Element 9 - Work Equipment

NEBOSH International General Certificate
in Occupational Health & Safety
Element 9: Work Equipment
9.1 General Requirements for Work Equipment.
9.2 Hand Tools and Portable Power Tools
9.3 Machinery Hazards
9.4 Control Measures for Machinery Hazards.
9.1 General Requirements of work equipment
Providing suitable equipment
Work equipment’ is almost any equipment used by a worker at work including:

• Machines such as circular saws, drilling machines, photocopiers, mowing machines,
tractors, dumper trucks and power presses;
• Hand tools such as screwdrivers, knives, hand saws and meat cleavers;
• Lifting equipment such as lift trucks, elevating work platforms, vehicle hoists, lifting
slings and bath lifts;
• Other equipment such as ladders and water pressure cleaners.
Employer must ensure that the work equipment you provide meets the requirements of
PUWER (Provision and Use of Work Equipment Regulations 1998). Should ensure that it is:
Suitable for use, and for the purpose and conditions in which it is to be used;
CE Marking: The CE mark is required for all new products which are
subject to one or more of the European product safety Directives. It
is a visible sign that the manufacturer of the product is declaring
conformity with all the Directives relating to that product.
What does the CE mark mean?

By affixing the CE mark the Responsible Person takes on responsibility for the conformity of
the product. CE marking is a visible sign that the product complies with all relevant product
supply law, and its presence together with the Declaration of Conformity gives the product
to which it is affixed presumption of conformity with relevant product safety Directives. CE
marked products are entitled to free movement throughout the European market (EU and
EEA).
UNIT IG2 - Element 9: Work Equipment 9-1

However, the CE mark is not a quality mark, nor a guarantee that the product meets all of
the requirements of relevant EU product safety law. Suppliers who install work equipment
and users should make reasonable checks of any new products looking for obvious defects.
Also, the suppliers should ensure that there are User Instructions and that these and warning
decals are in English if for the UK market. Where the instructions are not in English the
supplier must provide a translation in to English and supply this together with the original
instructions. In most cases the Declaration of Conformity must be supplied to the end
customer (note: electrical equipment does not have to be accompanied by a Declaration of
Conformity).
Maintained in a safe condition for use so that people’s health and safety is not at risk; and
Inspected, in certain circumstances, to ensure that it is and continues to be safe for use. Any
inspection should be carried out by a competent person (this could be an employee if they
have the necessary skills, knowledge and experience to perform the task) and a record kept
until the next inspection.
Employer should also ensure that risks created by using the equipment are eliminated where
possible or controlled as far as reasonably practicable by:
• Taking appropriate ‘hardware’ measures, e.g. providing suitable guards, protection

devices, markings and warning devices, system control devices (such as emergency stop
buttons) and personal protective equipment; and
• Taking appropriate ‘software’ measures such as following safe systems of work (e.g.
ensuring maintenance is only performed when equipment is shut down etc), and
providing adequate information, instruction and training about the specific equipment.
A combination of these measures may be necessary depending on the requirements of the

work, your assessment of the risks involved, and the practicability of such measures.
Prevention of access to dangerous parts of machinery
Think about how you can make a machine safe. The measures you use to prevent access to
dangerous parts should be in the following order. In some cases, it may be necessary to use
a combination of these measures:
• Use fixed guards (e.g. secured with screws or nuts and bolts) to enclose the dangerous
parts, whenever practical
• If fixed guards are not practical, use other methods, e.g. interlock the guard so that
the machine cannot start before the guard is closed and cannot be opened while the
machine is still moving. In some cases, trip systems such as photoelectric devices,
pressure-sensitive mats or automatic guards may be used if other guards are not
practical

• Where guards cannot give full protection, use jigs, holders, push sticks etc if it is
practical to do so
• Control any remaining risk by providing the operator with the necessary information,
instruction, training, supervision and appropriate safety equipment
• Use of work equipment should be restricted only competent operators only wherever
it is necessary
Repair, modification or maintenance of equipment should be restricted to designated
competent people only.
Information, Instruction and Training

Every employer shall ensure that all persons who use work equipment have available to them
adequate health and safety information and, where appropriate, written instructions
pertaining to the use of the work equipment.
Every employer shall ensure that any of his employees who supervises or manages the use
of work equipment has available to him adequate health and safety information and, where
appropriate, written instructions pertaining to the use of the work equipment.
The information and instructions required by either of those paragraphs shall include
information and, where appropriate, written instructions on—
• the conditions in which and the methods by which the work equipment may be
used;
• foreseeable abnormal situations and the action to be taken if such a situation were
to occur; and
• any conclusions to be drawn from experience in using the work equipment.
Ensure that any written instructions are available to the people, including any temporary
workers, who directly use the work equipment. Make sure that instructions are available to
other people who need them, for example maintenance instructions are made available or
passed to the people involved in maintaining the work equipment.
Supervisors and managers should also have access to the information and written
instructions. The amount of detailed health and safety information they will need to have
immediately available for day-to-day running of production lines will vary, but it is important
that they know what information is available and where it can be found.
Training: Every employer shall ensure that all persons who use work equipment have
received adequate training for purposes of health and safety, including training in the
methods which may be adopted when using the work equipment, any risks which such use
may entail and precautions to be taken.

