IGC 2.

4 WORK EQUIPMENT HAZARDS AND RISK CONTROL

1. A manufacturing company has decided to purchase a new machine

a) Identify the questions that must be answered before a purchase is made

Where and how it will be used

What it will be used for

Who will use

What risks to health and safety might result

How well health and safety risks are controlled by different manufacturers
b) Outline the issues that will need to be considered before the machine is put into use

Isolation switches and emergency controls

Suitability for the task

Safety devices in working conditions

Instructions for the use of the equipment availability

Machine operators training

Adequate lighting for the work
c) Identify the main issues when assessing the suitability of controls (including emergency controls) of
the new machine

Be easily reached

Not permit accidental starting of equipment

Move in the same direction as the motion being controlled

Vary in mode, shape and direction of movement to prevent inadvertent operation of the wrong
control

Incorporate adequate red emergency stop buttons of the mushroom-headed type and lock off

Have shrouded or sunken green start buttons to prevent accidental starting of the equipment

Be clearly marked to show what they do
2. A) Describe the contents of a Declaration of the Conformity that should be issued with a new machine

State the name and address of the manufacturer or importer into the EU

State the name and address of the person authorised to compile a technical file (a new requirement)

Contain a description of the machine, and its make, type and serial number

Indicate all relevant European Directives with which the machinery complies

State details of any notified body that has been involved

Specify which standards have been used in the manufacture

Be signed by a person with authority to do so
b) Outline the advantages and limitations of CE Marking on a new machine
advantages

it allows a common standard across Europe

it provides a means of selling to all European Union member states without barriers to trade

it ensures that instructions and safety information are supplied in a fairly standard way in most
languages in E U

it has encouraged the use of diagrams and pictorials which are common to all languages

it allows for independent type-examination for some machinery

disadvantages/limitations

instruction manuals have become very long

translations can be very poor and disguise the proper meaning of the instruction
manufacturers can fraudulently put on the CE marking
manufacturers might make mistakes in claiming conformity with safety laws

3. Outline a hierarchy of control measures that may be used to prevent contact with dangerous parts of the
machinery. Give an example of level of protection required at each stage of hierarchy.

Be easily reached from the operating positions

Not permit accidental starting of equipment

Move in the same direction as the motion being controlled

Vary in mode, shape and direction of movement to prevent inadvertent operation of the wrong
control

Incorporate adequate red emergency stop buttons of the mushroom-headed type with lock off

Have shrouded or sunken green start buttons to prevent accidental starting of the equipment

Be clearly marked to show what they do
4. An operator suffers a serious injury after coming into contact with a dangerous part of a machine, describe
a) possible immediate causes

lack of guards

incorrect operation

no warning signage

poor lighting
b) possible root (underlying) causes

lack of risk assessment

poor maintenance

lack of training

poor supervision

5. Employers are required to provide adequate information, instruction and training to ensure the safe use
of work equipment.
a) Identify THREE categories of employees that should receive information, instruction and training on
the safe use of the work equipment

Workers

Supervisors

Line managers
b) Outline the issues that could be included in said information, instruction and training

All safety and health aspects

Any limitations on the use of the equipment

Any foreseeable problems that could occur

Safe methods to deal with the problems

Any relevant experience with the equipment that would reduce the risks or help others to work
more safely, being recorded and circulated to everyone concerned.

6. A) describe THREE preventative maintenance schemes that may be used on machinery to prevent Health
and Safety risks

Preventative planned maintenance

Condition based maintenance

Breakdown based maintenance
b) Outline measures to be taken to reduce the risk of accidents associated with the routine maintenance
of machinery

The person should be competent, well trained maintenance engineer

The equipment being made safe for the maintenance work to be carried out cooling down,
isolation of the equipment etc.

