Question: ‘Coopers’ is a motor vehicle repair (MVR) workshop
13 Aug 2024,9:13 PMSCENARIO
‘Coopers’ is a motor vehicle repair (MVR) workshop located on a small industrial estate just off the public highway. The workshop carries out repairs and paint re-sprays on motor vehicles (including cars, vans, minibuses and trucks) involved in minor accidents. The workshop comprises of the following three main areas:
- Preparation area – activities in this area include the removal and replacement of body panels, bumpers and damaged parts, welding, flame cutting, body filling, sanding, and degreasing.
- Paint shop – this is a spray booth in which final preparation takes place, this includes spray-painting, heating and curing of newly sprayed paintwork and cleaning.
- Paint store – paint products are mixed and prepared in this area. Paint, cleaning products and equipment are stored here.
Most of the building is constructed of steel-reinforced, concrete sectional panels within a frame of connected steel beams. These steel beams are insulated with sprayed concrete for extra protection in a fire. Some of the recently extended parts of the building still have exposed steel beams. The roof is made of a fragile plastic corrugated sheeting. There are no fixed automatic fire detection, warning, or suppression systems on the MVR workshop premises. There is only a manually-operated fire alarm and portable fire extinguishers.
The MVR workshop is in an area of poor mobile phone reception. There is a public telephone (land line) 500 metres away on the public highway. Access to the MVR workshop is down an access road of about 100m, which connects directly to the public highway. The turn into the access road from the highway is very easy to miss, as it is quite narrow and on a bend in the road. Emergency services are 20 minutes away, but can be delayed due to busy traffic routes.
The MVR workshop is usually very busy. Occasionally, workers need to work overtime after closing hours, sometimes on their own. Oily rags can be found discarded all around the whole workshop. Smoking and use of mobile phones on the MVR workshop site is prohibited, but this policy is often ignored, and rarely enforced. Workers also often listen to loud music on the radio throughout the day.
Layout, equipment and activities in each area
Preparation area
The preparation area covers a floor area of 10m x 10m, and is 5m high. The entrance is fitted with a large steel roller shutter door that is kept open for most of the year, and only shut when it is too cold, or the weather is bad (ie mainly the winter months). The roller shutter door is raised or lowered manually using a steel chain pulley. Workers bring to work their own electric heaters during the winter months to keep warm.
There are also two inspection pits (2.5m deep by 1.0m wide and 3.5m long). These pits, below ground level, are used to access the underneath of the vehicles. Vehicles are often left idling while the workers carry out engine, exhaust condition and emission checks. Vehicles are driven over the pits and the wheels are secured to stop them rolling. The access steps into the pits are currently awaiting repair due to loose grip coverings. When in use, barriers are put around the pits to stop workers falling in, when not in use, the pits are fully covered.
The MVR workshop mainly carries out work on cars, but also on taller commercial vehicles such as minibuses and vans. To access the tops of the minibuses a mobile work platform was recently purchased. This consists of a 3m x 1m fixed height platform with guardrails, accessed by steps with a handrail. The mobile work platform is on four castors that have brakes, although the brakes do not work reliably. The mobile working platform can be manually moved around the workshop. It was much larger than expected so is stored outside and brought in when needed. Workers have not yet been trained on its safe use, but this has been planned for the coming months.
A number of power tools are used in the preparation area, but there is no system for regularly testing them. Compressed air blow guns are used for various tasks within the workshop. These air blow guns
are often mis-used where mischievous workers insert them into overalls and activate them to startle those concentrating on work tasks. Most of the tools provided are designed for light duty domestic use, rather than for heavy duty industrial use.
Cars arriving at the MVR workshop can have petrol or diesel fuel tanks that need to be drained when repair work is to be carried out near to a vehicle’s tank. In the preparation area, fuel tanks are emptied into open containers and fuel is mixed with waste oils. Where necessary, seatbelt tensioners, airbags and airbag curtains (which all contain explosive charges) are removed using metal hand tools. Inspection lamps are also used during the removal of vehicle parts, as the general lighting in the area can be poor.
