| 1 | Fire and explosion from hot workHSE: Welding | Welders, everyone in the workshop block, and on site jobs the customer's staff and building. Fire started by sparks, hot slag, flame or heat conducted through walls and pipes during welding, cutting, grinding, soldering or use of a blowtorch. Fires can start hours after the work has finished. Explosion if hot work is done near flammable liquids, gases or dust. | 5 | 3 | 15 | • Hot work is avoided where a cold method will do, for example mechanical cutting or push fit joints• A hot work permit is issued for each job, stating the checks before, during and after• Combustible materials are moved at least ten metres away or covered with fire resistant blankets, and openings are sealed• A fire watch is kept during the work and for at least an hour after, with an extinguisher to hand• Flammable liquids, gases and dust have been removed from the area, and containers that held them are checked before hot work• Gas cylinders are secured upright, fitted with flashback arrestors, and hoses and regulators are checked before use• Smoke detectors in the area are isolated only under the permit and reinstated afterwards• On customers' sites the customer's permit system is used where one exists; otherwise the firm's own permit is issued by the lead welderand 5 more | 5 | 1 | 5 | None |
| 2 | Burns, eye damage and fume from welding and cuttingHSE: Welding. COSHH assessments needed | Welders and the apprentice, and anyone in the workshop without protection. Burns from sparks, spatter and hot metal; arc eye and retinal damage from ultraviolet light; lung disease from welding fume, which is a carcinogen; noise from grinding and cutting. | 4 | 4 | 16 | • Local exhaust ventilation captures welding fume at source, and RPE is worn where extraction cannot control it• A COSHH assessment covers welding fume and any coatings on the metal• Welding helmets or goggles with the right shade are worn, and screens protect people nearby from the arc• Flame resistant overalls, gauntlets, leather apron and safety boots are worn, with no synthetic clothing underneath• Grinder guards are fitted, discs are the right type and within date, and eye and hearing protection are worn• Health surveillance is in place for regular weldersand 3 more | 3 | 2 | 6 | None |
| 3 | NoiseHSE: Noise at work | Everyone in the workshop when grinding or cutting is under way. Permanent hearing loss and tinnitus from loud machinery, tools and music over time. Noise also masks warnings and alarms. | 3 | 4 | 12 | • Noise levels have been checked where staff have to raise their voices to be heard, and the results are recorded• Hearing protection is provided, its use is required in marked zones, and staff have been shown how to wear it• Time spent in noisy areas is limited by rotating tasks• Hearing checks are arranged for staff regularly exposed above the upper action valueand 1 more | 3 | 2 | 6 | • Look for ways to cut noise at source: quieter equipment, damping, enclosure or distance. |
| 4 | Hand arm vibrationHSE: Hand arm vibration | Welders using angle grinders for preparation and finishing, up to two hours a day. Hand arm vibration syndrome and carpal tunnel syndrome from regular use of vibrating tools such as grinders, drills, breakers, sanders and strimmers. Permanent damage to nerves and blood vessels in the hands. | 4 | 4 | 16 | • Low vibration tools are chosen, kept sharp and maintained, and the vibration data for each tool is known• Daily trigger time is limited and tracked so exposure stays below the action value• Tasks are rotated between staff and breaks are taken from vibrating tools• Staff keep their hands warm and dry and know the symptoms to report• Health surveillance is in place for staff regularly exposed above the action valueand 2 more | 3 | 2 | 6 | None |
| 5 | Manual handling of loadsHSE: Manual handling at work | All staff moving steel sections, gas cylinders and welding sets. Back injury, strains and hernias from lifting, carrying, pushing and pulling loads that are heavy, awkward, or handled often. Musculoskeletal injuries build up over time as well as happening in one lift. | 3 | 3 | 9 | • Trolleys, sack trucks or other lifting aids are provided and used for heavy or repeated loads• Heavy loads are split into smaller ones or lifted by two people• Staff who lift regularly have been shown how to lift safely and how to assess a load before they pick it up• Heavy items are stored between knee and shoulder height, and the heaviest at waist height• Cylinders are moved on a cylinder trolley, never rolled or carriedand 2 more | 3 | 2 | 6 | • Look at whether each regular lift can be avoided: deliveries to the point of use, smaller packs, or equipment moved by the supplier.• Clear and shorten the routes loads are carried along.• Check who is doing the lifting and take heavy loads away from anyone with a health reason not to lift. |
| 6 | Electrical equipment and installationsHSE: Electrical safety at work | Welders using welding sets and grinders, on site sometimes in damp conditions. Electric shock and burns from damaged leads, plugs and equipment, faulty installations or water near electrics. Fire from overloaded sockets and faulty equipment. | 5 | 2 | 10 | • Staff look at plugs, leads and equipment before use and report anything damaged, which is then taken out of use• Portable equipment is inspected and, where needed, tested at intervals that match how it is used, and the record is kept• Equipment used outdoors or in wet areas runs through an RCD• Only a competent electrician does repairs or alterations; staff do not open equipment or replace fuses without training• Welding return clamps are placed close to the work so current cannot pass through structures or pipeworkand 2 more | 5 | 1 | 5 | • Book an inspection of the fixed electrical installation by a competent electrician.• Remove daisy chained and overloaded extension leads and add sockets where they are needed.• Move electrical equipment away from sinks and wet areas. |