Health and Safety

Executive

Example risk assessment for a motor vehicle mechanical repair workshop

Setting the scene ■■ listened to the employees’ own concerns about health
and safety; and Important reminder
The garage manager carried out the risk assessment. ■■ looked in the accident book.
The business employed 12 mechanics, including two This example risk assessment shows the kind of
apprentices who carried out mechanical repairs. 2 The manager then wrote down who could be harmed approach a small business can take. Use it as a
by the hazards and how. guide to think through some of the hazards in your
How was the risk assessment done? business and the steps you need to take to control
3 For each hazard identified, the manager recorded what the risks. Please note that it is not a generic risk
The garage manager followed the guidance in Five steps to controls, if any, were in place to manage these. He assessment that you can just put your company
risk assessment (www.hse.gov.uk/pubns/indg163.pdf). then compared these controls to the good practice name on and adopt wholesale without any thought.
guidance laid out in motor vehicle repair web pages, This would not satisfy the law – and would not be
1 To identify the hazards, the garage manager: the Health and safety in motor vehicle repair booklet, effective in protecting people.
Essentials of health and safety at work publication
■■ read HSE’s motor vehicle repair web pages and the manufacturers’ instructions or data sheets. Every business is different – you need to think
(www.hse.gov.uk/mvr/), the Health and safety in motor Where existing controls did not meet good practice, the through the hazards and controls required in your
vehicle repair booklet HSG67 (www.hsebooks.com) and manager wrote down what further actions were needed business for yourself.
the Essentials of health and safety at work publication to manage the risk.
(www.hsebooks.com ISBN 978 0 7176 6179 4) to learn
where hazards can occur; 4 Putting the findings of the risk assessment into
■■ checked the manufacturers’ instructions or data sheets practice, the manager decided and recorded who was
for chemicals and equipment; responsible for implementing the further actions and
■■ walked around the garage and took a note of things when they should be done. When each action was
that they thought might pose a risk, taking into completed it was ticked off and the date recorded.
consideration what they learnt from HSE’s guidance;
■■ talked to staff to find out what work methods were 5 The findings of the risk assessment were discussed
in use, what training they had been given, and any by the supervisors and their teams of mechanics. The
particular requirements that the two young apprentices manager decided that a review and update of the
may have; risk assessment would be made annually, or sooner if
■■ went over the arrangements for waste disposal with the things changed.
licensed disposal contractor on the telephone;

Example risk assessment: A motor vehicle mechanical repair workshop 1 of 6 pages

 Health and Safety
Executive

Company name: PQR Motor Vehicle Repair shop (mechanical repairs only) Date of risk assessment: 6/3/2006

What are the hazards? Who might be harmed and What are you already doing? What further action is necessary? Action by Action by Done
how? who? when?

Hazardous substances Skin contact over a long ■■ Nitrile gloves (EN 374 standard) gloves supplied and used. ■■ Supervisor to start keeping a check that JB 14/3/06 12/3/06
Contact with used period can lead to severe ■■ Garage overalls supplied and used. gloves are being used.
engine oil etc during dermatitis and skin cancer. ■■ Contract for regular cleaning of overalls. ■■ Risks from dermatitis and skin cancer to be JB 14/3/06 12/3/06
servicing explained to workers.

Car engine running The fumes may cause ■■ Car exhaust attached to extractor system when engine is ■■ No further action required.
inside, toxic exhaust workers eye irritation and running.
fumes, eg carbon breathing difficulties. ■■ Extractor system maintained and tested to prevent leaks.
monoxide

Fire Building could be burnt down, ■■ Smoking prohibited in all work areas. ■■ Manager to arrange some training on use of SP 1/5/06
General workers and visitors could be ■■ Fire alarms maintained and tested by manufacturer. extinguishers for all workers.
trapped in burning building. ■■ Extinguishers provided and inspected under contract. ■■ Annual fire drill to be carried out. RB 11/9/06
Workers could suffer severe ■■ Special fire exits not needed as all work areas have immediate
or fatal burns if petrol gets on access to outside.
them and is ignited.

