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6/9/03

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Page 1

Student Workbook

LV01
Health, Safety and
Housekeeping in a
Vehicle Workshop

LV01/SWB

Student Workbook for Technical Certificates

In Light Vehicle Maintenance and Repair

MODULE LV01
HEALTH, SAFETY AND
HOUSEKEEPING WITHIN A
VEHICLE WORKSHOP
Contents
Page
Introduction

The Law:
Health and Safety Commission and
Executive
Regulation and Codes of Practice
Powers of inspectors
Health and Safety Policy Statement
Working environment
Legislation that affects maintenance
and repair

Dangerous Substances (COSHH):

Types of dangerous substances
Labelling

Page
Accidents:
Causes of accidents
Direct causes
Unsafe acts
Unsafe conditions
Indirect causes
Exercise 2
Accident prevention
Reporting accidents
Exercise 3
Reporting faulty equipment

23
23
23
24
24
25
26
27
28
29
30

13
13
15

First Aid:
Priorities
Exercise 4

31
31
32

Safety Signs:
Progress check

16
18

Personal Protective Equipment

(PPE):
Exercise 1

19
21

Fire:
The Fire Precautions Act (1974)
Causes of fire
Extinguishing fire
Types of extinguishers
Exercise 5
Means of escape

33
33
33
34
34
36
36

Employee Duties under the Health

and Safety at Work Act (1974)

22

3
3
4
5
6
7

(Contd)

Page
Fire drill
Fire hazards within a motor
vehicle workshop
Petrol fires
Other fire hazards
Electrical fires
Exercise 6

37

Good Housekeeping:
Practice good engineering hygiene
What has to be cleaned
Cleaning agents and equipment
Environment Protection Act (1990)
Other cleaning duties

40
41
41
41
42
42

Maintaining Tools and Equipment:

Exercise 7
Cleaning equipment
Company resources
Care of equipment

43
43
44
44
45

Workshop Equipment The

Hazards:
Electrical equipment
Risks
Reducing electrical risk
Exercise 8
Safe removal of petrol from vehicles
Equipment fro removing petrol

46
46
46
47
48
48
49

Examples of Accidents:
Compressed air
Hydraulic jacks and axle stands
Vehicle lifts
Hoists
Using pits or sunken workshops
Exhaust extraction
Abrasive wheels
Guards

50
50
51
52
52
53
53
53
54

37
37
37
38
39

Page
Welding Equipment:
Electric arc
Arc eye
High current flow
Gas welding
Exercise 9

55
55
55
55
56
57

Asbestos:
Dangers
What does asbestos do?
What kind of work creates asbestos
dust?

58
58
59
59

Risk Assessment and Record

Keeping:
Exercise 10

61
62

Points to Remember

64

Introduction
The motor vehicle industry is by its very nature hazardous. If you are to avoid
injury you need to fully understand the nature of the risks that you are
exposed to and maintain a very high level of personal awareness that is,
awareness of your environment, your actions and the actions of those around
you.

The Law
Health and Safety Commission and Executive
The motor vehicle industry is highly regulated. The health and safety of the
people that work within it is of primary importance, and therefore subject to a
number of regulations.
The Health and Safety Commission has responsibility for:
general policy, research and dissemination of information
development of law through proposals for regulation and codes of practice
and to consult with employer and employee organisations where
appropriate.
The Health and Safety Executive, appointed by the Commission is
responsible for:
implementation of policy
inspection
enforcement
research, information and advice.

Regulation and Codes of Practice

The Health and Safety at Work Act (HASAWA) was introduced by the
Government in 1974 and facilitates regulation to:
modify or replace existing legislation
provide for new situations as they arise.

The Act enables approved codes of practice to be introduced and to provide

practical guidance.
Regulations are enforceable by law; codes of practice are not but are
admissible in evidence as failure to comply.

Powers of inspectors
HSE inspectors carry out periodic inspection of premises to ensure
compliance with the law. They have a number of powers and they are able to:
enter premises at any reasonable time (accompanied by a police
constable if necessary)
examine and investigate, and to this end can order premises to be left
undisturbed
take samples
issue improvement and prohibition notices and initiate prosecutions
take possession of any dangerous substance or article for examination or
use in legal proceedings.
Upon completion of an inspection, there are a number of options open to the
inspector.
Improvement notice: This is issued by the inspector and used to improve or
remedy a situation. A time limit for completion is specified.
Prohibition notice: A prohibition notice is used when an inspector decides that
there is a risk of serious injury and directs that certain activities cease until the
situation is remedied.
Fines: In the event of a prosecution-taking place, which could be against a
company or any individual from chief executive to vehicle technician, a
magistrate can impose heavy fines (unlimited). The offender can also be sent
to prison for a maximum of two years.

Health and Safety Policy Statement

An employer must: Ensure, so far as is reasonably practicable, the health,

safety and welfare at work of the people for whom they are responsible and
the people who may be affected by the work they do.
In order to comply with this requirement, an employer must:
prepare a written statement of general health and safety policy
set down the organisation and arrangements for carrying out the policy, i.e.
who is responsible and for what
revise and update this policy as necessary
bring the policy and arrangements to the notice of all employees.
The company health and safety policy is in short a statement answering the
following questions:
1) What are they going to do?
2) Who is going to do it?
3) How is it going to be done?

The working environment

Your employer must provide:
a safe place of work
safe systems of work
safe equipment to work with
a healthy and safe environment to work in.
Without active support, any attempt at organised accident prevention will be
useless. Avoidance of accidents requires a sustained, integrated effort from
all departments, managers, supervisors and workers in any organisation.
Only management can provide the authority to ensure everything is coordinated, directed and funded but every employee has a responsibility to
ensure that they do their bit - this includes you! Managements influence will
be seen in the policy made, the amount of scrutiny given to it and the ways in
which violations are handled.
The company policy should contain references to other arrangements not
contained in the safety policy itself, which should include:
training - identification of training needs
the environment - heating, ventilation, lighting, good housekeeping,
cleaning schedules
emergencies fire, accident and violent behaviour
reporting procedures - accidents, near misses and hazards
first aid
rules and procedures for using and maintaining equipment
COSHH mostly chemicals and dust (see next section).