Every employer shall ensure that any of his employees who supervises or manages the use
of work equipment has received adequate training for purposes of health and safety,
including training in the methods which may be adopted when using the work equipment,
any risks which such use may entail and precautions to be taken.
Why equipment should be maintained, and maintenance conducted safely
Frequency of Maintenance
Equipment may need to be checked
frequently to ensure that safety-related
features are
functioning correctly. A fault, which affects
production, is normally apparent within a
short time; however, a fault in a safety-critical
system could remain undetected unless
appropriate safety checks are included in
maintenance activities.
The frequency at which maintenance activities are carried out should also consider the:
• Intensity of use - frequency and maximum working limits;
• Operating environment, for example marine, outdoors;
• Variety of operations - is the equipment performing the same task all the time or
does this change?
• Risk to health and safety from malfunction or failure.
Maintenance should address those parts which have failed or are likely to deteriorate and
lead to health and safety risks. A number of maintenance management techniques could be
used:
• Planned preventive Maintenance - such as: servicing (replacement of
consumables); shutdown maintenance; and making working adjustments.
• Condition-based Maintenance - A better method is to carry out preventive
maintenance at what may be irregular intervals but to determine these by the
actual condition of the machine. A main function of condition monitoring is to
provide the knowledge of machine condition, and of its rate of change, which is
essential to the operation of this method. The knowledge may be obtained by
selecting a suitable parameter for measuring deterioration and recording its value
at intervals.
• Breakdown - Breakdown maintenance (interrupted production); running repairs
(without loss of time).

Plant and equipment must be made safe before maintenance starts.

Safe isolation
• Ensure moving plant has stopped and isolate electrical and other power supplies.
Most maintenance should be carried out with the power off. If the work is near
uninsulated, overhead electrical conductors, eg close to overhead travelling
cranes, cut the power off first
• Lock off machines if there is a chance the power could be accidentally switched
back on
• Isolate plant and pipelines containing pressured fluid, gas, steam or hazardous
material. Lock off isolating valves
Other factors you need to consider

• Release any stored energy, such as compressed air or hydraulic pressure that
could cause the machine to move or cycle
• Support parts of plant that could fall, e.g. support the blades of down-stroking
bale cutters and guillotines with blocks
• Allow components that operate at high temperatures time to cool
• Place mobile plant in neutral gear, apply the brake and chock the wheels
• Safely clean out vessels containing flammable solids, liquids, gases or dusts, and
check them before hot work is carried out to prevent explosions. You may need
specialist help and advice to do this safely
• Avoid entering tanks and vessels where possible. This can be very high-risk work.
If required, get specialist help to ensure adequate precautions are taken
• Clean and check vessels containing toxic materials before work starts
Importance of operation and emergency controls, stability, lighting, markings and warnings,
clear unobstructed workspace
• Every employer shall ensure that, where appropriate, work equipment is provided
with one or more readily accessible emergency stop controls unless it is not
necessary by reason of the nature of the hazards and the time taken for the work
equipment to come to a complete stop as a result of the action of any control
provided by virtue of regulation 15(1).
• Any control required by paragraph (1) shall operate in priority to any control
required by regulation 15(1).
Guidance
An emergency stop control should be provided where the other safeguards in place are not
adequate to prevent risk when an irregular event occurs. However, an emergency stop
control should not be considered as a substitute for safeguarding.

