NORTHERN TECHNICAL COLLEGE

PROGRAMMES: DIPLOMA AUTOMOTIVE TECHNOLOGY

AND
ADVANCED CERTIFICATE IN HEAVY EQUIPMENT REPAIR

SUBJECT: WORKSHOP PROCESSES AND PRACTICE

MODULE NUMBER: 166-01A

UNIT 01A: 1 WORKSHOP SAFETY

COPYRIGHT: No part of this module can be used or reproduced

Without the permission of the author or NORTEC

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 WORKSHOP SAFETY
DEFINATIONS OF TERMS

A WORKSHOP: Is a designed place where maintenance, or service or repair or assembling

work of motor vehicles or other equipments are carried out.

SAFETY: Is the freedom from danger – awareness of risks of injury, death or

damages at place of work.

It is the protection of people from physical injury or machinery,

equipment, tools from damage or misuse.

DANGER: Is or means chances of suffering liability to suffer injuries or loss of life.

ACCIDENT: Is an unplanned occurrence that could be caused by one’s carelessness or

negligence which might cause injury or loss of life or equipment.

HAZARD: A potential of a substance, activity or process to cause harm.

RISK: Is the likely hood of a substance, activity or process to cause harm.

DANGEROUS OCCURANCE: It is any incident that could have resulted in an accident “Near
miss”.

OCCUPATIONAL OR WORK RELATED ILL HEALTH: Is concerned with those illnesses

or physical and mental disorders that are either caused or triggered by
workplace activities.

ENVIRONMENTAL PROTECTION: arrangements to cover those activities in the workplace

which affect the environment.

WELFARE: The provision of facilities at workplace to maintain the health and well-
being of an individual at the work place.

OSHA: This represents Occupational Safety and Health Administration

MEANING OF RISKS

1. R – Remember to conduct risk assessment prior to commencement of any task.

2. I – Identify hazards, asses the risks and control/eliminate the risks.
3. S – Share the information on your risk assessment with your workforce.
4. K – Know the safe work procedure for all the tasks you perform.
5. S – Safety is everybody’s responsibility.

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PRECAUTIONS IN WORKSHOP

THE HEALTH AND SAFETY AT WORK ACT

PURPOSE

1. To safeguard the health, safety and welfare of the persons at work.

2. To protect the general public from risks to health and safety caused by the activities of
persons at work.
3. To control the keeping and use of explosives or highly flammable or otherwise dangerous
substances, and, generally prevent the unlawful acquisition, possession, and use of such
substances.
4. To control the emission into the atmosphere of harmful or offensive substances from
premises.

DUTIES OF EMPLOYERS

The employer should provide:

1. Healthy and safe plant and systems maintained in good order.

2. Healthy and safety facilities for handling, storage and transport of articles and substances.
3. Healthy and safety information, instruction, training and supervision.
4. A healthy and safe place of work maintained in good order, with a safe means of getting
to and from it.
5. A healthy and safe working environment with adequate facilities and arrangements for
welfare.

DUTIES OF EMPLOYEES

It shall be the duty of every employee while at work:

1. To take reasonable care of the health and safety of himself or herself, other workers, and
the general public.
2. To observe the provisions of the ACT wherever applicable to him/her or matters under
his/her control.
3. To co-operate with his employer in complying with the Act.
4. No person shall intentionally or recklessly interfere with or misuse anything provided in
the interests of health, safety or welfare to meet the legal requirements of the act.
5. To read the warning labels on materials.
6. Follow the instructions and warnings very carefully.
7. To use common sense when working with hazardous materials.
8. To take time to learn how to use protective materials.

HAZARDOUS MATERIALS

The four hazardous materials which can cause harm to a person’s wellbeing, or pollute the air,
land and water.

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 1. Flammable – flammable materials easily catch fire or explode.
2. Corrosive – corrosive materials are so caustic that they can dissolve metals and burn the
skin and eyes.
3. Reactive – reactive materials will become unstable (burn, explode, or give off toxic
vapours) if mixed with air, water, heat, or other materials.
4. Toxic – toxic materials are those materials which can cause illness or death after being
inhaled or upon contacting the skin.

HEALTH AT WORK PLACES

The industrial act contains basic provisions to ensure health working conditions and
these are:

1. Cleanliness and maintenance of reasonable temperature.

2. Effective ventilation.
3. Suitable lighting.
4. Proper drainage floors.
5. Adequate sanitary conditions.
6. Work people must be prevented from inhaling dust and fumes.
7. Operator must be protected from excessive noise.
8. Never drink or eat near poisonous substances.

WORKSHOP SAFETY RULES

Many regulation and safety rules are laid down and should be observed when one is on the
workshop rules to keep away from danger and prevent accidents, because accidents cost life, loss
of time, money etc.

The following could be some of safety precautions to observe:

1. CLEAN WORKSHOP ENVIRONMENT:

1.1 Clean the workshop and surrounding

1.2 Good housekeeping should be observed
1.3 A tidy and clean workshop is usually a safe working place

2. GOOD HEALTHY

2.1 Be of sound mind and healthy when operating or working on the machine.
2.2 Stop day-dreaming
2.3 When you are not well do not operate or work on the machine
2.4 Do not operate the machine when you are under the influence of strong drugs
(under medication) or on the influence of beer.
2.5 Workers must be prevented from inhaling harmful dust and fumes.
2.6 Have every injury treated however small it may be.
2.7 Never eat or drink near to poisonous substances.
2.8 Operator must be protected from excessive noise.

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3. DUST AND FUMES

3.1 Use an appropriate respirator.

3.2 Use a properly designed hood or exhaust system
3.3 Use a wet method to control dust.
3.4 Always totally enclose the process concerned, to prevent any escape of dust or
fumes.

4. INDUSTRIAL DERMATITIS

Dermatitis – is the reaction of the skin to substances used in the Industry.

- Can take many different forms, but usually starts with redness and irritation.
- Is not contagious, but any part of the body which comes in contact with the substance
may be affected.

