Risk Assessment

Welding locking plates into half soffit plate mounted in jig Horizontally
STEP 1 – HOW CAN PEOPLE GET HURT?
Use the list as a check and add other items, unique to your work area, if necessary. Step back and consider any other hazards! Involve the managers, staff and where
necessary the Health and Safety team in deciding what is to be included

IDENTIFY HAZARDS (put an X to denote those relevant to your area)

1. Access/Egress (Obstruction?) X 11. Flammable materials 21. Pressure Systems How Else Can People Get Hurt?
(Specify below)
2.Animals 12. Food Hygiene 22. Radiation (RF, Microwave) 31. Other Hazards – e.g. physical
Radiation (radioactive sources) exertion, work near water etc

3.Asbestos
4.Compressed Gas/Cryogenics
(Storage & Use)
5. Confined Spaces
6. Construction Work
7. Display Screen Equipment
(DSE)
8. Driving & Mobile Phones
9. Electricity (inc portable
appliances)
10. Fire (building fire safety)
13. Hand tools
14. Hazardous Substances
(COSHH)
15 Heights (ink Ladders, X 25. Transport (forklift trucks,
Scaffolding)
X 16. Lifting Equipment
17. Lone working
18 Manual Handling
19. Noise exposure
20. Office Equipment (Photo
copiers, shredders, etc.)
23. Slipping, Tripping, Falling X 32. Musculoskeletal Stress X
24. Storage (racks, shelves, filing, 33. Biological health Hazard
cabinets, etc.)
34. OTHER?
vehicles, tractors etc)
26. Violence (attack and public
disorder)
27. Weather (hot/cold/lighting etc)
28. Working environment (ink
Temporary Workplaces)
29. Working Patterns/ Work X
Organisation
30.Workshop Equipment

A SEPARATE ASSESMENT MAY BE REQUIRED FOR HAZARDS SHOWN IN BOLD

(Please check with your supervisor or local Safety Advisor)

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STEP 2 – GROUPS PARTICULARLY AT RISK
Any of the following groups might be particularly at risk from the hazards you have identified above. If this the case record in step 3 as extra controls may be necessary.
Young Persons (i.e. under 18) Contractors/ Sub-contractors / Staff X
from Other Departments
New& Expectant Mothers Individuals with disabilities or medical
conditions
New Employees / Inexperienced Workers X Members of the Public

STEP 3 – TRANSFER HAZARDS & GROUPS IDENTIFIED AT RISK FROM STEP 1 & 2
Now assess the risks from the hazards identified in Step 1 by completing the form below.
What could cause WHO might be EXISTING CONTROL MEASURES Severity Likelihood Risk Who is
HARM? harmed and What do you do already to minimize the risk? Rating RESPONSIBLE?
HOW?

Soffit plate is raised from
the surface of raised
bed.
Step down from soffit
plate onto raised bed.
Welder may fall • Employees are encouraged to be vigilant to hazards in 3 3 9 Welders
from plate and their area and this includes the edge of the beds.
Supervisors
sustain • Take 5 cards carried out by employees to encourage
sprain/fracture or them to survey area for hazards before commencing HSE department
work.
other
• Suitable light levels are maintained.
musculoskeletal
• Welders are suitably trained and qualified
injury • Only trained/competent operatives are allowed on soffit
plate.
Welder has • Welders are suitably trained and qualified 2 2 4 Welders
potential of • Step-ups have been provided to allow welder to safely
Supervisors
sustaining sprain/ access top of soffit plate
fracture due to • Only authorised persons are allowed on soffit plate. HSE department
height of soffit • Take 5 cards carried out by employees to encourage
them to survey area for hazards before commencing
plate whilst
work.
stepping down • Employees are encouraged to be vigilant to hazards in
their area and this includes trip hazards.
• Suitable light levels are maintained

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Edge of beds not visible Welder/plater • Hazard tape applied to edge of bed to aid visibility. This 3 3 9 Welders
enough, whilst standing potential to fall of tape is checked every morning with areas that are
Supervisors
on the beds, against off bed and sustain damaged or dirty being replaced to ensure visibility of
edge. HSE department
backdrop of floor sprain/fracture
• Employees are encouraged to be vigilant to hazards in
their area and this includes the edge of the beds.
• Take 5 cards carried out by employees to encourage
them to survey area for hazards before commencing
work.
• Suitable light levels are maintained.
• Only trained/competent operatives are allowed on
beds.
Step down from bed Welder has • Employees are encouraged to be vigilant to hazards in 3 2 6 Welders
potential of their area and this includes the step down from beds.
Supervisors
sustaining sprain/ • Take 5 cards carried out by employees to encourage
fracture due to them to survey area for hazards before commencing HSE department
work.
height of bed whilst
• Suitable light levels are maintained.
stepping down
• Only trained/competent operatives are allowed on
beds.