Emergency stop controls should be easily reached and actuated.
Common types are mushroom-headed buttons, bars, levers,

kick-plates, or pressure-sensitive cables. Guidance on
specific features of emergency stops is given in national,
European and international standards.
In addition to the requirements outlined earlier, there are

some other basic physical requirements that work
equipment should meet:
It should be stable, this may mean bolting it to the floor, or fitting outriggers, jacks or
stabilizers – to make sure the machine does not move while in operating.
It should be appropriately marked with labels on control panels, safe working loads,
maximum speeds, direction of movement, etc.
All work equipment should be marked in a clearly visible manner, giving any relevant health
and safety information, such as: -
• Stop and start controls
• Safe working loads
• Colour coding of pipework and gas cylinders for recognition of contents.
Have appropriate warning, such as warning signs by dangerous parts and, in some cases,
visible and audible warnings, such as flashing beacons and klaxons to warn of the start-up
or movement of machinery.
All work equipment should incorporate any warnings and warning devices that are
appropriate for health and safety. These can be in the forms of notices and safety signs
markings
All work equipment has to be marked in a clearly visible manner, giving any relevant health
and safety information, such as:
• ‘Stop’ and ‘start’ controls.
• Abrasive wheel rotation speeds.
• Safe working loads.
• Colour coding of gas cylinders for recognition of contents.
• Contents of storage vessels and nature of hazardous contents.
• Colour coding of pipework.

The physical environment around the work equipment must be considered, in particularly
lighting and space:
Lighting:
• Adequate general workplace lighting should be provided around equipment for
the safety of the both the operator and others.
• Local lighting such as spotlights positioned above machinery, must be required to
give higher levels of light in critical areas
• Lighting should be suitable for the environment
Space:
• Operators should have enough space to move around the work equipment safely
• Other people should be able to move around safely without coming into close
proximity to dangerous parts or presenting a hazard to the operator.
9.2 Hand-Held Tools
Hazards from manual and powered hand-held tools:

The misuse of hand-held tools often results in injuries such as lacerations, cuts and may cause
amputations of fingers.
One of the problem areas regarding hand held tools is that they are generally in the
possession of the individual employee and are not inspected. If the tools are supplied by
the employer this may not be a problem but if supplied by the employee, they are inclined
to hold on to them even if they are damaged.
It is important that the employer has a system for the inspection of hand-held tools for
defects which can include:
• Chisels which have become blunt
• Handles in hammers which have not been properly fitted which allows the head
to be loose
• Spanners which have become rounded
• Hammer heads which have become worn

Precautions:
• Tools must be suitable for the task and the environment in which they are used.
e.g. non-sparking tools (which do not produce sparks when struck) are suitable for
use in a potentially flammable atmosphere.
• Users should be provided with appropriate information, instruction and training
• Tools should be visually inspected routinely before use to ensure that they are In
good working condition. This should be done by the user. Spot checks by line
management will ensure that users comply.
• Tools should be maintained to make sure they are in safe condition
• Supervision is important to ensure that safe working practices are adhered to and
misuse does not become common
• Substandard tools should be repaired or discarded.
Hazards of portable power tools

Power tools can be hazardous when improperly
used. There are several types of power tools,
based on the power source they use. These are
commonly used In construction, maintenance
and manufacturing Industries.
Portable power tools create greater risk than

simple hand tools because:
• The forces generated by the tool are
far greater, so the potential for very
severe injury or death exists (a ruptured disc from a disc cutter will cut off an arm,
which would not happen when using a handsaw).
• Power tools have additional hazards not present with simple hand tools.
Additional hazards from power tools are:

• Electricity – which may result in electric shock, burns, arcing or fire
• Noise – leads to hearing loss
• Vibration – may lead to HAVS (Hand arm vibration syndrome)
• Fuel – which may lead to fire and explosion
• Dust – may be inhaled
• Ejection – of materials or tool parts
• Trip hazards from the cables lying on the floor

The following general precautions should be observed by power tool users:

• Never carry a tool by the cord or hose.
• Never yank the cord or the hose to disconnect it from the receptacle.
• Keep cords and hoses away from heat, oil and sharp edges.
• Disconnect tools when not in use, before servicing and when changing accessories
such as blades, bits and cutters.
• All observers should be kept at a safe distance away from the work area.
• Secure work with clamps or a vise, freeing both hands to operate the tool.
• Avoid accidental starting. The worker should not hold a finger on the switch button
while carrying a plugged-in tool.
• Tools should be maintained with care. They should be kept sharp and clean for
the best performance. Follow instructions in the user’s manual for lubricating and
changing accessories.
• Be sure to keep good footing and maintain good balance.
• The proper apparel should be worn. Loose clothing, ties or jewellery can become
caught in moving parts.
• All portable electric tools that are damaged shall be removed from use and
tagged “Do Not Use.”
Additional precautions are necessary when storing and handling petrol. It should be stored
in an appropriate, labelled metal container in a well-ventilated, secure area away from
ignition sources. It should be handled with care in a well-ventilated area (preferably outside)
away from ignition sources. Any spillages should be dealt with immediately.
Additional precautions must be taken when using electrical equipment. Battery-operated

tools might be used, or a low-voltage supply (e.g. 110 V rather than 230 V). Damage to the
electrical flex must be avoided.
The tool, flex and plug should be routinely inspected by the operator prior to use. It should
also be given a formal electrical safety inspection, and thorough examination and test.
9.3 Machinery Hazards
BS EN ISO 12100:2010 Safety of machinery- Basic concepts, general principles for design”
describes a range of hazards associated with both the normal operation of machinery and
unexpected eventualities arising from failures.
The intention is to provide designers with guidance for determining relevant, significant
hazards that may be generated by a given machine in the environment that it is intended to
be used.