Welding and flame cutting are carried out where required (with the exception that no welding or flame cutting is carried out when inside the inspection pits). Welding is carried out using ageing portable electrical tungsten inert gas (TIG) equipment, that has been somewhat neglected. While TIG welding, the alternating current supply to the workshop is notoriously troublesome and frequently blows associated circuit board fuses. In addition, the portable DC generator associated with TIG welding has some poorly-conducting electrical connections and some frayed rubber insulation. Despite all this, the welder (with 30 years’ experience) manages to get the greasy TIG welding equipment to work, although the experienced welder occasionally receives an electric shock in the process. Nonetheless they carry out delicate welding repairs to thin stainless steel car exhaust systems. Flame cutting is occasionally carried out, with an oxy-acetylene torch set up, where required.
Body fillers are used in this area to fill dents; this is then smoothed by powered mechanical sander, before proceeding to the paint shop. The total quantity of body fillers stored at any one time is 25kg. Empty body filler containers, without their lids, are stored with full ones.
Repairs in this area are carried out by two experienced workers along with an 18-year-old apprentice. The apprentice usually works alongside the experienced workers but is occasionally expected to carry out small repairs alone during busy times. A third worker has just returned from leave following a knee operation. This third worker is only taking on light administration duties until they are back to full fitness. All relevant personal protective equipment (PPE) is provided at the workshop, although the condition of the equipment varies.
Before moving to the paint shop for spray-painting, car body panels are degreased using solvents. These solvents are transferred into small open trays from large containers. Workers routinely leave two or three large containers open while working, only closing them at the end of the working day.
Paint shop
The 4m x 8m x 2.5m spray-painting booth has a forced ventilation system, drawing in air at ground level through dedicated grills. The ventilation system removes any vapours that are generated during the spraying process, that are filtered through an exhaust point. This has not been maintained for several years, and the workers believe that the filters need changing.
Solvent materials are kept in closed containers, but there are lots of open, partly-used 5 litre containers stored in different places around the paint shop. These solvents have multiple uses, including being used as hardeners. Rags are used to apply solvent and cleanse surfaces before spray-painting. Paint products are mixed and prepared in the paint store before being brought into the paint shop. The booth is illuminated with large filament bulbs at ceiling height.
A large number of paint colours are used in the paint shop. They are of a 2-stage type (known as a 2k process) requiring a base paint and a separate paint hardener. The total amount of base paint stored on site is 2 tonnes with a further 100kg of hardeners and solvents. Paint is sprayed from a high volume, low pressure (HVLP) spray gun, which is operated by an air compressor set at 2 Bar pressure. To reach the tops of taller vehicles, ladders are used. When fully sprayed, the paint is cured using electric heaters, that typically take two hours to complete
Paint store
The paint store is a very confined area. It has one narrow access route and a single domestic wooden door. The door remains closed except when accessing the store. Ventilation is by a very small basic 0.25m x 0.25m wooden framed window to the exterior.
Many 2.5 litre containers of base paint are stored on shelves in the paint store, some of the higher shelving is old and in need of repair. Paint cleaning and solvent-based paint cleaning materials are also to be found in the store. A high proportion of the containers have not been properly closed after use. Spray guns are cleaned by passing solvent under pressure through the spray nozzle. Coopers has chosen not to buy a dedicated spray gun cleaning machine, which are readily available and inexpensive. Waste materials are stored in enclosed containers which are removed once every two weeks by a waste contractor. There are a small number of electrical devices in the paint store, including inspection lamps, pumps to transfer waste to containers, and electrical paint stirring devices.
Car Park
The car park is compact, with limited room to manoeuvre, especially when the MVR workshop is at its busiest, and customers are often waiting for spaces. Cars often need to reverse to be able to exit the car park. Visitors have complained in the past that when leaving the site, large trees and bushes at the site entrance obscure the view of oncoming traffic. The car park also has an open-sided shed that houses new tyres. Once new replacement tyres are delivered, they are safely stored in purpose-built tyre storage racks. A recent accident occurred when a visitor was hit by a reversing delivery vehicle; as a result, nominated people are now used to help direct tyre delivery vehicles. Waste tyres are piled high to the back of the store, due to limited space, until they are collected for recycling. Lighting in the evenings is limited as there is no external lighting or security lighting. The car park has separate spaces marked out for ‘customer parking’ and ‘collection’. The apprentice moves customers’ cars to the ‘collection’ spaces once they are ready to collect.
