NEBOSH International Diploma in Occupational Health and Safety

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Version 1.3a (18/02/2013)

Element - IC5: Work Equipment (General).

Learning outcomes.
On completion of this element, candidates should be able to:

Outline the criterion for the selection of suitable work equipment for particular tasks
and processes to eliminate or reduce risks.
Explain how risks to health and safety arising from the use of work equipment are
controlled.
Explain safe working procedures for the maintenance, inspection and testing of work
equipment according to the risks posed.
Explain the role of competence, training, information and supervision in the control of
risks arising from the installation, operation, maintenance and use of work equipment.

Relevant Standards:
International Labour Standards, Guarding of Machinery Convention, C119, International Labour Organisation, Geneva, 1963.
NB ILO Draft code of practice on safety in the use of machinery - Draft Meeting of Experts
on the Code of Practice on Safety in the use of Machinery (Geneva, 29 November - 7 December 2011).

1.0 - Selection.
The main pieces of UK legislation concerning the suitability of the task and environment are:

The Provision and Use of Work Equipment Regulations 1998 (PUWER)

Supply of Machinery (Safety) Regulations 1992 as amended 1994

1.1 - The Provision and Use of Work Equipment Regulations 1998 (PUWER).
In general terms, PUWER requires that equipment provided for use at work is:

suitable for the intended use;

safe for use, maintained in a safe condition and, in certain circumstances, inspected
to ensure this remains the case;
used only by people who have received adequate information, instruction and training; and
accompanied by suitable safety measures, e.g. protective devices, markings, warnings.

1.2 - Supply of Machinery (Safety) Regulations 1992.

These regulations place duties upon those who supply machinery and safety components,

including manufacturers, importers and others in the supply chain. They set out the essential
requirements which must be met before machinery or safety components may be supplied in
the UK.
There are basically three steps to dealing with the requirements:

The responsible person should ensure that machinery and safety components satisfy
the relevant essential health and safety requirements of the Supply of Machinery
(Safety) Regulations and that, where appropriate, relevant conformity assessment
procedures have been carried out.
The responsible person must issue a declaration of conformity (or a declaration of
incorporation) which is issued with the finished product so that it is available to the
user. This will contain various details such as the manufacturer's address, the machinery type and serial number, and the harmonised European, or other, standards
used in design.
When the first two steps have been satisfactorily completed, the responsible person
or person supplying or assembling the final product should affix the CE marking if
they are satisfied it is safe.

The HSE is responsible for enforcing these Regulations in relation to machinery supplied for
use at work.

1.3 - Conformity with relevant standards CE marking.

With reference to the Supply of Machinery (Safety) Regulations 1992, the Health and
Safety Executive give the following advice and guidance:
What is the law on supplying new machinery?
There are several relevant pieces of law, including:

the Supply of Machinery (Safety) Regulations 1992, which implement the European
Machinery Directive, and which contain detailed requirements for manufacturing safe
new machinery;
the Health and Safety at Work etc Act 1974, which contains general requirements for
the manufacture and supply of safe workplace machinery (including second-hand
machinery);
other regulations which implement other European Directives, such as those on the
supply of electrical equipment or on gas appliances, which are important for many
suppliers of machinery.

To what do the Supply of Machinery (Safety) Regulations 1992 apply?

These Regulations apply to all new machinery manufactured or supplied in the UK,
wherever it is to be used in the European Economic Area (EEA) (The European Economic
Area comprises all EU and EFTA countries with the exception of Switzerland.) The term
'machinery' is broadly defined and includes what is generally understood by the term, as well
as some other products.
Examples include:

a complex production line;

a fork-lift truck;
a circular saw;
an agricultural plough;

lifting equipment and lifting tackle;

an escalator.

In brief, what are the requirements of these Regulations?

Most importantly, they require all UK manufacturers and suppliers of new machinery to make
sure that the machinery which they supply is safe. They also require manufacturers to make
sure that:

machinery meets relevant essential health and safety requirements (these are listed
in detail in the Regulations), which include the provision of sufficient instructions;
a technical file for the machinery has been drawn up, and in certain cases, the machinery has been type-examined by a notified body;
there is a 'declaration of conformity' (or in some cases a 'declaration of incorporation') for the machinery, which should be issued with it (see questions 18-20);
there is a CE marking affixed to the machinery (unless it comes with a declaration of
incorporation).

'C E Marking'
Does the same law apply in other European countries?
The Machinery Directive has now been implemented as national law in all countries in the
EEA. This means that the same legal requirements now apply to all new machinery
wherever it is supplied within the EEA.
What if I am directly importing machinery manufactured outside the EEA?
This machinery must still meet the Supply of Machinery (Safety) Regulations 1992 and
because you are importing it directly from outside the EEA, you take on the legal
responsibilities of the manufacturer. So you need to make sure either that the manufacturer
has met the relevant requirements or that you meet them yourself.
What law applies to the sale of second-hand machinery?
The Supply of Machinery (Safety) Regulations 1992 only applies to the first supply of
machinery into the EEA, and only if this takes place after 1 January 1993. Therefore, if you
are supplying second-hand machinery which was first in use before 1993, without
substantially refurbishing it, the machinery does not need to comply with these Regulations.
Also, if you are re-supplying used CE-marked machinery, these Regulations do not apply.
However, all machinery should be maintained in a safe state, and Section 6 of the Health
and Safety at Work etc Act 1974 will apply to the re-sale (in Great Britain) of all second-hand
workplace machinery, however old it is.
What if the old machinery I am supplying is substantially refurbished?
If machinery has been refurbished to such an extent that almost all the replaceable parts are
new, it would be considered to be new machinery and so you will need to comply with the

Supply of Machinery (Safety) Regulations 1992. For example, where CNC controls are
retrofitted to an older manual lathe, these Regulations apply. But if old machinery has simply
been given new guards or some improved controls or just repainted, this would not make it
'new' and the Regulations will not apply when it is re-sold. However, Section 6 of the Health
and Safety at Work etc Act 1974 will apply.

1.4 - What does the manufacturer have to do?

It is primarily the task of the manufacturer to design and construct new machinery so that it
can be used safely. In addition to meeting certain administrative and other requirements,
there are specific practical issues that need to be addressed by the manufacturer. Some of
these are as follows.
How does the manufacturer make sure that machinery can be used safely?
There are several procedures which they must follow, but in particular they should:

identify the health and safety hazards (trapping, crushing, electrical shock, dust or
fumes, noise, vibration, etc) that are likely to be present when the machinery is used;
assess the likely risks;
eliminate the risks, or if that is not possible:
provide safeguards (e.g. guarding dangerous parts of the machinery, providing noise
enclosures) or, if that is not possible:
provide information about any residual risks and place signs on the machinery to
warn of risks that cannot be reduced in other ways (e.g. 'noisy machine' signs).

Does new machinery have to be made to any particular standards?

No. Machinery must satisfy the essential health and safety requirements of the law, i.e. the
Supply of Machinery (Safety) Regulations 1992 in the UK. But there are an increasing
number of harmonised European Standards that will help manufacturers to do this. A
harmonised European Standard has an EN before the number, e.g. EN 474-1, and is
published as a British Standard e.g. BS EN 474-1:1995. The use of these standards is
voluntary, and manufacturers can design and manufacture their machinery in accordance
with other national or international standards if they wish, so long as the essential health and
safety requirements of the law are satisfied.

1.5 - What does the supplier have to do?

What do I need to do as a supplier before providing machinery to others?
If it is manufactured in the EEA, you must make sure as much as you can that the machinery is safe. If you are importing machinery from outside the EEA, you will need to make sure
that the machinery meets the requirements of the law in full. There may be information
available about machinery safety from your trade association, HSE or other sources, which
will help you to decide whether the machinery you are supplying is safe. You may also find
relevant British or other Standards helpful.
Can I regard CE marking as a guarantee of safety?
No. CE marking is not a quality mark and affixing it on machinery is only one of the several
requirements that the manufacturer has to meet. By affixing CE marking to machinery, the
manufacturer is claiming that all relevant legal requirements have been met, but you must

still make sure as far as you can that the machinery is safe.
What if the machinery is manufactured by someone else either in the UK or elsewhere
in the EEA and I (as a supplier) consider that the safeguards or other protective devices are inadequate?
There could be several reasons why this might happen. For example, the harmonised European Standard for that machinery may not yet have been agreed, and different interpretations of the level of protection that is required may exist in different countries. Alternatively, it
may be that the machinery does not meet agreed levels of protection and the law is clearly
not being met. If you are not satisfied with the levels of protection for the machinery you are
supplying, discuss the matter with the manufacturer or your UK Trade Association.
CHECKLIST: DO NOT SUPPLY OR USE MACHINERY WHICH YOU CONSIDER UNSAFE.
Before supplying new machinery:

Look for obvious defects, such as missing guards or other safety devices, or inadequately protected electric wiring.
Check that known risks (including risks from fumes or dust, noise or vibration) from
the machinery when it is in use will be properly controlled or that there is information
on how they can be controlled.
Make sure the manufacturer has provided instructions for safe installation, use, adjustment and maintenance, and that these are in English if the machinery is for use
in the UK (some maintenance instructions may be in another language if staff from
the manufacturer is to carry out specialised maintenance).
Check that data about noise and vibration emissions have been provided, where appropriate.
Make sure that any warning signs are visible and easy to understand.
Check that you have a properly-completed declaration of conformity, or a declaration
of incorporation if appropriate.
Check for CE marking.
Check with the manufacturer if you have concerns about any of the above matters.

When will machinery have a declaration of conformity?

When it is finished and ready for installation and use.
What should a declaration of conformity have on it?
A declaration of conformity must:

state the name and address of the manufacturer or (in the case of machinery made
outside the EEA) of the importer;
contain a description of the machinery, its make, type and serial number;
indicate all relevant European laws (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 (if any); and
be signed by a person with authority to do so.

For machinery supplied in the UK, the declaration of conformity must be in English. For
machinery exported to other countries in the EEA, instructions must be in the recognised
language of the country where it is to be used.
When is a declaration of incorporation appropriate rather than a declaration of

conformity?
If the machinery is intended for:

incorporation into other machinery; or

assembly with other machinery; and
if certain other conditions are met, the manufacturer may issue a declaration of incorporation instead of a declaration of conformity.

The declaration should contain similar information to that contained in the

declaration of conformity, but importantly, it must state that the machinery should not
be used until:

the machinery into which has been incorporated; or

the assembly to which it has been added has been declared to conform fully to the
legal requirements.

In practice, this means that the machinery should not be used until the final product has
been manufactured, all relevant essential health and safety requirements met, and a
declaration of conformity issued - by the final installer or assembler.
The machinery should not be CE marked if it has a declaration of incorporation; CE marking
should only take place at the end of incorporation or assembly.

1.6 - Regulation 5 - Maintenance.

This states that:

Every employer shall ensure that work equipment is maintained in an efficient state,
in efficient working order and in good repair.
Every employer shall ensure that where any machinery has a maintenance log, the
log is kept up to date.

Guidance to this regulation states:

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 take into
account 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.

The extent and complexity of maintenance can vary substantially from simple checks on
basic equipment to integrated programmes for complex plant. In all circumstances, for
maintenance to be effective it needs to be targeted at the parts of work equipment where
failure or deterioration could lead to health and safety risks. 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: Planned preventive maintenance involves replacing parts and

consumables or making necessary adjustments at preset intervals so that risks do
not occur as a result of the deterioration or failure of the equipment.
Condition-based: Condition-based maintenance involves monitoring the condition of
safety-critical parts and carrying out maintenance whenever necessary to avoid hazards which could otherwise occur.
Breakdown: Breakdown maintenance involves carrying out maintenance only after
faults or failures have occurred. It is appropriate only if the failure does not present
an immediate risk and can be corrected before risk occurs, for example through effective fault reporting and maintenance schemes.

Maintenance log.
There is no requirement for you to keep a maintenance log. However, it is recommended
that you keep a record of maintenance for high-risk equipment. A detailed maintenance log
can provide information for future planning of maintenance activities and inform
maintenance personnel and others of previous action taken. If you have a maintenance log,
you should keep it up to date. Maintenance procedures should be carried out in accordance
with any manufacturer's recommendations which relate to the equipment, for example
periodic lubrication, replacement and adjustment of parts.

1.7 - Regulation 7 - Specific Risks.

This states that:
(1) Where the use of work equipment is likely to involve a specific risk to health or safety,
every employer shall ensure that:
(a) the use of that work equipment is restricted to those persons given the task of using it;
and
(b) repairs, modifications, maintenance or servicing of that work equipment is restricted to
those persons who have been specifically designated to perform operations of that description (whether or not also authorised to perform other operations).
(2) The employer shall ensure that the persons designated for the purposes of subparagraph (b) of paragraph (1) have received adequate training related to any operations in
respect of which they have been so designated.
The guidance to the regulation further states that you should ensure that, wherever
possible, risks are always controlled by (in the order given):

eliminating the risks, or if that is not possible;

taking 'hardware' (physical) measures to control the risks such as the provision of
guards but if the risks cannot be adequately controlled;
taking appropriate 'software' measures to deal with the residual (remaining) risk,
such as following safe systems of work and the provision of information, instruction
and training.

1.8 - Regulation 8 - Information and Instructions.

This states that:
(1) 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.
(2) 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.
(3) Without prejudice to the generality of paragraphs (1) or (2), the information and instructions required by either of those paragraphs shall include information and, where appropriate, written instructions on (a) the conditions in which, and the methods by which, the work equipment may be used;
(b) foreseeable abnormal situations and the action to be taken if such a situation were to
occur; and
(c) any conclusions to be drawn from experience in using the work equipment.
Information and instructions required by this regulation shall be readily comprehensible to
those concerned.
The guidance to the regulation further states:
Regulation 8 places a duty on employers to make available all relevant health and safety
information and, where appropriate, written instructions on the use of work equipment to
their workforce. Workers should have easy access to such information and instructions and
be able to understand them.

1.9 - Regulation 9 - Training.

This states that:
(1) 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.
(2) 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.

2 - Risk Assessment of Work Equipment.

Work equipment risk assessment.
The need for a risk assessment of work equipment is found in Regulation 3 of the Management of Health and Safety at Work Regulations 1999, which calls for a 'suitable and sufficient risk assessment' to be carried out of work activities. The guidance in the PUWER approved code of practice states:

"Because of the general risk assessment requirements in the Management Regulations,

there is no specific regulation requiring a risk assessment in PUWER. The HSE has produced guidance in a booklet called '5 Steps to Risk Assessment'. Risks to health and safety
should be assessed taking into account matters such as the type of work equipment, substances and electrical or mechanical hazards to which people may be exposed."
Risk assessment should therefore follow the usual process as defined in the 5 steps
booklet:

'5 Steps'
The PUWER approved code of practice, however, does give some advice on control
measures:
Action to eliminate/control any risk might include, for example, during maintenance:

Disconnecting the power supply to the work equipment.

Supporting parts of the work equipment which could fall.
Securing mobile work equipment so that it cannot move.
Removing or isolating flammable or hazardous substances.
Depressurising pressurised equipment.

2.1 - Risk Control Measures.