Legislation that affects vehicle maintenance and repair

The Control of Substances Hazardous to Health Regulations (1988)
(COSHH)
This regulation requires that any risk arising from the use of substances within
the workplace is studied and the information made available to all affected
persons i.e. those employees who may come into contact with such
substances. COSHH data sheets must be made available so that any
employee, who has doubts about the safety of any substance and its use, can
study the relevant information. The availability of such data sheets should not
be considered as an acceptable substitute for training.
To be suitable and sufficient, the assessment must consider any risks arising
from the use (or generation of) hazardous substances. A collection of
suppliers data sheets will not suffice as a COSHH assessment. Only the
employer can establish the risk of exposure, as this arises from the way that
the substance is actually used. COSHH assessments must be formally
reviewed at least every five years. Other than in the most simple of cases, a
COSHH assessment should be recorded in writing.

The Health and Safety (Display Screen Equipment) Regulations (1992)

Employers must assess the risk to health and safety arising through the use of
display screen equipment, in particular, the risks of muscular-skeletal injury,
eye problems and mental stress. A record should be kept in retrievable form
except where the workstation is temporary, no significant risk was found, or
the assessment is easily repeatable.

The Manual Handling Operations Regulations (1992)

Where a hazardous manual handling operation cannot be avoided, a thorough
assessment of risk must be undertaken and measures must be introduced to
reduce risks of injury to an acceptable level.
The assessment must take into account the tasks, the loads, the working
environment, individual capability and other factors. Records of the
assessment must be kept unless:
the handling operation is short lived
there are no significant risks
the assessment is easily repeatable.

The Control of Asbestos at Work Regulations (1987)

A thorough assessment must be taken before commencing work in an
environment where exposure to asbestos may occur. The type of asbestos
should be established, as should appropriate control measures. The
effectiveness of control measures should be monitored, with records kept for
at least five years. Where the regulations require health records to be
maintained, these must be kept for a minimum of 40 years.

The Personal Protective Equipment at Work Regulations (1992)

Prior to selecting personal protective equipment (PPE), the employer or selfemployed person must ensure that an assessment has been made to
ascertain whether the proposed equipment is suitable. The assessment must
take account of risks to health or safety that have not been avoided by other
methods, the sort of performance and characteristics necessary for the
equipment to be effective and comparison of the proposed equipment with the
required performance and characteristics. When a person dons PPE, it is
only this equipment that provides a barrier to the risk. Could this risk have
been eliminated by other means?

Other record keeping requirements

There are many other situations in which records must be kept in addition to
those mentioned thus far. Accident books must be kept for a minimum of
three years and under COSHH, local exhaust ventilation inspection records
must be kept for a minimum of five years. Other records which should be kept
but without specific time scale include records of electrical equipment
inspection, details of examinations of hoists and lifts, lists of authorised lift
truck drivers and details of those qualified in first aid.

The European Directive

Known as the Framework Directive it deals generally with the introduction of
measures to encourage improvements in the health and safety of people at
work. It is based on article 118A of the Treaty of Rome and is activated
largely by the management regulations in the UK.

The Offices, Shops and Railway Premises Act (1963)

With the implementation of the Health and Safety at Work Act (1973) the
general health and safety of all persons at work was protected. However,
much of the specific legislation contained in The Offices, Shops and Railway
Premises Act (1963) is still in force for those specific premises covered by it
and follows closely the provisions identified in the Factories Act such as
machine guarding, ventilation, cleanliness and provision of sanitary
conveniences. Section 27 makes it an offence for an employee to misuse or
interfere with the facilities provided to meet with the requirements of the Act.

The Electricity at Work Regulations (1989)

This regulation introduces a control framework incorporating principles of
electrical safety applying to a wide range of plant, systems and work activities.
They apply to all places of work and electrical systems at all voltages. All
electrical systems must be constructed and maintained at all times to prevent
danger.

The Abrasive Wheels Regulations (1970)

These regulations do not apply to new equipment taken into use after the 1
January 1993, which is subject to the Provision and Use of Work Equipment
Regulations 1992. This regulation was introduced for a number of reasons
mainly due to the number of injuries arising from the use of abrasive wheels in
industry, a high proportion of which were due to faulty mounting of the wheel.
Under these regulations every person who changes an abrasive wheel must
be trained, competent and appointed in writing to do so.

The Reporting of Injuries, Diseases and Dangerous Occurrences

Regulations (1985) (RIDDOR)
The main purpose of RIDDOR is to provide enforcing authorities with
information on specific injuries, diseases and dangerous occurrences arising
from work activities covered by the Health and Safety at Work Act. The
authorities are not able to investigate all of these, so the regulations aim to
bring the most serious to their attention quickly.

These include:
the death of a person as a result of an accident arising out of or in the
connection of work
a dangerous occurrence, which could have resulted in deaths or injuries.
Records must be kept at the place of work or business for at least three years
from the date they were made.

The Workplace (Health, Safety and Welfare) Regulations (1992)

This implements most of the requirements of the Workplace Directive
concerning minimum standards for workplace health and safety. The
objective of the regulations is to place obligations on employers and others in
control of workplaces to reduce risks associated with work in or near
buildings.
Significant areas that affect vehicle maintenance and repair are:
traffic route - for pedestrians, vehicles (or both) and includes stairs, fixed
ladders, doors, ramps and loading bays and walk ways
Workplace means any non-domestic premises made available to any person
as a place of work; premises include any outdoor place, but not domestic
premises.

There are fourteen major topics in the Workplace (Health, Safety, and
Welfare) Regulations:
maintenance of workplace and equipment servicing
ventilation, temperature and lighting
cleanliness
workspace allocation
workstation design and arrangement
traffic routes and floors
fall protection
glazing
doors and gates
escalators
sanitary and washing facilities
drinking water supply
accommodation for dressing
facilities for changing, rest and meals.

The Noise at Work Regulations (1989)

These regulations are made under the provision of the Health and Safety at
Work Act (1974) and therefore apply to all places of work.
Employers must carry out an assessment of employees exposure to noise
where such exposure is at or likely to exceed the first action level (FAL) or the
peak action level (PAL). The FAL is 85dB(A) the second action level (SAL) is
90 dB(A), PAL is 200 Pascals sound pressure. Noise is measured by a noise
meter which is an instrument designed to respond to sound in the same way
as the human ear.

