By Phil Hughes MBE

and Ed Ferrett
Chapter 11
Work equipment
hazards and control
 Work equipment
hazards and control

After reading this chapter, you should be able to:

1. Outline general principles for selection, use and

maintenance of work equipment

2. Outline the hazards and controls for hand tools

3. Describe the main mechanical and non-mechanical hazards

of machinery

4. Describe the main methods of protection from machinery

hazards.
Figure 11.2 CE mark and typical
declaration used in the European Union
Figure 3 Work equipment hazards and control
Figure 11.4 Bench mounted abrasive wheel
Figure 11.6 Typical electrically powered
compressor with air receiver
Figure 11.7 Design features of
equipment controls
Figure 11.8 Emergency stop buttons
Figure 11. 9 Typical hand tools
Figure 11.10 Typical hand held power tools
Figure 11.11(a) Electric percussion drill
Figure 11(b) Heavy duty electric hammer drill
Figure 11.12 Disc sander
Figure 11.13(a) Rotary drum floor sander
Figure 11.13(b) Orbital finishing sander
Figure 11.14 Range of mechanical hazards
Figure 11.15 Range of fixed guards
 Pedestal
drill

Figure 11 Adjustable guard for a

rotating shaft such as a pedestal drill
Guard adjusts
itself as the saw
cuts through the
wood

Figure 17 Self-adjusting guard on a

circular saw for cutting wood
 Hinged guard
activates the switch
as it rotates

Sliding guard activates

the switch as it moves

Figure 11.18 Typical sliding and

hinged interlocking guards
Figure 11.19 Schematic diagram of a
telescopic trip device fitted to a radial drill
 Buttons need to be pressed
at the same time to
activate machine. Buttons
are shrouded to prevent
accidental starting

Figure 20 Pedestal-mounted free-standing

two-hand control device
 The machines are provided
with an all-enclosing case
which prevents access to the
internal moving, hot or
electrical parts

The access doors are

interlocked so that the
machine is automatically
switched off when gaining
access to clear jams or maintain
the machine. It is good practice
to switch off when opening the machine

Internal electrics are insulated and protected to prevent contact

Regular inspection and maintenance should be carried out

The machine should be on the PAT schedule

Good ventilation in the machine room should be maintained

Figure 11.21 Typical large office

photocopier safeguards
 Enclosed fixed guards surround the
cutters with restricted access for paper
only, which prevents fingers reaching the
dangerous parts

Interlocks are fitted to the cutter head

so that the machine is switched off when
the waste bin is emptied

A trip device is used to start the machine

automatically when paper is fed in

Machine should be on PAT schedule

and regularly checked

General ventilation will cover most dust problems except for very large
machines where dust extraction may be necessary

Noise levels should be checked and the equipment perhaps placed on a

rubber mat if standing on a hard reflective floor

Figure 11.22 Typical office shredder safeguards

 Wheel should be enclosed as much
as possible in a strong casing
capable of containing a burst wheel
Grinder should be bolted down to
prevent movement
An adjustable tool rest should be
adjusted as close as possible to the
wheel
Adjustable screen should be fitted
over the wheel to protect the eyes of
the operator. Goggles should also be worn
Only properly trained competent and registered people should mount
an abrasive wheel
The maximum speed should be marked on the machine so that the
abrasive wheel can be matched to the machine speed to ensure
that the wheel permitted speed exceeds or equals the machine
max speed
Noise levels should be checked and attenuating screens used if
necessary
The machine should be on the PAT schedule and regularly checked
If necessary extract ventilation should be fitted to the wheel encasing
to remove dust at source

Figure 11.23 Typical bench mounted

grinder safeguards
 Motor and drive should be fitted with
fixed guard
Machine should be bolted down to
prevent movement
The spindle should be guarded by an
adjustable guard, which is fixed in
position during the work
A clamp should be available on the
pedestal base to secure work-pieces
The machine should be on the PAT
schedule and regularly checked
Cutting fluid, if used, should be
contained and not allowed to get onto
clothing or skin A splash guard may be
required but is unlikely
Goggles should be worn by the
operator

