
surveillance




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13. Identify advantages and disadvantages of a fixed machine guard (8)

Advantages

Fixed guards are at the top of hierarchy because they have no moving parts and are
therefore very reliable and can be totally effective unless removed or damaged

Fixed machined guard

Require minimal maintenance because there are no moving parts
Can only be defeated by a deliberate act
Require only a visual inspection to check effectiveness
May protect operators from other hazards, e.g. noise, dust, ejection of materials

Limitations

A fixed guard

Is not linked to the machine controls
Provides no protection when removed during maintenance (some maintenance
work may require the machine to be run)
Allows people to access dangerous parts while the machine is running once the
guard has been removed
Is more difficult to remove, therefore, not practical where frequent access is
required for material feeding or for maintenance/adjustment/lubrication
Tends to be left in an unfixed condition when frequent access is required due to
machine problems
May hamper visibility of the work being performed

14. Outline the factors that consider the safe operation of work equipment (8)

To ensure the safe operation of work equipment number of factors may have to be
considered

The equipment should have appropriate protection against risk to employees from
failure of or in work equipment. This includes the risk of ejection of parts or fire and
explosion
Measures should be taken by employers to ensure that people do not come into
contact with work equipment and the materials therein likely to burn or scald
Clear layout of controls, e.g. for starting, or making a change in operating
conditions and readily identifiable and readily accessible emergency stops
All work equipment should be provided with means to isolate it from its source of
energy
Work equipment should be sufficiently stable to avoid risk to health or safety
Places where work equipment is used should be adequately lit by appropriate
means in line with the work to be carried out
It should be possible to carry out maintenance operations while the work equipment
is stopped. If this is not possible then other protective measures should be taken
Work equipment should have appropriate markings for purposes of health and
safety
Work equipment should have appropriate warnings or warning devices for purposes
of health and safety.

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15. Identify two mechanical and non mechanical hazards presented by bench top grinder
(8)

Mechanical hazards

Contact with the rotating wheel
Drawing into the trap between the tool rest and the wheel
Ejected parts from the machine or materials

Non-mechanical hazards

Dust
Electricity
Ergonomics
Fire / sparks
Noise
Stability of the machine
Vibration

16. Identify mechanical and non mechanical hazards associated with cement mixer in a
construction industry (8)

Mechanical hazards

Entanglement
Trapping between fixed and moving parts at rear

Non-mechanical hazards

Chemicals (corrosive cement)
Dust
Electricity
Ergonomics
Manual handling
Stability of the machine
Temperature

17. Outline the general precaution should be taken for portable power tools (8)

Never carry a tool by the cord or hose
Never pull the cord or the hose to disconnect it from the receptacle
Keep cords and hoses away from heat, oil, and sharp edges
Disconnect tools when not in use, before servicing, and when changing accessories
such as blades, bits and cutters
Keep all observers at a safe distance away from the work area
Secure work with clamps, freeing both hands to operate the tool
Avoid accidental starting the operators should not hold a finger on the switch
button while carrying a plugged-in tool;
Use RCDs or similar with electrical supplies to portable tools
Ensure good footing and maintain good balance

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Wear appropriate PPE loose clothing, ties, or jewellery can become caught in
moving parts
Maintain tools- they should be kept sharp and clean. Follow the user manual
instructions for lubricating and changing accessories
Regularly inspect tools and report defects and
Remove damaged portable electric tools from use.

18. Identify advantages and disadvantages of interlocked guards (8)

Advantages

Interlocked guards

Allow ready safe access for material feeding
Are convenient to use
Are less likely to be deliberately defeated than fixed guards where frequent access
is required
Speed up operations

Limitations

Interlocked guards

Increase the complexity of the machine
Are difficult to test and maintain
May need a brake or timed delay where machinery does not stop instantly
Rely on components which could fail in service
Require regular maintenance and testing
May not fail to safety, i.e. failures may not be apparent until it is too late which can
give a false sense of security.