Petrol fires ■■ Fuel retriever used to empty vehicle fuel tanks outside. ■■ Brief workers on safe working with petrol RB 2/5/06
■■ Spillages cleared immediately. (from HSE’s Safe use of petrol in garages
■■ Component cleaning in recirculating paraffin system, not petrol. INDG331).

LPG fires ■■ LPG fuelled vehicles ported in safe places. ■■ Brief workers on safe working with LPG RB 2/5/06
■■ Workers trained in hazards of LPG. (from HSE’s LPG-fuelled motor vehicles
INDG387).

Example risk assessment: A motor vehicle mechanical repair workshop 2 of 6 pages

 Health and Safety
Executive

What are the hazards? Who might be harmed and What are you already doing? What further action is necessary? Action by Action by Done
how? who? when?

Battery charging Workers could suffer burns ■■ Proprietary charger, installed by electrician, is used in ■■ No further action required.
from contact with battery acid accordance with instructions.
whilst charging, particularly ■■ Acid-resistant gloves and goggles supplied and used.
if battery is overcharged and
explodes.

Electrical equipment All workers could suffer ■■ Hand lamps etc are low voltage (24 volts). ■■ Manager to assess suitability of replacing SP 26/4/06
Fixed equipment: range potentially fatal shocks ■■ A few 240 volt tools are used, all have industrial plugs and 240 volt tools with air-powered or 110 volt
of portable appliances, or burns if they use faulty leads. alternatives.
eg hand lamps. electrical equipment – portable ■■ Testing carried out annually on all portable 240 volt tools and
equipment is particularly liable users trained to carry out visual checks and report defects.
to damage. Faulty equipment ■■ Installed equipment receives regular maintenance.
could also start a fire.

Mechanical equipment Moving parts can trap parts ■■ All mechanical equipment checked before use and faults ■■ No further action required.
Eg grinding equipment of the employee’s body (eg reported to supervisor.
fingers/hand/arm) causing ■■ Equipment not to be left running unattended.
crush injuries. Workers can ■■ Guarding provided.
also cut themselves on sharp ■■ Safety goggles provided and worn.
edges or scald themselves on ■■ Grinding wheels changed by trained person.
hot parts.

Falling objects Failure of a car lift or jack ■■ Car lifts and jacks serviced by supplier and inspected by insurers. ■■ No further action required.
Car lift failure may cause severe crush ■■ Jacks only used where ground conditions are firm, stable and
Car jack failure injuries to an employee if a level.
vehicle fell on an employee ■■ Axle stands regularly maintained and inspected.
– those who work in vehicle ■■ Axle stands used after lifting vehicle with jack.
repair are particularly at risk. ■■ Safe working loads not exceeded.

Example risk assessment: A motor vehicle mechanical repair workshop 3 of 6 pages

 Health and Safety
Executive

What are the hazards? Who might be harmed and What are you already doing? What further action is necessary? Action by Action by Done
how? who? when?

Work involving air Workers could suffer: ■■ Workers are trained in correct procedures. ■■ Brief workers on safe working with air- RB 5/7/06
conditioning systems ■■ Frostbite – through conditioning systems (from HSE’s Safe
skin or eye contact with working with vehicle air-conditioning systems
refrigerant liquid or gas. INDG349).
■■ Asphyxiation – if sufficient
quantities of gas escape
into confined space.
■■ Exposure to harmful
gases – through thermal
decomposition of
refrigerant if exposed to a
naked flame.

Compressed air All workers could suffer blast ■■ All workers trained in safe working procedures and dangers of ■■ No further action required.
Explosion of equipment injuries if the air receiver were horseplay.
tyres; injection of air in to explode; workers could suffer ■■ Airline has deadman’s handle.
the body damage to internal organs if air ■■ System inspected and serviced every year by insurers.
is introduced into the body.

Handling vehicle Air bags could explode when ■■ Units are stored in suitable cabinet of their own. ■■ Brief workers on safe handling of air RB 1/6/06
air bags not fitted, causing injury. ■■ Workers are trained in correct handling and fitting. bags (from HSE’s Airbags and seatbelt
■■ Faulty units are returned to supplier for disposal. pretensioners at garages and motor vehicle
repair workshops INDG280).