Beams of jig to which Welder may lose • Welders are suitably trained and qualified 3 2 6 Welders
soffit plate is mounted their footing when • Only authorised persons are allowed on soffit plats
Supervisors
are dark in colour and accessing or • Take 5 cards carried out by employees to encourage
are not clearly visible egressing from them to survey area for hazards before commencing HSE department
work.
against floor plate ant trip with
• Employees are encouraged to be vigilant to hazards in
potential for
their area and this includes trip hazards.
sprain/strain or • Suitable light levels are maintained
other
musculoskeletal
injury
Tools/equipment/welding Welder may trip • Housekeeping routines are in place to ensure trip 2 3 6 Welders
cables and hoses left on on or from plate hazards are minimised.
Supervisors
soffit plate and bed. and sustain • Regular toolbox talks to remind welders/platers of need
sprain/fracture or to remain vigilant regarding trip hazards HSE department
other

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 musculoskeletal • Welders encouraged to keep welding machine as close
injury as possible to workpiece to minimise length of
hoses/cables.
• Tools and equipment should be stored safely away soffit
plate.
• Take 5 cards carried out by employees to encourage
them to survey area for hazards before commencing
work.
• Employees are encouraged to be vigilant to hazards in
their area and this includes trip hazards.
• Supervisors instructed to be vigilant and to challenge
any operators who have an untidy working area.
• Suitable light levels are maintained
• Only trained/competent operatives are allowed on soffit
plate

Pre-heat pad cabling Welder may trip • Regular toolbox talks to remind welders of need to 2 3 6 Welders
around perimeter of both over cabling and remain vigilant regarding trip hazards
Supervisors
soffit plate and bed to sustain • Cable trays are provided to store cabling and their use
which jig is mounted. sprain/fracture or actively encouraged. HSE department
• Heating elements are attached to underside of plate to Cooperheat
other
ensure no cabling on top of plate.
musculoskeletal
• Take 5 cards carried out by employees to encourage
injury them to survey area for hazards before commencing
work.
• Employees are encouraged to be vigilant to hazards in
their area and this includes trip hazards.
• Supervisors instructed to be vigilant and to challenge
any operators who have an untidy working area.
• Suitable light levels are maintained
• Only trained/competent operatives are allowed on beds
and soffit plates.

Angle iron sections Welder may trip • Regular toolbox talks to remind welders of need to 2 3 6 Welders
welded to upper face of on or from plate remain vigilant regarding trip hazards
Supervisors
soffit plate and sustain • Employees are encouraged to be vigilant to hazards in
sprain/fracture or their area and this includes trip hazards. Managers

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 other • Take 5 cards carried out by employees to encourage HSE department
musculoskeletal them to survey area for hazards before commencing
injury work.
• Suitable light levels are maintained.
• Only trained/competent operatives are allowed on soffit
plate.
The jig to which soffit Welder may fall • Employees are encouraged to be vigilant to hazards in 2 2 4 Welders
plate is mounted is into opening and their area and this includes any openings around soffit
Supervisors
larger than plate leaving sustain plate.
openings on two sprain/fracture or • Take 5 cards carried out by employees to encourage HSE department
them to survey area for hazards before commencing
corners. other
work.
musculoskeletal • Suitable light levels are maintained.
injury • Only trained/competent operatives are allowed on soffit
plate.

Temperature to which Welder may • Welders are suitably trained and qualified. 2 2 4 Welders
inserts, and plate are sustain burn injury • PPE supplied to welders and required to be worn is
Supervisors
pre-heated (175-215 due to contact with constructed of heat resistant materials.
degrees Celsius) with insert, plate or jig. • Welding gauntlets are required to be worn at all times Managers
subsequent heat transfer • Welding cushions are available HSE department
• Supervisors are instructed to challenge when correct
to mounting jig.
PPE is not worn.
• Take 5 cards carried out by employees to encourage
them to survey area for hazards before commencing
work.
• Employees are encouraged to be vigilant to hazards in
their work area
• Signage has been installed warning of hot surface

Heat radiated by locking Welder must kneel • Welding cushions have been provided to insulate 3 4 12 Welders
and soffit plate on top of plate to welders from heat given off by soffit plate
Supervisors
carry out welding • Heat resistant insulating material (3 layers) wrapped in
operation and may welding blankets has been provided insulate welders Managers
from heat given off by soffit plate
develop heat HSE department
• Kneepads are freely available.
stress/exhaustion
• Welders are encouraged to take regular breaks.