The hazards outlined can be categorised as Mechanical and Non-mechanical.
Mechanical Hazards:
Where a body part comes into contact with a moving part of machinery, machine tool or
surface, the nature of the injury will be determined by the characteristics of the machine part
contacted; e.g. an abrasive wheel surface poses an abrasion hazard, a drill bit a puncture
hazard, and a saw blade a cutting or severing hazard.
Mechanical hazard associated with machinery, parts, tools, work pieces, loads and materials
are identified in ISO 12100 part 1 – Safety of Machinery:
Entanglement - Loose-fitting shirts might possibly become entangled in rotating spindles or

other kinds of moving machinery. Jewellery, such as bracelets and rings, can catch on
machine parts or stock and lead to serious injury by pulling a hand into the danger area.
Entanglement
Drawing in or trapping - These include drawing in/in running nips and traps are created
between cogs or rollers, or where a moving belt or chain meets a roller or toothed wheel.
Entrapment
Crushing - Where the body or a limb becomes trapped between moving, closing or
passing motions of the machinery.

Shearing - Where the body or a limb is caught in a shearing/cutting motion by two or more
parts moving past each other (e.g. scissors movement), or between one moving part and a
fixed surface (e.g. guillotine movement).
Impact - Injuries caused when the body is struck by moving parts of machinery. Traditional
machinery posing a risk of impact injury includes milling machines and fly wheel presses.
Robot arms are a more recent cause for concern.
Impact
Friction or abrasion - Contact with sharp or abrasive surfaces normally operating at high
speed resulting in burns from friction and abrasion injuries.
Stabbing or puncture - Injuries caused by sharp objects puncturing the skin e.g. sewing
machines, nail guns, drills.

Cutting or severing - Injuries arising from contact with a cutting blade
Ejection of materials including high-pressure fluid injections – injuries caused by flying

objects e.g. sparks, chips, molten or broken components being ejected from the machinery.
High pressure fluid injection is another potential cause of injury within this classification. A
puncture of a hydraulic hose, for example, could cause a release of hydraulic fluid under
high pressure.
High Pressure Fluid Injections
Non-Mechanical Hazards:
Electrical Hazard
The primary concern is electric shock arising from persons coming into contact with live
parts. This may be a direct contact – where the conductors or conductive parts are intended
to be energised in normal operation; or an indirect contact – where parts have become live
under fault conditions.
Additional concerns include projection of molten particles or chemical effects from short-
circuits or overloads and secondary consequences (e.g. objects dropped by persons as a
result of the surprise caused by electric shock).

Thermal Hazards
Contact with machine parts or materials at extremes of temperature (hot or cold) may cause
Burns or scalds. Heat sources may pose a fire or an explosion hazard. Health effects (heat
stress/frostbite) are also associated with working with hot or cold machinery.
Noise
Continual exposure to noise levels above 80 dB(A) can cause permanent hearing loss and a
range of other physiological and psychological effects. Noise may also impair verbal
communication or the perception of acoustic signals.
Vibration
Vibration can be transmitted to the whole body (use of mobile equipment) and particularly
to hands and arms (use of hand-held and hand-guided machines). Vibration can cause
vascular, neurological, and osteo-articular disorders.

Radiation
Radiation hazards may arise from ionising or non-ionising sources. Effects may be acute
(e.g. burns) or chronic (e.g. genetic mutations).
Ergonomic Hazards
A mismatch between machinery and human characteristics and abilities can result in:
physiological effects (e.g. musculo-skeletal disorders) from unhealthy postures, or repetitive
movements; psycho-physiological effects arising from mental overload or underload; or an
unacceptable level of human error/failure.
Slipping, Tripping and Falling Hazards

Inadequate floor surfaces or poor arrangements for access and egress may give rise to slips,
trips and falls. Ejected materials or substances may also create tripping or slipping hazards.
Environmental Hazards
Where machinery is required to operate under potentially hazardous environmental
conditions (e.g. temperature, wind, snow, lightning) those hazards should be considered at
the design stage.