CAUSES OF DERMATITIS

The main substances which cause industrial dermatitis are:

a) Mineral oil used as a cutting fluid in many applications.
b) Chemicals such as chromic acid (used in chromium plating) and synthetic resins.
c) Solvents such as paraffin, trichloroethylene, and turpentine – these dissolve the
natural grease from the skin and allow entry of the irritant.

PRECAUTIONS TO BE TAKEN

a) The use of mechanical aids such as tongs, scrapers and splash guards should be
encouraged.
b) Wearing protective clothing, this should be regularly cleaned and kept apart from
other clothing.
c) Using washing facilities with hot water and clean towels.
d) Using the appropriate barrier creams.
e) Having first-aid treatment for every injury, however trivial.

5. TOXIC SUBSTANCES

Toxic or poisonous substances can be solid, liquid or a gas given off as fumes or vapour.

a) Industrial solvents are flammable and also give off fumes or vapour.
 The common solvents are paraffin, petrol, turpentine, trichloroethylene and
carbon tetrachloride.
 The vapour can be inhaled into the lungs.
 Physical contact, through the skin or through the mouth.
b) Some metals give off toxic vapours when heated, for example when molten or during
welding. These include;
i) Aluminium – Inhalation of fumes causes the lungs condition known as
Aluminosis.

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 ii) Cadmium – Industrial poisoning is caused by inhalation of fumes during the
pouring of molten metal or when welding cadmium-plated articles.
iii) Chromium – In the chromium-plated industry, contact affects the skin and
inhaling fumes affects nasal membranes and lungs.
iv) Lead – Serious risk from fumes, dust or vapour, can be fatal.
v) Mercury – Acute poisoning usually results from swallowing or through
exposure to vapour; contact can cause dermatitis.
vi) Nickel – In nickel plating can cause dermatitis (known as ‘nickel itch’)
vii) Zinc – used in galvanizing, inhaling Zinc-oxide fumes results in ‘Metal-fume
fever’.
viii) Cyanide salts- used in industrial heat-treatment and electroplating process are
extremely dangerous and kill quickly and painfully. They can be absorbed
through the skin, by inhaling fumes, or through the mouth if contaminated
food is eaten.

PRECAUTIONS FOR TOXIC SUBSTANCES

1. Efficient fumes extractors should be in operation.

2. Protective clothing must be worn.
3. Always wash thoroughly after handling toxic substances
4. Never eat or drink in the near vicinity
5. If an accident occurs, seek medical attention immediately.
6. Antidotes should be available which are effective if given immediately – know
where they are and how to use them.
7. Ensure that drums containing cyanide are properly labeled and correctly stored.
8. Follow the correct procedures laid down for any process using cyanide salts.

6. GOOD HOUSEKEEPING

Good housekeeping is essential in the prevention of accidents. More accidents are caused
by people falling or burning into and stepping on things that are caused by Machinery. A
tidy factory and workplace reduces the risk of accident.

Factory act require that;

1. Floors, Steps, Stairs, passages and gangways must be soundly constructed, properly
maintained and kept free from obstruction and any substance likely to cause a person
to slip.
2. Handrails must be provided for stairs.
3. All ladders must be soundly constructed and properly maintained.

PRECAUTIONS FOR BETTER HOUSEKEEPING

The following precautions must be observed;

1. Always walk – never run.

2. Never throw rubbish on the floor.
3. Keep gangways and work areas free of metal bars, components etc.
4. Keep to gangways when moving about – never take short cuts.

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 5. If oil, water or grease is spilled, wipe it up immediately.
6. Wear safety shoes – shoes are available with anti-slip soles and with metal toe-caps to
protect the feet from falling objects.
7. Never use unstable piles of boxes, inadequate scaffolding, or unsecured ladders for
working at heights.
8. Always check ladders for damage before use.
9. Always position ladders on a firm base at the correct angle-the height of the top
support should be about four times the distance out at the base.
10. Ensure the ladders are long enough.

7. HAND TOOLS

The following precautions should be observed;

7.1 Regularly examine hand tools

7.2 Do not use hand tools if they are found to be defective, as they can cause serious
injury.
7.3 Ensure that handles are securely fitted to files; scrapers, screw drivers and
hammers and that they are not split.
7.4 Do not use hammers with chipped heads.
7.5 Use the correct size of spanners – the incorrect spanners can slip and injure the
hand.
7.6 Do not use chisels with “mushroomed” heads – a piece of metal could fly off and
injure your eyes or hand.
7.7 Always keep the bench or workplace clean and tidy and put tools in a safe place
after use.
7.8 Never carry loose tools in your pockets – you could slip and fall on them.
7.9 Choose the most suitable tools for carrying out the work safely and efficiently.
7.10 Prevent tools from slipping, by always wiping off any oil and keeping tools clean.
7.11 Use tools for their intended purpose.
7.12 Never use at tool unless you know how to use them.

8. MANUAL HANDLING OF OBJECTS

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 Lifting and moving objects by manual effort are a major cause of injury, usually resulting
in back strain. To avoid injury, the following precautions should be observed;
8.1 Lifting with the legs – not with the back.
8.2 Do not try to lift too heavy a load – get help.
8.3 Check for sharp edges, splinters, projecting nails, or other objects and sharp wire,
or other objects and wear protective gloves if necessary.
8.4 Before lifting, check that your path is clear, that you can see over or round the
object, and that there is sufficient space to put the object down.
8.5 Follow the correct procedure for lifting;
8.5.1 Stand close to the object with your feet slightly apart, facing the direction in
which you intend to move.
8.5.2 Bend the knees, keeping the back straight but not necessarily vertical.
8.5.3 Position your elbows close to your body, so that the body takes the weight
instead of the fingers, writs, and arm shoulder muscles.
8.5.4 Grip using the palm and the roots of the fingers – not the finger tips (using the
finger tips means more effort and more chance of dropping the object).
8.5.5 Straighten the knees, allowing the thigh muscles to do the work – not your
back.
8.5.6 Reverse the procedure when setting the object down.