19. Identify advantages and disadvantages of two hand control devices (8)

Advantages

Allow full visibility and access to the machine
Are a simple inexpensive design

Limitation

Require operator discipline and training
Only protect the operator, therefore, are only suitable in restricted areas
Are easily defeated








Page 24 of 32

ELEMENT 4: ELECTRICAL HAZARDS AND CONTROL
Short Questions
1. Outline the first-aid treatment that should be given following an electric shock. (8
marks)

Action to be taken following an electric shock:

Break any contact using non-conductive material or isolate the supply.
Artificial respiration should commence immediately and continue until either the
victim recovers or medical staff intervenes.
Emergency medical attention should always be sought, as there is a risk of internal
injury.

2. Identify and describe FOUR protective systems that can be incorporated within an
electrical circuit. (8 marks)

The following protective systems can be incorporated within an electrical circuit:

Fuse acts as a weak link.
Circuit breaker acts as a weak link.
Earthling prevents current from being carried.
Isolation physically separates the electricity from the power source.
Switching off deprives the equipment of power whilst
Remaining connected to the supply.
Low voltage using a transformer reduces the effect of any shock.
Residual current device
Double insulation encloses the item from danger.

3. Outline the practical measures to reduce the risk of injury from electricity when using
portable electrical tools on a construction site. (8 marks)

The following practical measures should be used to reduce the risk of injury when using
portable electrical tools:

Use of reduced voltage by means of a 110v centre tapped step down transformer.
Use of double-insulated (class II equipment) or battery operated (cordless)
equipment.
Use of tools with residual current devices which protect individuals by rapidly
disconnecting the power in the event of a fault occurring.
Ensuring earth continuity
Ensuring frequent and regular testing
Avoiding use in wet conditions/weather.
Carrying out regular visual inspections and user checks
(Note: The context given is in the use of the equipment on a construction site, but
this could equally be in any other remote area where similar conditions apply.)



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4. Outline FOUR control measures relating to the safety of electrical appliances. (8 marks)

Control measures relating to the safety of electrical appliances are:
Proper selection of suitable equipment
The use of protective devices
Effective inspection and maintenance by competent persons
Visual user checks

5. (a) Describe the possible effects of electricity on the body. (4 marks)

The following effects may be seen on the body on contact with electricity:

Burns are the most likely effects with the main sites of damage being entry and exit
points of electricity with possible damage to internal organs.
Other effects could include interference with nerve and muscle action which leads
to involuntary grip and cardiovascular effects, leading to disruption of heart rhythm
and possibly death.

(b) Outline FOUR factors that may affect the severity of injury resulting from contact with
electricity. (4 marks)

Electricity includes:

The nature of the current (AC/DC)
The frequency and level of the current
The length of time that the current flows through the body
The voltage involved
Individual body resistance due to age, sex, sweat on the skin surface and existing
medical conditions

6. A 30-year-old joiner received an electric shock from a hand-held 230v drill while fitting
wooden floorboards in a new construction. The drill was five years old and had never been
tested. The joiner was not seriously injured.
(a) Identify the factors that may have limited the severity of injury this time. (4 marks)

Factors leading to limitation of the current:

High earth path resistance due to wooden floor or dry conditions
The age and health of the joiner
The lengths of contact time possibly reduced by speed of action of fuse or contact
breaker

(b) Outline the physical effects on the body that the electrical contact could have caused
under different circumstances.(4 marks)

Physical effects on the body:

Burns - main sites of damage being entry and exit points of electricity with possible
damage to internal organs.
Interference with nerve and muscle action - results in spasm and/or involuntary
grip, cardio-vascular effects, e.g. cardiac arrhythmia, respiratory arrest and possibly
cardiac arrest and death in severe cases.