The MVR workshop has recently installed closed-circuit television (CCTV) and a perimeter gate to deter trespassers following previous incidents. The manager locking up also has a checklist to complete to help ensure everything is secure before they leave for the day. However, the perimeter gate can be climbed over quite easily. Discarded packaging is stored in two wheelie bins, situated just outside of the paint store.
Recent Events
The insurance assessor has recently visited the MVR workshop. They are dissatisfied with the fire risk assessment, particularly over the controls for the use of highly flammable paints and hardeners. They have asked for a review, believing that there is a significant risk of an explosive atmosphere forming. There have been several minor fires during the last three years.
SUPPORTING DOCUMENTS
1. Site plan of Coopers
Task 1: Transport management
1 (a) Explain the good aspects of traffic management in the car park.
Note: You should support your answer, where applicable, using relevant information from the scenario and the supporting document.
- What realistic improvements could be made to the traffic arrangements on-site?
Task 2: Hazardous area zoning
- Explain why the hazardous classification for the preparation area can vary during different times of the year.
Note: You should support your answer, were applicable, using relevant information from the scenario
Task 3: Risk of substances forming an explosive atmosphere
The spray-painting could form an explosive atmosphere. What should be considered when assessing the risk of an explosion occurring during the spray-painting activity in the booth?
Note: You should support your answer, where applicable, using relevant information from the scenario.
Task 4: Recognising confined spaces and adopting safe working practices
4 (a) Why is the inspection pit a confined space?
Note: You should support your answer, where applicable, using relevant information from the scenario.
- What possible safe working practices could minimise confined space risks when working in the inspection pit?
Task 5: On-site emergency planning
- Even though the law does not require it, the insurance assessor advises the organisation that it may be beneficial to prepare an on-site emergency plan.
- Based on the scenario only, explain why an on-site emergency plan may be beneficial.
- What elements would form part of a suitable and proportionate on-site emergency plan for the MVR workshop
Note: You should support your answer, where applicable, using relevant information from the scenario.
Task 6: Risk of using portable pneumatic equipment
- The workers use compressed air blow guns for various activities. (a) Based on the scenario, what would you expect these activities to be?
- What injuries could you foresee with using these compressed air blow guns AND, for EACH injury, briefly describe how it could occur?
- Based on hazards and risk, what specific aspects of using compressed air blow guns would you prioritise in a training session for those in the MVR workshop?
- Other than training, what control measures would you consider for compressed air blow guns?
Task 7: Electrical risks with TIG welding equipment
- Comment on the electrical risks associated with the TIG welding electrical equipment in the MVR workshop.
Note: You should support your answer, where applicable, using relevant information from the scenario.
Task 8: The behaviour of materials in a fire
- (a) Outline the effects of fire on the following structural materials in the MVR workshop
(i) Steel beams
(ii) Concrete panels
(iii) Wooden window frames and doors
(iv) Plastic Roof
- Comment on improvements that could be made to prevent failures of these materials in the event of a fire.
Note: You should support your answer, where applicable, using relevant information from the scenario.
Task 9: Working at height
- (a) What would you need to consider when choosing appropriate access equipment for work at height tasks?
- (i)What are the strengths and weaknesses of the existing controls used for work at height in the MVR workshop?
- Suggest additional controls to improve safety when working at height.
Note: You should support your answer, where applicable, using relevant information from the scenario.
DRAFT/STUDY TIPS
Introduction
In managing the operational safety of a Motor Vehicle Repair (MVR) workshop like Coopers, numerous considerations need to be addressed, spanning from traffic management to hazardous substance handling and fire safety. The unique operational challenges posed by such an environment necessitate a detailed risk assessment and the implementation of specific safety protocols. This essay aims to critically evaluate the safety and operational concerns presented in the Coopers workshop scenario, with a focus on traffic management, hazardous area zoning, risk of explosive atmospheres, confined spaces, emergency planning, use of pneumatic equipment, electrical risks, material behavior in fires, and working at height. Each section will provide a detailed analysis, supported by relevant literature, theories, and examples, culminating in a comprehensive safety management plan for the Coopers workshop.