Noise control
The following are ways of providing protection to reduce risk to hearing:
noise reduction techniques
earplugs
acoustic covers
hazard notices.
The first option for reducing noise exposure must be through the use of noise
reduction techniques rather than through the use of personal protection. In
order to determine the best approach to reduce noise levels, it is important to
identify noise sources and noise pathways and reduce the energy in either or
both of these areas.
With machinery, small changes at the design stage can result in large noise
reductions at very little cost.
Other methods of reducing noise are:
damping - adding a layer of a damping material to the vibrating structure
silencing - mufflers are devices which reduce the transmission of sound.

Dangerous Substances (COSHH)

Classification
Dangerous substances can be categorised in many ways. When describing
them in health and safety terms they are categorised according to the type of
harm they can cause. Some can cause harm after a single exposure or
incident, others may have long term effects on the body following repeated
exposure.

Speed of action
Chronic - the effects become apparent over a long period.
Acute - the effects are immediate or become apparent over a short period.

Site of action
Local - the site of action of the substance is where it penetrates the body.
Systemic - the site of action is away from the site of contact or absorption.

Types of dangerous substances

Explosive

These substances are hazardous through their ability to release large

amounts of energy very rapidly. The products of explosion or combustion
could also be harmful in other ways.
Organic solvents are often explosive. It should be noted that powders that at
face value would appear harmless, could become highly explosive when
mixed with oxygen in airborne form; even custard powder!

Harmful

Substances thus labelled are harmful if inhaled, ingested or absorbed through

the skin. They often present only a limited risk to health but must be treated
with respect.

Irritant

Substances labelled as an irritant adversely affect the skin or respiratory tract.

Acrylate is such a substance. Some people react more severely to irritants
than others.

Corrosive

Corrosive substances are those that have the ability to break down other
substances chemically. They can be mildly aggressive (battery acid) or
extremely aggressive (concentrated sulphuric acid).

Poison

Substances that interfere with body functions. Organs can be overloaded, i.e.
the liver and kidneys. Lead is a poison, as is mercury. Arsenic prevents the
body from absorbing oxygen; you effectively suffocate.

Oxidising agent

An oxidizing agent is a substance that gives off heat upon contact with other
substances, especially if flammable.

Labelling
Hazardous substances must be labelled clearly and accurately. The label
should be clear as to the nature of the hazard and the manufacturer should be
stated. Do not rely on the manufacturers packaging; make decisions (having
secured relevant advice) on safe storage, use, handling, transportation and
disposal.

Safety Signs
There are four types of signs, and to aid identification they are a different
colour and shape.

Warning

Triangular in shape with black information written on a yellow background.

Prohibition

Round, square or rectangular in shape; red text on a white background or

white text on a red background.

Mandatory

Round or square in shape; white text on a blue background.

Safe

Mostly square in shape; white text on a green background.

Fire regulation

Mainly square in shape; white text on a red background.

Progress check
1) What does the acronym COSHH stand for?

2) A vehicle falls off a two poster ramp, narrowly missing a technician working
nearby. Under which regulation must this incident be reported?

3) Can you be prosecuted under current health and safety law?

4) If a substance has been identified as an Irritant which of the labels should
the product display?

A)

B)

C)

5) List the four requirements placed upon an employer under the Health and
Safety at Work Act (1974)?
1.
2.
3.
4.

Personal Protective Equipment (PPE)

The use of Personal Protective Equipment (PPE) is a method of reducing
injury from risks that are recognised as present, but measures should be
taken to attempt to eliminate the risk rather than protect workers from it. This
is not always possible and therefore PPE is sometimes required and if so it
must be worn. You must protect yourself and ensure others do the same.

Technicians PPE
Your employer is legally obliged to provide you with all necessary PPE to
enable you to carry out your duties safely.
In addition to overalls, the following should be considered as a minimum:

Gloves

Latex or plastic gloves should be available in quantity. These should be worn

for all work carried out on vehicles and changed on a regular basis. Leather
gauntlets should be available for any hot work that you may be required to
carry out.

Ear defenders

Ear protection should be used for any work that may involve exposure to high
levels of noise. It is often the least obvious of situations that generate
hazardous levels of noise such as a hammer blow on cast iron.

Safety footwear

Safety footwear must be worn at all times. There are endless ways in which
your feet can be injured in a workshop environment.

Head protection

This need only be worn in circumstances that dictate (such as working under
a vehicle on a lift).
There are hard hats available now that are styled like a baseball cap.

Exercise 1
Complete the following table giving examples of situations and injuries arising
from such when failing to wear the appropriate PPE.

Personal Protective Equipment

Overalls

Plastic gloves

Safety footwear

Head dress covering long hair

Eye protection

Ear defenders

Hard hat

Dust mask

Situation / injury

Employee Duties under the Health and Safety at Work Act

(1974)

You have a duty of care to yourself and your colleagues. In order to fulfil your
responsibilities you must make yourself aware of the following:
what hazards may exist in your workplace
the nature of risk within your workplace and the precautions you must take
the importance of remaining alert to the presence of hazards in the
workplace
the importance of dealing with or promptly reporting hazards
the precautions to be taken
agreed workplace policies relating to controlling risks to health and safety
responsibilities for health and safety in your job description
the responsible persons to whom you report health and safety matters
the specific workplace policies covering your job role
suppliers and manufacturers instructions for the safe use of equipment,
materials and products
safe working practices for your own job role
the importance of personal presentation in maintaining health and safety in
the workplace
the importance of personal conduct in maintaining the health and safety of
yourself and others
your scope and responsibility for rectifying risks
workplace procedures for handling risks which you are unable to deal with.
Read your company health and safety policy. Anything you are unsure of
bring to the attention of your supervisor. Ensure you have had correct training
for the tools you use and do everything you can to minimise risks or hazards
that arise with your job.
Be aware of your safety and others who work with you.
The way you react to situations can either contribute to danger or reduce it.

Accidents
Accidents do not just happen they are caused. Quite often, accidents are the
result of a number of seemingly small insignificant failures which when
combined cause a failure of great significance.