Page 26 of 32


(c) Describe the types of inspection and/or test that the drill should have had. Also,
identify the features that should be checked by EACH type of inspection and the factor
that might affect the frequency of examination/test. (12 marks)

Three types of inspection exist at differing levels of importance:

First carried out by the user (joiner).
Visual check of general condition for damage or overheating, integrity of plug,
socket and cable should be carried out at every use.
Second formal, periodic, visual inspection - weekly or monthly dependent on
amount of use and conditions of use Inspect equipment, connectors (plug, socket)
and cable Also check correct fuse rating.
Third carried out by competent person, at three monthly, six monthly or yearly
intervals dependent on extent and conditions of use. Combined inspection and test
(PAT)
Checks that the equipment is working correctly and for potential faults, e.g. loss of
earth integrity, deterioration of insulation and possibly contamination of internal and
external surfaces

7. When using hand-held electrical tools at 220 240v AC, such as in a factory workshop:
(a) Outline the possible hazards. (8 marks)

Possible hazards when using 220-240V, hand-held electrical tools are:

Electric shock
Burns
Arcing
Explosion
Secondary effects, such as falls

(b) Describe the suitable precautions that should be taken to control these hazards. (12
marks)

Hazards:

Reduced voltage
Fuses
Residual current devices
Earthling
Double insulation
Testing
Visual inspection
Favourable environmental conditions



Page 27 of 32

8. List the items that should be included on an inspection checklist designed to ensure the
safety of portable electrical appliance
The main areas to consider when looking for the dangers in the use of portable electrical
equipment are:
The plug
No fuse or fuse replaced by nail, etc
Damage to plug casing
Incorrect wiring inside plug
Earth wire detached from connection
The cable / lead
Being run over by vehicles
Dragged over rough surfaces
Trapped in machinery
Exposed to hot surfaces or corrosive chemicals
Continuous flexing
Insulation failure

The joints and connections
Makeshift, temporary connections
Lead pulled out or cord grips
Connections wired incorrectly so that metal work becomes live
Wrong connections
Poor earth connections preventing fuse from working

The appliance
Damaged casing
Worn or damaged connections

9. Outline a range of check that should be made to ensure electrical safety in an office
environment
Precautions for electrical safety in office environments could include:
Equipment is of approved standard e.g. BS/EN Standard
Maintenance of fixed electrical installations
There is a means of isolation
All connections, wiring free from damage
Correct fuses
Plug correctly wired
Avoid overloading of outlets
Switch off appliances when not in use
Maintain good housekeeping around electrical equipment

Page 28 of 32

If required portable appliance testing in date
System not overloaded
Cables correctly routed to avoid hazards
RCDs used
System for reporting defects

10. Describe the function and limitation of a fuse as an electrical protection device (8)
A fuse is a weak link designed to melt, breaking the circuit at excessive currents. The fuse
is intended to protect the equipment and wiring from over currents and will not protect the
people from electric shock.
The flow of electric current generates heat. The higher the current, the more the heat.
Fault currents caused by a short circuit, e.g. to earth, are likely to allow much higher
currents to flow than the equipment or wiring was designed to carry. Without a fuse the
equipment might become damaged, the wiring would eventually become hot enough to
melt its insulation and start a fire.
Advantages
Cheap and readily available
Relatively easy to place
Protects equipment from overload

Disadvantages
Will not protect individuals from electric shock
Slow to operate
Inaccurate
Can be replace with unsuitable or wrongly rated fuse
Easy to override
Needs screwdriver or similar tool to replace

11. Describe the principles of operation of the following types of electrical protection
1. Earthing
2. Reduce voltage
Earthing
Electricity will always try to reach zero potential, i.e. earth. Earthing of conductive
materials, e.g. metal workbench, sinks and metal pipe work provides a low resistance path
to earth, lower than a human body. Earthing of exposed metal parts, which should not
normally carry current, ensures that under fault condition a higher than normal current can
flow, causing the fuse to overheat , melt, and the break the circuit.