9. MACHINERY

Equipment with moving parts is always a source of danger. This could be as a result of;
a) Operator’s attention may be disturbed.
b) Operator’s concentration may be distracted or affected.
c) Fault tools could affect the work output.
To avoid many accidents, the following precautions must be followed;
9.1 Ensure that you know how to switch and stop the machine before you set it in
motion.
9.2 Maintain your concentration while the machine is in motion.
9.3 Take care not to distract or startle other machine operators.
9.4 Never leave your machine unattended to while it is in motion.
9.5 Never clean a machine while it is in motion – always isolate it from the power
supply first.
9.6 Never use compressed air to clean a machine – it may blow in your face or
someone’s and causes an eye injury.
9.7 Never clean away swarf with your bare hands – always use a suitable rake, which
should be provided.
9.8 Keep hair short or under a cap – it can become tangled in drills or rotating shafts.
9.9 Avoid loose clothing – wear snug-fitting boiler suit, done up, and ensure that any
neck wear is tucked in and secure.
9.10 Do not wear rings or wrist watches at work.
9.11 Always ensure that all guards are correctly fitted and in position.

FOUR BASIC TYPES OF MACHINE GUARDS

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Do your employees know the different types of machine guards and the differences between
then? You can use the following to present key information on this topic.

There are four basic types of machine guards:

1. Fixed guards
2. Interlocked guards
3. Adjustable guards
4. Self-adjusting guards

Fixed guards are probably the most common because of their simplicity and effectiveness.
Fixed guards are attached permanently to equipment and can only be removed with
considerable effort. They usually cover power transmission units and can also be found
on band saws.

Interlocked guards are designed to be removed or opened to allow access to the hazard zone
—for example, to insert or remove material from the point of operation. Once the guard
is opened, however, the machine shuts down automatically, effectively eliminating the
hazard.

Adjustable guards allow a machine to handle a wide variety of material sizes while still
protecting the unused portion of the blade or the point of operation. These guards must be
adjusted manually. An example is the guard over the point of operation on a band saw.

Self-adjusting guards, typically found on saws, are pushed away from the point of operation
when material is fed into the machine. But they only open enough to allow the material
into the cutting zone, thus keeping the remainder of the blade covered.

Think about the types of guards on the machinery you use on the job. Machine safeguarding
is a crucial part of our machine safety program. But guards alone won’t keep you safe.
You also have to use your knowledge and experience about machine safety every day on
the job to be absolutely safe from amputation hazards.

10. EYE PROTECTION

Eye protectors represents equipment made to be worn by a person, such as spectacles,

goggles, eye shields, face shields and face screens.

Workshop processes which require eye protectors are;

10.1 The use of high-speed metal-cutting saws or abrasive cutting-off wheels.

10.2 Working at a furnace containing molten metal.
10.3 Pouring or skimming molten metal in foundries.
10.4 Truing or dressing an abrasive wheel.
10.5 Fettling of metal castings.
10.6 Machining of metals, including dry-grinding processes
10.7 Welding of metals by electrical-resistance methods

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 10.8 Sharpening a tool on a grinding wheel.
10.9

11. ACT SAFELY

11.1 Think before doing anything, have knowledge of what you want to do.
11.2 Think about your friend’s safety
11.3 It is important to learn or have first aid knowledge, to be able to help in
emergency

12. WEAR PROPER SAFETY ATTIRE

12.1 Do not wear loosely fitting clothes

12.2 Avoid wearing hanging pieces of clothing (i.e. ties) jewels and long sleeved
(loose calf’s)
12.3 Fold long sleeves up above the elbows.
12.4 Avoid wearing dirty overalls and torn safety boots etc.
12.5 Use safety glasses when using compressed air, using chisel and hammer, when
chipping metals, and when using a grind machine.
12.6 Dress properly for the work.

13. BE SAFETY CONSCIOUS

13.1 Running machinery: Do not work on running machinery

13.2 Learn or know the quickest and safe way of stopping the machines.
13.3 Remove the key from the ignition switch or remove one battery terminal to avoid
accidental switching of the engine.
13.4 Block the vehicle wheel and apply handbrake when working on the machine
13.5 Use the correct tools for the job to avoid damage and injuries.

14. WORKING ON ELECTRICAL

14.1 When working on electrical equipment, batteries, starter motors, generators,

alternators remember to use good insulator.
14.2 Take note of loose or un insulated electric cables.
14.3 Avoid short circuits on vehicles fitted with alternators

15. HAVE KNOWLEDGE OF FIRE FIGHTING

15.1 Know how to fight any danger of explosions e.g. Oxygen – acetylene gas
welding.
15.2 Know where the nearest fire alarm is located
15.3 Know where the nearest fire extinguisher is located
15.4 Have knowledge of how to operate and use the fire extinguishers
15.5 Know what type of extinguisher for each type of fire
15.6 Keep the fire extinguisher in good operating condition
15.7 Know the position of fire ream hoses

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 16. INFLAMABLES
 Keep safety inflammable liquids and gases
 Wipe up every oil spills
 Adhere to workshop or safety working signs and posts

TOOLS AND EQUIPMENT

INTRODUCTION

Every year there are many industrial accidents resulting from the use of tools and equipment.

 Which include power and manual driven

 Many industrial injuries result from the use of equipment not suited for a particular
purpose.
 Some examples:-
o Adjustable spanners being used instead of a ring or open ended to tighten nuts
o Tin snipes (opener) or pliers may be used were it is not applicable or with handles
bent towards each other at the ends.
o Pipe wrenches with worn out jaws
o Hammers with cracked handles etc.
o Impact tools (i.e. hammers, chisels, punches etc) should be made of iron for
correct hardness.
o Bars which can fly off and cause injuries should be removed.

HAZARDS DUE TO FAULTY WORK HABITS OR CONDITIONS

Some major hazards are:-

1. Smoking while handling dangerous materials such as gasoline or solvents which can
cause fire or explosion.
2. Careless or incorrect handling of gasoline, alcohol solvents or other inflammable fluids

Care must be taken when replacing tank, fuel gauge, filters during body and other
services.

A hand operated valve controls weather pumping the handle pumps fuel in or out of
vehicle fuel tank avoid touching ground wires to prevent sparks that might cause fire.