Example
An employer fails to regularly check and calibrate the workshop equipment. A
technician working for the employer fails to check the calibration date on a
tyre pressure gauge before use. The gauge is inaccurate and the tyre
pressures on a customers car are subsequently over-inflated.
The customer goes on holiday in the car with his extended family, towing a
caravan. The customer fails to adjust the tyre pressures in accordance with
the vehicles load. Its a very hot day and the customer is travelling above the
legal speed limit for a vehicle towing a caravan. The stresses on the tyre
prove too much and the tyre fails. A fatal accident results.
Any one of these failures in isolation would be unlikely to cause the accident.
However, all factors combined made an accident inevitable.

Causes of accidents
As we have seen from the above example, accidents have many causes.
These can generally be categorised into either indirect or direct causes.

Direct causes
Direct causes can be further sub-divided into the following:
unsafe acts
unsafe conditions.

Unsafe acts
This is a dangerous situation arising from something that is either done or
should have been done but was not (an omission).
The following are examples of these:
fooling around (horseplay)
not ensuring equipment is safe to work on
having PPE but not using it
removing guards
leaving spilt liquids on the floor
incorrect manual handling.

Unsafe conditions
This is a dangerous situation arising from the prevailing conditions. These
conditions could be the result of unsafe acts in some instances:
guards missing
poor maintenance
faulty materials
overloading
equipment not fit for purpose
wet floors.

Indirect causes
These are factors arising from the way in which an employee is made to feel
at work, and/or their actions outside work hours.
Social pressure:
fatigue
stress
alcohol
drugs
peer pressure
money
culture
family pressure.

Work pressure:
bureaucracy
deadlines
efficiency
economy
lack of experience
wrong person for job
financial constraints
piecework.

Exercise 2
Study the following scenario. The parts in italics fall into the previously
discussed categories. They will be one of the following:
1) Direct cause/unsafe act
2) Direct cause/unsafe condition
3) Indirect cause/social pressure
4) Indirect cause/work pressure
Write next to each italic part in the brackets provided which of the above
contributing factors (1, 2, 3 or 4) is applicable (the first 2 are done for you as
an example):
John the technician was late for work (4); the previous night he was out with
the lads and didnt get in until the early hours (3). It was Jacks idea to go out;
he wanted to celebrate his recent promotion to workshop supervisor. John
didnt really want to go - his wife had given him nothing but grief since hearing
of Jacks promotion (and the new house in a better area of town that was
bound to follow). ( ?) John decided to really go for it at work on that day - if
he could just improve his productivity by 10% or so ( ?), he may be picked
up for promotion as well.
His first job was a bit of a nightmare, a brake reline all round on an old
scrapper. To add to his frustration, his ramp was being used for a clutch
change (because he was late for work), so he had to do the brakes on the
floor. He hated doing brake relines at the best of times as the dust always
irritating his hands and arms (
?). He had asked the supervisor on a
number of occasions for plastic gloves but they refused due to the cost ( ?).
He jacked up the car at the rear and removed the wheels. Someone had
moved the axle stands (
?) from where they were usually kept so he
carried on without them. He knew he was taking a bit of a chance but he
didnt want to go back into the workshop office to ask about the stands in case
they noticed he wasnt wearing any safety boots (
?) (forgot them in his
hurry to get to work).
He was making good progress with the brakes at the rear when his good
friend Bill came over to give him a hard time about being late for work.
Bill had took the clock off the workshop wall and shouted:
Time flies when youre having fun, eh John?
And with that, threw the clock at him (
?). As John lunged to the left to
catch the clock, he knocked the car, and the jack (which had never been
much good) gave way (
?). The resulting accident cost John his left foot,
amputation had been the only option.

Accident prevention
Research has shown that for every event leading to a major injury there can
be as many as 10 causing minor injury, 30 causing property damage and
hundreds that result in neither injury nor damage. The latter are known as
critical incidents. Recognition and control of these incidents by the supervisor
and all other employees is the true basis of any accident prevention and
control system.
The situation is often likened to a tip of an iceberg, with only the tip of the
problem visible.

Major injury

Minor injuries
10

Root cause of
major injury

30

600 critical incidents

Property damage
or incidents

Reporting accidents

All accidents, no matter how small, must be reported to a supervisor. A minor

cut may not appear to be much, but if that cut becomes infected then it may
become a major issue.
The supervisor must enter all relevant details into the accident book. These
details will include the date and time of the accident, the nature of the
accident, any injury that resulted and the action taken by any first-aider or
other medical authorities.
It is possible that further reporting may be necessary under RIDDOR (see
page 8); it really depends on the nature of the incident.

Exercise 3
Label all the areas of the body that could become damaged, and how, in your
area of work:

Reporting faulty equipment

In the event of any failure of equipment you must isolate the source of energy
(electricity, engine, water, compressed air) from the equipment. Then, either
place the equipment in the control of your supervisor or label it clearly as
unserviceable. Inform your supervisor of the fault so that procedures can be
put in place to bring about a repair.
Do not attempt to repair the equipment yourself unless trained and authorised
to do so. If faulty equipment is not reported, the next person to use it may be
injured!

First Aid
Note: First aid practices change regularly. You should make efforts to keep
up with latest best practice and should consider anything in this publication as
out of date until proven otherwise.
First aid is help administered to an injured party until the medical authorities
arrive on the scene. There are two main principles:
1. To not become a casualty yourself.
2. To reduce the risk of further injury to the patient.
A typical sequence of events following the discovery of an accident resulting
in casualties would be to:
make the area safe
administer first aid
take appropriate action to reassure the injured party
raise the alarm
get help
report the accident.

Priorities
In the event of multiple injuries or perhaps multiple casualties, the following
priorities of treatment should be observed:
1) breathing
2) bleeding
3) breaks
4) burns.
This ensures that the most life threatening injuries are treated first.

Exercise 4
For the following scenarios, discuss what action should be taken. Consider
your priorities carefully in order to ascertain the correct sequence of events.
1. A member of staff falls whilst carrying a wheel, he falls over an empty milk
bottle, which smashes and causes a deep gash in his leg, which is now
bleeding very heavily.
What would you do?

2. A young trainee has climbed up onto a car bonnet with a pole in his hands
acting recklessly. The pole comes into contact with an overhead power
line and the young man becomes unconscious.
What would you do?