Hazards of a range of equipment:

Hazards of manufacturing/maintenance machinery
Bench Top Grinder Pedestal Drill

• Abrasion on contact with rotating • Entanglement with the rotating drill
abrasive wheel. bit or chuck.
• Drawing in at nip point between • Stabbing or puncture by the drill bit
wheel and tool rest. during normal use or if the bit
• Puncture by ejected parts of the • breaks.
wheel during normal use or if it • Puncture by swarf ejected during
bursts. metal cutting.
• Entanglement with the spindle on • Impact if struck by the workpiece if
which the wheel is mounted. the bit jams and the workpiece
• Electricity. • rotates.
• Hot parts caused by friction • Drawing in at nip points between
(especially the workpiece being motor and drive belts.
ground). • Electricity.
• Health hazard from dust. • Noise.
• Noise and vibration. • Hot parts (especially the drill bit).
• Health hazard from cutting fluid
(e.g. dermatitis).

Hazards Associated with agricultural/horticultural Equipment:
Brush Cutter Chainsaw
Strimmer/Brush Cutter Chain Saw

• Cutting on contact with moving • Cutting on contact with the moving
blades. blade.
• Impact or crushing if struck by the • Entanglement with the moving
mower. blade.
• Entanglement with various rotating • Drawing in at nip point between the
parts. blade and casing.
• Drawing in at various nip points. • Puncture by ejected parts (especially
• Noise. broken blade fragments).
• Vibration. • Noise.
• Fire and explosion from petrol (fuel). • Vibration (into hands).
• Health hazard from sensitisation to • Fire and explosion from petrol (fuel).
grass sap, pollen, etc. • Ergonomic from handling.
• Health hazards from dust and sap.
Hazards of Retail Machinery
Compactor
Compactor
• Crushing if inside during operation.
• Shearing between moving arms during operation.
• Crushing or impact by ejected bale or container lorry.
• Electricity.
• High-pressure fluid ejection from the hydraulic system.
• Ergonomic from handling material during loading.

Hazards of Construction Machinery
Cement Mixer Bench Mounted Circular Saw
Cement Mixer Bench mounted circular saw

• Entanglement with the rotating • Cutting on contact with the blade.
drum or drive motor. • Entanglement with the drive motor.
• Drawing in at nip point between the • Drawing in at nip points between
motor and drive mechanism. the motor and drive belt.
• Crushing between the drum and • Ejection of the workpiece during
drum stop when tipping. cutting.
• Friction or abrasion on contact with • Electricity.
the moving drum. • Noise and vibration.
• Electricity. • Health hazard from inhalation of
• Ergonomic from handling during wood dust.
loading.
• Health hazard from cement dust
inhalation and contact with wet
cement (corrosive).
Control Measures for Machinery Hazards
Machinery safeguarding methods:

Each piece of machinery has its own unique mechanical and non-mechanical hazards.
Machines can cause a variety of injuries ranging from minor abrasions, burns or cuts to severe
injuries such as fractures, lacerations, crushing injuries or even amputation. Machine guards
are your first line of defence against injuries caused by machine operation. Each machine
must have adequate safeguards to protect operators and other employees in the immediate
work area from hazards created by ingoing nip points, rotating parts, sparks and flying
debris. Guards are barriers which prevent access to danger areas.

There are four general types of guards:
Fixed Guards
As its name implies, a fixed guard is a
permanent part of the machine. It is not
dependent upon moving parts to perform its
intended function. It may be constructed of
sheet metal, screen, wire cloth, bars, plastic, or
any other material that is substantial enough to
withstand whatever impact it may receive and
to endure prolonged use. This guard is usually
preferable to all other types because of its
relative simplicity and permanence.
Fixed Guard
Advantages of fixed guards:
• Creates a physical barrier
• Requires a tool to remove it
• No moving parts therefore requires very little maintenance
• Easy to inspect
Disadvantages of Fixed Guards

• No protection if removed
• Requires a tool to remove
• If solid hampers visual inspection
• If solid may cause problems with heat
Interlock Guard
The machine will not operate and either the
guard remains locked closed until the
dangerous movement has ceased or, where
overrun is sufficient to create danger, opening
the guard disengages the drive. Interlocking
systems may be mechanical, electrical, hydraulic
or pneumatic or combinations of these.
Advantages of Interlock Guards:

• Can provide maximum protection
• Allows access to machine for removing jams without time-consuming removal of
fixed guards