3. BLOCKING GANGWAYS AND EXITS

 Keeps areas around exit doors and passage way leading to exits free of all
obstructions.
 If they ran explosion or fire, a blocked exit could mean serious injury or death.

4. Spilled oil or anti-freeze not cleaned up, serious injuries can result if some slips and falls
in the shop.

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  Lack of shop exhaust system or failing to connect the system to the tail pipe of a
vehicle with running engine.
 This is a hazard to everyone in the shop
 Exhaust gas contains carbon monoxide (CO) and other poisonous materials like
sulphur.

5. Allowing dangling hair ties, sleeves or jewelleries to fell into the engine fan, drive belt, or
any other moving parts, injury may occur.
6. Workshop accidents claim by far too many victims. Approximately 70% of the accidents
are caused by neglect or carelessness on the part of the workman.

7. A tide workshop helps reduce the number of accidents

8. Tools and components are not to be left where someone may fall over them and they
must not be allowed to obstruct gangways or passage.

9. They should not be laid carelessly on the bench.

10. A tidy bench reflects a tidy, methodical business like mind, which the basis or accidents
prevention.

11. Oils or grease on workshop floors is dangerous

It should be covered with sand or sawdust.

ACCIDENTS AT THE BENCH

1. The vice must be properly fastened before securing clamps the work in it.

2. A long component projecting beyond the edge of the bench must have a coloured piece of
material tied to the projecting end.

3. Always use the correct size, type and length of spanner for the job.

4. Before using a hammer make sure the head is firmly fixed to the handle

5. On no account should a file be used without a handle which be of the correct size.

6. Do not use a mushroomed chisel

7. Tools should not be placed close to the edge of the bench

8. Boots and shoes with metal toe-caps must be worn

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OPEN PITS AND FALLING OBJECTS

1. Pits must be guarded

2. Someone working from above the vehicle must avoid dropping tools or components to
someone working underneath.
3. A hydraulic hoist must be ascertained to be in good working order before put to use.

4. Before lowering a hoist make sure the bottom is clear

5. Observe the safe working load limit when using any jack, hoist or crane

6. Block unjacked wheels and place stands beneath the jacked axle.

COMPRESSED AIR

1. Compressed air should not be used for blowing off dust from one’s clothing’s.

2. Balls and roller bearings should not be compressed air-blow tangentially

WELDING PRECAUTIONS

1. Use goggles or shields when welding

2. Wear protective clothing

3. Make sure you know how to use the equipment correctly.

4. The oxygen cylinders and fittings must be kept free of oil or grease

5. Use soapy water when looking for leaks

6. Use hoses or pipes recommended by manufacturers

7. Never use acetylene bottle when lying on the floor

8. Always stand bootless upright and secure them properly

ELECTRICAL COMPONENTS AND CABLES

1. Trailing cables from portable tools must be kept away from sharp edges

2. All portable electric tools must have a three wire system i.e.

a) Positive Or Live (Red/Brown)

b) Neutral (Blue/Black)

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 c) Earth (Green/Yellow)

3. Avoid damp floors when operating portable electric tools

4. Inspect the wires regularly for damaged insulation

5. Damaged wires should be reported to the electricians

TIDINESS

The most important rule of all is that:-

1. A good mechanic detests untidiness and the accumulation of dirty that always goes with
it.

2. Vehicle repairing is never clean work, but a good mechanic does not have to be dirty
himself should he allow tools and equipment to remain dirty longer than necessary.

3. Tidiness entices working to a logical and definite system during each task.

4. The job can progress smoothly from one stage to the next with fewer efforts and with few
delays.

TIME KEEPING

Time lost or wasted costs the workshop charging time – money which should be coming in.

1. Good time keeping is an essential part of a duty of a mechanic to his employer

2. Work must start and finish on time throughout the working day

SKY LARKING (HORSE OR MONKEY PLAY)

Playing practical jokes must not be permitted in workshops

Apart from ill feeling and time wasted caused, it always results in someone being hurt or
equipment being damaged.

Workshop rules vary between garages and are often never written down.

Mechanics are expected to understand the conditions and also behave in a responsible and
reasonable manner

HAZARDS DUE TO EQUIPMENT DEFECTS OR MISUSE

Some of the hazards are:-

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 1. In correct safety guarding of moving machinery. The guard should be placed around the
belts and pullies on the shop air compressor because if the fan and its blades are exposed
they will cause injuries.

2. Asbestos dust from brakes and clutch linings. Before working on brakes, dust collected
from brake mechanisms and wheels should be removed (use a special vacuum cleaner
with a high efficiency particulate air cleaner filter.

3. Misuse of compressed air, shop air nozzles or blow guns:-

 Discharge compressed air t blow parts dry and clean.

 A diffuser on the blow gun reduces the discharged pressure to less than 30 pounds
per square (207 KPA).
 Never point a blow gun to another person or use it to dust particles at high speed
on your clothes because dust particles can penetrate your skin and eyes.

CAUTION

High pressure air directed at an open wound can send air into the blood stream, this can cause
death.

1. Flexible electric cord that is worn or spliced. Flexible cord should not run through holes
in the wale or be tacked into the wall. Any of these could cause fire, shock or
electrocution.

2. Compressed gas cylinders properly stored or misused.

 Do not store gas cylinders near room heaters or other heat sources.
 Never store cylinders in an unventilated lockers or closets.
 They must not stand free and must have at least 20 feet (6.1 metres between
stored oxygen and acetylene cylinders)
 A chain must be used to secure them.

CAUTION

Never use cylinders as a support or roll them to move another object. Cylinders can explode.

1. Hand electric tools not properly ground (held). They must have a separate ground lead or
double insulation to guide against electric shock.

2. Automotive lifts not properly used. Never raise a vehicle with passengers on it.

 To prevent damage – first close the door, hoot and the trunk lid.
o If the lid has a mechanical locking device engage it before going under the
vehicle
o Do not use a hydraulic lift that jumps, jerks or settles slowly when it
should not.

