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Workshop Practice

How different aspects of work in the workshop should be carried out in practice.

INTRODUCTION

This is not intended as a comprehensive guide to Health and Safety at Work and should not be used in place of specific instructions, but should be viewed as a common sense guide to create a safer and healthier environment within the workshop and when undertaking engineering activities.

These are to be read and the advice and procedures given are to be followed at all times.

GENERAL GUIDANCE

When working on the Railway:-

  • Carry out your work in a safe and proper way.
  • Wear the correct protective clothing and equipment.
  • Adhere to the laid down safety requirements.
  • Beware of hazards.
  • Follow any specific instructions, codes of practice, etc, relating to the work being carried out.
  • Use 'Not to be Moved’ or other notices and signs where necessary.
  • Keep the site tidy.

PERSONAL PROTECTIVE EQUIPMENT

  • Safety hats must be worn at all times when there is danger of falling objects. This is mandatory where Construction work is being undertaken.
  • Where protective equipment is provided, persons are required for their own safety to wear it. This includes footwear, ear defenders and hats.
  • Eye protection is a special case. Persons are required by law to wear safety goggles at any place where there is a foreseeable risk of injury to the eyes.
  • Safety equipment should be changed immediately any part of it becomes defective – Destroy non repairable items and report it to an Appointed Engineer or Director, if necessary.
  • Where persons are issued with personal protective equipment, it is their responsibility to look after it.

TOOLS AND EQUIPMENT

  • Persons must ensure that they have the right hand tools for the job.
  • Tools are to be stowed safely, particularly when working at heights.
  • Eye protection must be worn whenever there is a foreseeable risk of injury.
  • All hand tools should be inspected before use and damaged or defective items not used. Destroy defective, non-repairable items and report it to an Appointed Engineer or Director, if necessary.
  • 110V or battery operated power tools should always be in use in preference to 240V. If 240V tools have to be used, then they must incorporate a Residual Current Breaker that should be frequently tested.
  • Extension cables should be kept to a minimum and then placed in such a way as to avoid them being damaged, or being a hazard to other people.
  • All worn or dangerous tools must be replaced immediately.
  • The correct plug for the supply socket must always be used.

LADDERS

  • Ladders should not be painted as paint hides defects.
  • Ladders, steps and trestles should be inspected before use by the person who is going to use them. . Defective ladders must not be used and the defects must be reported.
  • The ladder should be set up at the correct angle - 4 up to 1 out.
  • The ladder should protrude at least one metre above any landing place and should be secured by lashing the stiles at the top. While this is being done a colleague should foot the bottom of the ladder.
  • Before climbing a ladder, always ensure that the rungs and boots/shoes are clean.
  • Never over reach sideways from a ladder. Always follow the golden rule of maintaining three-point contact. i.e. Two hands and one foot or one hand and two feet.
  • Ladders should be fitted with non skid feet.
  • Ladders/steps/trestles if on load, must always be inspected for serviceability before use.
  • When using a ladder near an entrance, railway line or any other place where there is a possibility of someone walking or driving into it, a barrier should be erected with warning notices or a second man deployed to warn anyone.

TRESTLES AND STEPS

  • When using trestles, always ensure that they are set on a firm level surface.
  • Trestles should not be more than 1.5 metres apart when 38mm boards are being used.
  • Working platforms on trestles must be at least two scaffold boards wide.         Always use correct staging and good condition scaffold boards for platforms.
  • Scaffold boards must not overhang the trestles by more than the minimum amount to ensure stability and the ends of the boards must not be stood upon
  • Trestles must not be used if a person is liable to fall more than 1.5 metres from the working platform.
  • Before using any steps, always inspect them for cracks, damaged stiles or treads, broken hinges or worn ropes. Any defects must be repaired correctly or replaced.

MOBILE SCAFFOLDS

  • Scaffold towers must only be used on firm level ground.
  • The maximum height of a mobile scaffold should not exceed the manufacturers stipulated limits. If this is not known, when used outside the height should not be more than three times the minimum base width (which must not be less than 1.20 m) and 3½ times base width when used inside. Where outriggers are deployed, this height can be increased by 1 metre.
  • Where castors are used, these must be securely locked before the tower is used.
  • Guard rails must be fixed to mobile scaffolds.
  • The inbuilt ladder access must be used when provided. If a ladder is provided for access, this should be lashed vertically to the shortest side of the scaffold. Ascending the tower by any other means is prohibited.
  • Never increase the height by working off a pair of steps or a ladder.
  • When the mobile scaffold has to be moved, it should be pushed from the base, but never with someone on it.
  • Wheels must be firmly fixed to the uprights and locked.