Disadvantages of Interlock Guards

• More complex and therefore, potentially unreliable/can fail to unsafe condition
• More difficult to inspect/test
• Difficult to maintain/subject to wear
Adjustable Guards
These guards can be adjusted to the work being carried out or work-piece, and the guard,
when correctly adjusted, remains fixed for a given operation. Adjustable guards are
prevalent on traditional engineering workshop and woodworking machines such as band
saws, circular saws, pillar drills and lathes. Adjustable guards require the operator to set
the guard up properly for each operation to allow the work piece to be fed into the
machine whilst minimising the likelihood of the operator coming into contact with the
exposed dangerous parts.
Adjustable guards can be easily misused, e.g. set to their maximum opening thus affording
minimal protection; or totally removed for convenience. Adjustable guards are often used
in conjunction with protection appliances (which are discussed later).
Adjustable Guard
Advantages:
• Can be constructed to suit many specific applications
• Can be adjusted to admit varying sizes of stock
Disadvantages:
• Hand may enter danger area-protection may not be complete at all times
• May require frequent maintenance and /or adjustment
• The guard may be made ineffective by the operator
• May interfere with visibility

Self-Adjusting Guards
Self-Adjusting guards automatically open and close as the work-piece is put in and pulled
out. They allow entry of the material to the machine in such a way that the material itself
actually forms part of the guarding arrangement, e.g. hand held circular saw.
Self-Adjusting guards of this type do not afford protection beneath the material.
Disadvantages:
• Does not always provide maximum protection
• May interfere with visibility
• May require frequent maintenance and adjustment
Self-Adjusting Guard
Foot operated switches / Hold to run Controls

A foot operated switch is used when the operator has to hold the material during processing.
The pedal must have a safety cover to prevent unintentional start. For seated work, one must
also have a foot support to facilitate the operator holding his foot in the pedal´s off position.
The highest safety level is secured by monitoring the pedal with a safety relay.

Sensitive protective equipment (Trip devices)

Protection devices do not prevent access to the danger zone but stop the movement of
dangerous parts before contact is made. They are normally used in conjunction with
guards and include:
Mechanical Trip Device - Mechanical trip devices incorporate a physical barrier, which is
contacted by part of the body as it approaches the danger area. Examples include: a
safety trip bar for horizontal two-roll mills used in the rubber industry; a bump strip along
the lower edges of a scissor lift platform or a “whisker guard” to a pedestal drill.
Impacting upon a mechanical trip device causes the dangerous movement of the
machinery to stop safely (sometimes incorporating a reverse movement) thus preventing or
minimizing injury.
Photoelectric devices - The photoelectric (optical) presence-sensing device uses a system

of light sources and controls which can interrupt the machine's operating cycle. If the light
field is broken, the machine stops and will not cycle. This device must be used only on
machines which can be stopped before the worker can reach the danger area. The design
and placement of the guard depends upon the time it takes to stop the mechanism and
the speed at which the employee's hand can reach across the distance from the guard to
the danger zone.

Pressure sensitive mats – Pressure sensitive mats may be appropriate in circumstances

where the use of a fixed guard or an interlocking guard is impracticable. They are mats
with a sensitive upper surface so that the pressure applied by a person standing on them
will cause the dangerous motion of the protected machine to stop. The dimensions and
the positioning of the mat should take account of a person’s speed of approach, length of
stride, and the overall response time of the safety system.
Pressure sensitive mats tend to be less sensitive at the edges. Where a number of mats are
used together, they should be installed so that adjoining inactive areas, do not provide the
operator with a pathway to any hazard.
Care should be taken to ensure that the danger zone cannot be reached without actuating
the mat.
Limitations of Trip Device:

• Does not protect against mechanical failure
• Limited to machines that can be stopped
• Does not provide a physical barrier
• Can be overridden
• May not operate fast enough to prevent harm
• May be very sensitive, which might lead to frequent trips and production delays,
which will allow the operator to bypass or disable them.
• Is more complicated than simple physical guards

Two-hand Control Devices - A two-hand control device is used when it must the guaranteed
that the operator's hands will be kept outside the risk area. If there is a risk that someone
else other than the operator can reach into the machine without the operator seeing it, the
safety device must be supplemented by something more, e.g. a light beam.
Two handed Controls
To be able to operate the machine with the two-hand device, all the buttons on the device
have to be operated within 0.5 seconds of each other. This is called concurrence. All the
buttons also have to be returned to their initial position before one can start again. If any
button is released during the machine movement the machine will be stopped. Using the
stopping time, one can calculate the necessary safety distance. A safety distance of less than
100 mm must not be used. The highest safety level is assured by connecting the buttons of
the two-hand device to a safety relay. The safety relay checks for concurrence and that all
the buttons have returned to their initial position before a new start can be made. The safety
relay also gives a stop signal if any of the buttons are released.
Emergency Stop Controls:

So, what is the Emergency Stop function, or E-stop
function, and when do you need to have one? Let’s look
at a few definitions:
Emergency situation - an immediately hazardous

situation that needs to be ended or averted quickly in
order to prevent injury or damage.
Emergency stop - a function that is intended to

avert harm or to reduce existing hazards to persons,
machinery, or work in progress.
Emergency stop button - a red mushroom-headed Emergency Stop Button

button that, when activated, will immediately start the
emergency stop sequence.