3. A piece of swarf flies into the eye of one of your co-workers.

What would you do?

Fire
The Fire Precautions Act (1974)
Six classes of premises are defined which may, by designating order, be
required to apply for a fire certificate.

premises providing sleeping accommodation

iinstitutions providing treatment or care
places of public entertainment, clubs etc.
premises for teaching, training or research
premises providing public access
place of work.

Premises that do not require a certificate must provide an adequate means of

escape and means for fighting fire.

Causes of fire

Fuel

Oxygen

Heat
For a fire to start there must be three elements present - fuel, oxygen and
heat. If any one constituent is missing or removed then a fire is unlikely.
Oxygen is provided from the air all around us and exists in sufficient quantity
for the combustion of most fuels, though other sources are provided in the
form of oxidising agents or oxygen cylinders. Fuels, the second constituent,
surround us in furniture, fittings and decorations in our homes and
workplaces. The third constituent, heat, is also always present, though
generally there is not enough for a fire to start. When more heat is provided,
then the temperature rises and when fuels reach their ignition point a fire will
begin. This has the ability to spread rapidly because of the generation of
excessive quantities of heat (the flame).
Fire prevention requires us to keep any one of the three elements away from
the other two.

Extinguishing fire
Once a fire does start, we must deprive it of one or more of the three vital
constituents if the fire is to be extinguished successfully:
cooling - removal of heat
smothering - separation of oxygen
starving - separation from fuels.
Types of extinguishers

Extinguishers smother and cool the fire. They are colour coded to aid
recognition of the type of fire they are designed to put out. They are either
entirely the coded colour or predominantly red with a bold coloured block in
the relevant colour stating its type as in the picture shown below.
Water (red) - used for cooling. Fires that are extinguished by cooling are
CLASS A fires which could involve wood, paper, cloth etc.
Foam (cream) - A variety of different types of foam are available for use in
portable extinguishers. Foams are used for CLASS B fires involving
flammable liquids and work by smothering.
Powder (blue) - The most common powder is general purpose. This
smothers a CLASS B fire and can also be used to cool a CLASS A fire.
BCF Halon - These extinguishers are used in similar circumstances to the
carbon dioxide extinguisher. They work by smothering and can be used on
CLASS B fires.

Carbon Dioxide (black) - This is contained in a pressure vessel as a liquid

and is released to smother a fire as an inert gas (turns gaseous upon
expansion). It is normally used on electrical fires as it is non-conducting and
does not damage electrical circuits.
Special powders - CLASS D fires are those involving metals such as
magnesium and require special extinguishing powders not normally found in
portable extinguishers.
Gas fires - fires involving gases are called CLASS C fires and are not
normally extinguished through a traditional extinguisher. Instead, they are
extinguished by starvation; that is turning off the gas supply. If the flame were
extinguished then the leaking gas would produce an explosive hazard.

Exercise 5
Complete the following table:
TYPE OF FIRE

CLASS

EXTINGUISHER
USED

COLOUR

WOOD
PETROL
ELECTRICAL
CLOTH

Fire spreads very rapidly; only if there is little risk and the fire is caught
promptly must it be tackled. Raise the alarm to evacuate and arrange for
someone to call the emergency services.

Means of escape

The provision of a safe means of escape is a requirement under the Fire

Precautions Act 1971. Means of escape include rooms, corridors and stairs.
This extends to a point outside the building where assembly may take place in
relative safety.
Routes should be unobstructed and doors unlocked. They should be well
signposted, provided with artificial light where necessary and free from
combustible materials and ignition sources. Such routes should provide a
protected passage to a final exit door, kept clear on the outside to allow rapid
dispersal to safe assembly points.

Fire drill
By law you should have one fire drill per year. When fire does break out, it is
essential that the occupants of the premises are clear and well practised in
what they should do. All staff should assemble at a pre-arranged point and the
roll taken, so that the fire brigade can be advised of any need of rescue. The
roll should be taken by a nominated fire marshal. Accounting for people
can only be done effectively if some means of recording peoples whereabouts
is in place (such as a sign in/out procedure).

Fire hazards within a motor vehicle workshop

Petrol fires
Petrol fires in garages are severe; many cause serious burns and occasionally
death. Petrol vapour is invisible and heavier than air and will disperse over a
considerable area. Matches, cigarettes or heaters with naked flames easily
ignite petrol vapour.
Vapour may be contained within clothing so never attempt to dry clothing
using heaters or naked flames. Never attempt hot work on a petrol tank
send it to a specialist.
When working on a non-starter, do your ignition checks first before checking
for fuelling faults!

Other fire hazards

Oily clothes and cloths are a serious fire hazard. Where possible, avoid their
use.
Welding equipment always presents a fire risk. Never weld anything without
the appropriate PPE - your oily overalls are perfect for starting a fire with
sparks from such equipment.
Electric arc welders create clouds of sparks when using fluxed rods. This
effect is much worse if the flux is damp.
LPG (Liquid Petroleum Gas) powered vehicles present a huge fire risk and
such vehicles must only be worked on by authorised personnel.

Electrical Fires

Vehicle batteries and ignition systems can create sparks. A vehicle battery
also gives off large amounts of hydrogen gas. Never go near a vehicle battery
with a source of ignition. Vehicle batteries should only be charged in a
suitable charging station.
Oxy-acetylene welding equipment must never be repaired using copper parts.
The acetylene reacts with the copper to produce an explosive compound!

Exercise 6
At your place of work:

1. Who is your fire marshal?

2. Where is your nearest fire exit?

3. Where is your fire assembly point?

Good Housekeeping

Working on and around vehicles is a dirty business. It is very easy to allow

your working environment to degrade to the point where it presents a hazard.
Under the general duties of the Health and Safety at Work Act, your employer
is required, amongst other things, to provide a safe place of work, safe
equipment and a healthy environment to work in.
In addition, under the Factories Act your employer has to facilitate cleaning of
the workplace.
You have a responsibility to keep your own work area clean and tidy. The
cleaning of the workplace is often referred to as housekeeping. A clean
working environment presents many benefits. It is safer and promotes quality
work. You do not see rubbish laying around in a Formula 1 pit do you? Bins
that are overflowing with rubbish present a health risk and a fire risk.
A clean, tidy environment improves productivity. Everything is in its proper
place and therefore easy to find. All equipment is in a clean state and fit for
purpose.
Your customers are far more likely to bring their vehicle to you again if they
can see that your place of work is clean. It shows that you have pride in your
place of work and this attitude is likely to be carried over to any work that you
carry out on their vehicle.