MACHINE TOOLS

  • Operation of machine tools must only be carried out by persons who are authorised.
  • All guards must be in place.
  • In this context machine tools are defined as powered tools that are not hand held or portable.

MACHINE GUARDS

  • All moving parts of machinery must be guarded sufficiently to prevent injury.
  • Use machine guards where they are provided.
  • The serviceability of guards is to be checked before using the machines. Faults are to be reported to an Appointed Engineer or Director.
  • Eye protection is to be used when using any machines where there is a possible danger of materials emissions.

MOBILE PLANT

  • Mobile plant (forklift, JCB, etc) must only be operated by persons who are authorised to do so.

FIRE PREVENTION

  • Suitable fire extinguishing equipment should be close at hand when welding, cutting and/or grinding.
  • The operative's personal safety is paramount and flame retardant clothing and gloves MUST be worn.
  • Whenever welding or burning is to be carried out, all flammable materials such as paper, rags and oils must be cleared from the immediate area. Good housekeeping will assist in preventing any build-up of such materials.
  • All welding and burning must cease at least 30 minutes before people leave the premises and the building(s) are locked up.
  • Flammable waste should be stored in closeable metal bins and disposed of daily. Oily rags, when stored for use on locomotives must be kept in a closed metal bin.
  • All fire exits, door and site entrances must be kept clear.

SITE HAZARDS

  • Persons should report to an Appointed Engineer or Director any hazards that they may encounter in their working areas. If it is practical to do so, the person noticing the hazard should take action to eliminate it.
  • There should always be sufficient lighting in which to work.
  • Pathways, stairs and working platforms should be kept free from debris etc.
  • All pits should be adequately covered or provided with a suitable barrier.

USE OF GLOVES

The wearing of gloves is generally to be encouraged as they protect the hands from a multitude of hazards, both major and minor. However, the wearing of inappropriate gloves can in itself create hazards. In particular, heavy gloves must not be worn when using rotating machinery as there is a real risk of a glove becoming caught, leading to major hand injury.

COMPRESSED GASES

  • Full and empty cylinders should be stored in the cage and marked accordingly.
  • All cylinders must be stored away from inflammable objects.
  • Acetylene cylinders should always be stored and used in the upright position.
  • Cylinders must only be changed by those competent to do so.
  • If a leak is suspected, test with a leak detection spray or, if not available, soap and water.
  • Compressed gas equipment must always be checked for serviceability before use.

ELECTRICAL

  • Work on electrical equipment must only be carried out by those competent to do so.
  • Ensure that all electrical connections and cables are in a serviceable condition.
  • When equipment has been switched off to work on, it should be locked off or the fuses removed.
  • When changing electrical components the power should be isolated and locked off or fuses removed.
  • IEE 18th Edition Regulations should be followed at all times.

CHEMICALS

  • Good housekeeping is essential where chemicals are stored and used.
  • Chemicals, including oils and fuel must not be decanted into unmarked containers.
  • All containers must be clearly marked with the chemical and any particular hazard.
  • Always wash before eating, smoking or going to the toilet.
  • When paint spraying or using solvents a suitable filtered mask MUST be worn at ALL times.
  • Absolute care must be exercised at all times when handling chemicals.
  • The most common hazard from chemicals is from splashes. Eye and body protection MUST be worn at ALL times when handling chemicals.
  • On no account are chemicals to be poured down drains.
  • A suitable and sufficient COSHH assessment must be in place and understood before any work is carried out involving chemical substances.

OILS AND LUBRICANTS

  • Remove any oil from the skin promptly with soap and warm water.
  • Only disposable 'wipes' or clean rags should be used - contaminated rags or tools should never be put in pockets.
  • Do not wear overalls or clothes soaked in oil.

SOLVENTS AND ADHESIVES

  • All solvents and solvent-based adhesives must only be used in well ventilated areas.
  • When using adhesives, always use a suitable barrier cream.
  • When storing solvents/adhesives or any other inflammable substances, these must be stored in a metal cupboard or other suitable cupboard/container.
  • The storage and use of solvents/adhesives in workshops and confined spaces should be restricted areas where there is no naked light or other source of ignition.
  • Before any solvents or adhesives are disposed of, they must be identified and the correct procedure followed.