Figure 11.24 Typical Pedestal drill safeguards

 Machine should be designed
to operate with the grass
collection box in position to
restrict access to the bottom
blade trap. A warning sign
should be fitted on the
machine

On pedestrian-controlled
machines the control handle
should automatically stop the
blade rotation when the
operators hands are removed. It should take two separate actions
to restart

Ride-on machines should be fitted with a device to automatically

stop the blades when the operator leaves the operating position.
This is normally a switch under the seat and it should be tested to
ensure that it is functioning correctly and is not defective

Figure 11.25 Typical cylinder mower

for fine grass cutting safeguards
 Drives and motor should be
completely encased with a
fixed guard
The machine should only
be refuelled in the open
air with a cool engine,
using a suitable container
for highly flammable fuel
with a pourer to restrict
spillage. No smoking
should be allowed
Hot surfaces like the
exhaust should be covered
Engine must only be run in the open air to prevent a build up of fumes
Noise levels should be checked and if necessary an improved silencer
fitted to the engine and where required hearing protection used
Hay-fever-like problems from grass cutting are difficult to control.
A suitable dust mask may be required to protect the user

Figure 11.25 Typical cylinder mower

for fine grass cutting safeguards
 Moving engine parts should be enclosed
Rotating shafts should be encased in a fixed
drive shaft cover
Rotating cutting head should have a fixed
top guard, which extends out on the user
side of the machine
Line changes must only be done either
automatically or with the engine switched off
Engine should only be run in the open air
Refuelling should only be done in the open air
using a proper highly flammable liquid
container with pouring spout
Boots with steel toe cap and good grip, stout
trousers and non-snagging upper garments
should be worn in addition to hard hat fitted
with full face screen and safety glasses

Figure 11.26 Typical petrol

driven brush cutter safeguards
 If the noise levels are sufficiently high (normally
they are with petrol-driven units) suitable
hearing protection should be worn

Low-vibration characteristics should be

balanced with engine power and speed of work
to achieve the minimum overall vibration
exposure. Handles should be of an anti-
vibration type. Engines should be mounted on
flexible mountings. Work periods should be
limited to allow recovery

Washing arrangements and warm impervious

gloves should be provided to guard against
health risks

Properly constructed harness should be worn

which comfortably balances the weight of the
machine.

Figure 11.26 Typical petrol driven

brush cutter safeguards
1 hand guard with integral chain brake; 2 exhaust outlet directed to the
RHS away from the operator; 3 chain breakage guard at bottom of rear
handle; 4 chain designed to have low-kickback tendency; 5 rubber anti-
vibration mountings; 6 lockout for the throttle trigger; 7 guide bar
(should be protected when transporting chainsaw); 8 bottom chain
catcher; 9 PPE hand/eye/ear defender signs; 10 on/off switch

Figure 11. 27 Typical rear

handle chainsaw components
 May only be operated by
fully trained, fit and
competent people. Using
chainsaws in tree work
should require a relevant
certificate of competence or
National competence award,
unless the users are undergoing such training and are adequately
supervised.
Avoid working alone with a chainsaw. Where this is not possible,
establish procedures to raise the alarm if something goes wrong.
These may include:
regular contact with others using either a radio or telephone
someone regularly visiting the work site
carrying a whistle to raise the alarm
an automatic signalling device which sends a signal at a preset time
unless prevented from doing so
checks to ensure operators return to base or home at an agreed time

Figure 11. 27 Typical rear

handle chain saw safeguards
 Moving engine parts should
be enclosed
Electrical units should be
double-insulated and cables
fitted with residual current
devices
The saw must be fitted with
a top handle and effective brake mechanism
Chainsaws expose operators to high levels of noise and hand-arm
Vibration which can lead to hearing loss and conditions such as
vibration white finger. These risks can be controlled by good
management practice including:
purchasing policies for low-noise/low-vibration chainsaws (e.g.
with anti-vibration mounts and heated handles)
providing suitable hearing protection
proper maintenance schedules for chainsaws and protective
equipment
giving information and training to operators on the health risks
associated with chainsaws and use of PPE, etc.