Practice good engineering hygiene

What has to be cleaned
the area in which you personally work
the equipment you use
the machinery you use.
The practices you undertake will generally be as follows:
The removal of any waste materials such as paper, rags and packaging and
the sweeping of floors, pits and sunken workshops to remove dust and dirt. It
is important that work surfaces and machinery are regularly cleaned and that
your own tools are kept immaculate.

Cleaning agents and equipment

Under the Control of Substance Hazardous to Health Regulations 1998
(COSHH), information about the cleaning agent obtained from a supplier or
manufacturer must be given with the cleaning agent. You must read and
follow all instructions that it contains. If you are in doubt about the instructions
you must ask your supervisor for clarification.
To assist in the removal of severe oil stains it is usual to use a steam-cleaning
appliance. Steam cleaning equipment is itself hazardous and you must not
attempt to use it unless you have received training.
When cleaning workshop area floors with recommended cleaning agents or
chemicals you must follow all safety instructions and wear any safety
equipment such as gloves, boots and overalls as indicated on the containers.

Environment Protection Act (1990)

Your employer has certain duties under the Environment Protection Act and
an offence may be committed if the disposal of waste material is not carried
out correctly. Your employer and supervisors are aware of the restrictions
placed on the undertaking and will instruct you in the methods to be used in
the disposal of waste.
Do:
follow instructions given by your supervisor
place all flammable soiled rags into a flameproof bin whilst waiting for
disposal.
Do not:
dispose of soiled detergents or solvents in watercourses
dispose of soiled detergents or solvents in sewerage systems.
Offences against waste disposal laws may result in prosecution of you or your
employer, resulting in heavy fines.

Other cleaning duties

return equipment used for a job to its storage location
mop up any spillages, such as water, coolant and solvents and discard
absorbent material in waste bins
coil up hoses, cables, and airlines (these could present a trip hazard)
return any specialised item to its secure store
wipe down working surface before your next job begins
return hand tools to trays and boxes, cleaning off any grease and oil
pick up packaging items such as cardboard, paper and plastic and
discard in waste bin or incinerator
remove any oil spillage using rags or absorbent material.
The use of spillage absorbent granules is ill advised in a motor vehicle
workshop - an environment where highly precise parts are often stripped
down.

Maintaining Tools and Equipment

Your tools are your living. Look after them and they will look after you! A high
quality tool, well maintained will give a lifetimes service.

Exercise 7
Identify the faults with the following tools and describe the risks that these
faults present:

Fault -

Risk -

Fault -

Risk -

Fault -

Risk -

Fault -

Risk

Cleaning equipment

There are many different brands of cleaning equipment and materials

available. In order to maintain a safe, clean, productive working environment
the following should be made available:

brushes
mops
absorbent paper
surface cleaner
general purpose detergent
vacuum cleaner
steam cleaner.

This equipment/resource should be stored in a place where all staff can

access it easily. Any strong cleaning substances must be stored in
accordance with COSHH regulations.
Company resources
Company resources are all of the items that you need to use in your everyday
job in order to carry out that job efficiently and professionally. This could
range from a hydraulic press to a mop and bucket.
These resources should be used in the way that is intended in order to work to
a high standard - but remember - each item has to be supplied and paid for by
your company. Your employment depends on the solvency of that company
so do not abuse this arrangement!

Care of equipment
With regard to cleaning materials, the following should be observed:
choose the correct material for the correct application (what is the best
material for the job?)
follow diluting recommendations carefully
measure materials
correctly store materials to avoid loss
select suitable storage to avoid spillage
use suitable protective material to avoid soiling of vehicles and work areas.
With health and safety in general, an employer is expected to spend what is
necessary to render the working environment safe. This can be kept within
reasonable bounds.

Risk

Cost

Risks should be reduced so far as is reasonably practicable. This means

the duty-holder (in most cases the employer) can balance the cost against the
degree of risk; although any health and safety inspector would expect that
relevant good practice is followed, whether the employer can afford it or not.
Remember the acronym:
BATNEEC
Best Available Technique Not Entailing Excessive Cost

Workshop Equipment - The Hazards

Electrical equipment

There are many items of electrical equipment in the motor vehicle workshop.
Fatalities arising from electrical accidents are higher than any other category.
If an electrical accident occurs, the chances of fatality are about one in forty.
The consequences of contact with electrical current are electric shock,
electrical burns and electrical fires.

Risks
If you receive an electric shock from an appliance, your muscles will contract.
If your hand is in contact with the faulty appliance it is likely that this muscle
contraction effect will prevent you from letting go. Electrical current flowing
through your body can upset normal heart activity resulting in death.
Where possible, most workshop equipment will be double insulated. This
means that the appliance is earthed and constructed of a non-conducting
material. Inevitably, some workshop equipment will have a metallic outer
construction (conductive). If this is the case, it must be earthed. If it is not
and a fault results in the outer case becoming live, the current will earth
through you!
Where possible, always choose air powered tools over electrical.

Reducing electrical risk

The following factors can help to contribute to electrical safety in a motor
vehicle workshop:

safe systems of work

earthing
insulation
fuses
circuit breakers
residual current devices - detect earth faults and cut off supply to the
circuit
competency.
Portable electrical tools should only be used where there is no alternative
system. Use only if you are trained and competent. Ensure the tool has been
electrically tested and is not damaged in any way before you use it. Use a
minimum length of lead; if extensions need to be used ensure others are
aware and do not drive over the cables.
Do not let leads lie in any liquids, they could short out or perish. In any event,
do not leave cables running across floors for longer than necessary. When
work is complete, switch off, remove plug and store safely.

Exercise 8

A worker suffers an electric shock whilst using a drill outside. What factors
might have contributed to this accident?