Task 1: Transport Management in the Car Park
(a) Good Aspects of Traffic Management in the Car Park
Effective traffic management within the car park is crucial for ensuring the safety of both workers and visitors at the MVR workshop. The Coopers car park is relatively compact, which helps in controlling traffic flow within a confined space. The use of marked spaces for 'customer parking' and 'collection' is a positive aspect, as it provides a clear designation for where vehicles should be parked, reducing the likelihood of congestion. Additionally, the nomination of personnel to direct delivery vehicles is an effective control measure, particularly after the recent incident where a visitor was hit by a reversing vehicle. This measure not only enhances safety but also demonstrates a proactive approach to managing traffic risks.
The installation of Closed-Circuit Television (CCTV) and a perimeter gate further enhances security and deters unauthorized access. These elements, although primarily focused on security, indirectly contribute to better traffic management by ensuring that the site is only accessed by authorized personnel, thus reducing the potential for traffic-related incidents.
(b) Improvements to Traffic Arrangements On-Site
Despite the existing traffic management measures, several improvements could be made to enhance safety further. One significant issue is the limited space within the car park, which often requires vehicles to reverse to exit. This is a high-risk maneuver, especially in a busy workshop environment. The introduction of a one-way traffic system could mitigate this risk by reducing the need for reversing. Additionally, the installation of mirrors at strategic points could improve visibility, particularly when exiting the car park.
The obscured view of oncoming traffic due to large trees and bushes at the site entrance poses a significant hazard. Trimming or removing these obstructions would greatly improve visibility and reduce the risk of accidents. Moreover, the lack of external and security lighting in the evenings is another critical area that needs addressing. Installing adequate lighting would not only enhance safety during late hours but also act as a deterrent to potential trespassers.
Furthermore, the introduction of speed bumps and clear signage indicating speed limits within the car park could help control vehicle speed, reducing the likelihood of accidents. The use of designated walkways for pedestrians, separate from vehicle paths, would further enhance safety for visitors and workers moving around the site.
Task 2: Hazardous Area Zoning in the Preparation Area
The classification of hazardous areas within the preparation area can vary throughout the year due to several factors. Hazardous area classification is influenced by the presence of flammable substances, ventilation, and environmental conditions such as temperature and humidity. During the colder months, the large steel roller shutter door in the preparation area is kept closed, which reduces ventilation and increases the concentration of flammable vapors, thus raising the risk of an explosive atmosphere. Conversely, in warmer months, the door is often left open, allowing for better ventilation and reducing the concentration of hazardous substances in the air.
According to the Dangerous Substances and Explosive Atmospheres Regulations (DSEAR), workplaces must be classified into hazardous zones based on the likelihood of explosive atmospheres occurring. The preparation area at Coopers could be classified as Zone 1 or 2, depending on the time of year and specific activities being carried out. For example, during winter, when ventilation is poor, the area could be classified as Zone 1, indicating that an explosive atmosphere is likely to occur during normal operations. During summer, the classification might shift to Zone 2, where an explosive atmosphere is less likely but still possible.
To manage these risks, it is essential to implement control measures such as improved ventilation systems that can be adjusted according to seasonal changes. Additionally, regular monitoring of the air quality and concentration of flammable substances should be conducted to ensure that the area is classified accurately and appropriate safety measures are in place.
Task 3: Risk of Substances Forming an Explosive Atmosphere During Spray-Painting
The spray-painting activity in the paint booth at Coopers poses a significant risk of forming an explosive atmosphere, primarily due to the use of solvent-based paints and hardeners. Several factors must be considered when assessing the risk of an explosion occurring during spray-painting.
Firstly, the ventilation system in the paint booth is crucial for dispersing flammable vapors and preventing the accumulation of an explosive atmosphere. However, the scenario indicates that the ventilation system has not been maintained for several years, and the filters likely need replacing. Poor ventilation increases the concentration of vapors, creating a hazardous environment. Regular maintenance and inspection of the ventilation system are essential to ensure it operates effectively.