A hierarchy of control measures relating to work equipment is recommended in Reg
11 of PUWER 1998:
A Fixed enclosing guards.
B Other guards or protection devices such as interlocked guards and pressure mats.
C Protection appliances such as jigs, holders and push sticks etc.
D The provision of information, instruction, training and supervision.
Further and more detailed advice is give as follows:
Guards are physical barriers which prevent access to the danger zone. Fixed Guards have
no moving parts and are fastened in a constant position relative to the danger zone. They
are kept in place either permanently, by welding for example, or by means of fasteners
(screws, nuts, etc) making removal/opening impossible without using tools. If by themselves,

or in conjunction with the structure of the equipment, they enclose the dangerous parts, fixed
guards meet the requirements of the first level of the hierarchy. Note that fixed enclosing
guards - and other types of guard - can have openings provided that they comply with appropriate safe reach distances.
Other guards include movable guards which can be opened without the use of tools, and
fixed guards that are not fully enclosing. These allow limited access through openings,
gates, etc for feeding materials, making adjustments, cleaning, etc.
Moveable guards may be power-operated, self-closing, adjustable, etc and are likely
to require an interlocking device so that:

the hazardous machine functions covered by the guard cannot operate until the
guard is closed;
if the guard is opened while hazardous machine functions are operating, a stop instruction is given;
when the guard is closed, the hazardous machine functions covered by the guard
can operate, but the closure of the guard does not by itself initiate their operation.

Interlocking guards may be fitted with a locking device so that the guard remains closed and
locked until any risk of injury from the hazardous machine functions has passed. A control
guard (interlocking guard with a start function) is a particular type of interlocking guard which
should be used only in certain situations where frequent access is required. It should also
fulfil specific conditions in particular, where there is no possibility of an operator or part of
their body remaining in the danger zone or between the danger zone and the guard while
the guard is closed.
Protection devices are devices which do not prevent access to the danger zone but stop the
movement of the dangerous part before contact is made. They will normally be used in
conjunction with a guard. Typical examples are mechanical trip devices, active optoelectronic devices such as light curtains, pressure mats and two-hand controls.
Protection appliances are used to hold or manipulate in a way which allows operators to
control and feed a loose work piece at a machine while keeping their body clear of the
danger zone. They are commonly used in conjunction with manually-fed woodworking
machines and some other machines such as band saws for cutting meat, where it is not
possible to fully guard the cutting tool. These appliances will normally be used in addition to
guards.
Adequate 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 the hardware measures mentioned above. It may
be necessary to lay down procedures to define what information, instruction, training and
supervision must be given, and to restrict use of equipment to those who have received
such instructions etc.

2.2 - Statutory requirements for training, certification and authorisation.

In this section, we will look at the training requirements as detailed in the Approved Code of
Practice for the Provision and Use of Work Equipment Regulations 1998 and the Lifting Operations and Lifting Equipment Regulations 1998.

2.3 - Training requirements: PUWER 1998.

It is not possible to detail here what constitutes 'adequate training' as requirements
will vary according to the job or activity and work equipment etc. In general, you will
need to:

evaluate the existing competence of employees to operate the full range of work
equipment that they will use;
evaluate the competence they need to manage or supervise the use of work equipment; and
train the employee to make up any shortfall between their competence and that required to carry out the work with due regard to health and safety.

Account should be taken of the circumstances in which the employee works. For example,
do they work alone or under close supervision of a competent person?
Training needs are likely to be greatest on recruitment. However, training needs are
also required:

if the risks to which people are exposed change due to a change in their working
tasks; or
because new technology or equipment is introduced; or
if the system of work changes.

Also, you should provide refresher training if necessary. Skills decline if they are not used
regularly. Pay particular attention to people who deputise for others on occasions, as they
may need more frequent refresher training than those who do the work regularly.
Training for young people.
Training and proper supervision of young people is particularly important because of their
relative immaturity and unfamiliarity with the working environment. Induction training is of
particular importance. There are no general age restrictions in legislation relating to the use
of work equipment, although there is some ACOP material in the relevant publications
dealing with lifting, power presses and woodworking. All employees should be competent to
use work equipment with due regard to health and safety, regardless of their age.
The Management Regulations contain specific requirements relating to the employment of
young people under the age of 18. These require employers to assess risks to young people
before they start work, taking into account their inexperience, lack of awareness of potential
risks and their immaturity. Employers must provide information to parents of school-age
children (for example when they are on work experience) about the risks and the control
measures introduced, and take account of the risk assessment in determining whether the
young person should undertake certain work activities.

2.4 - Training requirements: LOLER 1998.

The training requirements for LOLER are referred to in regulation 8:
The person planning the operation should have adequate practical and theoretical knowledge and experience of planning lifting operations. The plan will need to address the risks
identified by the risk assessment and identify the resources required, the procedures and
the responsibilities so that any lifting operation is carried out safely.

2.5 - Statutory restrictions on use of work equipment.

The most specific restriction relating to the use of work equipment is when dealing with
young people. The training requirements laid out in PUWER are specific in relation to the
amount of training required for the young person - this has already been mentioned in 2.2.1.

2.6 - Essential health and safety requirements.

Hazard identification and the subsequent risk assessment/risk elimination or reduction is a
fundamental and mandatory element in meeting the requirements of the EHSRs of the Machinery Regulations. This procedure is covered in some detail by the two A-type standards "BS EN ISO 12100:2003 Parts 1 and 2 Safety of Machinery" and "BS EN 1050 Risk Assessment" and the following prcis of the process should not be taken as a substitute for
using the standards.
Specifying the limits of the machine - the use and lifetime, space, services, number of employees, special training required. See BS EN ISO 12100:2003 Part 1 clause 5.
Systematic assessment of the hazards and risks - intended and unintended use, normal and
abnormal use. See BS EN ISO 12100:2003 Part 1 clause 3 and 4 and BS EN 1050.
The above procedure, if properly carried out, will ensure that machines which are safe for
the intended use will be placed on the market.
However, to execute the procedure with success it is essential that the designer has a
clear understanding of:

The performance requirements of the machine.

How the machine will be used (not always the same as the performance requirements).
The accident history of similar machines.
The legal requirements applied to the machine or industry.
Sources of information - national standards, professional publications.

These requirements may seem obvious, but it is surprising how many designers are quite
remote from the workplace and, if left by themselves, may have little idea of the realities of
the environment in which their machines are to be used.
The accident history for machines in the same product area or for similar machines is an
essential element in this process. Some accident data are published by the Health and
Safety Executive (HSE) in their annual reports but in most cases, it is not detailed enough to
give anything but generalised trends. Some manufacturing associations may give more
information but the best source is from the HSE who record and investigate accidents as
part of their enforcement duties.
Inspectors have a wealth of information on accidents and remedial measures and
information can be obtained from:

HSE, Field Operations Directorate (FOD) Safety Unit on 0161 952 8222.
HSE "Infoline" on 0845 345 0055

In addition, HSE publish a series of guides dealing with machines that have given specific
problems. The guides are very comprehensive and give details of recommended protective
measures.

2.7 - Essential health and safety requirements (Cont'd).

The essential health and safety requirements as laid out in Schedule 3 of the Supply of Machinery (Safety) Regulations 1992 are as follows:
Definitions:
Danger Zone
Means any zone within and/or around machinery in which an exposed person is subject to a
risk to his health or safety.
Exposed Person
Means any person wholly or partially in a danger zone.
Operator
The person or persons given the task of installing, operating, adjusting, maintaining, cleaning, repairing or transporting machinery.
Principles of safety integration.
Machinery must be so constructed that it is fitted for its function, and can be adjusted and
maintained without putting persons at risk when these operations are carried out under the
conditions foreseen by the manufacturer. The aim of measures taken must be to eliminate
any risk of accident throughout the foreseeable lifetime of the machinery, including the
phases of assembly and dismantling, even where risks of accident arise from foreseeable
abnormal situations.
In selecting the most appropriate methods, the manufacturer must apply the following
principles, in the order given:

Eliminate or reduce risks as far as possible (inherently safe machinery design and
construction).
Take the necessary protection measures in relation to risks that cannot be eliminated.
Inform users of the residual risks due to any shortcomings of the protection measures adopted.
Indicate whether any particular training is required.
Specify any need to provide personal protection equipment.

When designing and constructing machinery, and when drafting the instructions, the
manufacturer must envisage not only the normal use of the machinery but also uses which
could reasonably be expected. The machinery must be designed to prevent abnormal use if
such use would engender a risk. In other cases, the instructions must draw the user's
attention to ways -which experience has shown might occur -in which the machinery should
not be used.
Under the intended conditions of use, the discomfort, fatigue and psychological stress faced
by the operator must be reduced to the minimum possible taking ergonomic principles into
account.
When designing and constructing machinery, the manufacturer must take account of the
constraints to which the operator is subject as a result of the necessary or foreseeable use
of personal protection equipment (such as footwear, gloves, etc).
Machinery must be supplied with all the essential special equipment and accessories to
enable it to be adjusted, maintained and used without risk.

Materials and products.

The materials used to construct machinery or products used and created during its use must
not endanger exposed persons' safety or health. In particular, where fluids are used,
machinery must be designed and constructed for use without risks due to filling, use,
recovery or draining.
Lighting.
The manufacturer must supply integral lighting suitable for the operations concerned where
its lack is likely to cause a risk despite ambient lighting of normal intensity.
The manufacturer must ensure that there is no area of shadow likely to cause nuisance, that
there is no irritating dazzle and that there are no dangerous stroboscopic effects due to the
lighting provided by the manufacturer. Internal parts requiring frequent inspection and
adjustment and maintenance areas must be provided with appropriate lighting.
Design of machinery to facilitate its handling.
Machinery or each component part thereof must:

be capable of being handled safely;

be packaged or designed so that it can be stored safely and without damage (e.g.
adequate stability, special supports, etc).

Where the weight, size or shape of machinery or its various component parts
prevents them from being moved by hand, the machinery or each component part
must:

either be fitted with attachments for lifting gear; or

be designed so that it can be fitted with such attachments (e.g. threaded holes); or
be shaped in such a way that standard lifting gear can easily be attached.

Where machinery or one of its component parts is to be moved by hand, it must:

either be easily movable; or

be equipped for picking up (e.g. hand-grips etc) and moving in complete safety.

Special arrangements must be made for the handling of tools and/or machinery parts, even
if lightweight, which could be dangerous (shape, material, etc).

2.8 - Controls.
Safety and reliability of control systems.
Control systems must be designed and constructed so that they are safe and reliable,
in a way that will prevent a dangerous situation arising. Above all, they must be designed and constructed in such a way that:

they can withstand the rigours of normal use and external factors;
errors in logic do not lead to dangerous situations.

Control devices.

Control devices must be:

clearly visible and identifiable, and appropriately marked where necessary;

positioned for safe operation without hesitation or loss of time, and without ambiguity;
designed so that the movement of the control is consistent with its effect;
located outside the danger zones, except for certain controls where necessary, such
as emergency stop or a console for training of robots;
positioned so that their operation cannot cause additional risk;
designed or protected so that the desired effect, where a risk is involved, cannot occur without an intentional operation;
made so as to withstand foreseeable strain; particular attention must be paid to
emergency stop devices liable to be subjected to considerable strain.

Where a control is designed and constructed to perform several different actions, namely
where there is no one-to-one correspondence (e.g. keyboards, etc), the action to be
performed must be clearly displayed and subject to confirmation where necessary. Controls
must be so arranged that their layout, travel and resistance to operation are compatible with
the action to be performed, taking account of ergonomic principles. Constraints due to the
necessary or foreseeable use of personal protection equipment (such as footwear, gloves,
etc) must be taken into account. Machinery must be fitted with indicators (dials, signals, etc)
as required for safe operation. The operator must be able to read them from the control
position.
From the main control position, the operator must be able to ensure that there are no
exposed persons in the danger zones. If this is impossible, the control system must be
designed and constructed so that an acoustic and/or visual warning signal is given
whenever the machinery is about to start. The exposed person must have the time and the
means to take rapid action to prevent the machinery starting up.
Starting.
It must be possible to start machinery only by voluntary actuation of a control provided for
the purpose.
The same requirement applies:

when restarting the machinery after a stoppage, whatever the cause;

when effecting a significant change in the operating conditions (e.g. speed, pressure,
etc), unless such restarting or change in operating conditions is without risk to exposed persons.

This essential requirement does not apply to the restarting of the machinery or to the change
in operating conditions resulting from the normal sequence of an automatic cycle. Where
machinery has several starting controls and the operators can therefore put each other in
danger, additional devices (e.g. enabling devices or selectors allowing only one part of the
starting mechanism to be actuated at any one time) must be fitted to rule out such risks. It
must be possible for automated plant functioning in automatic mode to be restarted easily
after a stoppage, once the safety conditions have been fulfilled.

2.9 - Stopping device.

Normal Stop.
Each machine must be fitted with a control whereby the machine can be brought safely to a
complete stop. Each workstation must be fitted with a control to stop some or all of the moving parts of the machinery, depending on the type of hazard, so that the machinery is ren-

dered safe. The machinery's stop control must have priority over the start controls. Once the
machinery or its dangerous parts have stopped, the energy supply to the actuators concerned must be cut off.
Emergency stop.
Each machine must be fitted with one or more emergency stop devices to enable actual or impending danger to be averted. The following exceptions apply:

Machines in which an emergency stop device would not lessen the risk, either because it would not reduce the stopping time or because it would not enable the special measures required to deal with the risk to be taken.
Hand-held portable machines and hand-guided machines.

This device must:

have clearly-identifiable, clearly visible and quickly accessible controls;

stop the dangerous process as quickly as possible, without creating additional hazards;
where necessary, trigger or permit the triggering of certain safeguard movements.

The emergency stop control must remain engaged; it must be possible to disengage it only
by an appropriate operation; disengaging the control must not restart the machinery, but only
permit restarting; the stop control must not trigger the stopping function before being in the
engaged position.
Complex installations.
In the case of machinery or parts of machinery designed to work together, the manufacturer
must so design and construct the machinery that the stop controls, including the emergency
stop, can stop not only the machinery itself but also all equipment upstream and/or
downstream if its continued operation can be dangerous.
Mode selection.
The control mode selected must override all other control systems with the exception of the
emergency stop. If machinery has been designed and built to allow for its use in several
control or operating modes presenting different safety levels (e.g. to allow for adjustment,
maintenance, inspection etc), it must be fitted with a mode selector which can be locked in
each position. Each position of the selector must correspond to a single operating or control
mode. The selector may be replaced by another selection method which restricts the use of
certain functions of the machinery to certain categories of operator (e.g. access codes for
certain numerically controlled functions, etc).
If, for certain operations, the machinery must be able to operate with its protection
devices neutralized, the mode selector must simultaneously:

disable the automatic control mode;

permit movements only by controls requiring sustained action;
permit the operation of dangerous moving parts only in enhanced safety conditions
(e.g. reduced speed, reduced power, step-by-step, or other adequate provision)
while preventing hazards from linked sequences;
prevent any movement liable to pose a danger by acting voluntarily or involuntarily
on the machine's internal sensors.

In addition, the operator must be able to control operation of the parts on which he is
working at the adjustment point.

Failure of the power supply.

The interruption, re-establishment after an interruption or fluctuation in whatever manner of
the power supply to the machinery must not lead to a dangerous situation.
In particular:

the machinery must not start unexpectedly;

the machinery must not be prevented from stopping if the command has already
been given;
no moving part of the machinery or piece held by the machinery must fall or be
ejected;
automatic or manual stopping of the moving parts, whatever they may be, must be
unimpeded;
the protection devices must remain fully effective.

Failure of the control circuit.

A fault in the control circuit logic, or failure of or damage to the control circuit must
not lead to dangerous situations. In particular:

machinery must not start unexpectedly;

the machinery must not be prevented from stopping if the command has already
been given;
no moving part of the machinery or piece held by the machinery must fall or be
ejected;
automatic or manual stopping of the moving parts, whatever they may be, must be
unimpeded;
the protection devices must remain fully effective.

Software.
Interactive software between the operator and the command or control system of a machine
must be user-friendly.

2.10 - Protection against mechanical hazards.