Safe removal of petrol from vehicles

Most fires directly associated with vehicle fuel systems occur during fuel
draining operations, rather than routine repair work on the fuel system itself.
Removal of petrol is often required to effect repairs, however the risk also
arises during the removal of contaminated fuel from tanks following misfuelling e.g. where a diesel vehicle has been fuelled with petrol.
Transferring petrol from one container to another will result in the giving off of
petrol vapour from the receiving container. Unless the vapour is contained, it
could disperse into the workplace and be ignited. Spillages of small quantities
of petrol can generate large volumes of a flammable gas mixture and a petrol
spillage can be ignited a long way from the site of the spillage due to the
spread of the vapours.

Equipment for removing petrol

The use of a fuel retriever is the safest and most strongly recommended
method for draining petrol. A proprietary fuel retriever incorporates a number
of essential features:
one or more containers for temporary storage of different fuels
a hand operated pump for transfer of fuel to and from the retriever
flexible hoses for access through the fuel filler neck
earthing straps.
Correct use eliminates spillage, minimises petrol vapour and provides a
suitable and stable container. Earthing straps eliminate dangerous static
discharge.
Complete removal of fuel from the tank may require a combination of
methods. The main volume of fuel removed by using the retriever and the
remaining fuel may require removal via a fuel feed line for a carburettor
system or via the fuel feed line for a fuel injected system.
Hot work (including drilling) must never be carried out on a fuel tank that may
still contain fuel of fuel vapour. This type of work is best left to a specialist
who will have access to specialist equipment for measuring residual fuel
vapour levels.

Examples of Accidents
An employee suffered severe burns (62%) when petrol leaked from the tank
while he was changing the sender unit. The tank was not pumped out before
work began and a hand lamp ignited the petrol. Fire also caused extensive
damage to the premises.
The deceased was changing a sender unit, working on a vehicle over a small
inspection pit. He drained some petrol from the tank into a plastic bucket.
The petrol vapour in the pit ignited. The source of ignition was thought to be a
light fitting.
Four people were in a small railway arch garage with the door closed. Petrol
ignited while being drained from a car tank. Two died and two received
severe burns.
During the removal of a faulty sender unit from a fuel tank, a vehicle was
raised on a hoist and two men were soaked in petrol when the unit was
removed. The tank was nearly full and petrol ignited by a gas fire about five
metres away. Both died in the resulting fire.

Compressed air

There are three types of health problems, which can occur when working with
compressed air:
Barotrauma - where a change in surrounding pressure causes damage to aircontaining cavities in the body directly connected to the surrounding
atmosphere, principally ears and sinuses.
Decompression illness - which involves pains around the joints or more
rarely as a life threatening condition which may affect the heart and lungs.

Dysbaric osteonecrosis - which is a long term chronic condition damaging

the long bones, hip and shoulder joints.
Never direct compressed air onto exposed areas of skin - the air can
penetrate and cause heart failure!

Hydraulic jacks and axle stands

These items are regularly used in motor vehicle workshops. The following
actions must be observed:
check that the jack is not leaking or has any damage
ensure that the jack you propose to use is safe for the job (safe working
load - SWL)
ensure the handbrake is applied and the grounded wheels are chocked
do not use any unsafe packing i.e. bricks or soft wood
for maximum safety ensure axle stands are correctly placed and if you are
working under the vehicle inform others that you will be working there
ensure all operating levers are not in such a way that they may be
accidentally released
never lift the vehicle onto more than two axle stands at one time.

Vehicle lifts

When working on a vehicle supported by a lift ensure that:

the lift has a sufficiently high safe working load (SWL)

the vehicle is central
no-one ever works above you
the area below the vehicle is free from equipment
the vehicle is secured on the lift and unable to roll.

Hoists

Hoists are commonly used to aid the removal of heavy assemblies such as
engines and gearboxes. A few factors must be taken into account during their
use:

never exceed the SWL

ensure that the boom pin is fitted securely
never remove the boom pin in order to gain extra extension
use on flat, level ground
ensure that all ancillary equipment such as chains and shackles are
serviceable and have a suitable SWL.

Using pits or sunken workshops

Remember:

wear protective headgear and goggles

do not drain petrol from a vehicle over a pit
apply the handbrake
inform your work colleagues that you are in the pit under the vehicle
in case of emergency always leave one end of the pit free from obstruction
as a means of escape
do not work in the pit if it is untidy, dirty or oily.

Exhaust extraction

Motor vehicles generate through the process of combustion many noxious

gases. Amongst these is Carbon Monoxide (CO). CO is highly poisonous.
Continued exposure to CO can have a severe affect on your health.
If you intend to run the engine on a vehicle in a confined space such as a
workshop, always use exhaust extraction equipment.

Abrasive wheels

Severe friction burns; crushed fingers and loss of eyesight are common
injuries arising from accidents that occur when using abrasive wheels. The
main hazards arise from the ejection of pieces of the wheel or work piece,
contact with the wheel, and trapping of fingers between the wheel and work
rest.

In one case an apprentice mechanic lost the sight in one of his eyes when it
was struck by debris from a disintegrating wheel. The wheel was poorly fitted
and was operated at a greater speed than its design speed. A burst wheel
can kill!
Never replace wheels on such equipment unless you are trained and
authorised to do so. Never use the side of the wheel unless the equipment is
specifically designed for that purpose. Always ensure that the tool rest is as
close to the wheel as possible without fouling the wheel. To ensure that the
tool rest does not foul the wheel, always spin the wheel by hand before
switching on.
Be aware that grinding wheels take a considerable time to stop once switched
off.

Guards

Guards are fitted to machinery that poses a risk to the operator through its
action. Guards when fitted must always be used. Do not treat guards as a
substitute for eye protection (or vice versa).
If guards are making work difficult due to damage such as scratches, report it
so the guards can be replaced. Do not wait until someone is tempted to use
such machinery without the guards in place.

Welding Equipment

Welding equipment presents its own unique combination of hazards. There

are numerous different types of welding equipment but most can either be
categorised as electric arc or gas.