Limitations:
• They are only used once danger has been sensed by the operator and by then it may
be too late
• Despite good design, a person trapped by a machine may not be able to reach the
emergency stop
• It may not be possible to emergency brake the machine quickly enough to prevent
the injury.
Protective appliances
Protection appliances are devices that are used to hold or manipulate a loose work-piece
at a machine in a way, which allows the operator to control and feed the work-piece, while
keeping their body, clear of the danger zone.
Examples include jigs, push sticks and holders.

• Jigs - A jig is a device into which the work piece can be fitted and takes into the
dangerous part of the machine in the correct position.
• Holders - A holder is a hand-held device that secures the work piece in such a way
that it can be placed in to the dangerous part of the machine without risk to the
operator’s hands e.g. tongs.
• Push Stick - A push stick is a device which is used to push the item being used into
the dangerous part of the machine without danger to the operator’s hands e.g. a stick
used to push wood into a circular saw.
Protection appliances are normally used in addition to guards

Information, Instruction, Training and Supervision
Information, instruction, training and supervision are always important, even if the
hazard is protected by hardware measures, however, they are especially important when the
risk cannot be adequately eliminated by hardware measures alone and adjustable guards
and protective devices are in use.
Procedures are required to define what information, instruction training and

supervision is necessary. Use of machinery should be restricted to those who have received
all necessary instruction and information or are being trained under an appropriate level of
supervision.
Personal Protective Equipment
As we now know machinery work can be extremely hazardous and in addition to safe work
methods being established and implemented workers need to be provided with the
adequate personal protective equipment to minimise the harm done by accidental contact
with dangerous machinery parts.
These PPE include gloves, long sleeve clothing etc. that are designed to reduce the risk from
certain hazards in a workplace, such as contact with sharp edges, hot surfaces or limiting
exposure to dangerous chemicals or atmospheres.
Workers need to remember that PPE can also increase risks in some operations, in particular
the risk of entanglement with rotating components. Workers should also be aware that PPE
should not be the only safety measure employed but should actually be the last control
measure.
Where PPE is used at a workplace, it should be appropriate for all tasks being performed.
Where different tasks require different PPE, the safe work procedures should specify this,
and there should be measures in place to reduce the risk of workers accidentally using
incorrect PPE. Workers should be trained on the correct PPE for every situation and how to
utilise it effectively. An example of the types of issues the training should cover includes not
wearing gloves when operating rotating machinery.

Use of the above control methods for the range of equipment listed in 9.3
Manufacturing and Maintenance Machinery

Secure grinder in position Fixed Guards and adjustable guards
Fixed enclosed guards Clamp to secure workpiece
Eye protection Eye protection
Only trained persons operating Hearing protection
Hearing protection Maintenance, inspection and portable
Installation of LEV appliance testing
Maintenance, inspection and portable Trained persons only
appliance testing
Regular checks of grinding wheel
Avoid loose clothing
Breaks and job rotation
Agricultural and Horticulture Machinery

Cylinder Mower Chainsaw
Fixed guard Fixed enclosing guards
Safety switch PPE Face and eye protection
Trained operators only Hand guard for front hand grip
Hearing protection Job rotation
Refuelling in well ventilated area Refuelling in ventilated area
Job rotation Trained persons only
Retail machinery
Compactor Checkout conveyor system
Fixed perimeter guard loading area and Fixed and interlock guards
mechanism Trip fitted to conveyor to prevent drawing in
Interlocked guards to allow access to loading Inspection and portable appliance testing.
area Use restricted to trained persons only
Inspection and portable appliance testing.
Use restricted to trained persons only

