NEBOSH General Certificate in

Occupational Safety and Health

Unit GC2
Element 4: Work Equipment Hazards and
Risk Control
 Learning Outcomes
• Outline general requirements for work
equipment.
• Explain the hazards and controls for hand-held
tools.
• Describe the main mechanical and non-
mechanical hazards of machinery.
• Explain the main control measures for reducing
risk from machinery hazards.
General Requirements for Work
Equipment
 Types of Work Equipment

• Simple hand tools.

• Hand-held power tools.
• Single machines.
• Mobile work equipment.
• Machine assemblies.
 Suitability
Work equipment should be carefully selected to ensure it is
appropriate for the:
• Task.
• Environment and conditions.

Employers in the EU and UK have to ensure that any

equipment they purchase for work use has a CE mark and
complies with European standards.
 Manufacturer’s Duties

EU ‘Machinery Directive’ (2006/42/EC)

Manufacturers are required to:

● Meet the ‘essential health and safety requirements’.

● Create a technical file.
● Fix a Conformité Européenne (CE) mark.
● Provide a written Declaration of Conformity.
Implemented in UK as the Supply of Machinery (Safety)
Regulations 2008.
 Preventing Access to Dangerous
Parts of Machinery
Provision and Use of Work Equipment Regulations 1998
(PUWER)
Access to dangerous parts is prevented or movement of
dangerous parts is stopped:
• fixed guards,
• other guards and protection devices,
• protection appliances,
• information, instruction, training, and supervision,
to the extent that it is practicable.
 Preventing Access to Dangerous
Parts of Machinery
Access to dangerous parts is prevented or movement of
dangerous parts is stopped:
• fixed guards,
• other guards and protection devices,
• protection appliances,
• information, instruction, training and supervision,
to the extent that it is practicable.
 Restricting Use
Work equipment use restricted to trained and
competent operators:

• Highly specialised equipment.

• Range of hazards.

Maintenance of work equipment restricted to

trained and competent persons.
 Information, Instruction and
Training
Work equipment users:
• Low-risk equipment - reading instructions.
• High-risk equipment - formal training, check effectiveness.
Managers
Maintenance staff:
• To minimise risk.
• Understand maintenance requirements.
 Maintenance Requirements
Maintenance Regimes
• Planned Preventive Maintenance (PPM):
‐ E.g. car engine oil change.
‐ Scheduled at regular intervals.
• Condition-based maintenance:
‐ E.g. vehicle brake pads.
‐ Following routine inspection.
• Breakdown maintenance:
‐ Emergency repairs.
 Group Discussion Point
Maintenance is often seen as a “high-risk” activity.

What is it about maintenance work that increases

the risk?
 Risk to Maintenance Staff
• Guards and enclosures removed.
• Safety devices removed or disabled.
• Power sources exposed.
• Stored power released, e.g. compressed spring.
• Access awkward.
• Manual handling heavy parts.
• Additional hazards, e.g. power tools.
• Pressure to get the equipment running quickly.
 Maintenance Precautions
• Competent staff.
• Power sources isolated/locked off.
• Stored power released or secured or:
‐ Cover live parts with insulating material.
‐ Use additional PPE.

• If dangerous moving parts are accessed:

‐ Run at very slow speed.
‐ Fit purpose-made maintenance guards.
• Precautions for safe access.
• Use manual handling aids.
 Equipment Controls
Controls should be:
• Well designed, easy to use.
• Suitably located.
• Easily identifiable.
• In good working order.
• Compliant with relevant standards.
• Emergency stops:
‐ Buttons.
‐ Pull cords.
 Environmental Factors
• Equipment should be:
‐ Stable.
‐ Controls appropriately marked.
‐ Have appropriate warning signs.
• Lighting should be:
‐ Adequate.
‐ Suitable (note "strobe" effect).
‐ Environmentally suitable.
• Space should be adequate.
 Responsibilities of Users
Users of work equipment should:
• Only operate equipment they are authorised to use.

• Operate equipment in accordance with instruction and training.

• Only use equipment for its intended purpose.

• Carry out safety checks before using equipment.

• Not use equipment if it is unsafe.

• Report defects immediately.

• Not use equipment under the influence of drugs or alcohol.

• Keep equipment clean and maintained in safe working order.