Electric arc
All welding equipment represents a fire risk. In addition to this, electric arc
welding equipment presents the following hazards:

Arc eye
The light rays given off are a combination of infrared, ultraviolet, and visible
radiation. If you look at the arc you will damage your eyes. This damage is
not normally permanent but feels like someone has rubbed sand and chilli into
your eyes! It should be noted that reflected light radiation from an arc welder
is just as likely to cause arc eye. Never look at the arc either directly or
indirectly without the protection of approved welding lenses. Always shield
other workers from the arc through judicious use of screens and put warning
signs up.

High current flow

When welding a vehicle, always disconnect the vehicle battery. Never use an
arc welder on systems that contain flammable gas - the current flow could
cause a spark when you least want one.

Gas welders

Treat the bottles with respect. They are often very heavy and somewhat
unstable. Only move the bottles through the use of a recognised trolley and
always ensure that the bottles are chained securely to the trolley.
Never repair acetylene welding equipment with copper components - it reacts
with the gas to create an explosive compound.

Exercise 9
Guarding
1. Identify machinery likely to be found in a motor vehicle workshop, which, in
your view, has dangerous parts which should be guarded:

2. Which, if any, of these machines are permitted by a regulation to have

dangerous parts partially exposed?

3. Name a machine used in some large vehicle workshops, which is

impossible to guard effectively and still use:

Asbestos
The Asbestos at Work Regulations 1987 requires asbestos to be substituted
where practical, and the substituting material safer than asbestos. From the
1st October 1999 it has not been permissible to:
fit asbestos brake linings to any new motor vehicle
to fit replacement brake linings containing asbestos to any motor vehicle
first used after the end of 1972
to supply motor vehicle brake friction materials containing asbestos or to
hold such materials for supply for fitment to any motor vehicle first used
after the end of 1972.
It is understood that there are asbestos-free substitutes available now as
replacements for all vehicles originally designed to use asbestos brake parts.
Only if garages or vehicle operators are unable to obtain asbestos-free parts
from any source for a particular application, is it permissible to fit asbestos
products.
If anyone is found to have supplied or fitted asbestos brakes simply because
they are cheaper this would be seen as a breach of the control of Asbestos at
Work Regulations and legal proceedings would be considered by the HSE.
There are three types of asbestos:
1. chrysotile, which is white and found in brakes
2. amosite, which is brown
3. crocidolite, which is blue.

Dangers

This is an asbestos fibre in the lung. Many people die of lung cancer - most
deaths are due to smoking. An unknown proportion of those may have been
occupational deaths, for example caused by asbestos.

Working with asbestos can release small fibres into the air. Breathing in these
fibres can cause fatal diseases. Although the body will rid itself of most of the
larger fibres that can enter the nose and mouth, tiny fibres can pass into the
lower parts of the lung. They can stay there for years and in some cases work
their way through the lung lining.
The body naturally gets rid of any asbestos fibres that you might take in with
food and water and asbestos fibres cannot be absorbed through the skin.

What does asbestos do?

Breathing in asbestos fibres can eventually lead to a number of diseases.
These include:
asbestosis or fibrosis (scarring) of the lungs
lung cancer
mesothelioma, a cancer of the inner lining of the chest wall or abdominal
cavity.
There is no cure for any asbestos-related disease. Repeated low-level
exposure such as could occur during routine repair work, may lead to
asbestos-induced cancers. The amount of exposure is unclear, but the more
you inhale the greater the risk to your health.

What kind of work creates asbestos dust?

Some processes or products give off dust more easily than others, but work
on any of the following is likely to produce some:
the removal of old asbestos insulation materials from buildings or
machinery; this should be carried out by a contractor licensed by the HSE
the manufacture of products wholly or partly made from raw asbestos
the installation, maintenance, repair and general handling of products
containing asbestos for example asbestos cement products, insulating
board and friction materials such as brake pads and clutch linings
routine installation, repair and maintenance work by plumbers, electricians
and carpenters.

If you have to work with this dangerous material, ensure you protect yourself
by:
wearing a mask/respirator and wear protective clothing which you must not
take home contaminated with asbestos
keep the asbestos damp wherever possible and ensure all waste material
is put in a polythene bag and labelled with the asbestos warning sign
dont eat drink or smoke in the working area.
Dont take any chances with this deadly material.

Risk Assessment and Record Keeping

Where the employer has five or more employees, significant findings of an
assessment must be recorded, together with details of any group of
employees found to be especially at risk.
No record is necessary where risk is clearly so small as to be insignificant.
The record should include:
the significant hazards found as a result of the assessment
the control measures in place
the population exposed to the risks, including any group of people
especially at risk.
A record of the employers health and safety arrangements must be kept. If it
is found appropriate to carry out health surveillance, individual health records
should be kept. A record of those appointed as competent persons to assist
the employer should be maintained.
Records do not have to be in written form, but it must be possible to readily
retrieve information when required. Such a requirement may arise from a
request by a safety representative or an inspector from the enforcement
authority. Records may be kept separately, or can form part of the same
document as that containing the health and safety policy required by s.2(3) of
the Health and Safety at Work Act (1974).

Exercise 10
Complete the following risk assessment checklist for your current job role.

Risk assessment checklist

Detail of activity / process:
Date of assessment:
Who by:
1. What are the hazards to health and safety?

2. Do these present a risk? (Yes/No)

3. What is the risk to people?

4. Risk to property?

5. Likely severity of injury?

6. What are the present procedures and control measures?

7. What additional action do we need to take?

8. How urgent is this?

9. When do we need to review our assessment?

Practical health and safety

Look out for risks in the workshop. Use the inspection checklist while in the
workshop, noting the item and observation.
Then complete the reason, risk factor and consequence. An example has
been completed on the first line for you.

Inspection checklist
ITEM

OBSERVATION

REASON

RISK
FACTOR
H/M/L

CONSEQUENCE

Fire exits

Doors locked

Means of
escape

High

Persons could
become trapped if
there was a fire

Points to Remember
Although health and safety may sometimes seem to take the fun out of what
you do, you should now understand the importance of your own actions and
those of your colleagues.
Hundreds of people have been killed or injured in the motor vehicle industry;
many of the accidents could have been avoided. It may not feel cool to wear
a pair of safety goggles, but how much value do you place on your sight?
Gloves may hinder you, but not as much as painful blistered hands.
Never forget that no matter how expensive the car is that you are working on,
it is not as valuable as you.
Please remember what you have learnt and NEVER take any chances!