A safe system of working - this may involve permit to work system

Correct tools and safety equipment being made available
c) Identify FOUR non-mechanical hazards that could lead to injury and /or ill health when undertaking
maintenance work on machinery in the workplace

Heat

Slips and trips

Ergonomics

Dust
7. A brick layer uses a hammer and chisel to break a building block
a) Identify FOUR unsafe conditions, associated with the tools, which could affect the safety of the
bricklayer

Broken handles can cause chisel to result cuts to hands and can make hammer head to fly off

Chipped or loose hammer heads can slip off

Flying particles that can damage eyes from breaking up stone or concrete
b) Outline suitable control measures for minimising the risk of injury to the brick layer when using the
tools

Keep all tools in good condition with regular maintenance

Use the right tool for the job

Examine each tool for damage before use and do not use damaged tools

Use tools according to the manufacturers instructions

Provide and use properly the right personal protective equipment
8. A carpenter regularly uses a hand-held electric sander for the preparation of wooden doors before
painting them.
a) Outline the checks that should be made to ensure the electrical safety of the sander

Work pieces must be securely clamped or held in position during sanding

Abrasive sanding belts, discs and sheets should be properly and firmly attached to the machine
without any torn parts or debris underneath.

Old nails and fixings should be sunk below the surface

Always hold the equipment by the proper handles and particularly on large disc and floor
sanders

Ensure that the dust extraction is working properly

b) Other than the electricity, identify EIGHT hazards associated with the use of the sander

High noise levels

Injury from poorly secured work pieces

Potential of entanglement from rotation discs and drum sanders

Sanding attachments may become loose in the chuck and fling off

Injury from contact with abrasive surfaces

Hand arm vibration hazard

Health hazards from extensive dust emission

Fire hazards

Manual handling hazards

Slip and tripping hazards from trailing cables
9. A) identify FOUR non-mechanical hazards that may be encountered on woodworking machines and
outline the possible health and safety effects from exposure in each case

Hand arm vibration hazard - white finger or hand arm vibration syndrome

Health hazards from extensive dust emission respiratory problems

Fire hazards fatal, burns, smoke inhalation

Manual handling hazards musculoskeletal disorders, work related upper limb disorder
c) Identify EIGHT mechanical hazards associated with moving parts of machinery
a. Crushing

Shear

Cutting

Drawing in

Abrasion and ejection

Entanglement

Friction

Nip hazards
10. Identify THREE mechanical hazards, TWO non-mechanical hazards and associated control measures with
the use of the following items of equipments
a) A bench top grinder
Mechanical hazards

contact with the rotating wheel causing abrasion the wheel should be enclosed as much as
possible in a strong casing capable of containing a burst wheel

drawing in between the rotating wheel and a badly adjusted tool rest an adjustable tool rest
should be adjusted as close as possible to the wheel

bursting of the wheel, ejecting fragments which puncture the operator grinder should be
bolted down to prevent movement
Non-Mechanical hazards

Electrical through faulty wiring and/or earth bonding or during maintenance the machine
should be on the PAT schedule and regularly checked

Fragments given off during the grinding process causing eye injury an adjustable screen should
be fitted over the wheel to protect the eyes of the operator. Goggles should also be worn

Hot fragments given off which could cause a fire or burns 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 produced during the grinding process noise levels should be checked and attenuating
screens used if necessary

b) Document shredder
Mechanical hazards

Drawing in between the rotating cutters when feeding paper into the shredder - interlocks are
fitted to the cutter head so that the machine is switched off when the waste bin is emptied.

Contact (cutting or severing) with the rotating cutters when emptying the waste container or
clearing a jam - enclosed fixed guards surround the cutters with restricted access for paper only,
which prevents fingers reaching the dangerous parts.

Entanglement with the electrical cables attached re-route the cables
Non-Mechanical hazards

Electrical through faulty plug and wiring or during maintenance the machine should be on PAT
schedule and regularly checked

Possible noise from the cutting action of the machine noise levels should be checked and the
equipment perhaps placed on a rubber at if standing on a hard reflective floor

Possible dust from the cutting action general ventilation will cover most dust problems except
for very large machines where dust extraction may be necessary

Possible vibration from the use of the machine installing the machine on a rubber matting
c) A photocopier
Mechanical hazards:

Contact(cutting or abrasion) with moving parts when clearing a jam 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.

