9.3 Machinery Hazards

Potential consequences of contact with, or exposure to, mechanical and other hazards

Machines, especially those with moving parts, expose workers to the risk of bodily injury. Common machine hazards and risks are:

• Entanglement. A body part, or loose items worn by the worker, get caught in moving machine parts.
• Impact. Impact from moving machine parts can cause abrasions and bruises.
• Crushing. People can be crushed between parts moving together, or between a moving part and a fixed part of the machine, a wall or another object. Two parts moving past one another can cause shearing.
• Cutting. Contact with moving cutting elements such as blades can cause severe injury or amputation.
• Stabbing or puncture. Sharp-pointed parts can stab or puncture the skin.
• Friction or abrasion. Rough surfaces can cause friction burns or abrasion.
• Ejection. Parts of the equipment, or of the material being worked on, can fly off and hit the body.
• Emissions. Parts of the machine, materials and emissions such as steam or water can be hot or cold enough to cause burns or scalds.
• Electrical. Contact with faulty electrical components, such as live wires, can cause electrocution.
• Heat. Contact with hot machine surfaces can burn the skin.
• Loud noise. Excessive noise from machines can cause noise-induced hearing loss after prolonged exposure.
• Vibration. This can happen when the machine is not properly balanced or when there is a break in the vibration-damping material, and can also be a hazard when the machine is not properly shielded.
• Radiation. High-intensity light, such as laser or ultraviolet.
• Slips, trips and falls. Cable or hose connections and oil leaks from machinery can cause them.
• Ergonomics. Poor ergonomic conditions can lead to injury of the muscles, tendons and nerves, and to back pain and other musculoskeletal disorders.
• Fire and explosion. These can occur when flammable materials are present near heat sources or when electrical equipment is not properly maintained.
• Psychosocial hazards. For example stress, job content, work organisation and cognitive factors.

Because there are many different types of machine and process, a risk assessment should be carried out for each machine or situation, and in some cases before each use. It may be necessary to involve people with specialised or technical expertise.

Hazards of a range of equipment

Different types of machine are used in different workplaces.

The hazards and risks of each type of machine follow.

Bench-top grinder

The main hazards and risks are:

• high-speed abrasive wheels hold a large amount of energy and are a contact hazard
• improper fitting of the wheel, or a worn-out wheel, can lead to malfunction and a flying-object hazard
• rotating parts can entangle loose clothing, hair or jewellery
• work pieces kicked back by the rotating wheel create flying-object hazards
• the grinding wheel produces sparks, which create a fire hazard
• the wheel is hot after use, creating a burn, heat or fire hazard
• dust exposure may create a health hazard

The main control measures are:

• do not touch the wheel, and keep all guards in place at the proper distances
• use competent wheel selection, fitting and inspection and any tests appropriate to that wheel type and the manufacturer's instructions. A ring test is not suitable for every wheel and cannot guarantee safety
• do not wear loose clothing or jewellery in the workshop, and tie long hair up and back
• secure all objects on the work rest while they are ground
• do not touch the wheel after use
• keep all combustible materials away from sparks
• know the hazards the work material may create
• keep work areas clean of dust and other foreign materials

Pedestal drill

The main hazards and risks are:

• hair or clothing caught in moving machine parts
• eye or face injury from flying swarf and chips
• sharp edges and burns from swarf and chips
• electric shock and electrocution
• noise from the drill
• drawing in at the nip point between the motor and drive belts
• health hazards from cutting fluids, for example dermatitis

The main control measures are:

• make sure operators know all the machine's operations and controls and where they are
• make sure all guards are fitted, secure and working, and do not operate the drill if guards are missing or faulty
• make sure the chuck key, if used, has been removed from the chuck
• follow correct clamping procedures so the work is secure
• use the assessed procedure before adjustment or clearing swarf: stop and securely isolate where access could expose the person to danger, verify that movement has ceased and use suitable tools rather than hands
• feed with care as the drill breaks through the underside of the work
• use a safe working posture
• switch off the machine when the work is finished
• leave the machine in a safe, clean and tidy state
• do not use faulty equipment, and report suspect equipment immediately
• never leave the machine running unattended
• do not hold the item being drilled with your hands. Use a clamp

Summary notes for Element 9 · Cheat sheet · Glossary. A study aid, not published or endorsed by NEBOSH.