Stability.
Machinery, components and fittings thereof must be so designed and constructed that they
are stable enough, under the foreseen operating conditions (if necessary taking climatic
conditions into account) for use without risk of overturning, falling or unexpected movement.
If the shape of the machinery itself or its intended installation does not offer sufficient stability, appropriate means of anchorage must be incorporated and indicated in the instructions.
Risk of break-up during operation.
The various parts of machinery and their linkages must be able to withstand the stresses to
which they are subject when used as foreseen by the manufacturer. The durability of the
materials used must be adequate for the nature of the workplace foreseen by the manufacturer, in particular as regards the phenomena of fatigue, ageing, corrosion and abrasion.
The manufacturer must indicate in the instructions the type and frequency of inspection and
maintenance required for safety reasons. He must, where appropriate, indicate the parts
subject to wear and the criteria for replacement. Where a risk of rupture or disintegration
remains, despite the measures taken (e.g. as with grinding wheels) the moving parts must
be mounted and positioned in such a way that in case of rupture, their fragments will be contained.

Both rigid and flexible pipes carrying fluids, particularly those under high pressure, must be
able to withstand the foreseen internal and external stresses and must be firmly attached
and/or protected against all manner of external stresses and strains; precautions must be
taken to ensure that no risk is posed by a rupture (sudden movement, high pressure jets,
etc).
Where the material to be processed is fed to the tool automatically, the following
conditions must be fulfilled to avoid risks to the persons exposed (e.g. tool breakage):

When the work piece comes into contact with the tool the latter must have attained
its normal working conditions.
When the tool starts and/or stops (intentionally or accidentally), the feed movement
and the tool movement must be coordinated.

Risks due to falling or ejected objects.

Precautions must be taken to prevent risks from falling or ejected objects (e.g. work pieces,
tools, cuttings, fragments, waste, etc).
Risks due to surfaces, edges or angles.
In so far as their purpose allows, accessible parts of the machinery must have no sharp
edges, no sharp angles and no rough surfaces likely to cause injury.
Risks related to combined machinery.
Where the machinery is intended to carry out several different operations with the manual
removal of the piece between each operation (combined machinery), it must be designed
and constructed in such a way as to enable each element to be used separately without the
other elements constituting a danger or risk for the exposed person. For this purpose, it
must be possible to start and stop separately any elements that are not protected.
Risks relating to variations in the rotational speed of tools.
When the machine is designed to perform operations under different conditions of use (e.g.
different speeds or energy supply), it must be designed and constructed in such a way that
selection and adjustment of these conditions can be carried out safely and reliably.
Prevention of risks related to moving parts.
The moving parts of machinery must be designed, built and laid out to avoid hazards or,
where hazards persist, fixed with guards or protective devices in such a way as to prevent
all risk of contact which could lead to accidents. All necessary steps must be taken to
prevent accidental blockage of moving parts involved in the work.
In cases where, despite the precautions taken, a blockage is likely to occur, specific
protection devices or tools, the instruction handbook and possibly a sign on the machinery
should be provided by the manufacturer to enable the equipment to be safely unblocked.
Choice of protection against risks related to moving parts.
Guards or protection devices used to protect against the risks related to moving parts must
be selected on the basis of the type of risk.

2.11 - Required characteristics of guards and protection devices.

General requirement

Guards and protection devices must:

be of robust construction;
not give rise to any additional risk;
not be easy to bypass or render non-operational;
be located at an adequate distance from the danger zone;
cause minimum obstruction to the view of the production process;
enable essential work to be carried out on installation and/or replacement of tools
and also for maintenance by restricting access only to the area where the work has
to be done, if possible without the guard or protection device having to be dismantled.

2.12 - Protection against other hazards.

Electricity supply.
Where machinery has an electricity supply, it must be designed, constructed and equipped
so that all hazards of an electrical nature are, or can be, prevented. The specific rules in
force relating to electrical equipment designed for use within certain voltage limits must apply to machinery which is subject to those limits.
Static electricity.
Machinery must be so designed and constructed as to prevent or limit the build-up of potentially dangerous electrostatic charges and/or be fitted with a discharging system.
Energy supply other than electricity.
Where machinery is powered by energy other than electricity (e.g. hydraulic, pneumatic or
thermal energy, etc), it must be so designed, constructed and equipped as to avoid all potential hazards associated with these types of energy.
Errors of fitting.
Errors likely to be made when fitting or refitting certain parts which could be a source of risk
must be made impossible by the design of such parts or, failing this, by information given on
the parts themselves and/or the housings. The same information must be given on moving
parts and/or their housings where the direction of movement must be known to avoid a risk.
Any further information that may be necessary must be given in the instructions. Where a
faulty connection can be the source of risk, incorrect fluid connections, including electrical
conductors, must be made impossible by the design or, failing this, by information given on
the pipes, cables, etc and/or connector blocks.
Extreme temperatures.
Steps must be taken to eliminate any risk of injury caused by contact with, or proximity to,
machinery parts or materials at high or very low temperatures. The risk of hot or very cold
material being ejected should be assessed. Where this risk exists, the necessary steps must
be taken to prevent it or, if this is not technically possible, to render it non- dangerous.
Fire.
Machinery must be designed and constructed to avoid all risk of fire or overheating posed by
the machinery itself or by gases, liquids, dusts, vapours or other substances produced or
used by the machinery.
Explosion.
Machinery must be designed and constructed to avoid any risk of explosion posed by the
machinery itself or by gases, liquids, dusts, vapours or other substances produced or used

by the machinery. To that end the manufacturer must take steps to:

avoid a dangerous concentration of products;

prevent combustion of the potentially explosive atmosphere;
minimise any explosion which may occur so that it does not endanger the surroundings.

The same precautions must be taken if the manufacturer foresees the use of the machinery
in a potentially explosive atmosphere. Electrical equipment forming part of the machinery
must conform, as far as the risk from explosion is concerned, to the provision of the specific
Directives in force.
Noise.
Machinery must be so designed and constructed that risks resulting from the emission of
airborne noise are reduced to the lowest level, taking account of technical progress and the
availability of means of reducing noise, in particular at source.
Vibration.
Machinery must be so designed and constructed that risks resulting from vibrations
produced by the machinery are reduced to the lowest level, taking account of technical
progress and the availability of means of reducing vibration, in particular at source.
Radiation.
Machinery must be so designed and constructed that any emission of radiation is limited to
the extent necessary for its operation, and that the effects on exposed persons are
nonexistent or reduced to non-dangerous proportions.
External radiation.
Machinery must be so designed and constructed that external radiation does not interfere
with its operation.
Laser equipment.
Where laser equipment is used, the following provisions should be taken into account:

Laser equipment on machinery must be designed and constructed so as to prevent

any accidental radiation.
Laser equipment on machinery must be protected so that effective radiation, radiation produced by reflection or diffusion and secondary radiation do not damage
health.
Optical equipment for the observation or adjustment of laser equipment on machinery must be such that no health risk is created by the laser rays.

Emissions of dust, gases, etc.

Machinery must be so designed, constructed and/or equipped that risks due to gases,
liquids, dust, vapours and other waste materials which it produces can be avoided. Where a
hazard exists, the machinery must be so equipped that the said substances can be
contained and/or evacuated. Where machinery is not enclosed during normal operation, the
devices for containment and/or evacuation must be situated as close as possible to the
source of the emission.

2.13 - Maintenance.
Machinery maintenance.

Adjustment, lubrication and maintenance points must be located outside danger zones. It
must be possible to carry out adjustment, maintenance, repair, cleaning and servicing
operations while machinery is at a standstill. If one or more of the above conditions cannot
be satisfied for technical reasons, these operations must be possible without risk. In the
case of automated machinery and, where necessary, other machinery, the manufacturer
must make provision for a connecting device for mounting diagnostic fault-finding
equipment. Automated machine components which have to be changed frequently, in
particular for a change in manufacture or where they are liable to wear or likely to deteriorate
following an accident, must be capable of being removed and replaced easily and in safety.
Access to the components must enable these tasks to be carried out with the necessary
technical means (tools, measuring instruments, etc) in accordance with an operating method
specified by the manufacturer.
Access to operating position and servicing points.
The manufacturer must provide means of access (stairs, ladders, catwalks, etc) to allow
access in safety to all areas used for production, adjustment and maintenance operations.
Parts of the machinery where persons are liable to move about or stand must be designed
and constructed to avoid falls.
Isolation of energy sources.
All machinery must be fitted with means to isolate it from all energy sources. Such isolators
must be clearly identified. They must be capable of being locked if reconnection could
endanger exposed persons. In the case of machinery supplied with electricity through a plug
capable of being plugged into a circuit, separation of the plug is sufficient. The isolator must
also be capable of being locked where an operator is unable, from any of the points to which
he has access, to check that the energy is still cut off. After the energy is cut off, it must be
possible to dissipate normally any energy remaining or stored in the circuits of the
machinery without risk to exposed persons. As an exception to the above requirements,
certain circuits may remain connected to their energy sources in order, for example, to hold
parts, protect information, light interiors, etc. In this case, special steps must be taken to
ensure operator safety.
Operator intervention.
Machinery must be so designed, constructed and equipped that the need for operator
intervention is limited. If operator intervention cannot be avoided, it must be possible to carry
it out easily and in safety.
Cleaning of internal parts.
The machinery must be designed and constructed in such a way that it is possible to clean
internal parts which have contained dangerous substances or preparations without entering
them; any necessary unblocking must also be possible from the outside. If it is absolutely
impossible to avoid entering the machinery, the manufacturer must take steps during its
construction to allow cleaning to take place with the minimum of danger.

2.14 - Indicators.
Information devices
The information needed to control machinery must be unambiguous and easily understood.
It must not be excessive to the extent of overloading the operator. Where the health and
safety of exposed persons may be endangered by a fault in the operation of unsupervised
machinery, the machinery must be equipped to give an appropriate acoustic or light signal
as a warning.

Warning devices
Where machinery is equipped with warning devices (such as signals, etc), these must be
unambiguous and easily perceived. The operator must have facilities to check the operation
of such warning devices at all times. The requirements of the specific Directives concerning
colours and safety signals must be complied with.
Warning of residual risks
Where risks remain despite all the measures adopted or in the case of potential risks which
are not evident (e.g. electrical cabinets, radioactive sources, bleeding of a hydraulic circuit,
hazard in an unseen area, etc), the manufacturer must provide warnings. Such warnings
should preferably use readily understandable pictograms and/or be drawn up in one of the
languages of the country in which the machinery is to be used, accompanied, on request, by
the languages understood by the operators.
Marking
All machinery must be marked legibly and indelibly with the following minimum particulars:

name and address of the manufacturer;

CE mark, which includes the year of construction;
designation of series or type;
serial number, if any.

Furthermore, where the manufacturer constructs machinery intended for use in a potentially
explosive atmosphere, this must be indicated on the machinery. Machinery must also bear
full information relevant to its type and essential to its safe use (e.g. maximum speed of
certain rotating parts, maximum diameter of tools to be fitted, mass, etc). Where a machine
part must be handled during use with lifting equipment, its mass must be indicated legibly,
indelibly and unambiguously. Interchangeable equipment must bear the same information.
Instructions
All machinery must be accompanied by instructions including at least the following:

a repeat of the information with which the machinery is marked, together with any
appropriate additional information to facilitate maintenance (e.g. addresses of the
importer, repairers, etc);
workstation(s) likely to be occupied by operators;
instructions for safe:
putting into service;
use;
handling, giving the mass of the machinery and in various parts where they are regularly to be transported separately;
assembly, dismantling;
adjustment;
maintenance (servicing and repair);
where necessary, training instructions;
where necessary, the essential characteristics of tools which may be fitted to the machinery.

Where necessary, the instructions should draw attention to ways in which the machinery
should not be used.
The instructions must be drawn up by the manufacturer or his authorised representative
established in the EU in one of the languages of the country in which the machinery is to be
used and should preferably be accompanied by the same instructions drawn up in another
EU language, such as that of the country in which the manufacturer or his authorised

representative is established. By way of derogation from this requirement, the maintenance

instructions for use by the specialised personnel frequently employed by the manufacturer or
his authorised representative may be drawn up in only one of the official EU languages.
The instructions must contain the drawings and diagrams necessary for putting into service,
maintenance, inspection, checking of correct operation and, where appropriate, repair of the
machinery and all useful instructions in particular with regard to safety.

2.15 - Additional essential health and safety requirements for certain categories of
machinery.
Agri-foodstuffs machinery.
In addition to the essential health and safety requirements set out previously, where machinery is intended to prepare and process foodstuffs (e.g. cooking, refrigeration, thawing,
washing, handling, packaging, storage, transport or distribution), it must be so designed and
constructed as to avoid any risk of infection, sickness or contagion and the following hygiene
rules must be observed:
(a) materials in contact or intended to come into contact, with the foodstuffs must satisfy the
conditions set down in the relevant Directives. The machinery must be so designed and
constructed that these materials can be cleaned before each use;
(b) all surfaces including their joinings must be smooth, and must have neither ridges nor
crevices which could harbour organic materials;
(c) assemblies must be designed in such a way as to reduce projections, edges and recesses to a minimum. They should preferably be made by welding or continuous bonding.
Screws, screw heads and rivets may not be used except where technically unavoidable;
(d) all surfaces in contact with foodstuffs must be easily cleaned and disinfected, where possible after removing easily-dismantled parts. The inside surfaces must have curves of a radius sufficient to allow thorough cleaning;
(e) liquid deriving from foodstuffs as well as cleaning, disinfecting and rinsing fluids should
be able to be discharged from the machine without impediment (possibly in a "clean" position);
(f) machinery must be so designed and constructed as to prevent any liquids or living creatures, in particular insects, entering, or any organic matter accumulating in areas that cannot
be cleaned (e.g. for machinery not mounted on feet or casters, by placing a seal between
the machinery and its base, by the use of sealed units, etc);
(g) machinery must be so designed and constructed that no ancillary substances (e.g. lubricants, etc) can come into contact with foodstuffs. Where necessary, machinery must be designed and constructed so that continuing compliance with this requirement can be checked.
Portable hand-held and/or hand-guided machinery.
Portable hand-held and/or hand-guided machinery must conform to the following essential
health and safety requirements:

According to the type of machinery, it must have a supporting surface of sufficient

size and have a sufficient number of handles and supports of an appropriate size
and arranged to ensure the stability of the machinery under the operating conditions

foreseen by the manufacturer.

Except where technically impossible or where there is an independent control, in the
case of handles which cannot be released in complete safety, it must be fitted with
start and stop controls arranged in such a way that the operator can operate them
without releasing the handles.
It must be designed, constructed or equipped to eliminate the risks of accidental
starting and/or continued operation after the operator has released the handles.
Equivalent steps must be taken if this requirement is not technically feasible.

Portable hand-held machinery must be designed and constructed to allow, where necessary,
a visual check of the contact of the tool with the material being processed.
The instructions must give the following information concerning vibrations transmitted by
hand-held and hand-guided machinery.
The weighted root mean square acceleration value to which the arms are subjected, if it
exceeds 2.5m/s2 as determined by the appropriate test code. Where the acceleration does
not exceed 2.5m/s2, this must be mentioned. If there is no applicable test code, the
manufacturer must indicate the measurement methods and conditions under which
measurements were made.

2.16 - Machinery for working wood and analogous materials.

Machinery for working wood and machinery for working materials with physical and
technological characteristics similar to those of wood, such as cork, bone, hardened rubber,
hardened plastic material and other similar stiff material must conform to the following
essential health and safety requirements:
(a) the machinery must be designed, constructed or equipped so that the piece being
machined can be placed and guided in safety; where the piece is hand-held on a workbench, the latter must be sufficiently stable during the work and must not impede the
movement of the piece;
(b) where the machinery is likely to be used in conditions involving the risk of ejection of
pieces of wood, it must be designed, constructed or equipped to eliminate this ejection, or, if
this is not the case, so that the ejection does not engender risks for the operator and/or
exposed persons;
(c) the machinery must be equipped with an automatic brake that stops the tool in a
sufficiently short time if there is a risk of contact with the tool whilst it runs down;
(d) where the tool is incorporated into a non-fully automated machine, the latter must be so
designed and constructed as to eliminate or reduce the risk of serious accidental injury, for
example by using cylindrical cutter blocks, restricting depth of cut, etc.