Impact injuries schedule the work and reduce the speed

Ejection of toner material while loading - take adequate are while loading
Non-Mechanical hazards:

Electrical when clearing a jam, maintaining the machine or through poorly maintained plug and
wiring

Heat through contact with hot parts when clearing the jam regular inspection and
maintenance should be carried out

Inhalation of dust from empyting toner and dust from toners in the eyes wear a suitable dust
mask and eye protection when changing toner powder if the cartridge is to be refilled
d) A bench mounted circular saw
Mechanical hazards:

Cutting and severing from high speed cutting chain a fixed guard should be fitted to the blade below the
bench

Drawing in when the chain is caught and the saw is pulled forward fixed guards should be fitted to the
motor and drives

Impact injuries - space around the machine should be kept clear
Non-mechanical hazards:

High noise levels noise attenuation should be applied to the machine for example damping, special quiet
saw blades, and, if necessary, fitting in an enclosure. Hearing protective may have to be used.

Burns from hot parts of the engine suitable warm or cool clothing will be needed when used in hot or cold
locations

Electric shock, if electrically powered the electrical parts should be regularly checked in addition to all the
mechanical guards

e) A strimmer
Mechanical hazards:

Entanglement with rotating parts of motor and shaft - moving engine parts should be enclosed; rotating
shafts should be encased in a fixed drive shaft cover

Cutting or severing from contact with cutting head / line rotating cutting head should have a fixed top
guard, which extends out on the user side of the machine

Friction and abrasion regular maintenance of the machine needs to be carried out
Non-Mechanical hazards:

Back strain from carrying the machine while operating competent person to operate the equipment with
good posture

Burns from hot parts of the engine the operator to use suitable PPE to ensure there is no direct contact
with the equipment

Fire from the use of highly flammable petrol as a fuel refuelling should only be done in the open air using
the correct container for highly flammable fuel with pouring spout

Possible noise hazard from the driver motor and cutting action suitable hearing protection shuld be worn

11. A new pedestal (pillar) drill is to be used in a maintenance workshop.

a) Identify issues that should be addressed before it is first used so that the risk of injury to operator of
the machine is reduced

Motor and drive should be fitted with fixed guards

The 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

To safeguard from cutting fluid, a splash guard may be required but is unlikely
b) Identify FOUR mechanical hazards presented by the machine and outline in each case how injury may
occur and appropriate control measures

Entanglement with the moving motor if the operator is wearing loose clothing

Puncturing from the drill bit if the operators hands are too close to the drill bit and not
wearing gloves

Ejection of the material if there no guarding of the machine, the cutting material bits may hit
into the operators eye

Impact injuries if the pedestal base is not clamped or secured
12. A bench mounted circular saw used in a carpentry workshop on a regular basis.
a) Identify FOUR risks to the health and FIVE risks to the safety of the circular saw operator
Health Risks:

Exposure to high noise levels

Hand arm vibration causing white finger and other problems
Back strain, WRULDS due to supporting the weight of the chain while operating
Possible health hazards from cutting due to wood dust, particularly if wood has been seasoned

Safety Risks:

A very serious cutting or severing by contact with the high speed cutting chain

Kickback (impact, cutting, severing) due to being caught on the wood being cut or contact with the top front
corner of the chain in motion with the saw chain being kicked upwards towards the face in particular

b) Outline the control measures that can be implemented to minimise the health and safety risks to
these operators
May only be operated by fully trained, fit and competent people
Moving engine parts should be enclosed
The saw must be fitted with a top handle and effective brake mechanism
Electrical units should be double-insulated and cables fitted with residual current devices
Suitable hearing protection to be worn to protect from high noise levels
Anti-vibration mounts to be fitted in
Proper maintenance schedules for chainsaws and protective equipment

