Maintenance Repair Hazards Safety

Maintenance is a high-risk activity with specific hazards and risks and these include working alongside a running process and in close contact with machinery. During normal operation, automation typically diminishes the likelihood of human error that can lead to accidents. In maintenance activities, contrary to normal operation, direct contact between the worker and machine cannot be reduced substantially - maintenance is an activity where workers need to be in close contact with processes. Maintenance often involves unusual work, non-routine tasks and it is often performed in exceptional conditions, such as working in confined spaces. Maintenance operations typically include both disassembly and reassembly, often involving complicated machinery. This can be associated with a greater risk of human error, increasing the accident risk.

Hazards 

This will depend on the work you are doing and where you are doing it. The hazards are commonly grouped as physical, chemical, biological and psychosocial. The hazards may vary significantly between planned preventive and repair or corrective maintenance tasks. It is essential that maintenance workers and those supervising the works understand the potential consequences of their actions or their lack of attention to detail. The following table outlines the groups of hazards to take into consideration:

Types of Hazards

Physical

• Mechanical movement - rotating elements e.g. flywheels; compressed springs; gravity; unexpected startups e.g. blockages cleared, trapped air in lines operating valves, restoration of power, computerized auto-start; instability; failure of sub-standard parts; homemade machines
• Electrical - capacitors; high voltage; static
• Hydraulics - high-pressure fluids
• Pneumatic - high-pressure steam, gases, vapours
• Engulfment - oxygen-deficient atmospheres; radiation
• Fire/explosion - extreme heat/cold; noise; vibration
• Work at Height - weather; animals; ergonomics; visibility

Chemical

• Dust & fibres e.g. asbestos, silica, respiratory sensitizers
• Dangerous substances e.g. chlorine, oxygen, hydrogen
• Toxic, oxidizing, explosive, flammable, corrosive
• Hydraulic fluids, oils, acids, alkalis, organic solvents

Biological

• Pathogenic bacteria, viruses, parasites, moulds and fungi

Psychosocial

• Time pressure; long hours; shift work
• Poor work organisation; unsocial working hours