2.17 - Essential health and safety requirements to offset the particular hazards due to
the mobility of machinery.
Machinery presenting hazards due to mobility must be designed and constructed to meet
the requirements below. Risks due to mobility always exist in the case of machinery which is
self-propelled, towed or pushed or carried by other machinery or tractors, is operated in
working areas and whose operations requires either mobility while working, be it continuous

or semi-continuous movement, between a succession of fixed working positions.

Risks due to mobility may also exist in the case of machinery operated without being moved,
but equipped in such a way as to enable it to be moved more easily from one place to another (machinery fitted with wheels, rollers, runners, etc. or placed on gantries, trolleys, etc).
In order to verify that rotary cultivators and power harrows do not present unacceptable risks
to the exposed persons, the manufacturer or his authorised representative must, for each
type of machinery concerned, perform the appropriate tests or have such tests performed.
Definition.
"Driver" means an operator responsible for the movement of machinery. The driver may be
transported by the machinery or may be on foot, accompanying the machinery, or may be
guiding the machinery by remote control (cables, radio, etc).
Lighting.
If intended by the manufacturer to be used in dark places, self-propelled machinery must be
fitted with a lighting device appropriate to the work to be carried out, without prejudice to any
other regulations applicable (road traffic regulations, navigation rules, etc).
Design of machinery to facilitate its handling.
During the handling of the machine and/or its parts, there must be no possibility of sudden
movements or of hazards due to instability as long as the machine and/or its parts are handled in accordance with the manufacturer's instructions.
Work stations.
The driving position must be designed with due regard to ergonomic principles. There may
be two or more driving positions and, in such cases, each driving position must be provided
with all the requisite controls. Where there is more than one driving position, the machinery
must be designed so that the use of one of them precludes the use of the others, except in
emergency stops. Visibility from the driving position must be such that the driver can, in
complete safety for himself and the exposed persons, operate the machinery and its tools in
their intended conditions of use.
Where necessary, appropriate devices must be provided to remedy hazards due to inadequate direct vision. Machinery must be so designed and constructed that, from the driving
position, there can be no risk to the driver and operators on board from inadvertent contact
with the wheels or tracks.
The driving position must be designed and constructed so as to avoid any health risk due to
exhaust gases and/or lack of oxygen. The driving position of ride-on drivers must be so designed and constructed that a driver's cab may be fitted as long as there is room. In that
case, the cab must incorporate a place for the instructions needed for the driver and/or operators. The driving position must be fitted with an adequate cab where there is a hazard
due to a dangerous environment.
Where the machinery is fitted with a cab, this must be designed, constructed and/or
equipped to ensure that the driver has good operating conditions and is protected against
any hazards that might exist (for instance: inadequate heating and ventilation, inadequate
visibility, excessive noise and vibration, falling objects, penetration by objects, rolling over,
etc). The exit must allow rapid evacuation. Moreover, an emergency exit must be provided in
a direction which is different from the usual exit. The materials used for the cab and its fittings must be fire-resistant.
Seating.
The driving seat of any machinery must enable the driver to maintain a stable position and
be designed with due regard to ergonomic principles. The seat must be designed to reduce

vibrations transmitted to the driver to the lowest level that can be reasonably achieved. The
seat mountings must withstand all stresses to which they can be subjected, notably in the
event of rollover.
Where there is no floor beneath the driver's feet, the driver must have footrests covered with
a slip-resistant material. Where machinery is fitted with provision for a rollover protection
structure, the seat must be equipped with a safety belt or equivalent device which keeps the
driver in his seat without restricting any movements necessary for driving or any movements
caused by the suspension.
Other places.
If the conditions of use provide that operators other than the driver are occasionally or regularly transported by the machinery, or work on it, appropriate places must be provided which
enable them to be transported or to work on it without risk, particularly the risk of falling.
Where the working conditions so permit, these work places must be equipped with seats.
Should the driving position have to be fitted with a cab, the other places must also be protected against the hazards which justified the protection of the driving position.
Controls.
The driver must be able to actuate all control devices required to operate the machinery
from the driving position, except for functions which can be safely activated only by using
control devices located away from the driving position. This refers in particular to working
positions other than the driving position, for which operators other than the driver are responsible or for which the driver has to leave his driving position in order to carry out the
manoeuvre in safety. Where there are pedals, they must be so designed, constructed and
fitted to allow operation by the driver in safety with the minimum risk of confusion; they must
have a slip-resistant surface and be easy to clean.
Where their operation can lead to hazards, notably dangerous movements, the machinery's
controls, except for those with preset positions, must return to the neutral position as soon
as they are released by the operator. In the case of wheeled machinery, the steering system
must be designed and constructed to reduce the force of sudden movements of the steering
lever caused by shocks to the guide wheels.
Any control that locks the differential must be so designed and arranged that it allows the
differential to be unlocked when the machinery is moving.
Starting/moving.
Self-propelled machinery with a ride-on driver must be so equipped as to deter unauthorised
persons from starting the engine. Travel movements of self-propelled machinery with a rideon driver must be possible only if the driver is at the controls.
Where, for operating purposes, machinery must be fitted with devices which exceed its normal clearance zone (e.g. stabilisers, jib, etc), the driver must be provided with the means of
checking easily, before moving the machinery, that such devices are in a particular position
which allows safe movement. This also applies to all other parts which, to allow safe movement, have to be in particular positions, locked if necessary.
Where it is technically and economically feasible, movement of the machinery must depend
on safe positioning of the aforementioned parts. It must not be possible for movement of the
machinery to occur while the engine is being started.
Travelling function.
Without prejudice to the provisions of road traffic regulations, self-propelled machinery and
its trailers must meet the requirements for slowing down, stopping, braking and immobilisa-

tion so as to ensure safety under all the operating, loading, speed, ground and gradient
conditions allowed for by the manufacturer and corresponding to conditions encountered in
normal use. The driver must be able to slow down and stop self-propelled machinery by
means of a main device.
Where safety so requires in the event of a failure of the main device, or in the absence of the
energy supply to actuate the main device, an emergency device with fully-independent and
easily-accessible controls must be provided for slowing down and stopping.
Where safety so requires, a parking device must be provided to render stationary machinery
immobile. This device may be combined with one of the devices referred to in the second
paragraph, provided that it is purely mechanical. Remote-controlled machinery must be designed and constructed to stop automatically if the driver loses control.
Movement of pedestrian-controlled machinery.
Movement of pedestrian-controlled self-propelled machinery must be possible only through
sustained action on the relevant control by the driver. In particular, it must not be possible for
movement to occur while the engine is being started. The control systems for pedestriancontrolled machinery must be designed to minimise the hazards arising from inadvertent
movement of the machine towards the driver, in particular crushing or injury from rotating
tools.
Also, the speed of normal travel of the machine must be compatible with the pace of a driver
on foot. In the case of machinery on which a rotary tool may be fitted, it must not be possible
to actuate that tool when the reversing control is engaged, except where movement of the
machinery results from movement of the tool. In the latter case, the reversing speed must be
such that it does not endanger the driver.
Control circuit failure.
A failure in the power supply to the power-assisted steering, where fitted, must not prevent
machinery from being steered during the time required to stop it.

2.18 - Protection against mechanical hazards.

Uncontrolled movements.
When a part of a machine has been stopped, any drift away from the stopping position, for
whatever reason other than action at the controls, must be such that it is not a hazard to exposed persons. Machinery must be so designed, constructed and where appropriate placed
on its mobile support as to ensure that when moved, the uncontrolled oscillations of its centre of gravity do not affect its stability or exert excessive strain on its structure.
Risk of break-up during operation.
Parts of machinery rotating at high speed which, despite the measures taken, may break up
or disintegrate, must be mounted and guarded in such a way that, in case of breakage, their
fragments will be contained or, if that is not possible, cannot be projected towards the driving
and/or operation positions.
Rollover.
Where, in the case of self-propelled machinery with a ride-on driver and possibly ride-on operators, there is a risk of rolling over, the machinery must be designed for and be fitted with
anchorage points allowing it to be equipped with a rollover protective structure (ROPS). This
structure must be such that in case of rolling over, it affords the ride-on driver and where appropriate, the ride-on operators an adequate deflection-limiting volume (DLV). In order to
verify that the structure complies with the requirement laid down in the second paragraph,

the manufacturer or his authorised representative must, for each type of structure concerned, perform appropriate test or have such tests performed. In addition, the earth-moving
machinery listed below with a capacity exceeding 15kW must be fitted with a rollover protective structure:

Crawler loaders or wheel loaders.

Backhoe loaders.
Crawler tractors or wheel tractors.
Scrapers, self-loading or not.
Graders.
Articulated steer dumpers.

Falling objects.
Where, in the case of machinery with a ride-on driver and possibly ride-on operators, there
is a risk due to falling objects or material, the machinery should be designed for, and fitted
with, if its size allows, anchorage points allowing it to be equipped with a falling object
protective structure (FOPS). This structure must be such that in the case of falling objects or
material, it guarantees the ride-on operators an adequate deflection-limiting volume (DLV).
In order to verify that the structure complies with the requirement laid down in the second
paragraph, the manufacturer or his authorised representative must, for each type of
structure concerned, perform appropriate tests or have such tests performed.
Means of access.
Handholds and steps must be designed, constructed and arranged in such a way that the
operators use them instinctively and do not use the controls for that purpose.
Towing devices.
All machinery used to tow or to be towed must be fitted with towing or coupling devices
designed, constructed and arranged to ensure easy and safe connection and disconnection,
and to prevent accidental disconnection during use. In so far as the tow-bar load requires,
such machinery must be equipped with a support, with a bearing surface suited to the load
and the ground.
Transmission of power between self-propelled machinery (or tractor) and recipient
machinery.
Transmission shafts with universal joints linking self-propelled machinery (or tractor) to the
first fixed bearing of recipient machinery must be guarded on the self-propelled machinery
side and the recipient machinery side over the whole length of the shaft and associated
universal joints. On the side of the self-propelled machinery (or tractor), the power take-off to
which the transmission shaft is attached must be guarded either by a screen fixed to the
self-propelled machinery (or tractor) or by any other device offering equivalent protection.
On the towed machinery side, the input shaft must be enclosed in a protective casing fixed
to the machinery. Torque limiters or free wheels may be fitted to universal joint transmissions
only on the side adjoining the driven machine. The universal-joint transmission shaft must be
marked accordingly.
All towed machinery whose operation requires a transmission shaft to connect it to selfpropelled machinery or a tractor must have a system for attaching the transmission shaft so
that when the machinery is uncoupled, the transmission shaft and its guard are not
damaged by contact with the ground or part of the machinery. The outside parts of the guard
must be so designed, constructed and arranged that they cannot turn with the transmission
shaft. The guard must cover the transmission shaft to the ends of the inner jaws in the case
of simple universal joints, and at least to the centre of the outer joint or joints in the case of
"wide-angle" universal joints. Manufacturers providing means of access to working positions
near to the universal joint transmission shaft must ensure that shaft guards as described in

the sixth paragraph cannot be used as steps unless designed and constructed for that
purpose.
Moving transmission parts.
In the case of internal combustion engines, removable guards preventing access to the
moving parts in the engine compartment need not have locking devices if they have to be
opened either by the use of a tool or key or by a control located in the driving position if the
latter is in a fully enclosed cab with a lock to prevent unauthorised access.

2.19 - Protection against other hazards.

Batteries.
The battery housing must be constructed and located and the battery installed so as to
avoid, as far as possible, the chance of electrolyte being ejected on to the operator in the
event of rollover and/or to avoid the accumulation of vapours in places occupied by operators. Machinery must be so designed and constructed that the battery can be disconnected
with the aid of an easily-accessible device provided for that purpose.
Fire.
Depending on the hazards anticipated by the manufacturer when in use, machinery must,
where its size permits:

either allow easily accessible fire extinguishers to be fitted; or

be provided with built-in extinguisher systems.

Emissions of dust, gases, etc.

Signs and warning.
Machinery must have means of signalling and/or instruction plates concerning use,
adjustment and maintenance, wherever necessary, to ensure the health and safety of
exposed persons. They must be chosen, designed and constructed in such a way as to be
clearly visible and indelible.
Without prejudice to the requirements to be observed for travelling on the public
highway, machinery with a ride-on driver must have the following equipment:

an acoustic warning device to alert exposed persons;

a system of light signals relevant to the intended conditions of use such as stop
lamps, reversing lamps and rotating beacons.

The latter requirement does not apply to machinery intended solely for underground working
and having no electrical power.
Remote-controlled machinery which, under normal conditions of use, exposes persons to
the hazards of impact or crushing must be fitted with appropriate means to signal its
movements or with means to protect exposed persons against such hazards.
The same applies to machinery which involves, when in use, the constant repetition of a
forward and backward movement on a single axis where the back of the machine is not
directly visible to the driver. Machinery must be so constructed that the warning and
signalling devices cannot all be disabled unintentionally. Where this is essential for safety,
such devices must be provided with the means to check that they are in good working order
and their failure must be made apparent to the operator.

Where the movement of machinery or its tools is particularly hazardous, signs on the
machinery must be provided to warn against approaching the machinery while it is working;
the signs must be legible at a sufficient distance to ensure the safety of persons who have to
be in the vicinity.
Marking.
The minimum requirements must be supplemented by the following:

nominal power expressed in kW;

mass in kg of the most usual configuration and, where appropriate:
maximum drawbar pull provided for by the manufacturer at the coupling hook;
maximum vertical load provided for by the manufacturer on the coupling hook.

Instruction handbook.
Apart from the minimum requirements already explained, the instruction handbook must
contain the following information:
(a) regarding the vibrations emitted by the machinery, either the actual value or a figure
calculated from measurements performed on identical machinery:

the weighted root mean square acceleration value to which the arms are subjected, if
it exceeds 2.5 m/s2; should it not exceed 2.5 m/s2, this must be mentioned;
the weighted root mean square acceleration value to which the body (feet or posterior) is subjected if it exceeds 0.5 m/s2; should it not exceed 0.5 m/s2, this must be
mentioned.

Where the harmonised standards are not applied, the vibration must be measured using the
most appropriate methods for the machinery concerned. The manufacturer must indicate the
operating conditions of the machinery during measurement and which methods were used
for taking the measurements;
(b) in the case of machinery allowing several uses depending on the equipment used,
manufacturers of basic machinery to which interchangeable equipment may be attached and
manufacturers of the interchangeable equipment must provide the necessary information to
enable the equipment to be fitted and used safely.