Hand Tools and Portable Power
Tools
 Hand-Held Tools

Include:
• Hammer.
• Chisel.
• Screwdriver.
• Axe.
 Group Exercise
Discuss:
● what accidents can occur with hand-held tools, and
● How the tools became damaged.
 Hazards of Hand-Held Tools
• Tool may shatter.
• Handle may come loose.
• Tool may be blunt requiring
excessive force.
• Human error, e.g. hit thumb
with hammer.
• Misuse, e.g. wrong tool for
job.
 Precautions
• Tools suitable for the task and environment of
use.

• Information, instruction and training.

• Visual inspection of tools.

• Substandard tools repaired or discarded.

• Maintenance of tools.

• Supervision of practices.
 Portable Power Tools
Higher risk because:
• Forces are greater, meaning potential for very severe
injury.
• Additional hazards present, such as:
‐ Electricity.
‐ Petrol.
‐ Noise.
‐ Vibration.
‐ Dust.
‐ Ejected material.
‐ Trip hazards.
 Controls for Portable Power Tools
• Careful selection:
‐ Task.
‐ Environment.
• Instructions:
‐ Manufacturer's instructions.
‐ In-house rules.
• Training and information, competence.
• Supervision.
• Routinely inspected.
• Repair or disposal of unsafe tools.
• Regular maintenance - by competent staff.
 Safe Use of a Portable Power Tool
• Tools used within design specification
(e.g. disc speeds).
• Guards and safety devices in place.
• PPE used.
• Power cables controlled.
• Ejected parts controlled, e.g. secured
work area.

• Control of any noise, dust, vibration.

• Safe storage and handling of fuel
(e.g. petrol).
• Inspection and testing of electrical
equipment.
Machinery Hazards
 Mechanical and Non-Mechanical
Hazards
Mechanical hazards:
• Contact with or being caught up in moving parts.

Non-mechanical hazards:
• From power source or things being emitted by the
machine.
 Mechanical Hazards
• Crushing.
• Shearing.
• Cutting or severing.
• Entanglement.
• Drawing in or trapping.
• Impact.
• Stabbing or puncture.
• Friction or abrasion.
• High-pressure fluid injection.
Crushing
Shearing
Cutting or Severing
Entanglement
Drawing In or Trapping
Impact
Stabbing or Puncture
Friction or Abrasion
 High-Pressure Fluid Injection
• Injuries caused by liquids released under pressure.

• May have small entry wound but travel through

tissue.
 Group Exercise
What are the non-mechanical hazards which are associated
with machinery?
 Non-Mechanical Hazards
• Electricity.
• Noise.
• Vibration.
• Hazardous substances.
• Ionising radiation.
• Non-ionising radiation.
• Extreme temperatures.
• Ergonomics.
• Slips, trips and falls.
• Fire and explosion.
 End-of-Section Quiz
1. Identify the mechanical
hazards.

1. Identify the non-

mechanical hazards.
Control Measures for Machinery
Hazards
 Machinery Safeguarding Methods
• Fixed guards.
• Interlocked guards.
• Adjustable/self-adjusting guards.
• Trip devices.
• Protective devices:
- Two-hand controls.
- Protective appliances.
- Emergency stop controls.
- Personal protective equipment.
- Information, instruction, training and supervision.
Control Measures for Reducing Risk
from Machinery Hazards
Types of machinery guards:
Fixed
Interlocked
Adjustable/self adjusting
Trip
 Fixed Guards
• Completely prevent access to
dangerous parts of machinery.
• Are fixed in place.
• Require a tool for removal:
– Limitation.
 Group Discussion Point
Apart from the mechanical hazards, what hazards can fixed
guards provide protection against?
 Group Discussion Point
Apart from the mechanical hazards, what hazards
can fixed guards provide protection against?
• Electricity.
• Radiation.
• Hot surfaces.
• Noise.
• Ejection of swarf or dust.
 Interlocked Guards
Guard open:
• Power to the machine is disabled when the guard is
open and it will not operate until the guard is in
place.
Guard closed:
• the guard is locked shut until the machine has
returned to a safe condition, OR
• the act of opening the guard stops the dangerous
parts of the machinery and disables power.
 Adjustable/Self-Adjusting Guards
Used when it is not possible to
prevent access to dangerous
parts.
Adjustable guard:
• Set manually to a range of
positions by the operator.
Self-adjusting guard:
• Usually spring-loaded to
adjust itself to the workpiece.
• Requires no adjustment by
the operator.
 Interlocked Guards

Limitations:
• Can bypass the system.
• Person may gain access by closing the guard
around them.
• Needs rule to be enforced.
 Sensitive Protective Equipment
(Trip Devices)
• Not a physical barrier.