Secondly, the presence of open, partly-used containers of solvents in the paint shop further exacerbates the risk. These containers should be properly sealed when not in use to prevent the release of flammable vapors. Additionally, the use of filament bulbs in the spray booth is concerning, as these bulbs can generate heat and act as an ignition source if an explosive atmosphere is present. Switching to explosion-proof lighting fixtures designed for use in hazardous areas would mitigate this risk.
The use of High Volume Low Pressure (HVLP) spray guns, operating at 2 Bar pressure, is standard practice in spray-painting. However, ensuring that the equipment is properly grounded to prevent static electricity buildup is critical, as static discharge could ignite the vapors. Furthermore, the curing process, which involves the use of electric heaters, should be carefully managed to prevent overheating and potential ignition of the solvent vapors.
In assessing the risk of explosion, it is also important to consider the training and awareness of the workers. Proper training on the safe handling of flammable substances and the importance of maintaining a clean and organized workspace is essential in minimizing the risk of accidents. Implementing a permit-to-work system for high-risk activities like spray-painting could provide an additional layer of safety by ensuring that all necessary precautions are taken before the activity commences.
Task 4: Recognizing Confined Spaces and Adopting Safe Working Practices
(a) Why the Inspection Pit is a Confined Space
The inspection pit at Coopers qualifies as a confined space under the Confined Spaces Regulations 1997, which defines a confined space as any place that is substantially enclosed and where serious injury can occur from hazardous substances or conditions. The inspection pit is 2.5m deep, with limited means of access and egress, making it difficult for workers to exit quickly in an emergency. The pit's depth and the presence of vehicles idling above it increase the risk of exposure to hazardous gases, such as carbon monoxide, which can accumulate in the confined space.
Furthermore, the pit's enclosed nature and the potential for poor ventilation mean that any hazardous atmosphere, such as flammable vapors or toxic gases, can build up quickly, posing a significant risk to workers. The combination of these factors makes the inspection pit a high-risk area that requires stringent safety measures.
(b) Safe Working Practices for Minimizing Confined Space Risks
To minimize the risks associated with working in the inspection pit, several safe working practices should be adopted. Firstly, ensuring proper ventilation is critical. This could involve the use of portable ventilation equipment to extract harmful gases and introduce fresh air into the pit. Secondly, continuous atmospheric monitoring should be conducted to detect the presence of hazardous gases, with alarms set to alert workers if dangerous levels are detected.
The use of appropriate personal protective equipment (PPE), such as respirators, is essential, particularly when there is a risk of exposure to harmful substances. Workers should also be equipped with harnesses and lifelines that can be used to rescue them in an emergency. Additionally, the inspection pit should be clearly marked as a confined space, with warning signs and barriers to prevent unauthorized access.
Training is another critical component of confined space safety. Workers should be trained on the specific hazards associated with the inspection pit and the emergency procedures to follow if something goes wrong. This training should include practical exercises in confined space rescue techniques, ensuring that all workers are prepared for potential emergencies.
Finally, implementing a permit-to-work system for entry into the inspection pit would ensure that all necessary precautions are taken before work begins. This system would require a thorough risk assessment to be completed and approved by a competent person, with specific control measures identified and implemented.
Task 5: On-Site Emergency Planning
(a) Benefits of an On-Site Emergency Plan
Despite not being legally required, an on-site emergency plan for Coopers would be highly beneficial, particularly given the various risks identified in the scenario. An emergency plan would provide a structured response to incidents, such as fires, explosions, or chemical spills, ensuring that all workers know their roles and responsibilities in an emergency. This is particularly important given the workshop's location, with poor mobile phone reception and a 20-minute delay for emergency services.
Having a clear emergency plan would also minimize confusion during an incident, reducing the likelihood of injuries or fatalities. The plan would outline specific actions to be taken in different scenarios, such as evacuating the premises, shutting down equipment, or containing a chemical spill. By having a predetermined plan, workers can respond quickly and effectively, reducing the impact of the incident.
Moreover, an emergency plan would help ensure compliance with insurance requirements. The insurance assessor has already expressed concerns about the fire risk assessment, and implementing an emergency plan would demonstrate a commitment to safety, potentially leading to more favorable insurance terms.
The plan could also serve as a training tool, with regular drills conducted to ensure that all workers are familiar with the procedures. This would enhance overall preparedness and reduce the likelihood of panic during an actual emergency.