Figure 11. 27 Typical rear handle

chain saw safeguards continued
 Operators need to be trained
in the correct chain
sharpening techniques and
chain and guide bar
maintenance to keep the
saw in safe working condition
Make sure petrol containers:
are in good condition and clearly labelled, with securely fitting caps.
do not allow operators to use discarded engine oil as a chain lubricant
when starting the saw
Operators should maintain a safe working distance from other people and
ensure the saw chain is clear of obstructions
Kickback is the sudden uncontrolled upward and backward movement of the
chain and guide bar towards the operator
To avoid pull-in, always hold the spiked bumper securely against the tree or
limbs
To avoid push-back, be alert to conditions that may cause the top of the guide
bar to be pinched and do not twist the guide bar in the cut
Training in good manual handling techniques and using handling aids/tools
should reduce the risk of back injuries
Avoid overhead and other service hazards

Figure 11. 27 Typical rear handle

chain saw safeguards continued
Kevlar gloves, over-trousers
and overshoes providing
protection against chainsaw
cuts. Helmet, ear and face
shields protect the head

Figure 11.28 Personal protective

clothing for chain saw use
 Access doors to the loading
area, which gives access to the
ram, should be positively
interlocked with electrical
and/or hydraulic mechanisms
The ram pressure should be
dumped if it is hydraulic
Drives of motors should be
properly guarded
If the waste unit is removed
by truck, the ram mechanism
should be interlocked with the unit so that it cannot operate when
the unit is changed for an empty one
The machine should be regularly inspected and tested by a
competent person
If the hydraulic ram can fall under gravity, mechanical restraints
should automatically move into position when the doors are opened
Emergency stop buttons should be fitted on each side

Figure 29 Typical retail compactor safeguards

 Operating position for the hopper hoist should
be designed so that anyone in the trapping
area is visible to the operator. The use of the
machine should be restricted to designated
operators only. As far as possible the trapping
point should be designed out. The hoist
operating location should be fenced off just
allowing access for barrows, etc., to the
unloading area
Drives and rotating parts of engine should be
enclosed
The drum gearing should be enclosed and persons kept away from the rotating
drum, which is normally fairly high on large machines
No one should be allowed to stand on the machine while it is in motion
Goggles should be worn to prevent cement splashes
If petrol-driven, care is required with flammable liquids and refuelling;
Engines must only be run in the open air
Electric machines should be regularly checked and be on the PAT schedule
Noise levels should be checked and noise attenuation, for example silencers
and damping, fitted if necessary

Figure 30 Typical cement mixer safeguards

 A fixed guard should be fitted to
the blade below the bench

Fixed guards should be fitted to

the motor and drives

An adjustable top guard should

be fitted to the blade above the
bench which encloses as much
of the blade as possible. An
adjustable front section should
also be fitted

A riving knife should be fitted behind the blade to keep the cut timber apart
and prevent ejection

A push stick should be used on short workpieces (under 300mm) or for the
last 300mm of longer cuts

Blades should be kept properly sharpened and set with the diameter of the
smallest blade marked on the machine

Figure 31 Work Bench mounted

circular saw - safeguards
 Noise attenuation should be
applied to the machine, for example
damping, special quiet saw blades,
and, if necessary, fitting in an
enclosure. Hearing protection may
have to be used

Protection against wet weather

should be provided

The electrical parts should be

regularly checked in addition to all
the mechanical guards

Extraction ventilation will be required for the wood dust and shavings and
suitable dust masks should be worn

Suitable warm or cool clothing will be needed when used in hot or cold locations

Space around machine should be kept clear

Figure 31 Work Bench mounted

circular saw safeguards continued