• Use sensors to detect presence

of operator and stop the
machine.

• They include:
‐ Pressure mats.
‐ Trip bars.
‐ Photoelectric devices.
• Limitations?
 Two-Hand Controls
Designed to protect the
operator's hands:

• Controls should be more than

a hand span apart.

• Must activate at the same

time (within 0.5s of each
other).

• Releasing controls must stop

the machine immediately.

Limitations.
 Emergency Stop Controls
• Should bring the machine to a safe stop as quickly
as possible.
• Machine can only be re-started using the re-set
button.
• Release of the button should not re-start the
machine.
• Limitations.
 Protective Appliances
Designed to keep operators’ hands away from
danger.

Include:
• Push-sticks.
• Jigs.
• Clamps.
 Specific Equipment
Office machinery: Retail machinery:
• Photocopier. • Compactor.
• Document shredder.
• Checkout conveyor system.
Manufacturing machinery: Construction machinery:
• Bench-top grinder.
• Cement mixer.
• Pedestal drill.
• Circular saw.
Agricultural machinery:
• Cylinder mower.
• Strimmer.
• Chainsaw.
 Group Exercise
Choose one of the ‘specific machines’ and outline:
• The hazards (mechanical and non-mechanical).
• Control measures.
 Hazards and Control Measures

• Photocopier.
• Paper shredder.
• Bench-top grinder.
• Pedestal drill.
• Cylinder mower.
• Strimmer or brush-cutter.
• Chainsaw.
• Compactor.
• Check-out conveyor system.
• Cement mixer.
• Bench-mounted circular saw.
 Office Machinery

Photocopier Document Shredder

 Manufacturing Machinery
Bench-Top Grinder Pedestal Drill
Agricultural Machinery

Chainsaw
Retail Machinery

Compactor
Construction Machinery

Cement Mixer
Requirements for Guards and Safety
Devices
• Meets relevant standards.
• Strong and robust.
• Compatible with machine operation.
• Not easy to defeat.
• Allows vision.
• Allows ventilation.
• Easy to maintenance.
• Designed to allow for maintenance.
• Does not increase overall risk.
 End-of-Section Quiz
Identify the types of guards and protective devices.
 Summary
• Described some of the basic management issues that must be
considered when introducing work equipment.
• Outlined the hazards and precautions associated with simple
hand tools, such as hammers and chisels.
• Outlined the hazards and precautions associated with portable
power tools, such as a portable electric drill or disc cutter.
• Explained the mechanical hazards of machinery as: crushing,
shearing, cutting or severing, entanglement, drawing in or
trapping, impact, stabbing or puncture, friction or abrasion, and
high-pressure fluid injection.
• Identified the non-mechanical hazards of machinery as:
electricity; noise; vibration; hazardous substances; radiation
(ionising and non-ionising); extreme temperatures; ergonomics;
slips, trips and falls; and fire and explosion.
 Summary
• Explained the basic characteristics of fixed guards, adjustable
and self-adjusting guards, and interlocked guards as well as the
characteristics of trip devices, two-hand controls, protective
appliances and emergency stops.
• Outlined the basic requirements of guards and safety devices,
where they: must meet relevant standards, be strong and
robust, compatible with machine operation, not be easy to
defeat, allow visibility and ventilation, take maintenance into
account, and not increase overall risk.
• Described the hazards associated with photocopiers, shredders,
bench grinders, pedestal drills, cylinder mowers, strimmers,
chainsaws, compactors, checkout conveyors, cement mixers
and bench-mounted circular saws.
 Summary
• Identified the types of guard and other protection measures to
ensure safety in the use of photocopiers, shredders, bench
grinders, pedestal drills, cylinder mowers, strimmers, chainsaws,
compactors, checkout conveyors, cement mixers and bench-
mounted circular saws.