2.20 - Essential health and safety requirements to offset the particular hazards due to
a lifting operation.
Definitions.
(a) "lifting accessories" means components or equipment not attached to the machine and
placed between the machinery and the load or on the load in order to attach it;
(b) "separate lifting accessories" means accessories which help to make up or use a slinging
device, such as eyehooks, shackles, rings, eyebolts, etc;
(c) "guided load" means the load where the total movement is made along rigid or flexible
guides, whose position is determined by fixed points;
(d) "working coefficient" means the arithmetic ratio between the load guaranteed by the
manufacturer up to which a piece of equipment, and accessory or machinery is able to hold
it and the maximum working load marked on the equipment, accessory or machinery
respectively;

(e) "test coefficient" means the arithmetic ratio between the load used to carry out the static
or dynamic tests on a piece of equipment, an accessory or machinery and the maximum
working load marked on the piece of equipment, accessory or machinery;
(f) "static test" means the test during which the machinery or the lifting accessory is first
inspected and then subjected to a force corresponding to the maximum working load
multiplied by the appropriate static test coefficient, and then re-inspected once the said load
has been released to ensure no damage has occurred;
(g) "dynamic test" means the test during which the machinery is operated in all its possible
configurations at maximum working load with account being taken of the dynamic behaviour
of the machinery in order to check that the machinery and safety features are functioning
properly.
Protection against mechanical hazards.
Risks due to lack of stability.
Machinery must be so designed and constructed that stability is maintained both in service
and out of service, including all stages of transportation, assembly and dismantling, during
foreseeable component failures and also during the tests carried out in accordance with the
instruction handbook. To that end, the manufacturer or his authorised representative must
use the appropriate verification methods; in particular, for self-propelled industrial trucks with
lift exceeding 1.80 m, the manufacturer or his authorised representative must, for each type
of industrial truck concerned, perform a platform stability test or similar test, or have such
tests performed.
Machinery must be provided with devices which act on the guide rails or tracks to prevent
derailment. However, if derailment occurs despite such devices, or if there is a failure of a
rail or a running component, devices must be provided which prevent the equipment,
component or load from falling or the machine overturning.
Mechanical strength.
Machinery, lifting accessories and removable components must be capable of withstanding
the stresses to which they are subjected, both in and, where applicable, out of use, under
the installation and operating conditions provided for by the manufacturer, and in all relevant
configurations, with due regard, where appropriate, to the effects of atmospheric factors and
forces exerted by persons.
This requirement must also be satisfied during transport, assembly and dismantling.
Machinery and lifting accessories must be designed and constructed so as to prevent failure
from fatigue or wear, taking due account of their intended use. The materials used must be
chosen on the basis of the working environments provided for by the manufacturer, with
special reference to corrosion, abrasion, impacts, cold brittleness and ageing.
The machinery and the lifting accessories must be designed and constructed to withstand
the overload in the static tests without permanent deformation or patent defect.
Pulleys, drums, chains or ropes.
Pulleys, drums and wheels must have a diameter commensurate with the size of rope or
chains with which they can be fitted. Drums and wheels must be so designed, constructed
and installed that the ropes or chains with which they are equipped can wind round without
falling off. Ropes used directly for lifting or supporting the load must not include any splicing
other than at their ends (splicings are tolerated in installations which are intended from their
design to be modified regularly according to needs for use).

Complete ropes and their endings have a working coefficient chosen so as to guarantee an
adequate level of safety; as a general rule, this coefficient is equal to five. Lifting chains
have a working coefficient chosen so as to guarantee an adequate level of safety; as a
general rule, this coefficient is equal to four. In order to verify that an adequate working
coefficient has been attained, the manufacturer or his authorised representative must, for
each type of chain and rope used directly for lifting the load, and for the rope ends, perform
the appropriate tests or have such tests performed.
Separate lifting accessories.
Lifting accessories must be sized with due regard to fatigue and ageing processes for a
number of operating cycles consistent with their expected life-span as specified in the
operating conditions for a given application.
Moreover:
(a) the working coefficient of the metallic rope/rope end combination is chosen so as to
guarantee an adequate level of safety; this coefficient is, as a general rule, equal to five.
Ropes must not comprise any splices or loops other than at their ends;
(b) where chains with welded links are used, they must be of the short link type. The working
coefficient of chains of any type is chosen so as to guarantee an adequate level of safety;
this coefficient is, as a general rule, equal to four;
(c) the working coefficient for textile ropes or slings is dependent on the material, method of
manufacture, dimensions and use. This coefficient is chosen so as to guarantee an
adequate level of safety; it is, as a general rule, equal to seven, provided the materials used
are shown to be of very good quality and the method of manufacture is appropriate to the
intended use. Should this not be the case, the coefficient is, as a general rule, set at a
higher level in order to secure an equivalent level of safety. Textile ropes and slings must not
include any knots, connections or splicing other than at the ends of the sling, except in the
case of an endless sling;
(d) all metallic components making up, or used with, a sling must have a working coefficient
chosen as to guarantee an adequate level of safety; this coefficient is, as a general rule,
equal to four;
(e) the maximum working capacity of a multi-legged sling is determined on the basis of the
safety coefficient of the weakest leg, the number of legs and a reduction factor which
depends on the slinging configuration;
(f) in order to verify that an adequate working coefficient has been attained, the
manufacturer or his authorised representative must, for each type of component referred to
in (a), (b), (c) and (d) perform the appropriate tests or have such tests performed.
Control of movements.
Devices for controlling movements must act in such a way that the machinery on which they
are installed is kept safe:
(a) machinery must be so designed or fitted with devices that the amplitude of movement of
its components is kept within the specified limits. The operation of such devices must, where
appropriate, be preceded by a warning;
(b) where several fixed or rail-mounted machines can be manoeuvred simultaneously in the
same place, with risks of collision, such machines must be so designed and constructed as
to make it possible to fit systems enabling these risks to be avoided;
(c) the mechanisms of machinery must be so designed and constructed that the loads

cannot creep dangerously or fall freely and unexpectedly, even in the event of partial or total
failure of the power supply or when the operator stops operating the machine;
(d) it must not be possible, under normal operating conditions, to lower the load solely by
friction brake, except in the case of machinery, whose function requires it to operate in that
way;
(e) holding devices must be so designed and constructed that inadvertent dropping of the
loads is avoided.
Handling of loads.
The driving position of machinery must be located in such a way as to ensure that widest
possible view of trajectories of the moving parts, in order to avoid possible collisions with
persons or equipment or other machinery which might be manoeuvring at the same time and
liable to constitute a hazard. Machinery with guided loads fixed in one place must be
designed and constructed so as to prevent exposed persons from being hit by the load or
the counter-weights.
Lightning.
Machinery in need of protection against the effects of lightning while being used must be
fitted with a system for conducting the resultant electrical charges to earth.

2.21 - Essential health and safety requirements for machinery intended solely for
underground work.
Risks due to lack of stability.
Powered roof supports must be so designed and constructed as to maintain a given direction when moving and not slip before and while they come under load and after the load has
been removed. They must be equipped with anchorages for the top plates of the individual
hydraulic props.
Movement.
Powered roof supports must allow for unhindered movement of exposed persons.
Control devices.
The accelerator and brake controls for the movement of machinery running on rails must be
manual. The deadman's control may be foot-operated, however. The control devices of
powered roof supports must be designed and laid out so that, during displacement operations, operators are sheltered by a support in place. The control devices must be protected
against any accidental release.
Stopping.
Self-propelled machinery running on rails for use in underground work must be equipped
with a deadman's control acting on the circuit controlling the movement of the machinery.
Fire.
The braking system of machinery meant for use in underground working must be designed
and constructed so as not to produce sparks or cause fires. Machinery with heat engines for
use in underground working must be fitted only with internal combustion engines using fuel
with a low vaporising pressure and which exclude any spark of electrical origin.

2.22 - Ergonomic, Anthropometric & Human Reliability Considerations.

Controls should meet the criteria that are laid down in Schedule 3 of the Supply of Machinery (Safety) Regulations 1992. This says that they must be:

Clearly visible.
Appropriately marked.
Positioned for safe operation.
Designed so that movement of the control is consistent with the effect required.
Located outside the danger zone, except for certain controls, e.g. emergency stop.
Positioned so that their operation cannot cause additional risk.
Designed to prevent unintentional operation.
Made to withstand foreseeable strain, particularly emergency controls.
Fitted with dials, etc. if required for safe operation.
Starting of the machine can only be by means of the control, particularly after adverse conditions, e.g. a power cut.
Stopping devices to be fitted.
Emergency stopping devices to be fitted, clearly marked and to work effectively.
The control must override any part of the system except the emergency control.
Any fault or failure must not lead to danger.
Interactive software must be user-friendly to the operator.

The following is a list (not exhaustive) of control characteristics:

Displacement.
Operating force.
Friction, inertia or drag.
Number of positions.
Direction of movement.
Predetermined stops (detents).
Appropriate identification.
Compatibility with displays.
Size.

Location is also an important factor and the following should be considered:

Minimise the number of controls; the fewer there are, the less chance of the wrong
one being operated.
Arrange them to encourage a range of postures for the operator, thus allowing
movement to keep the body "fresh".
Arrange them so that the sequence of operations is in an arc, so that the control layout is representative of the process.
Where large forces are required to be exerted, use foot pedals or have power assistance.
Have a clear distinction between normal and emergency controls.
Keep consistent groupings of displays and controls; ideally the display should be
above the control.
Prevent accidental operation by recessing or shielding the control or by distance to
prevent them being knocked by an elbow, etc.

Selection of appropriate controls is therefore vital and the following table is of particular use:
Control Type Use at Speed Accuracy

Mounting
Space Required

Ease of Use
in an Array

Ease to
Check
Reading in

Array
toggle switch good

good

small

good

good

rotary switch good

good

small

good

fair

push button

very good

very poor

small

good

poor

rotary
selector

good

good

medium

good

good

knob

fair

fair

small-medium poor

good

hand wheel

poor

good

large

poor

poor

crank

fair

poor

medium-large poor

poor

lever

good

fair

large

good

good

foot pedal

good

poor

large

poor

poor

'Table 1'

2.23 - PUWER 1998 also lays down the following criteria.

Regulation 14 : Controls for starting or making a significant change in operating conditions.
It should only be possible to start the equipment by using appropriate controls. Operating the
control need not necessarily immediately start the equipment as control systems may require certain conditions (for example, those relating to operation or protection devices) to be
met before starting can be achieved.
Restarting the equipment after any stoppage is subject to the same requirements. The stoppage may have been deliberate or may have happened, for example, by the activation of a
protection device. You should not normally be able to restart the equipment simply by resetting a protection device such as, for example, an interlock or a person's withdrawal from
an area covered by a sensing device - operation of the start control should also be required.
Any change in the operating conditions of the equipment should only be possible by the use
of a control unless the change does not increase risks to health and safety. Examples of operating conditions include speed, pressure, temperature and power. For example, certain
multifunctional machines are used in the metal-working industry for punching or shearing
metal using different tools located on different parts of the machines. Safety in the use of
these machines is achieved by means of a combination of safe systems of work and physical safeguards which match the characteristics of the work piece. It is essential that the
function of the machine (for example punching or shearing) is changed by a conscious, positive action by the operator and that unused parts of the machine cannot start up unintentionally.
The start control can be separate, combined with controls for operating conditions, or more
than one of each type of control can be provided. The controls can be combined with stop
controls as required by regulation 15 but not with an emergency stop control provided in accordance with regulation 16. 'Hold-to-run' devices are examples of combined stop and start
controls. These should be designed so that the stop function has priority following the release of the control. The controls provided should be designed and positioned so as to prevent, so far as possible, inadvertent or accidental operation. Buttons or levers, for example,
should have an appropriate shrouding or locking facility. It should not be possible for the
control to 'operate itself, for example due to the effects of gravity, vibration or failure of a
spring mechanism. Starting that is initiated from a keyboard or other multifunction device

should require some form of confirmation in addition to the start command. Furthermore, the
results of the actuation should be displayed
Reg 15: Stop controls.
Regulation 15(1) requires that the action of the stop control should bring the equipment to a
safe condition in a safe manner. This acknowledges that it is not always desirable to bring all
items of work equipment immediately to a complete stop if this could result in other risks. For
example, stopping the mixing mechanism of a reactor during certain chemical reactions
could lead to a dangerous exothermic reaction.
The stop control does not have to be instantaneous in its action and can bring the equipment to rest in sequence or at the end of an operating cycle if this is required for safety. This
may be necessary in some processes, for example to prevent the unsafe build-up of heat or
pressure or to allow a controlled run-down of large rotating parts with high inertia.
Regulation 15(2) is qualified by 'where necessary for reasons of health and safety'. Therefore, all accessible dangerous parts must be rendered stationary which may mean they need
to be locked into position and may be allowed to idle. However, parts of equipment which do
not present a risk, such as suitably guarded cooling fans, do not need to be positively
stopped.
Regulation 15(3) requires that the control should switch off all sources of energy from the
equipment after it has stopped, if this is necessary to prevent or minimise risk to health or
safety. Where it is necessary to retain power for production reasons and a hazard could
arise due to unexpected movement giving rise to risk of injury, control systems should be
designed so as to immediately remove the power, should such an event occur. Where internally-stored energy could lead to risk, it should be cut off by the action of the stop control.
For example, horizontal plastic injection moulding machines may store hydraulic energy in
internal hydraulic reservoirs which, under certain fault conditions, may cause uncovenanted
movements which could cause injury. In this case, the stop control should effectively isolate
or dissipate the stored energy so as to ensure safety.
The stop control should take priority over any operating or start control. Where possible, it
should not require anything other than a short manual action to activate it, even though the
stop and disconnection sequence so initiated may take some time to complete. Further information on the categories of stop function can be found in BS EN 60204-1. Although this
standard (which deals with specifications for general requirements for an individual machine)
applies to new machinery, it gives valuable guidance which may be useful for any equipment
- new or used.
Regulation 16: Emergency stop controls
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.
Where it is appropriate to have one, based on the risk assessment, you should provide an
emergency stop at every control point and at other appropriate locations around the equipment so that action can be taken quickly. The location of emergency stop controls should be
determined as a follow-up to the risk assessment required under the Management Regulations. Although it is desirable that emergency stops rapidly bring work equipment to a halt,
this must be achieved under control so as not to create any additional hazards.
As emergency stops are intended to affect a rapid response to potentially dangerous situations, they should not be used as functional stops during normal operation.
Emergency stop controls should be easily reached and actuated.

Common types are mushroom-headed buttons, bars, levers, kick-plates, or pressuresensitive cables. Guidance on specific features of emergency stops is given in national,
European and international standards.
Regulation 17: Controls.
It should be possible to identify easily what each control does and on which equipment it
takes effect. Both the controls and their markings should be clearly visible. As well as having
legible wording or symbols, factors such as the colour, shape and position of controls are
important; a combination of these can often be used to reduce ambiguity. Some controls
may need to be distinguishable by touch, for example inching buttons on printing machines.
Few controls will be adequately identifiable without marking of some sort.
The marking and form of many controls is covered by national, European and international
standards either generic or specific to the type of equipment (BS 3641, prEN 50099). However, additional marking may often be desirable.
Regulation 17(2).
Controls used in the normal running of the equipment should normally not be placed where
anybody using them might be exposed to risk. However, controls used for setting-up and
fault-finding procedures may have to be positioned where people are at some risk, for example on a robot-teaching pendant. In such cases, particular precautions should be employed to ensure safety; examples include using hold-to-run controls, enabling controls,
emergency stop controls. Further precautions include the selection of reduced/limited capability of the work equipment during such operations.
Regulation 17(3)(a).
The provisions of regulation 17(3) (a) apply where physical safeguarding methods employed
in accordance with regulation 11 (2) (a) and (b) do not completely prevent access to dangerous parts of work equipment, or where people are at risk from other aspects of the operation, e.g. noise, or harmful radiation. The preferred aim is to position controls so that operators of equipment are able to see from the control position that no-one is at risk from anything they set going. To be able to do this, operators need to have a view of any part of the
equipment that may put anyone at risk. A direct view is best, but supplementing by mirrors
or more sophisticated visual or sensing facilities may be necessary.
There will normally be little difficulty in meeting this requirement in the case of small and
compact equipment. With larger equipment, there is normally some latitude in the positioning of controls and the safety aspect should be considered in deciding their location; this
would apply, for example, on large process plant such as newspaper printing machinery or
chemical plant.
Where people are at risk from dangerous parts of machinery, normal safeguarding procedures should restrict the need for surveillance to vulnerable areas; an example would be on
large newspaper printing machines. However, where regular intervention is necessary,
which involves entry into, removal of, or opening of safeguards, for example for maintenance
purposes, interlocks or similar devices may be necessary as appropriate to prevent start-up
while people are at risk. You may need to employ additional measures to ensure that people
do not remain inside safeguards at start-up. Similarly, where sensing devices are employed
to aid surveillance, they may be interlocked with the controls so as to prevent start-up when
people are at risk.
If anyone other than the operator is also working on the equipment, they may use permissive start controls. Such controls can indicate to the operator that everyone is clear and
permit a start. These can be located at a position of safety from where they can ascertain

that no-one is at risk.