Construction Machinery
Cement Mixer Bench mounted circular saw
Location of the mixer on firm, level ground Fixed guards
Location away from traffic Adjustable top guard fitted
Fixed guards Hearing protection
Use restricted to trained persons only Eye protection
Routine inspection and maintenance LEV
Safe storage of petrol and control of ignition Routine inspection and portable appliance
sources testing
Reduction of manual handling, keeping cement Use restricted to trained persons only
bags close to the mixer
Hand protection and respiratory protection, eye
protection
Basic requirements for guards and safety devices:
Having an understanding of how a machine works, and how the guards can protect you, will
result in a reduced risk of injury. In order to be in compliance with OSHA requirements, all
guards must:
Prevent contact – machine guards must provide a physical barrier that prevents the operator
from having any part of his/her body in the “danger zone” during the machine’s operating
cycle;
Be secured in place or otherwise be tamper proof – machine guards must be secure and
strong so that workers are not able to bypass, remove, or tamper with them. They must be
attached to the machine where possible. If the guard cannot be physically attached to the
machine it must be attached elsewhere;
Create no new hazard – A safeguard defeats its own purpose if it creates a hazard of its own
such as a shear point, a jagged edge, or an unfinished surface which can cause a laceration.
The edges of guards, for instance, should be rolled or bolted in such a way that they
eliminate sharp edges. Machine guards should not obstruct the operator’s view;
Allow for lubrication with the guard still in place - If possible, one should be able to lubricate
the machine without removing safeguards. Locating oil reservoirs outside the guard, with a
line leading to the lubrication point, will reduce the need for the operator or maintenance
worker to enter the hazardous area.
Not interfere with the machine operation - Any safeguard which impedes a worker from
performing the job quickly and comfortably might soon be overridden or disregarded.

Proper safeguarding can actually enhance efficiency since it can relieve the worker’s
apprehensions about injury. It is not easy to defeat or bypass.
Vision – it must not interfere with any need to see in.
Ventilation – it must not interfere with any ventilation required.
Ease of maintenance – it should be easy to maintain and maintained in good condition.
Removal for maintenance – ideally, the guard should not have to be removed to allow
maintenance on the machine to take place.
End of Element 9

Element 9 - Work Equipment

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Element 9 - Work Equipment

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NEBOSH International General Certificate

in Occupational Health & Safety

Element 9: Work Equipment

9.1 General Requirements for Work Equipment.

9.2 Hand Tools and Portable Power Tools

9.3 Machinery Hazards

9.4 Control Measures for Machinery Hazards.

9.1 General Requirements of work equipment

Providing suitable equipment

Work equipment’ is almost any equipment used by a worker at work including:

What does the CE mark mean?

UNIT IG2 - Element 9: Work Equipment 9-1

• Taking appropriate ‘hardware’ measures, e.g. providing suitable guards, protection

A combination of these measures may be necessary depending on the requirements of the

Prevention of access to dangerous parts of machinery

UNIT IG2 - Element 9: Work Equipment 9-2

Information, Instruction and Training

UNIT IG2 - Element 9: Work Equipment 9-3

Why equipment should be maintained, and maintenance conducted safely

UNIT IG2 - Element 9: Work Equipment 9-4

Plant and equipment must be made safe before maintenance starts.

Other factors you need to consider

UNIT IG2 - Element 9: Work Equipment 9-5

Emergency stop controls should be easily reached and actuated.

Common types are mushroom-headed buttons, bars, levers,

In addition to the requirements outlined earlier, there are

UNIT IG2 - Element 9: Work Equipment 9-6

9.2 Hand-Held Tools

Hazards from manual and powered hand-held tools:

UNIT IG2 - Element 9: Work Equipment 9-7

Hazards of portable power tools

Portable power tools create greater risk than

Additional hazards from power tools are:

UNIT IG2 - Element 9: Work Equipment 9-8

The following general precautions should be observed by power tool users:

Additional precautions must be taken when using electrical equipment. Battery-operated

9.3 Machinery Hazards

UNIT IG2 - Element 9: Work Equipment 9-9

The hazards outlined can be categorised as Mechanical and Non-mechanical.

Entanglement - Loose-fitting shirts might possibly become entangled in rotating spindles or

UNIT IG2 - Element 9: Work Equipment 9-10

UNIT IG2 - Element 9: Work Equipment 9-11

Cutting or severing - Injuries arising from contact with a cutting blade

Ejection of materials including high-pressure fluid injections – injuries caused by flying

High Pressure Fluid Injections

UNIT IG2 - Element 9: Work Equipment 9-12

UNIT IG2 - Element 9: Work Equipment 9-13

Slipping, Tripping and Falling Hazards

UNIT IG2 - Element 9: Work Equipment 9-14

Hazards of a range of equipment:

Bench Top Grinder Pedestal Drill

Bench Top Grinder Pedestal Drill

UNIT IG2 - Element 9: Work Equipment 9-15

Hazards Associated with agricultural/horticultural Equipment:

Brush Cutter Chainsaw

Strimmer/Brush Cutter Chain Saw

Hazards of Retail Machinery

UNIT IG2 - Element 9: Work Equipment 9-16

Hazards of Construction Machinery