ACCIDENT REPORTING

  • After a serious accident, which results in a major or fatal injury, an appropriate person must be notified immediately by telephone, giving full details. This must be followed by an accident report. Nothing must be touched at the scene of the accident until an investigation has been carried out, unless it is deemed hazardous or a danger to others.
  • All accidents which cause personal injury, however small, must be accurately entered into the Accident Book.
  • Accident reports should be made out as soon as possible, whilst details are fresh in the person's mind.
  • An accident report must also be completed for an accident/dangerous occurrence in which no personal injury occurs. (A ‘near miss’ occurrence.)

ASBESTOS

If work is to be carried out and you suspect that asbestos may be present then the necessary precautions and actions must be followed. The Asbestos Register gives details of where asbestos is known or suspected.

LIFTING EQUIPMENT

  • All lifting gear will be examined by a Competent Person, certified and approved safe for use, as required by the Lifting Operations and Lifting Equipment Regulations (LOLER)
  • All chains, slings and lifting gear must, before being used, be inspected for damage or defects by the person going to use them. In particular, webbing slings must be particularly examined and not be used if they exhibit any sign of damage.
  • When lifting with a chain and block, always ensure that the safe working load is adequate, the block is securely fixed and that the structure that the blocks are secured to is strong enough to carry the load.
  • All sharp corners on loads being lifted must be packed out.
  • When slinging rails or girders using a hitch and multi leg slings, timber or other means should be used to prevent the slings from slipping.

MATERIALS HANDLING

This is one of the areas where most injuries are caused, (mainly injuries to the back, hernia and damaged feet).

  • When attempting to lift anything, the following rules should be followed:-

GRIP   -           Take a good grip of the item being lifted.

BACK -                The back should be kept straight, knees bent to enable one to get down close to the load and then raise it pushing upwards with the leg muscles to regain the upright position.

CHIN -                  The chin should be kept well in so that it is fairly near the chest.

FEET -                  The proper position of the feet is approximately the width of the hips apart with one foot slightly in front of the other and pointing in the direction of travel.

ARMS   -           Should be kept close to the body for balance.

BODY       -           The body being kept in its normal position should act as a counter weight to the load.

  • It should always be possible to see where you are going when lifting a load.
  • If a load appears too heavy or is too unwieldy, then assistance is required to lift it.
  • Protective clothing should always be worn when lifting, i.e. safety footwear and gloves.

LONE WORKING

The hazards involved with undertaking most tasks do not alter with lone working and thus the risks associated with them do not alter. For this reason, lone working is largely an acceptable situation. The normal rules of the workshops will still apply, such as only authorised people using machinery, having guards in place and wearing personal protective equipment. Some tasks are, however, not permitted by law. These include entry into confined spaces so work inside, fireboxes, tanks or similar is not allowed unless there is someone else present.

When people are working alone, there is always the risk that people will improvise where a task really requires a second person to give assistance. Examples of this are moving heavy objects and supporting things to enable them to be aligned or fastened together. Such improvisation is not allowed and any task undertaken must be capable of being carried out without recourse to such actions.

There is also the possibility that a person working alone will be taken ill or otherwise become incapacitated. For this reason it is important that the following conditions are complied with:

  • The lone worker must have a working and charged mobile phone on his person and it must be switched on. In this respect it is not acceptable for it to be kept in a locker, bag or similar remote place.
  • The lone worker must inform another person of his whereabouts and what time he/she expects to finish and return home. Where the duration of lone working is for an extended period, the lone worker must arrange to make contact with the relevant person from time to time.
  • In the event of the lone worker requiring assistance from the emergency services or others, they must be able to gain quick access to render assistance. For this reason, the main gates and relevant buildings must not be locked so as to allow easy and quick access if required.

Lone working includes situations where there may be another person on the premises but not in the same building. In such cases the above still applies.

GENERAL TIDINESS

  • Put tools and equipment away after use.
  • Tidy up after each job.
  • Clear up after each job.
  • Do not leave litter lying around.
  • All solvent containers are to be kept closed.

BEHAVIOUR

  • No horseplay or boisterous behaviour.
  • No operational short cuts or malpractice.
  • No dangerous actions.

HYGIENE

  • Wash hands and/or face when contaminated or splashed with oils or chemicals.
  • Obtain medical treatment for any contagious infections and cuts or abrasions.

Steve Roberts

Substantially Revised 27/05/20