Where there is a risk other than from dangerous parts of machinery (for example noise, radiation), people at some distance from the work equipment may be affected. In such circumstances, it may not always be reasonably practicable for operators to have sight of all parts
of the work equipment, so it may be necessary to employ systems of work or warning devices. Warning devices only provide limited protection and additional measures may be required if the risks are high. For example, it would not be acceptable to rely on audible or
visible alarms where the risk is of an imminent potentially fatal dose of ionising radiation, but
they may be adequate where the risk is from noisy plant.
Regulation 17(3)(b).
If the nature of the installation is such that it is not reasonably practicable for the operator at
the control position to ensure that no one is at risk, then a system of work must be devised
and used to achieve that aim. This should implement procedures to eliminate or reduce the
probability of any workers being at risk as a result of starting-up. An example is the use of
systems using signallers; these are often used to assist crane drivers, or tractor drivers setting a manned harvester in motion.
Regulation 17(3)(c).
The warning should comply with regulation 24, i.e. it should be unambiguous, easily perceived and easily understood. Signals may be visual, audible, tactile or a combination of the
three, as appropriate.
Regulation 17(4).
Warnings given in accordance with regulation 17(3)(c) should be given sufficiently in advance of the equipment actually starting to give those at risk time to get clear or take suitable actions to prevent risks. This may take the form of a device by means of which the person at risk can prevent start-up or warn the operator of their presence.
The provisions of regulation 17 do not preclude people from remaining in positions where
they are at risk. Their aim is to prevent an operator unintentionally placing people at risk.
Regulation 11, in its hierarchical approach to safeguarding, recognises that in exceptional
circumstances people may have to approach dangerous parts of machinery, such as for
maintenance purposes. Access to such positions should only be allowed under strictly controlled conditions and in accordance with I regulation 1
Regulation 18: Control Systems.
Another way of defining a control system is:
'a system or device which responds to input signals and generates an output signal which
causes the equipment under control to operate in a particular manner.'
The input signals may be made by an operator via a manual control, or from the equipment
itself, for example from automatic sensors or protection devices (photoelectric guards, guard
interlock devices, speed limiters, etc). Signals from the equipment may also include information (feedback) on the condition of the equipment and its response (position, whether it is
running, speed).
Failure of any part of the control system or its power supply should lead to a 'fail-safe' condition. Fail-safe can also be more correctly and realistically called 'minimised failure to danger'. This should not impede the operation of the 'stop' or 'emergency stop' controls. The
measures which should be taken in the design and application of a control system to mitigate against the effects of its failure will need to be balanced against the consequences of
any failure. The greater the risk, the more resistant the control system should be to the effects of failure. Bringing a machine to a safe halt may achieve the objective. Halting a

chemical process, however, could create further hazards. Care should be taken to fully assess the consequences of such events and provide further protection, i.e. standby power
plant or diverting chemicals to a place of safety. It should always be possible to recover to a
safe condition.
There are national, European and international standards both current and in preparation
(BS EN 60204- 1, BS EN 954-1) which provide guidance on design of control systems so as
to achieve high levels of performance related to safety. Though they are aimed at new machinery, they may be used as guidance for existing work equipment

2.24 - Reducing the need for access (automation and remote systems).
Automation.
Replacing workers with automated (automatic) systems can be achieved by the use of computer which controls the work through robots, etc. This system takes away the need for the
human and with it the likelihood of human factors becoming a hazard i.e. fatigue, behaviour
etc. However, maintenance procedures and repairs are required which are also hazards.
Remote systems.
This system refers to the process where an employee or operator operates the equipment
removed from the place where the equipment is housed or located. This has the advantage
of segregating the employee from the equipment (and its hazards).

2.25 - Lighting.
Lighting is covered by Schedule 3 of the Supply of Machinery (Safety) Regulations
1999 and is stated as:

The manufacturer must supply integral lighting suitable for the operations concerned
where its lack is likely to cause a risk, despite ambient lighting of normal intensity.
The manufacturer must ensure that there is no area of shadow likely to cause nuisance, that there is no irritating dazzle and that there are no dangerous stroboscopic
effects due to lighting provided by the manufacturer.
Internal parts requiring frequent inspection and adjustment and maintenance areas
must be provided with appropriate lighting.

Lighting is also covered under regulation 21 of the PUWER 1998 which states:
"Every employer shall ensure that suitable and sufficient lighting, which takes account of the
operations to be carried out, is provided at any place where a person uses work equipment."
Further advice in the Approved Code of Practice continues with the following
guidance:

Any place where a person uses work equipment should be suitably and sufficiently
lit. If the ambient lighting provided in the workplace is suitable and sufficient for the
tasks involved in the use of the equipment, special lighting need not be provided. But
if the task involves the perception of detail, for example to comply with the regulation.
The lighting should be adequate for the needs of the task.
When the construction of the machine and/or its guards renders the normal lighting
inadequate for the safe and efficient operation of the machine, you should provide
local lighting of the work area. Local lighting may be needed to give sufficient view of

a dangerous process or to reduce visual fatigue.

You should also provide additional lighting in areas not covered by general lighting
when work, such as maintenance or repairs, is carried out on them. The arrangement for the provision of lighting could be temporary, by means of hand or other
portable lights.
Where access is foreseeable on an intermittent but regular basis, you should always
consider providing permanent lighting.

2.26 - Layout of Plant & Machinery.

Stability.
Machinery, components and fittings thereof must be so designed and constructed that they
are stable enough, under the foreseen operating conditions (if necessary taking climatic
conditions into account) for use without risk of overturning, falling or unexpected movement.
If the shape of the machinery itself or its intended installation does not offer sufficient stability, appropriate means of anchorage must be incorporated and indicated in the instructions.
Risk of break-up during operation.
The various parts of machinery and their linkages must be able to withstand the stresses to
which they are subject when used as foreseen by the manufacturer.
The durability of the materials used must be adequate for the nature of the workplace foreseen by the manufacturer, in particular as regards the phenomena of fatigue, ageing, corrosion and abrasion. The manufacturer must indicate in the instructions the type and frequency of inspection and maintenance required for safety reasons.
He must, where appropriate, indicate the parts subject to wear and the criteria for replacement. Where a risk of rupture or disintegration remains despite the measures taken (e.g. as
with grinding wheels) the moving parts must be mounted and positioned in such a way that
in case of rupture their fragments will be contained.
Both rigid and flexible pipes carrying fluids, particularly those under high pressure, must be
able to withstand the foreseen internal and external stresses and must be firmly attached
and/or protected against all manner of external stresses and strains; precautions must be
taken to ensure that no risk is posed by a rupture (sudden movement, high pressure jets,
etc).
Where the material to be processed is fed to the tool automatically, the following
conditions must be fulfilled to avoid risks to the persons exposed (e.g. tool breakage):

When the work piece comes into contact with the tool, the latter must have attained
its normal working conditions.
When the tool starts and/or stops (intentionally or accidentally) the feed movement
and the tool movement must be coordinated.

Risks due to falling or ejected objects.

Precautions must be taken to prevent risks from falling or ejected objects (e.g. work pieces,
tools, cuttings, fragments, waste, etc).
Risks due to surfaces, edges or angles
In so far as their purpose allows, accessible parts of the machinery must have no sharp
edges, no sharp angles, and no rough surfaces likely to cause injury.

Risks related to combined machinery.

Where the machinery is intended to carry out several different operations with the manual
removal of the piece between each operation (combined machinery), it must be designed
and constructed in such a way as to enable each element to be used separately without the
other elements constituting a danger or risk for the exposed person. For this purpose, it
must be possible to start and stop separately any elements that are not protected.
Risks relating to variations in the rotational speed of tools.
When the machine is designed to perform operations under different conditions of use (e.g.
different speeds or energy supply), it must be designed and constructed in such a way that
selection and adjustment of these conditions can be carried out safely and reliably.
Prevention of risks related to moving parts.
The moving parts of machinery must be designed, built and laid out to avoid hazards or,
where hazards persist, fixed with guards or protective devices in such a way as to prevent
all risk of contact which could lead to accidents. All necessary steps must be taken to
prevent accidental blockage of moving parts involved in the work. In cases where, despite
the precautions taken, a blockage is likely to occur, specific protection devices or tools, the
instruction handbook and possibly a sign on the machinery should be provided by the
manufacturer to enable the equipment to be safely unblocked.

2.27 - Training.
PUWER 1998 calls for:
(1) 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. The regulations go on to further state:
(2) 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.
What is 'adequate training'?
It is not possible to detail here what constitutes 'adequate training' as requirements will vary
according to the job or activity and work equipment etc.
In general, you will need to:

evaluate the existing competence of employees to operate the full range of work
equipment that they will use;
evaluate the competence they need to manage or supervise the use of work equipment; and
train the employee to make up any shortfall between their competence and that required to carry out the work with due regard to health and safety.
take account of the circumstances in which the employee works. For example, do
they work alone or under close supervision of a competent person?

When is training necessary?

Training needs are likely to be greatest on recruitment. However, training needs are
also required:

if the risks to which people are exposed change due to a change in their working
tasks; or
because new technology or equipment is introduced; or
if the system of work changes.

Also, you should provide refresher training if necessary. Skills decline if they are not used
regularly. Pay particular attention to people who deputise for others on occasions, as they
may need more frequent refresher training than those who do the work regularly.
Training for young people:
Training and proper supervision of young people is particularly important because of their
relative immaturity and unfamiliarity with the working environment. Induction training is of
particular importance. There are no general age restrictions in legislation relating to the use
of work equipment although there is some ACOP material in the relevant publications
dealing with lifting, power presses and wood working; all employees should be competent to
use work equipment with due regard to health and safety regardless of their age.
The Management Regulations contain specific requirements relating to the employment of
young people under the age of 18. These require employers to assess risks to young people
before they start work, taking into account their inexperience, lack of awareness of potential
risks and their immaturity. Employers must provide information to parents of school-age
children (for example when they are on work experience) about the risks and the control
measures introduced and take account of the risk assessment in determining whether the
young person should undertake certain work activities.

2.28 - The size of openings, height of barriers, distance from danger.

Size of openings
Technical information relating to this subject can be found in BS EN 294:1992 Safety of machinery. The information in this document relates to the measurements and distances permissible in relation to operatives of machines putting either their arm or fingers through
openings and slots etc.
Arm:
Dimensions in millimetres
Limitation of Movement

Safety Distance (sr)

Limitation of movement only at shoulder and armpit

850

Arm supported up to elbow

550

Arm supported up to wrist

230

Arm and hand supported up to knuckle joint

130

'Table 1'
Fingers:
Dimensions in millimetres
Part of Body

Opening

Safety Distance (sr)

Fingertip

Finger up to knuckle joint or Hand

Arm up to junction with shoulder

Slot

Square

Round

e4

4<e6

20

10

10

6<e8

40

30

20

8 < e 10

80

60

60

10 < e 12

100

80

80

12 < e 20

900(1)

120

120

20 < e 40

900

550

120

30 < e 100

900

900

900

'Table 2'

2.29 - Height of barriers.

In certain work areas there are obvious risks from overhead - in other workplaces, they may
be more discreet. Nonetheless, these hazards can be realised if not controlled.

2.30 - Distance from danger.

Relevant distances in relation to machinery guarding are expressed in BS EN
294:1992 and can be viewed in the following tables:
Minimum distance for low risk
Height of Height of protective structure
Danger
1000
1200
1400
1600
Zone

1800

2000

2200

2400

2500

Horizontal distance from danger zone

2500

2400

100

100

100

100

100

100

100

100

2200

600

600

500

500

400

350

250

2000

1100

900

700

600

500

350

1800

1100

1000

900

900

600

1600

1300

1000

900

900

500

1400

1300

1000

900

800

100

1200

1400

1000

900

500

1000

1400

1000

900

300

800

1300

900

600

600

1200

500

400

1200

300

200

1100

200

1100

200

'Table 1'
Minimum distance for high risk:
Height of
danger
zone

Height of protective structure

1000

1200

1400

1600

1800

2000

2200

2400

2500

2700

Horizontal distance to danger zone

2700

2600

900

800

700

600

600

500

400

300

100

2400

1100

1000

900

800

700

600

400

300

100

2200

1300

1200

1000

900

800

600

400

300

2000

1400

1300

1100

900

800

600

400

1800

1500

1400

1100

900

800

600

1600

1500

1400

1100

900

800

500

1400

1500

1400

1100

900

800

1200

1500

1400

1100

900

700

1000

1500

1400

1000

800

800

1500

1300

900

600

600

1400

1300

800

400

1400

1200

400

200

1200

900

1100

500

'Table 2'

3 - Maintenance.
When equipment is maintained, there is always a risk of hazards being realised
through a number of ways. The following is a suggested list of some of the hazards
that may present themselves and should be considered in the risk assessment process:

Hazardous substances (paints, solvents, thinners, greasers, chemical, acids and alkalis etc.)
Physical hazards such as manual handling.
Isolation procedures - ensuring that the equipment cannot be turned on when being
maintained.
Cuts from sharp edges.
Confined spaces and restrictions on movement.
Hot work that may be required.
Noise.
Environmental issues such as lighting levels, heat, ventilation etc.

Obviously this is not an exhaustive list, but does give a flavour of the types of hazards that
must be controlled.

3.1 - Maintenance strategies.

The approved code of practice for PUWER 1998 sets out (in Reg 5) the maintenance
requirements and gives adequate guidance on frequency etc. The specific regulation
states:
1. Every employer shall ensure that work equipment is maintained in an efficient state,
in efficient working order and in good repair.
2. Every employer shall ensure that where any machinery has a maintenance log, the
log is kept up to date.
The guidance to this regulatory requirement states:
This Regulation builds on the general duty in the HSW Act, which requires work equipment
to be maintained so that it is safe. It does not cover the maintenance process (that is
covered by the general duties of the HSW Act) or the construction of work equipment so that
maintenance can be carried out without risk to health or safety (these are the subject of
regulation 10 and regulation 22).
It is important that equipment is maintained so that its performance does not deteriorate to
the extent that it puts people at risk. In regulation 5, 'efficient' relates to how the condition of
the equipment might affect health and safety. It is not concerned with productivity. Some
parts of equipment such as guards, ventilation equipment, emergency shutdown systems
and pressure relief devices have to be maintained to do their job at all times. The need to
maintain other parts may not be as obvious, for example failure to lubricate bearings or
replace clogged filters might lead to danger because of seized parts or overheating. Some
maintenance routines affect both the way the equipment works and its safety. Checking and
replacing worn or damaged friction linings in the clutch on a guillotine will ensure it operates
correctly, but could also prevent the drive mechanism jamming, so reducing the risk of
repeat un-covenanted strokes.

3.2 - 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 take into
account 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 management.
The extent and complexity of maintenance can vary substantially from simple checks on
basic equipment to integrated programmes for complex plant. In all circumstances, for
maintenance to be effective it needs to be targeted at the parts of work equipment where
failure or deterioration could lead to health and safety risks. 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:
1. planned preventative;
2. condition-based;
3. breakdown.
Appropriate techniques should be selected through risk assessment and used
independently or in combination to address the risks involved.
Simple hand tools usually require minimal maintenance, but could require repair or
replacement at intervals. More complex powered equipment will normally be accompanied
by a manufacturer's maintenance manual, which specifies routine and special maintenance
procedures to be carried out at particular intervals. Some of the procedures will be
necessary to keep the equipment in working order; others will be required for safety
reasons.
It should be remembered that different maintenance management techniques have different
benefits.
Planned preventive maintenance involves replacing parts and consumables or making
necessary adjustments at preset intervals so that risks do not occur as a result of the
deterioration or failure of the equipment.
Condition-based maintenance involves monitoring the condition of safety-critical parts and
carrying out maintenance whenever necessary to avoid hazards which could otherwise
occur.
Breakdown maintenance involves carrying out maintenance only after faults or failures have
occurred. It is appropriate only if the failure does not present an immediate risk and can be
corrected before risk occurs, for example through effective fault reporting and maintenance
schemes.