13. A petrol driven chainsaw is to be used to remove several branches from a large tree.
a)

Identify 8 hazards associated with the use of chainsaw for these works
Exposure to high noise levels
Hand arm vibration causing white finger and other problems
Back strain, WRULDS due to supporting the weight of the chain while operating
Possible health hazards from cutting due to wood dust, particularly if wood is being seasoned
A very serious cutting or severing by contact with the high speed cutting chain
Kickback (impact, cutting, severing) due to being caught on the wood being cut or contact with the top
front corner of the chain in motion with the saw chain being kicked upwards towards the face in
particular

Falls from height if using the chainsaw in trees

Lone working

Contact with overhead power lines if falling trees
b)

Outline 8 safeguards that should be in place to ensure the safe use of the chain saws
May only be operated by fully trained, fit and competent people
Avoid working alone with a chainsaw
Moving engine parts should be enclosed
The saw must be fitted with a top handle and effective brake mechanism
Electrical units should be double-insulated and cables fitted with residual current devices
Suitable hearing protection to be worn to protect from high noise levels
Anti-vibration mounts to be fitted in
Proper maintenance schedules for chainsaws and protective equipment

c)

Identify the items of PPE that should be used by the chainsaw operatives
Kevlar gloves
Overtrousers
Overshoes
Helmet
facesheild

14. A local authority uses a rider operated petrol powered motor mower to cut the grass on road side verges.
a) Identify FIVE mechanical and FOUR non-mechanical hazards that the operator could be exposed to
while using the mower
Mechanical hazards:

Trapping hands or fingers in the shear caused by the rotating cutters

Contact with moving cutters
Entanglement with moving parts of the drive motor
Drawing in between chain and sprocker drives
Impact and cutting injuries from the machine starting accidentally

Non-Mechanical hazards:

Burns from hot parts of the engine

Possible noise hazard from the drive motor
Electrical if electrically powered, but this is unlikely
Possible sensitisation health hazard from cutting grass, for example: hay fever

b) Outline the precautions that should be taken to address the hazards identified in part A.

The 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 operator 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

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 the correct container for
highly flammable fuels with a pourer to restrict spillage. No smoking should be allowed.

Hot surfaces like the exhaust should be covered

The 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.

15. Outline the principal of operation, advantages and limitations of the following guards and safeguarding
devices
a) Fixed
A physical barrier between the operator and the component
Advantages

Always in position

Maintenance free
Limitations

Not always prevent access

Difficult to carry out maintenance works

b) Interlock
Is a guard which is movable (or which has movable part) whose movement is connected with the power
or control system of the machine
Advantages

They allow safe access

Maintain the machine without dismantling the safety devices
Limitations

Constant need to ensure it operates correctly and designed to be fail safe

Maintenance and inspection procedures must be very strict
c) Adjustable
These are fixed or moveable guards, which are adjustable for a particular operation during which they
remain fixed.
Advantages

Best option to enclose dangerous parts during an operation

Can be adjusted as per the operation requirement
Limitations

Access to the dangerous parts can still be possible

May not be adjusted properly
d) Trip devices
A trip device does not physically keep people away but detects when a person approaches close to a
danger point.
Advantages

Self-resetting

Stop quickly
Limitations

May delay the production cycle

May fail if not maintained regularly
e) Two hand control devices
These are devices which require the operator to have both hands in a safe place (the location of the
controls) before the machine can be operated.
Advantages

Operator hands are safe from the dangerous parts contact

Design cannot be adopted all types of the equipment
Limitations

Unless controls are in place, the device does not function

Protects only hands of the operator and not the ejection issues to the persons face
16. Other than contact with the dangerous parts, identify FOUR types of hazards against which fixed guards
on machines may provide protection
1. Prevents ejection of material
2. Contains the heat within
3. Does not leave space between the equipment and the guard preventing entrapment issues
4. Can withstand the environmental issues