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• Drinking water is freely available.
• An air-conditioned area for welders to cool down has
been provided and its use actively encouraged
• Plate is heated from below to reduce radiated heat.
• Take 5 cards carried out by employees to encourage
them to survey area for hazards before commencing
work.
• Employees are encouraged to be vigilant to hazards in
their work area
• Working patterns have been organised to ensure that
welders are working for as short a time as possible
between breaks
• Supervisors have been instructed to ensure working
patterns are adhered to.
• Toolbox talk regarding heat stress has been created
and delivered to welders

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PERSONAL PROTECTIVE EQUIPMENT (state type)
Hard Hat - X Bump Cap - Other: Please specify? Chin strap to be worn

General Overalls - Flame Retardant - X Paper Overalls Other: Please specify?

Boots/ Shoes - Welding Boots - X Other: Please Specify?

Glasses - X Goggles - Spoggles - Full Face Visor- Other:

Cut 5 Gloves Gauntlets X Nitrile Gloves - Cut 1 Gloves Other: Please Specify?

Ear Plugs X Ear Defenders Other: Please specify?

Dust Mask Half Face Mask Full Face Mask - Other:

Harness Restraint Lanyard Fall arrest Other: Please specify?

Additional P.P.E. Air fed welding helmet

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 Risk Assessment Matrix: Severity

Severity Criteria: Harm to Personnel Environment Damage Schedule

1 = Insignificant Injuries or ailments not requiring No environmental impacts, easily Insignificant damage to
medical treatment controlled plant, equipment, or Delay up to 1 hr
product
2= Minor Minor injury or First Aid Treatment Slight environmental impact within site Slight damage to plant,
area (controllable) equipment, or product Delays of 1-12 hrs
Serious injury causing hospitalisation Localised pollution causing significant Significant damage to
3 = Moderate or multiple medical treatment environmental impact beyond working plant, equipment, or Delays of 1-2 days
area requiring external assistance product
4 = Major Life threatening injury or multiple Severe environmental impact beyond Severe damage to plant,
serious injuries causing site working area requiring external equipment, or product Delays of up to 7 days
hospitalisation assistance
5 = Catastrophic Death or multiple life-threatening Chronic pollution damage to Total loss of plant, Delay extending over 7
injuries environment extending significantly equipment, or product days+
beyond site area

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 Likelihood Likelihood
1 = Rare May occur but only in exceptional circumstances Severity 1 2 3 4 5

2 = Unlikely Could occur but improbable

1 1 2 3 4 5
2 2 4 6 8 10
3= Possible Might occur at some time
3 3 6 9 12 15
4 = Likely Will probably occur 4 4 8 12 16 20

5 = Almost Certain Is expected to occur in most circumstances 5 5 10 15 20 25

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RISK ASSESSMENT FORM

Potential Control Measures • Construct/purchase jig to hold soffit plate vertically to allow welding
operations to commence without need to work at height
• Construct/purchase step up/stair and designate this as only point of
access/egress-install signage indicating this
• Paint top of beams/angle iron sections in high visibility colour
SOURCES OF INFORMATION REFERENCED • Only heat and weld one quarter/opposite sides of soffit plate at a time to
make operations more comfortable for welders
The Health & Safety at Work Act 1974 • Purchase heat reflecting material to deflect heat from welders
Workplace Health and Safety Welfare Regulations 1992 • Purchase material with low thermal conductivity to line top of plate
• Purchase 3m wide Aluminium scaffold boards and construct rail either side of
The Manual Handling Operation Regulations 1992 jig to allow safe access to top of plate.
Management of Health and Safety Regulations at Work 2002 • Fabricate steel plates to cover over openings between soffit plate and jig.
Provision and Use of Work Equipment Regulations 1998
Safe System of Work
Training Requirements
Statutory Inspections
Permits to Work
Procedure (Required/ Ref Number

Is it reasonably practicable to control the risk without P.P.E.? No-Welding boots due to work environment
Hard hat due to overhead crane activity
Ear plugs due to work environment
Gauntlets due to work environment
Flame retardant overalls due to work environment
Safety glasses due to work environment
Is Health Surveillance required?
Specify type of waste generated by the process (hazardous/ non-hazardous)
COSHH Assessment Number (Required/ Reference Number?)

All Risks shall be assessed to achieve a Risk level of ALARP for all relevant tasks, prior to task commencing.
Should there be any significant changes noted – Stop the Job – shall be introduced and the TRA and TBT / Pre-
Job Daily Plan revisited.

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