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  Both work and tool must be securely clamped
 Do not remove turnings and swarf by hand. Use a brush or metal scraper
 Never feel for a burr round the edge of component
 When using a grinding machine, make sure the glass vision is in position or wear
safety goggles.

FIRE AND FUELS

1. Do not carelessly dispose still burning matches or cigarette ends

2. All traces of fuel must be removed before applying heat to the fuel tank

3. Every possible access to the inside of the tank must be open filter caps, drain plug and
outlet connection.

4. Immerse the tank in boiling water containing an alkaline degreasing agent.

5. Continue heating the tank for at least 30 minutes

6. A strong alkaline e.g. caustic soda should not be allowed in cleaning aluminum or
aluminum alloy tanks.

7. Fill the tank with water before commencing to welding or soldering. Allow a small air
space.

REMEMBER

1. Compressed air is not enough to remove fuel traces

2. Neither is rising and soaking in hot or cold water

3. If possible remove any baffles in the tank

4. Weld or solder in an open air wherever possible

5. Exhaust fumes must be directed out of the workshop

6. Doors and windows must be opened when engines are running

CAUTION

Do not use a lifter that works slowly or leaks oil

1. Jacks or stand improperly placed:

 Vehicles and major components are heavy

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  Always place jacks and safety stands so that they support the vehicle or
components
 If a jack or safety stand slips, damage or injury may result

2. Using a wheel and tyre balancer with a hood place

 Safety regulations (OSHA) require all the dynamic (Spinner Type) wheel balancer
to have the hood.
 It protects someone if a stone or other objects flies out of the spinning wheel or
type threading.

3. Letting tester lids fell into the engine fan

 This can cause damage to the lids, topple the tester and injure someone
 Sudden start of an electric fan for the engine cooling system

4. These fans can run even if the ignition key is off.

 To protect oneself, disconnect the lead connector before working around the
engine
 Otherwise, if the engine is still hot the fan could start running and injure you.

5. Leaving a tool in an awkward place unattended.

 Someone might come along without realizing it and get hurt.

6. Playing with a fire extinguisher

 Playing with a fire extinguisher is dangerous because the liquid or spray discharge
may stick on the floor.
 Someone may slip and fall and injure himself
 Someone may have eyes damaged from being hit by the discharge

HAND TOOL HAZARDS

Hand tools must be kept clean and in good condition:-

1. Any grease and oil tools are difficult to use and handle

2. Do not use a hardened hammer or punch on a hardened surface

3. The hardened steel is brittle and can shatter from heavy blows – slivers may fly out and
enter the hand or an eye

SPECIAL INFORMATION

They are other hand tool hazards to watch out for. These are:-

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 1. Hammers with broken or cracked handles
2. Files without handles

3. Broken or bent wrenches

 Never use a tool that is poor in condition or not for the right job

ACCIDENTS WITH MACHINES

1. Before using a machine make sure you can control it and that you know the quickest way
of stopping it

2. Guards around rotating parts should not be removed

 Switch off the machinery before making any adjustment

3. Do not wear loose – fitting clothes when operating rotating machinery.

SAFE AND CORRECT USE OF EQUIPMENT

Use of lifting equipment, particular attention should be paid to the following:-

1. Avoid lifting and handling hazards.

1.1. When lifting heavy objects seek assistance. Use appropriate lifting equipment and
ensure that correct lifting practice is followed.
1.2. Use trolleys of sound construction and adequate capacity to move components.
1.3. Secure loads when transporting on trolleys.
1.4. Ensure that only competent persons (that is, those trained and authorized) operate
lifting equipment. Consider possible danger to persons in the vicinity.
2. Use the correct type of sling.
2.1. Chain Slings
Used for lifting loads having sharp edges such as rolled steel joists or for lifting
hot metals.

2.2. Wire Rope Slings

These are the most widely used. They should not be used for lifting hot materials,
nor should they be allowed to become rusty.

18
 2.3. Fibre Rope Slings
These are generally used for lifting light articles, particularly those with machined
surfaces.

3. Know the safe Working Load (SWL) of lifting tackle in use. Chain slings and wire rope
slings always have the SWL marked on them.
Always:

3.1. Examine slings before use.

3.2. Reject slings which are defective.
3.3. Check the SWL.
4. Protect slings and the load to be lifted. Avoid sharp bends on wire rope slings.
5. Chain blocks – chain blocks are geared to reduce the manual effort necessary to lift may
be stopped where required and the suspended load will stay safely in position when the
hands are removed from the chain. Lowering is usually effected by reversing the
direction of the pull on the hoisting chain. Chain blocks should not be slung hook to
hook. A sling or lashing should be used.

When using the chain blocks:

1. Ensure that the SWL of the block is adequate for the load to be lifted.
2. Attach the head fitting to a suitable anchorage.
3. Pull the operating chain to determine the hoisting and lowering sides of the chain.
4. Attach the load to the hook using the correct slings and/or shackles.
5. Pull down the relevant side of the operating chain to hoist or lower the load.

19
6. Jig Cranes
Jig cranes are marked with the safe working load. Check the SWL of the hoist: it may
differ from that of the jig, if so work to the lower figures.

7. Hydraulic Lifts

Look for the load figure or marks on the telescopic beam.

A 1 tonne hydraulic lift will raise only 0.5 tonne at full extension.

20
21
 MODULE166 -01A: WORKSHOP SAFETY

ASSIGNMENT

DATE GIVEN:

DATE DUE:

QUESTION1

a) When should one conduct housekeeping 2 marks

b) Define tidiness. 2 marks
c) State six merits of tidiness. 6 marks

QUESTION 2

a) Define Skylarking. 2 marks

b) A large number of accidents occur in the garages and factories every day. About two
thirds are the fault of individual Technicians who may or may not be injured. Describe
four incidences which could result in an accident due to an individual.
8 marks

QUESTION 3

a) Define Asphyxiation. 2 marks

b) Outline four precautions to be observed when working under the vehicle.
8 marks

QUESTION 4

Discuss ten benefits of good housekeeping practices. 10 marks

QUESTION 5

Outline ten elements of an effective housekeeping programme. 10 marks

22
FIRE HAZARDS AND CONTROL

FIG. 1
INTRODUCTION
This lecture is intended to educate students in how fires burn and how best they can be
extinguished using the right fire fighting appliances. The fires we are mostly concerned
with are not the fires under control or under controlled burning, but fires which threaten
life and property.
It follows therefore that for any fire to burn, there must be three factors involved namely:-
1. Oxygen
2. Heat
3. Fuel

This is best explained in a form of Triangle and it is known as triangle of Combustion.