Where safety-critical parts could fail and cause the equipment, guards or other protection
devices to fail and lead to immediate or hidden potential risks, a formal system of planned
preventative or condition-based maintenance is likely to be needed.
Some equipment may not be owned by the user. Many items of plant and equipment are
hired. It is important for both the hire company and the person responsible for hiring
equipment to establish which party will carry out safety-related maintenance. This is
particularly important for equipment on long-term hire and the terms of the agreement set
out or recorded in writing.
In many cases, safety-related maintenance work is not carried out by the person with
ultimate responsibility for the work equipment, in the mistaken belief that the other party will
do it. If the hire company is some distance from the user site, it would be uneconomical for
their staff to carry out simple checks and make minor adjustments, so the user may agree to
carry them out. However, both parties should agree on a clear delineation of responsibilities.

3.3 - Maintenance log.

There is no requirement for you to keep a maintenance log. However, it is recommended
that you keep a record of maintenance for high-risk equipment. A detailed maintenance log
can provide information for future planning of maintenance activities and inform maintenance personnel and others of previous action taken.
If you have a maintenance log, you should keep it up to date.
Maintenance procedures should be carried out in accordance with any manufacturer's recommendations which relate to the equipment, for example periodic lubrication, replacement
and adjustment of parts.
However, additional maintenance measures may be required if particularly arduous conditions of use are foreseen or have been experienced in use. There may be times when these
additional measures need to be reviewed and revised in the light of ongoing operating experiences.
Maintenance workers.
Maintenance work should only be done by those who are competent to do the work.

3.4 - Planned Maintenance Programme.

A written planned preventative plan is always good practice. The following questions
should be asked when considering a plan for the maintenance:

What importance does the work equipment play in the overall business?
Costs of the equipment maintenance in terms of direct costs and indirect costs, i.e.
indirect costs of down time for parts if the equipment is not maintained, and direct
costs of labour etc.
The dependency of the equipment on other machines. Is it a stand-alone piece of
equipment or does it play a part in a much bigger system?
Can the equipment be easily replaced?
Does the equipment require any peculiar parts - that may have to be ordered in ad-

vance of the actual maintenance?

Does the equipment have a shelf life - or other life expectancy (either as a whole or
for the various parts of the equipment)?
Are there environmental factors to be considered - such as the disposal of any waste
oil for example?

The benefits of planned preventative maintenance.

The main benefits of a planned preventative maintenance system are linked to the
main three reasons of health and safety management:
Ethical.
Business managers should follow their duty of care in as much as avoiding accidents and
incidents linked to the maintenance requirements of work equipment.
Legal.
The legal requirements in PUWER 1998 as well as the overall safety obligations contained
in the Health and Safety at Work Act 1974 and the Management of Health and Safety at
Work Regulations 1999.
Financial.
The costs of accidents and injury to employees and work equipment should be avoided by
installing a rigorous maintenance procedure.
Such a recorded procedure may go some way as evidence as to your attempts to maintain
work equipment in a proper and correct manner.

3.5 - Statutory requirements for maintenance/inspection.

The main pieces of legislation and associated regulations are listed as follows:
Main Legislation

Regulations

Provision and Use of Work

Equipment Regulations.

Regulation 5: maintenance of work equipment in

general.
Regulation 22: maintenance of work equipment in
general.
Regulation 6: inspection (except power presses)
Regulation 32: inspection of power press guards.

Lifting Operations and Lifting

Equipment Regulations 1998

Regulation 9: inspection of lifting equipment.

Control of Substances Hazardous Regulation 9: maintenance of control measures.

to Health Regulations 2002 (as
amended in 2005)
Pressure Systems Safety Regula- Regulation 12: maintenance of pressure systems.
tions 2000
Carriage of Dangerous Goods
There are various regulations in this piece of law
and Use of Transportable Pres- that deals with maintenance and inspection of tanks
sure Equipment Regulations 2004 and transportable pressure equipment.

Personal Protective Equipment at Regulation 7: maintenance.

Work Regulations 1992
Electricity at Work Regulations
1999

Regulation 4: maintenance of electrical systems.

3.6 - Statutory examinations.

Statutory examinations, as the name suggests, exist in order to place legal requirements on
persons to carry out such examinations to prevent the work equipment failing at a critical
time.
Competent persons are called upon in order to carry out the examination. A competent person is often defined or referred to as someone with the practical and theoretical knowledge
as well as sufficient experience of the specific machinery involved. So to be competent in
one form of statutory examination, for example steam boilers, does not necessarily make
you automatically competent in another form of statuary examination, for example, lifts.
Competent persons.
The need for competent persons is defined in the Management of Health and Safety at Work
Regulations 1999 and also in more specific detail (as they relate to work equipment) in the
PUWER 1998 approved code of practice which states:
You should ensure that persons who determine the nature of the inspections required and
who carry out inspections are competent to do so.
The competent person should have the necessary knowledge and experience.
'Determining the nature of the inspection' - the knowledge and experience required by a person to determine the nature of the inspection needs to be sufficient for them to be able to
decide what the inspection should include, how it should be done and when it should be carried out. Experienced, in-house employees such as a department manager or supervisor
may be able to do this. They should know what will need to be inspected to detect damage
or faults resulting from deterioration. They should also be able to determine whether any
tests are needed during the inspection to see if the equipment is working safely or is structurally sound.
'Carrying out the inspection' - the person who actually carries out the inspection may not
necessarily be the same person who determines the nature of the inspections.
The actual inspection will normally be done by an in-house employee with an adequate knowledge of the equipment to:
1. enable them to know what to look at (know the key components);
2. know what to look for (fault-finding); and
3. know what to do (reporting faults, making a record, to whom to report).
Where necessary, you should give them appropriate information, instruction and training so
they can carry out the inspection properly and avoid danger. They should also be aware of
and able to avoid danger to themselves and others.
The necessary level of competence will vary according to the type of equipment and where
and how it is used. For some equipment, the level of competence to determine the nature of

the inspections or even to carry them out may not be available in-house, in which case the
help of another body with relevant competence may be necessary. An example of this will be
the person who carries out the annual inspection under these Regulations of some
fairground rides.

3.7 - Notification and record keeping.

Under Regulation 10 of the Lifting Operations and Lifting Equipment Regulations
1998, there is a specific duty related to notification and record keeping which is
stated as:
(1) A person making a thorough examination for an employer under regulation 9 shall:
(a)notify the employer forthwith of any defect in the lifting equipment which in his opinion is
or could become a danger to persons;
(b) as soon as is practicable make a report of the thorough examination in writing authenticated by him or on his behalf by signature or equally secure means and containing the information specified in Schedule 1 to:

(i) the employer; and

(ii) any person from whom the equipment has been hired or leased;

(c) where there is, in his opinion, a defect in the lifting equipment involving an existing or
imminent risk of serious personal injury, send a copy of the report as soon as is practicable
to the relevant enforcing authority.
(2) A person making an inspection for an employer under regulation 9 shall:
(a) notify the employer forthwith of any defect in the lifting equipment which in his opinion is,
or could become, a danger to persons;
(b) as soon as is practicable make a record of the inspection in writing.
(3) Every employer who has been notified under paragraph (1) shall ensure that the
lifting equipment is not used
(a) before the defect is rectified; or
(b) in a case to which sub-paragraph (c) of paragraph 8 of Schedule 1 applies, after a time
specified under that sub-paragraph and before the defect is rectified.
(4) In this regulation "relevant enforcing authority" means:
(a) where the defective equipment has been hired or leased by the employer, the Executive;
and
(b) otherwise, the enforcing authority for the premises in which the defective equipment was
thoroughly examined.

3.8 - Cranes and lifting equipment, hoists and lifts.

Regulation 9 of the Lifting Operations and Lifting Equipment Regulations (LOLER)
relate to the inspection frequencies of cranes, lifting equipment, hoists and lifts, and
states the following:

(1) Every employer shall ensure that before lifting equipment is put into service for
the first time by him, it is thoroughly examined for any defect unless either:
(a) the lifting equipment has not been used before; and
(b) in the case of lifting equipment for which an CE declaration of conformity could or (in the
case of a declaration under the Lifts Regulations 1997) should have been drawn up, the
employer has received such declaration made not more than 12 months before the lifting
equipment is put into service; or if it is obtained from the undertaking of another person, it is
accompanied by physical evidence referred to in paragraph (4).
(2) Every employer shall ensure that, where the safety of lifting equipment depends
on the installation conditions, it is thoroughly examined:
(a) after installation and before being put into service for the first time; and
(b) after assembly and before being put into service at a new site or in a new location, to ensure that it has been installed correctly and is safe to operate.
(3) Subject to paragraph (6), every employer shall ensure that lifting equipment which
is exposed to conditions causing deterioration which is liable to result in dangerous
situations is:
(a) thoroughly examined:

(i) in the case of lifting equipment for lifting persons or an accessory for lifting, at
least every 6 months;
(ii) in the case of other lifting equipment, at least every 12 months; or
(iii) in either case, in accordance with an examination scheme; and
(iv) each time that exceptional circumstances which are liable to jeopardise the
safety of the lifting equipment have occurred; and,

(b) if appropriate for the purpose, is inspected by a competent person at suitable intervals
between thorough examinations, to ensure that health and safety conditions are maintained
and that any deterioration can be detected and remedied in good time.
(4) Every employer shall ensure that no lifting equipment:
(a) leaves his undertaking; or
(b) if obtained from the undertaking of another person, is used in his undertaking, unless it is
accompanied by physical evidence that the last thorough examination required to be carried
out under this regulation has been carried out.

3.9 - Power presses.

The periodic examination of a power press, along with its guards and protection devices, is
required at least once in every period of six months or, where the tools are fenced
exclusively by means of fixed fencing, every 12 months. The periodic examination is
intended to ensure that safe conditions are maintained and that any defect or deterioration is
remedied in good time.
The competent person can use the information gained during the initial thorough
examination and test to focus on the things that are most likely to cause problems.
However, the competent persons may be asked to carry out a thorough examination at an
existing, used press that has not previously been seen by them or the organisation for which
they work. At the competent person's first thorough examination of such a press, the
flywheel should be completely or partially removed or the clutch dismantled (as appropriate),

unless clear verifiable records indicate that this has been done, for example at a recent
thorough examination, and that any defects have been rectified.
The competent person will need to see records of electrical maintenance and evidence that
this has been done in accordance with the manufacturer's instructions (if still available) or
another reasonable maintenance regime. If this evidence is not available, the competent
person may ask the employer to obtain it. This may involve having tests carried out where
the competent person considers this necessary following a visual inspection and other
relevant functional checks.

3.10 - Pressure systems.

The Pressure Systems Safety Regulations give clear definitions as to what constitutes:

Pipe-work.
Pressure system.
Relevant fluid.
Pipe-work.

Pipe-work means a pipe or system of pipes together with associated valves, pumps,
compressors and other pressure-containing components and includes a hose or bellows but
does not include a pipeline or any protective devices.
Pressure System.
Pressure system means:
(a) a system comprising one or more pressure vessels of rigid construction, any associated
pipe-work and protective devices;
(b) the pipe-work with its protective devices to which a transportable pressure receptacle is,
or is intended to be, connected; or
(c) a pipeline and its protective devices, which contains or is liable to contain a relevant fluid,
but does not include a transportable pressure receptacle.
Relevant fluid.
Relevant fluid means:
(a) steam;
(b) any fluid or mixture of fluids which is at a pressure greater than 0.5 bar above
atmospheric pressure, and which fluid or mixture of fluids is

(i) a gas, or
(ii) a liquid which would have a vapour pressure greater than 0.5 bar above atmospheric pressure when in equilibrium with its vapour at either the actual temperature
of the liquid or 17.5 degrees Celsius; or

(c) a gas dissolved under pressure in a solvent contained in a porous substance at ambient
temperature, and which could be released from the solvent without the application of heat.
The maintenance and examination requirements for pressure systems will be discussed in
detail in Element IC11: Pressure System Hazards and Controls .

4 - Training and Competence.

Competence can be defined as the ability to undertake responsibilities and perform activities
to a recognised standard on a regular basis. It is a combination of skills, experience and
knowledge. The inadequate management of competence has not only contributed to disasters such as Esso Longford and BP Texas City, but also to fatalities, personal injuries and ill
health.
Key principles in competence
Competence assurance should be linked to key responsibilities, activities and tasks identified in risk assessments.
Competency assurance systems should aim to establish and maintain competency for all
those involved in safety-related work, including managers. This is particularly important in
the management and prevention of major accidents.
Training is an important component of establishing competency but is not sufficient on its
own. For example, consolidation of knowledge and skills through practice is a key part of
developing competency.
Competence assurance systems should take account of foreseeable work and operating
conditions - including infrequent and complex activities, emergency situations and upsets,
maintenance etc.
Training and competence assessment methods should be appropriate to the hazard profile
of the tasks being undertaken. For example, competency assurance systems for safety critical tasks should be more robust.
'On-the-job' training should be structured and linked to risk assessments and associated
control measures including procedures. In safety critical environments, on-the-job training
should be supported by other forms of training where appropriate e.g. classroom training,
simulation.
Training should be validated ('Did it deliver what it was supposed to?'), and evaluated ('Is
this the right kind of training for our needs?') and recorded.
There should be refresher training for infrequent, complex or safety critical tasks and this
may include appropriate reassessment.
Vocational qualifications should include site-specific aspects and link appropriately to the
hazards and risks in your workplace.
Aim to achieve a suitable balance between competence and supervision.
Careful consideration should be given to the potential consequences of outsourcing of
safety-related work. Companies must take steps to ensure that contractors are competent to
carry out health and safety-related work. Companies should seek to retain intelligent customer capability to ensure that they can appropriately manage and oversee the work.

4.1 - When Training is Likely to be Required.

It should not be assumed that training is a one-off process that need not be undertaken on
subsequent occasions. Indeed, the need for training may well occur at several points during
a worker's time at a company and in different forms.
Training will be required during the following situations:

Induction
Changes in work activity
Introduction of new technology and equipment
Refresher training

Induction
One of the first things that a new employee requires is an introduction to the company, but
this does not just mean the geographical details, such as the location of the toilets, the fire
escapes and the coffee machine (although these are important). The new entrant will be at a
disadvantage unless they quickly acquire a knowledge of such things as the company
culture, both formal and informal and the company ethos on such things as bullying,
behaviour, harassment, discrimination and ethical behaviour.
An induction programme therefore needs to take these things into account or it will come as
no surprise when the new entrant feels isolated and unable to integrate into the work
environment - particularly to become known among other staff members. Departmental tours
and personal introductions are an absolutely vital part of induction. Organisations depend on
its people being able to work together, to liaise and cooperate - these capabilities in turn
depend on contacts and relationships. Well-planned induction training can greatly accelerate
the development of this crucial organisational capability.
Changes in work activities
There is, in any organisation, a certain inertia that tends to mean things continue much as
they have been. It is often the case that a change in the way that a company carries out
certain activities can founder on the rock of inertia unless positive and proactive action is
taken to ensure that the members of staff who are going to be involved in or affected by the
change are fully trained on the implications of the change and the knowledge requirements
that it will need.
These changes are often more than just moving a few desks around or changing offices.
They bring with them a new way of thinking and acting and therefore a single training
session with no follow-up or reinforcement will not suffice to embed the new system. Without
monitoring and evaluation of how the changes are progressing, they will most likely become
memories rather than everyday thought and deed, eventually becoming just another
management initiative that didn't work out.
Introduction of new technology

Technology progresses and unless a company wants to be left behind, it too must
embrace changes in the way that its industry works. Making use of all the available
resources when introducing new technology can greatly enhance the chances of it
being a success.
Manufacturer's training facilities
Input of staff on their training needs
Pre-change training
Initial facilitation training
Follow-up checks with staff on how the changes are being handled
Repeated training if it is clear that this is needed
The introduction of new equipment and technology can be viewed by elements of the
workforce with suspicion but well-handled, the changes can be an opportunity to
bring the workforce along on the journey and the benefits can be increased thereby.