Manual handling All workers (particularly those ■■ Forklift truck used to move material into store and take ■■ Manager to arrange manual handling SP 10/5/06
In the store; movement in stores) could suffer from components to work shop. training for the workers in the store.
of components back pain if regularly lifting/ ■■ Manual handling still required. ■■ Brief workers on handling tyres (from HSE’s RB 22/3/06 22/3/06
carrying heavy or awkward Collection and delivery of tyres guidance:
objects. www.hse.gov.uk/mvr/handlingtyres.pdf).
■■ More detailed assessment to be carried out JB 22/6/06
(using HSE’s Manual handling assessment
charts INDG383).

Example risk assessment: A motor vehicle mechanical repair workshop 4 of 6 pages

 Health and Safety
Executive

What are the hazards? Who might be harmed and What are you already doing? What further action is necessary? Action by Action by Done
how? who? when?

Operation of lift truck Injuries such as fractures can ■■ All operators trained and competent for use of the lift truck. ■■ Supervisor to assess suitability of pedestrian JB 01/6/06
be caused by: ■■ Truck serviced regularly and examined every six months. operated lift trucks.
■■ the driver crashing lift ■■ Flooring maintained to reasonable standard. ■■ Refresher training for operators to be SP 21/5/07
truck; ■■ Stores laid out to enable truck to load and unload safely and arranged every 3 years.
■■ workers and visitors being pedestrians to pass safely.
hit by lift truck;
■■ workers falling from lift
truck;
■■ objects falling from lift
truck onto workers and
visitors; and
■■ the lift truck toppling over.

Vehicle movements Injuries such as fractures can ■■ Safe parking provided for customers without need for reversing. ■■ Supervisor to monitor speed of cars in/out JB 29/3/06 31/3/06
occur if vehicles hit workers ■■ Marked walkways for pedestrians. and around premises.
or visitors. ■■ Vehicles driven slowly in/out and around premises.

Slips and trips All workers and visitors may ■■ Good housekeeping standards maintained through training and ■■ Walkways and storage areas designated by JB 12/4/06 10/4/06
suffer a strain/sprain or even monitoring. yellow lines.
a fracture through slipping on ■■ Floors degreased weekly. ■■ Weekly housekeeping check to be started. JB 10/3/06 17/3/06
oil/water spillages. ■■ Absorbent granules and sawdust put on spills as soon as possible.
■■ Entrances and exits maintained.

Falls from height Injuries such as fractures ■■ Access equipment provided for work on trailers and tops of ■■ Supervisor to monitor use of portable JB 7/4/06 7/4/06
may be incurred by workers/ commercial vehicles. ladders, access equipment when working on
visitors if they fall from ■■ Handrails fitted at edges of raised storage areas and access vehicles, and safety at inspection pits.
ladders, the top of vehicles, stairway provided.
or raised storage areas. ■■ Workers trained to use ladders safely.
■■ Vehicle inspection pits clearly marked and covered when not in use.

Example risk assessment: A motor vehicle mechanical repair workshop 5 of 6 pages

 Health andand
Health Safety
Safety
Executive
Executive

What are the hazards? Who might be harmed and What are you already doing? What further action is necessary? Action by Action by Done
how? who? when?

Hygiene and All workers. ■■ Heated mess room with kitchen area provided. ■■ No further action required.
comfort ■■ Toilets and sinks available, cleaned daily.
■■ Locker room for drying and storage of own clothes and work
clothing/equipment provided.
■■ Portable heaters used during the winter in the workshop.
■■ Drinking water and cups provided.

Public access to Customers could suffer ■■ Signs up banning customers from the workshop, viewing ■■ Workers to be reminded to challenge anyone SP 19/5/06
workshop various injuries if they wander window provided in reception. entering the workshop without permission.
into the workshop.

Assessment review date: 8/1/07

Example risk assessment: A motor vehicle mechanical repair workshop 6 of 6 pages

Published by the Health and Safety Executive 11/08