Removal of one of them, leads to the collapse of the triangle and combustion stops.
FIRE is a phenomenon in which combustible materials especially those containing carbon
react chemically with oxygen in the presence of fuel, heat and oxygen.
Fire can be started by:
1. Malicious ignition.
2. Misuse of faulty electrical equipment.
3. Cigarettes and matches thrown carelessly.
4. Mechanical heat and sparks.
5. Rubbish burning.

PRECAUTIONS

The meaning of general fire precautions is set out and covers:

a) Instruction and training of employees.
b) Reduction of fire risks.
c) Fire detection
d) Fire warning.

23
 e) Reduction of fire spread.
f) The means of fire escape.
g) Action to be taken in the event of fire.
h) Fire fighting.

DUTIES
Duties are placed on a responsible person who is:-
a) The employer in a workplace, to the extent they have control.
b) Other person who has control of the premises or
c) The owner of the premises.

Specific fire Precautions in work place

1. Know the correct fire drill and the position of fire alarms, firefighting equipment and
emergency exists.
2. Know the correct appliance to use for a particular type of a fire and know how to use it.
3. Never smoke in ‘NO SMOKING AREA’
4. Avoid spillage of flammable liquids.
5. Do not block fire exits.
6. Report defective electrical equipment.

Every employee should know:

1. Where the portable fire extinguishers are placed.
2. Where the hose reels and the controls for extinguishing are located
3. How to operate the extinguishers in their working area. The training must include the use
of extinguishers on simulated fires.

Hence;
1. Fire fighting should only be attempted if it is safe to do so and that an escape route is
safe and available.
2. A fire requires fuel, oxygen and heat. If one element is removed so is the fire.
3. The extinguishing of a fire is generally brought about by depriving the burning
substances of oxygen and by cooling them to a temperature below which the reaction
is not sustained.
4. By far the most important extinguishing agent, by reason of its availability and
general effectiveness, is water. It is more effective than any other common substance.

FIG: 2-TRIANGLE OF FIRE AND FIRE EXTINGUISHING

24
HEAT – Sources of ignition.
1. Naked flames – from smoking materials, cooking appliances, heating appliances, and
process equipment.
2. External sparks - from grinding metals, welding, impact tools, and electrical switch
gear.
3. Internal sparking – from electrical equipment (faulty and normal), machinery, and
lighting.
4. Hot surfaces – from lighting, cooking, heating appliances, process equipment, poorly
ventilated equipment, faulty and/or badly lubricated equipment, hot bearings and drive
belts.
5. Static electricity – causing significant high voltage sparks from the separation of
materials such as unwinding plastic, pouring highly flammable liquids, walking across
insulated floors, or removing synthetic overalls.

FUEL – sources of fuel

If it can burn, it can be fuel for fire.
1. Solids – these include, wood, paper, cardboard, wrapping materials, plastics, rubber,
foam (polystyrene, tiles and furniture upholstery), textiles (e.g. furnishings and clothing),
wall paper, hardboard and chipped used as building materials, waste materials (e.g. wood
shavings, dust, paper etc), hair.
2. Liquids – these includes, paint, varnish, thinners, adhesives, petrol, white spirit,
methylated spirits, paraffin, toluene, acetone, and other chemicals. Most flammable
liquids give off vapours which are heavier than air so they will fall to the lowest levels. A
flash flame or an explosion can occur if the vapour catches fire in the correct
concentrations of vapour and air.
3. Gases – flammable gases include LPG (liquefied petroleum gas in cylinders, usually
butane or propane), acetylene (used for welding) and hydrogen. An explosion can occur
if the air/gas mixture is within the explosive range.

OXYGEN
Oxygen is of course provided by the air all around but this can be enhanced by wind, or by
natural or powered ventilation systems which will provide additional oxygen to continue
burning.
Cylinders providing oxygen for medical purposes or welding can also provide an additional
very rich source of oxygen.
In addition some chemicals such as nitrates, chlorates, chromates and peroxides can release
oxygen as they burn and therefore need external source of air.

CONTROL MEASURES
1. Reduce the amount of dangerous substances to a minimum.
2. Avoid or minimize release.
3. Control release at source.

25
 4. Prevent the formation of an explosive atmosphere.
5. Use a method such as ventilation to collect, contain and remove any releases to a safe
place.
6. Avoid adverse conditions (e.g. exceeding the limits of temperature or other control
settings) that could lead to danger.
7. Keep incompatible substances apart.

MITIGATION MEASURES

CLASSES OF FIRE
1. CLASS – A: these are fires involving solid materials normally of an organic nature
(compounds of carbon) in which combustion generally occurs with the formation of
glowing embers. Class – A fires are the most common and the most effective
extinguishing agent is generally water in form of a jet.
2. CLASS – B: these are fires involving flammable liquids, such as oils, spirits, alcohol,
petrol, grease and certain plastics. This class of fire is best handled by using Foam,
Vapourising liquids, carbon dioxide and dry chemical powders.
3. CLASS – C: These are fires involving flammable gases such as methane, propane,
butane, acetylene and also live electrical equipment and wiring. Foam or dry chemical
powder can be used to control fires involving shallow liquid spills. Water in the form of
spray is generally used to cool the container.
4. CLASS – D: these are fires involving metals. Extinguishing agents containing water are
ineffective and even dangerous; carbon dioxide may also be hazardous if applied to most
of the metal fires. Powdered graphite, powdered tale, soda ash, limestone and dry sand
are normally suitable for class D fires.