Consolidation of training
Gaining basic training and a certificate of competence should only be seen as an entry into
industry; the training and development process lasts throughout an entire career. The initial

step following entry-level training is consolidation of the training, which is usually in the form
of a probationary period operating under supervision among qualified and experienced
colleagues.
Only when newly qualified workers have demonstrated their ability and experience over a
length of time should they be considered as fully proficient and qualified. The length of this
period will vary according to the individual, but advice is that six months is likely to be a
minimum. A record should be kept of their work and tasks completed. It is the responsibility
of the worker and their employer to keep this record (for example by the use of checklists) to
demonstrate their experience and developing levels of proficiency.
Update or refresher training
There is a risk that when workers spend time on other tasks, their proficiency can lapse.
This, along with the introduction of new techniques, brings with it a need for refresher and
update training at various stages in the worker's career. This occasional further training
should add value to the worker's growing skills and experience and provide a structure for
staff development.
In general, proficient workers who regularly practise their skills in the presence of colleagues
and employers will require training less often. However,
advances in technology may justify specific update training, and certain trained skills will
need specific, regular practice and updating. This can often be incorporated as part of
training for more advanced skills. It is important to record and plan for refresher/update
training and the employer must record the structure of the training received by the worker
based on the type of work undertaken.
For most machinery operations, recorded refresher/update training should take place at
least every five years. However, where a supervisor identifies specific weaknesses in an
operator's abilities, this will need to be addressed, irrespective of the date of previous
training.

4.2 - Specific Training Needs of Young People.

Young people (under 18 years) should not be allowed to use high-risk woodworking machinery unless they have the necessary maturity and competence which includes having
completed appropriate training.
High-risk woodworking machinery includes any woodworking machine which is
hand-fed, in particular:

any sawing machine fitted with a circular blade or saw band;

a planing machine when used for surfacing; and
a vertical spindle moulding machine.

However, young people may operate high-risk woodworking machinery during training
providing they are sufficiently mature and are adequately supervised. They should also be
properly supervised after training until they reach the appropriate level of competence and
can work safely unsupervised. The Approved Code of Practice and Guidance Safe use of
woodworking machinery: Provision and Use of Work Equipment Regulations as applied to
woodworking contains further information.
A recent HSE study of woodworking accidents found that a quarter of those injured under
the age of 25 had received no specific training or instruction for the machine they were
working on and in small firms, half of those injured had received 'on the job' training only.

4.3 - Competence, External Supervision & Self-Supervision.

Training and supervision
Poor supervision and inadequate training are two of the main causes of accidents. The law
requires that all workers must receive adequate training. It also makes good business sense
to make sure your employees are working efficiently and safely. Hear an interview with a
training provider, an employee and the HSE which explains why training is so important.
Demonstrating competence
After the training has taken place the operator's competence should be assessed to see if
the training has been successful. The assessor must be someone who knows the machining
process, its risks and the safe working practices that should be used.
Operators can only be classed as competent when they can demonstrate that they use the
required knowledge and safe working practice all the time.
Competence checklist
A competent worker should be able to demonstrate:

that they can select the correct machine and tooling

the ability and confidence to say 'this is the wrong machine for this job, it can be
done more safely on.'
what the guards do and how to use and adjust them properly, as well as any other
protection devices. For example, on a circular saw, why you need a riving knife and
how to set it and adjust the top guard
a knowledge of safe methods of working including appropriate selection of jigs, holders, push-sticks and similar protection appliances
their understanding of the legal requirements for the guards to be used correctly
a knowledge of the nature of the wood and the hazards that this can cause, such as
kickback, snatching and ejection.

Keeping records
Once the operator has received the necessary training and has demonstrated their
competence, it is good practice to authorise them in writing for the machines and operations
that they can use.
Self-supervision
The concept of supervision in the workplace environment has been studied by many
professional experts. Self-supervision became a critical area of research since experts want
to find out whether self-supervision can be obtained relying heavily on technology and
resources or with a change in the organisational structure.
If self-supervision is practised in the workplace for utilising technology, it means that the
workers function on their own without a supervisor to guide or direct them as long as there
are sufficient resources and technology needed to carry out the tasks. On the other hand, if
self-supervision is used in a company to modify the traditional hierarchical structure, it
means that direct supervision is removed and employees are taught to become crossfunctional in order to be equipped with the right skills and knowledge needed for
management functions.
There are various models of self-supervision, which are the results of experts' studies on
different working conditions.
Supervision Models

One of the classifications of supervision based on how it is carried out is internal

supervision, otherwise known as self-supervision. Contrary to direct supervision, the internal
supervision model is based on the concept that low-level employees can perform their roles
without the presence of first-line supervision. This requires them to understand the basic
skills of supervision and to have some knowledge of management functions.
External supervision or direct supervision model focuses on first-line supervision of people in
the management such as managers and supervisors. In this model employees directly
report to them.
In a corporate setting, self-supervision can exist even with direct supervision as the main
structure. If this happens, there is a change in organisational structure wherein both
management and employees agree on their respective roles and their expectations from
each other. This set-up is another supervision model called integrated supervision.
Another type of supervision model is called the parallel supervision wherein the
management or direct supervisors do not recognise the worth or value of self-supervision,
and do not acknowledge the supervision efforts performed by the self-supervised
employees.

4.4 - Training Needs for Chainsaw Use.

Chainsaws
Chainsaws are used for many projects involving the management of woodland, the removal
of trees and the clearance of scrub. In inexperienced hands, a chain saw is lethal and training and formal certification is now a requirement of most employers and insurance companies.
Training covers the basic skills needed to safely use and maintain a chain saw. Assessment
is provided to the National Proficiency Tests Council (NPTC) standards.
CS30 - Maintain and Operate the Chainsaw
Learning Outcomes
The candidate will be able to:
1. Identify, inspect and comment on key parts of the chain saw
2. Prepare the chain saw for work safely without risk to themselves, other people or the
environment
3. Carry out daily and routine maintenance on the chain saw
4. Operate the chainsaw safely and effectively and comfortably in accordance with the
practical risk assessment
5. Operate the chainsaw safely without risk to themselves, other people and the environment
6. State the identified knowledge that underpins understanding of operating a chainsaw
7. Identify the risk assessment and emergency procedures on a work site
The assessment is divided into 2 compulsory units

Unit 30.1 Maintenance of the Chainsaw

Unit 30.2 On-site preparation and basic crosscutting

Candidates must successfully achieve all Assessment Activities unless otherwise specified.

4.5 - Training for Woodworking Machines.

Woodworking machines
When compared to other industries, woodworking accounts for a disproportionately high
number of serious machinery accidents. Woodworking machines often have high-speed cutters which cannot be totally enclosed owing to the nature of the work which they do.
It is a legal requirement under The Provision and Use of Work Equipment 1998 (PUWER)
that all staff who use Woodworking Machinery receive training in the Safe use of the machines those persons work on.
The aim of training courses is to provide machine woodworking training to comply with the
Health & Safety at Work Act and the Provision and Use of Work Equipment Regulation 1998
(PUWER)
As can be imagined, the range of woodworking machinery is wide and each machine will
have its own individual features and hazards. It is therefore important to ensure that a training programme covers all features of the range of machinery that will be used by the trainee.
A list, not exhaustive, of the types of machines likely to be encountered is given below:

Bench Circular Saw

Dimension Saw
Pull Over Cross Cut Saw
Radial Arm Saw
Band Saw
Band Resaw
Surface Planer
Panel Planer
Combination Planer
Mortiser
Spindle
High Speed Fixed-Head Router
Tenoner
Sanders
Moulders

4.6 - Training for Power Presses.

Power presses
A power press is a machine that uses strong forces to bend, shape and mould components
in a manufacturing environment. These forces are exceptionally strong and can present serious hazards to a machine operator. A power press injury can result in the amputation of
fingers, hands, or arms and cause other disabling injuries. Proper safeguards, employee
training, press maintenance, and inspections are vital to the prevention of injuries.
A power press can be used in more than one production system and there may be several
ways to safeguard each system. For operators, the greatest danger is at the point where

stock is inserted, held, or withdrawn by hand. Safeguards are designed to eliminate the possibility of the operator or other workers from placing hands or any other body part from making contact with hazardous moving parts. Operators should never remove or tamper with
safeguards.
A power press can be made safe but only its user can prevent machine guarding injuries.
Press operators must receive a minimum of eight hours of on-the-job training under supervision before being assigned to operate a press. Operators of complex equipment may need
two weeks or more of training before they run the equipment alone. Those working with
presence-sensing device initiation equipment must receive training at least annually.
Press operators must know how to use press controls, where possible pinch points or moving parts are located, and where safety devices are located. Operators should be trained to
lock out machinery, lubricate it, remove stuck work, and know to whom they should report
any problems. Training should also include why, when, and how too use personal protective
equipment.
Supervisors must understand all the hazards associated with power presses, how the safeguards work, and how to adjust them. They must check the setup and ensure that each operator has been properly trained. Supervisors should visually inspect each press at the start
of a shift or whenever a new operator comes on duty. Each press must be inspected weekly
to be sure that all functions are operating properly; and periodically, an in-depth inspection
must be conducted.
The Power Presses Regulations have now been superseded by the Provision and Use of
Working Equipment Regulations (PUWER).
Young people (under 18 years) should not be allowed to use a power press unless they
have the necessary maturity and competence. This includes having successfully completed
appropriate training. However, they may operate a power press during training as long as
they are adequately supervised. They should also be supervised after training if considered
insufficiently mature.
Refresher training
You should provide refresher training if necessary. Skills decline if they are not used regularly. Pay particular attention to people who deputise for others on occasions - they may
need more frequent refresher training than those who do the work regularly.
When should training take place?
The Management of Health and Safety at Work Regulations 1999 specify that health and
safety training should take place within working hours.
Young People
Young people are often exposed to risks to their health and safety when using work equipment as a consequence of their immaturity, lack of experience or awareness of existing or
potential risks. Therefore you should not allow such people to use a power press unless they
have the necessary maturity and competence which includes having successfully completed
appropriate training. However, during the training they may operate a power press providing
they are adequately supervised. Adequate supervision should also be provided after training
if a young person is not sufficiently mature.
'Young person' means any person who has not yet reached the age of eighteen.
Competence and maturity are not simply a matter of the age of the worker. Training in itself
will not ensure competence but it is part of what is necessary. The level of supervision
needed will depend on how mature the worker is and whether they can work safely without
putting themselves or others at risk. Even when they have been trained, young people need
to be supervised to ensure that they do not act irresponsibly or take short cuts which put

themselves and others at risk.*

Regulation 9 - Training
(1) 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.
(2) 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.
Training appointed people
You should provide training for people appointed under regulation 33(1)(a) to inspect power
presses which includes suitable and sufficient practical instruction in the following areas in
relation to each type of power press and guard and/or protection device used in respect of
which it is proposed to appoint the person being trained:
1. power press mechanisms, particularly their safety aspects and including the nature
and function of clutch mechanisms, flywheels, brakes and ancillary equipment;
2. guards and protection devices - types and functions of each type of guard or protection device, including closed tools where used; method of installation;
3. the causes and prevention of accidents involving power presses;
4. the work of the tool setter - safe methods of working, lubrication and co-operation
with the press operator;
5. tool design - in relation to safe systems of work;
6. how to carry out an inspection and test of the guard protection device or closed tool,
including how to detect defects.
The training needed under regulation 9(1) for a person appointed to inspect guards and
protection devices can be undertaken at an external course and/or in the workplace.
Wherever it takes place, it should include appropriate practical instruction on the topics
listed. It is not possible to give precise guidance for the content of the training as this will
depend on the duties involved in each case.
When is training necessary?
Press operators are most likely to need training when they are recruited. However,
training needs are also required:
1. if the risks to which people are exposed change;
2. if new equipment or technology is introduced;
3. if the system of work changes.
Training managers and supervisors
Regulation 9(2) requires you to provide adequate training for people who supervise or
manage the use of power presses.

4.7 - Abrasive Wheel Training Requirements.

Abrasive wheels are used in grinding, polishing and finishing machines. They are, as the
name suggests, highly abrasive and rotate at particularly high speeds in order to do their
job. As such, should a part of the body come into contact with one as it turns, the resulting
injury can be quite horrific. Severe friction burns, crushed fingers and loss of eyesight are

common injuries arising from accidents which occur when using abrasive wheels. The main
hazards arise from contact with the wheel and trapping of fingers between the wheel and
work rest, but there is also the risk of fragments being ejected from the machine at very high
speed which can cause severe damage to the unprotected operator.
The number of accidents and the circumstances in which they occur show that most can be
avoided by a knowledge of the risks and by adopting safety measures.
There is no substitute for thorough practical training in all aspects of the mounting
and use of abrasive wheels. Any training programme should cover at least the following:
1. hazards and risks arising from the use of abrasive wheels and the precautions to be
observed;
2. methods of marking abrasive wheels with their type, size and maximum operating
speed;
3. how to store handle and transport abrasive wheels;
4. how to inspect and test abrasive wheels for damage;
5. the functions of all the components used with abrasive wheels such as flanges, blotters, bushes, nuts etc;
6. how to assemble abrasive wheels correctly to make sure they are properly balanced
and fit to use;
7. the proper method of dressing an abrasive wheel (removing dulled abrasive or other
material from the cutting surface and/or removing material to correct any uneven
wear of the wheel);
8. the correct adjustment of the work rest on pedestal or bench grinding machines;
9. the use of suitable personal protective equipment, for example eye protection.
It is recommended that a record of training in the safe mounting of abrasive wheels is kept,
showing the trainee's name and date of training.
Training courses are offered by many organisations which usually provide a certificate of
attendance, not competence. Further information can be obtained from the British Abrasives
Federation.

Question 1.
An Operator is defined as the person or persons given the task of
Multiple Choice (HP)
Answer 1:

All of these

Response 1:
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Answer 2:

installing

Response 2:
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Answer 3:

operating

Response 3:
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Answer 4:

adjusting

Response 4:
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Answer 5:

maintaining

Response 5:
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Answer 6:

cleaning

Response 6:
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Answer 7:

repairing

Response 7:
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Answer 8:

transporting machinery

Response 8:
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Question 2.
CE marking is not a quality mark
True/False (HP)
Answer 1:

True

Response 1:
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Answer 2:

False

Response 2:
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Question 3.
It is primarily the task of the ____________ to design and construct new machinery so that it
can be used safely.
Multiple Choice (HP)
Answer 1:

Manufacturer

Response 1:
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Answer 2:

Operator

Response 2:
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Answer 3:

Cleaner

Response 3:
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Answer 4:

Supplier

Response 4:
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Question 4.
The manufacturer must supply _____________ suitable for the operations concerned where
its lack is likely to cause a risk despite ambient lighting of normal intensity.
Multiple Choice (HP)
Answer 1:

Integral lighting

Response 1:
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Answer 2:

Cleaning fluid

Response 2:
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Answer 3:

Personal protective equipment

Response 3:
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Question 5.
Following safe systems of work and the provision of information, instruction and training are
examples of
Multiple Choice (HP)
Answer 1:

software measures

Response 1:
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Answer 2:

hardware measures

Response 2:
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