Page 29 of 32

Advantages
May prevent indirect electric shock by providing a very low resistance path to earth
Readily identified

Disadvantages
Requires specialist testing and maintenance with professional installation
Protection defeated if removes

Reduced voltage
Reduced voltage systems are recommended in all situations where there is risk of
mechanical damage to equipment and cables. By reducing the voltage present the
consequences of electrical shock can be greatly reduced.
Advantages
As available voltage difference is 55V ac injury is highly unlikely
Colour coded cabling system for easy recognition

Disadvantages
Specialist equipment required for 110V
Lead from supply to transformer will be protecting with a RCD

12. Outline practical measures to reduce the risk of electrical shock when using portable
electrical appliances
The precautions required to prevent accidents using portable equipment are:
Reduced voltage operation
Use of residual current devices
Apparatus and cables should be protected against overload by fuses and or circuit
breakers
All cables should be insulated and protected against mechanical damage
Correct types of sheathing to suit working conditions
Sufficient socket outlets to minimise the need for trailing cables
The use of cable drums wherever possible
The use of cable drums wherever possible
Correct maintenance and repair
Correct connections
Regular inspection and checks to remove damaged equipment
Properly trained operators


Page 30 of 32

13. In relation to electrical safety, explain the meaning of the following terms
1. Isolation
2. earthing
3. Double insulation
4. Over current protection

Isolation
Isolation means shutting off the electrical supply to an item of equipment or part of
an electrical system and preventing the system being mistakenly reconnected and
is used for example during maintenance work.
Advantages
Safest option in that it eliminates the electricity
May be physically locked off

Disadvantages
It may isolate other equipment
May be reconnected unless locked off
Prevents live fault finding

Earthing
Electricity will always try to reach zero potential, i.e. earth. Earthing of conductive
materials, e.g. metal workbench, sinks and metal pipe work provides a low resistance path
to earth, lower than a human body. Earthing of exposed metal parts, which should not
normally carry current, ensures that under fault condition a higher than normal current can
flow, causing the fuse to overheat , melt, and the break the circuit.
Advantages
May prevent indirect electric shock by providing a very low resistance path to earth
Readily identified

Disadvantages
Requires specialist testing and maintenance with professional installation
Protection defeated if removes

Double insulation
Double insulation is where two separate layers of insulation are provided. This allows of
insulation are provided. This allows for fault detection where one layer has failed but the
second layer still provides protection for the user.

Page 31 of 32

Advantages
Two layers prevent contact with live parts
No earth required

Disadvantages
Damage to equipment casing defeats double insulation
No earth therefore no protection if used with equipment that requires earth.

Over current protection
Over current protection is a method of preventing the flow of excess current by cutting the
supply under fault conditions by means of a fuse or circuit breaker.
14. Identify the advantages and disadvantages of RCD
RCD provide protection against leakage to earth and consequential risk of shock by
comparing the electricity flow to the equipment with the return flow to the equipment with
the return flow along the neutral wire. If any difference is detected the equipment is
isolated.
Advantages
Rapid response
Difficult to defeat
Easy to use, test, and reset
Cannot be reset with a fault on the circuit

Disadvantages
May isolate other important equipment
Mechanical device which could fail
No overload protection

15. In relation to the use of electrical cables and plugs in the workplace:
1. Identify FOUR examples of faults and bad practices that could contribute to
electrical accidents
2. Outline the corresponding precautions that should be taken for EACH of the
examples identified in 1.
1.Failure to select the right equipment for the environment (e.g. armoured or heat resistant
cable might be required in arduous conditions)
Incorrect rating of fuses
Ineffective or discontinuous earthing
Overloading of socket outlets
Cables unnecessarily long (or short)

Page 32 of 32

The use of coiled extension leads
Poorly wired plugs (e.g. wires under tension or outer protective sheath not
clamped)
The use of defective cables or plugs

2. Earthing
Calculate correct rating for a fuse
RCD residual current device
Reduced voltage
Battery powered
Double insulation

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