FIRE CLASS OF FUEL INVOLVED EXTINGUISHER

COLOURS FIRE
For ordinary 1. Wood Water
combustible 2. Paper Foam
materials. Put 3. Cloth Multipurpose
A – GREEN out a class A fire 4. Rubber dry chemical
by lowering the 5. Plastics
temperature or 6. Rubbish
by coating the 7. Upholstery est.
burning
combustibles.
For flammable 1. Gasoline, Carbon dioxide
liquids. Put out a 2. Oil Halogenated
class B fire by 3. Grease agent
smothering it. 4. Paint Standard dry
Use an 5. Light fluid est. chemical
B – RED extinguisher that Purple dry
gives a chemical
blanketing, Multipurpose
flame dry chemical
interrupting foam

26
 effect. Cover the
whole flaming
liquid surface.
For Electrical 1. Motors Carbon dioxide
Equipment. Put 2. Appliances Halogenated
out a class C fire 3. Wiring agent
by shutting off 4. Fuse Box Standard dry
C – BLUE power as 5. Switchboards chemical
quickly as Purple dry
possible and try chemical
always using a Multipurpose
non-conducting dry chemical
extinguishing
agent to prevent
electrical shock.
For combustible 1. Aluminium Dry powder
metals. Put out a 2. Magnesium extinguisher
class D fire of 3. Potassium and agents
D - YELLOW metal chips by 4. Sodium only.
smothering or 5. Titanium
coating with a 6. Zirconium
specially
designed
extinguishing
agent

FIG. 3
ELECTRICAL FIRES

It is not considered, according to present day ideas that electrical fires constitute a class,
since any fire involving or started by electrical equipment, in fact could be fire of class
A, B, or D. The normal procedure in such circumstances is to cut off the electricity and
use an extinguishing method appropriate to what is burning. Only when this can be done
with certainty with special extinguishing agents be required which are non-conductors of
electricity and non-damaging to equipment, although the latter’s cooling and
condensation may affect sensitive electronic equipment.

27
TYPES OF PORTABLE FIRE EXTINGISHERS

FIG. 4A FIG.4B

1. Water Type

(Colour coded red). This is suitable for class A type of fire.

This can be used for electrical and liquid fires.
Water from a hose is the most commonly used.
For highly flammable materials or liquid in a container which will not be spread,
water can be sprayed over the dire as a fine mist to blanket off the air and so
extinguish it. The foregone method should not be used when the burning liquid is
likely to be spread by the water.
2. Chemical or Spray Foam type
– (Colour coded Cream). This is ideal in multi risk situations where both class A and
B type of fires are likely.
– Spray Foam has a blanketing effect which is smoothening the flame and preventing
re-ignition.
– It can be used against petrol and similar liquid fires.
– The liquid should be directed against the container if the fire is in a container.
3. Dry powder
– (Colour coded Blue).
– This is suitable for class A, B, and C fires and for vehicle protection.
– It is also ideal for electrical hazards because it is non-conductive.
– These are a specially milled superfine powder, which is expelled by CO2 gas from a
cartridge fitted inside the extinguisher.

28
 – The powder cools the fire by absorbing heat and also displaces oxygen to extinguish
the fire.
– They are suitably used on flammable liquids.
4. Carbon dioxide
– (Colour coded Black).
– This is suitable for all types of fires with special emphasis on class B and C type of
fires. Also ideal for electrical hazards.
– This extinguisher consists of a heavy pressure cylinder which contains compressed
carbon dioxide.
– When directed at a fire, the gas rapidly cools the burning materials to below
combustible temperature to extinguish the fire quickly.
5. B.C.F
- There are painted yellow.
- The chemical is discharged as a fine mist to blanket the fire.
- They can be used on electrical fires effectively.
6. Soda-acid
- It is red in colour.
- It contains a mixture of soda and water.
- It has a small container of acid.
- When the container is inverted, the stopper comes out of the acid container to allow
the acid to mix with the soda and water.
- The mixture of acid, soda and water causes a chemical reaction which produces a
pressure to force the liquid from the nozzle of the extinguisher hose.
- It is used to extinguish general fires.
- The liquid should be directed at the base of the flame.
- It is not suitable for petrol or electrical fires.
7. Carbon Tetrachloride
- It is a small brass extinguisher with a T- shaped pump handle on top and a nozzle at
the bottom.
- The brass cylinder contains the chemical which is sprayed from the nozzle by the
action of the handle.
- This extinguisher is portable and often carried in commercial motor vehicle.
- It can be used on liquid or electrical fires.
- Caution: This type of extinguisher should not be used in confined spaces; the gas
given off from the chemical is poisonous and should not be inhaled.
8. Sand and fire blankets
- These are also used to cover the fire.
- Blankets are made of special materials to resist the heat.

29
FACTORIES ACT: CAP 514 – section 40, subsection 1, 2, and 3
THE LAW OF ZAMBIA
1. States that; in every factory, there shall be provided and maintained appropriate means
for fighting fires, which shall be so placed as to be readily available for use, and persons
trained in the correct use of such shall be present during all working periods.
2. The minister may by regulations prescribe for any class or description of factory or part
thereof specified means for fighting fire and any such regulations may provide for
fighting fire and any such regulations may provide for the testing or examination of the
means so specified and for the recording of particulars of the tests or examinations and of
any defects found and action taken to remedy the defects.
3. The minister may make regulations requiring means to be provided in any class or
description of factory for notifying the fire brigade in case of fire and requiring employed
persons to be made familiar with their use.

ESCAPE IN CASE OF FIRE

30
FACTORIES ACT CAP 514, SECTION 41
1. Every factory shall be provided with adequate means of escape routes in case of fire
breaking, for the persons employed therein and all such means shall be properly
maintained and kept free from obstruction.
2. The contents of any room in which persons are employed shall be so arranged or
disposed that there is a free passage-way for all persons employed in the room to a means
of escape in case of fire.