Task 6: Use of Pneumatic Equipment and Hazards of Compressed Air
The use of compressed air and pneumatic tools in the MVR workshop presents several risks that must be managed to ensure the safety of workers. Compressed air is often used for tasks such as cleaning parts or operating pneumatic tools. However, it is important to recognize the potential hazards associated with compressed air.
Firstly, the high-pressure air can cause serious injuries if it comes into contact with the skin or eyes. Air embolism, where air is forced into the bloodstream, is a particularly dangerous risk that can occur if compressed air is directed at the body. To mitigate this risk, workers should be trained never to use compressed air for cleaning themselves or their clothing. Instead, they should use safer alternatives, such as vacuum systems.
Pneumatic tools, while highly effective, also present risks such as noise, vibration, and the potential for accidents if the tools are not properly maintained or used. Regular inspection and maintenance of pneumatic tools are essential to ensure they are in good working condition. Additionally, workers should be provided with appropriate PPE, such as hearing protection and gloves, to protect against noise-induced hearing loss and hand-arm vibration syndrome.
Task 7: Electrical Risks and Safety Management
The electrical systems and equipment used in the MVR workshop pose several risks, particularly in relation to the potential for electric shock, short circuits, or electrical fires. One specific concern is the use of extension leads, particularly in the workshop area where they may be exposed to mechanical damage or water. Damaged or poorly maintained extension leads can cause short circuits, leading to fires or electric shocks.
To mitigate these risks, it is important to conduct regular inspections of all electrical equipment, including extension leads, to identify and address any damage. Additionally, all electrical installations should be regularly tested and certified by a qualified electrician to ensure compliance with the relevant standards.
Workers should also be trained on the safe use of electrical equipment, including the importance of not overloading circuits and the safe use of extension leads. Implementing a lockout/tagout procedure for electrical maintenance work would further enhance safety by ensuring that equipment is de-energized before any work is carried out.
Task 8: Material Behavior in Fires and Fire Safety Management
The materials used in the MVR workshop, including paints, solvents, and lubricants, can significantly influence the behavior of a fire. Many of these substances are flammable and can contribute to the rapid spread of a fire if not properly managed. Understanding the fire behavior of these materials is crucial for developing effective fire safety strategies.
For example, solvent-based paints and thinners can produce flammable vapors that ignite easily, creating a flash fire or explosion. Proper storage of these materials in fire-resistant cabinets and the use of flame-proof containers can reduce the risk of fire. Additionally, ensuring that all flammable materials are stored away from ignition sources, such as welding equipment or electrical appliances, is critical.
The workshop should also be equipped with appropriate fire detection and suppression systems, including smoke detectors and fire extinguishers. Workers should be trained on the use of fire extinguishers and the importance of not attempting to fight a fire if it puts them at risk. Regular fire drills should be conducted to ensure that all workers know how to evacuate the premises safely in the event of a fire.
Task 9: Working at Height and Managing Fall Risks
Working at height presents significant risks, particularly in the MVR workshop where workers may need to access vehicles on lifts or work on the roof of the building. Falls from height are a leading cause of workplace fatalities and injuries, making it essential to implement robust safety measures.
One key aspect of managing fall risks is the use of proper equipment, such as ladders, scaffolding, and fall arrest systems. All equipment should be regularly inspected to ensure it is in good condition and fit for purpose. Workers should be trained on the safe use of this equipment, including the importance of securing ladders and wearing harnesses when working at height.
Additionally, the workshop should implement a policy that prohibits working at height without appropriate fall protection measures in place. This could include the use of guardrails, safety nets, or personal fall protection systems, depending on the specific task and the height involved.
Conclusion
In conclusion, the safety and operational concerns at Coopers MVR workshop highlight the importance of a comprehensive approach to risk management. By addressing the issues related to traffic management, hazardous area zoning, confined spaces, emergency planning, pneumatic equipment, electrical risks, material behavior in fires, and working at height, Coopers can create a safer working environment for its employees and visitors. Implementing the recommended control measures and ensuring that all workers are properly trained and equipped to handle the hazards present will significantly reduce the likelihood of accidents and incidents in the workshop.
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