FIRE DRILLS IN FACTORIES

PLAN OF ACTION
Each person should know what to do in case of fire. In each factory there should be a practice
and carefully considered plan, the details of which will vary according to the
circumstances, but it should normally cover the points listed below:-
1. Sound the alarm.
2. Inform the fire brigade.
3. Evacuate the premises.
4. Assemble at the fire assembly point. *
5. Carry out a roll call. *
6. Fire fighting pending the arrival of the fire brigade.
7. The stopping of machinery and certain processes and if necessary,
the isolation of power supplies.

SOUNDING THE ALARM

The alarm should normally be sounded as an informative and precautionary measure

immediately an outbreak is discovered. While it is preferable that the persons discovering
the fire should give the alarm, authority to sound it may be entrusted to certain persons
where this seems necessary. Where this is done, it must be ensured that there is no delay
in its operation in an emergency.
In larger premises it will be necessary to form a ‘central point’ for transmission of
information on fire alarms. The position of this ‘central point’ will depend on
circumstances. It may be the works telephone switchboard or the general office.

INFORMING THE FIRE BRIGADE

The duty of informing the fire brigade immediately the alarm is sounded must be specifically
allotted to a particular person or persons. Facilities must be made available at all times
when persons are on the premises.

EVACUATING OF PREMISES

31
It is of the utmost important for everyone to be able to escape from danger. In most premises
personnel who do not have specific duties to carry out should start to leave the building
as soon as the alarm sounds unless instructions have been given to the contrary.
Personnel should leave in an orderly manner by the most direct route. Departure must not be
delayed by personnel collecting belongings from any other building.

ASSEMBLY POINTS

In certain circumstances extreme difficulty will be experienced in finding a suitable assembly

point and in these cases arrangements should be sought with neighbouring factories.

ROLL CALL

Due to the numbers involved and lack of suitable assembly points being available, for the
larger factory premises the following is suggested:-
1. A reasonable member of the staff in each section or department (with a deputy to cover
absences) should answer for the safe and complete evacuation of that department or
section.
2. On an evacuation signal being sounded, these officials should search their departments or
section, checking with the official of any upper floors and report their findings to person
in charge of the factory at that time.

FIRE FIGHTING

Persons who are required for firefighting should make their way to an appointed place
immediately the alarm is sounded, (usually the central call point), from which they can be
directed to the outbreak of fire.

STOPPING OF MACHINERY

These tasks should be carried out by those persons who have been designated to carry out
duties when a fire breaks out, which will ensure the safety of all concerned.

INSTRUCTION AND TRAINING

The emergency plan will only work effectively if everyone has had clear instructions and
been given any necessary training. This will necessitate repeated practices in the form of
regular fire drills until a good standard of efficiency has been attained. Four minutes is
the maximum evacuation time to be aimed at in the case of the largest premises.

FREQUENCY OF DRILLS
The extent of the necessary instruction and training will vary according to the degree of risk
i.e. the liability of the first and the size, construction and layout of the premises. Premises
can therefore be classified into three groups.
1. GROUP 1 – LOW RISKS

32
Premises in which there are little or no combustible materials stored and even though they
may be multi-storied, are of fire resisting construction.
Drills should be held every six to twelve months.

2. GROUP 2 – MODERATE RISKS

Premises in which the fire is likely to remain localised or will spread vary slowly or where
there is little risk of the structure of the premises taking fire.
Drills should be held four times per year.

3. GROUP 3 – HIGH RISKS

Premises where a fire once started is likely to spread rapidly and persons may have to escape
from a number of floors.

Drills should be more frequently.

FIRE ON A VEHICLE

1. Shut off the vehicle’s engine and set brakes.

2. Evacuate the vehicle and secure a hand portable fire extinguisher.
3. Approach the fire from the upwind side.
4. Actuate the hand portable fire extinguisher as per instructions printed on the
extinguisher’s nameplate.
5. Once the fire is extinguished, stand by in case the fire re-flashes

VEHICLE FIRE PREVENTION MAINTENANCE

The following is a suggested daily maintenance outline which can help reduce the risk of fire
on your vehicle.

CAUTION:

Take care during vehicle maintenance, cleaning, or welding. To avoid unintentionally setting
off the system and the discharge of agent, do not cut, pinch, or apply heat exceeding 200
°F (93 °C) to the detection lines of the system.

1. Check all oil, hydraulic fluid and gas lines for cuts, abrasions or undue wear.
Replace as needed.
2. Inspect all oil, hydraulic and gas line fittings for tightness
Clean off all residues and tighten.
3. Inspect and clean engine area. Depending upon the operation of the vehicle, use water or
steam to clean it.
4. Schedule cleaning for the end of the work shift when heat build-up may occur after the
engine is shut down.

33
 5. Check braking system for proper adjustment – especially if brakes overheat when not
engaged.
6. Check all possible ignition points (engine block, exhaust manifolds, turbochargers, etc.).
Make sure oil, hydraulic fluid and gas lines are not in contact with these ignition points.
7. Clean vehicle of all combustible debris – dry vegetation, grain particles, coal dust, etc.
Also, remove any oil and fuel drippings.
8. Check all electrical lines and connections for tight fit, wear or abrasion. Replace any
defective electrical equipment or wiring.

FIRES TYPES USE OPERATION

A Foam: Don’t spray
Class A fires ordinary Foam solution Ok for AB, not stream into the
combustive Aluminum for C burning liquid.
material such as: Sulphate and Allow to fall on
wood paper, Bicarbonate fire.
textiles and so Soda.
forth. Requires
cooling or
quenching.
Carbon dioxide Not for A, ok Carbon dioxide:
B gas under for BC Direct the close to
Class B fires pressure the fire. First at
flammable liquids, age flames and
grease, gasoline, gradually forward
oils, paints and so and upwards
forth
Requires blanket or Dry chemical Ordinary BC Dry chemical: direct
smoothening Multi-purpose type, not for stream at base of
C Ok for A, B and C A, ok for B flames. Use rapid
Class C fires electrical C left to right
equipment motors motion low to the

34
 switches and so flames
forth
Requires a non Soda, acid Ok for A, not Soda acid: Direct
conducting agent bicarbonate of for B C stream at a base
soda solution of flame
and sulphuric
acid

35