Risk Assessments appropriate to the Composites Manufacturing laboratory (Brunel 007)
being guidance for student projects and for modules MATS232, MATS334, MATS347 and MATS 348		 Lecture
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The information below is generic: YOU must consider whether the analysis is appropriate for YOUR OWN WORK.
The assessments were variously originated by Bob Bray [RGB], Richard Cullen [RKC], Brian Lord [BDL], Samuel Pickard [SP], Will Rogers [WR], Julian Spooner [JSp] and John Summerscales [JSu] with probability and severity moderated by JSu for consistency.

One example of best practice is the UK Police Forces' National Decision Model (NDM) which can be applied:

Decision makers can use the NDM to structure a rationale of what they did during an incident and why.

NOTE:

  1. the RISK FACTOR is the product of PROBABILITY x SEVERITY (it is not assessed separately).
  2. if it is not in the list, it may still be hazardous (you should prepare a risk assessment).
  3. the quoted values are for generic materials - you should take especial care to consider any special circumstances associated with you own work which might alter the calculation.

The parameters when this page was compiled were:

PROBABILITY: SEVERITY: RISK FACTOR:
1 = unlikely 1 = minor 1-3 = low risk
2 = possible 2 = serious 4 = medium risk (shown in orange below)
3 = probable 3 = critical 6-9 = high risk (shown in red below)

The University of Plymouth now (May 2022) uses a five point scale:

PROBABILITY: SEVERITY: RISK SCORE: RISK LEVEL: CATEGORY: DESCRIPTION:
1 = very unlikely 1 = insignificant 1-3 = low risk      
2 = unlikely 2 = minor 1-4 LOW Acceptable No further actions needed.
3 = possible 3 = moderate 5-9 MEDIUM Tolerable
Adequate		 Should be reviewed to ensure that there is nothing more that can be done.
4 = likely 4 = major 9-15 HIGH Undesirable Immediately review current control measures,
and where appropriate decide on further actions.
5 = almost certain 5 = fatal 16-25 VERY HIGH Unacceptable Stop activity and make immediate improvements.

The First-Aiders for laboratories associated with composites laboratories are:

Person/Building Extension Telephone
Bob Mann/BRL 86188 01752 586188
Tony Tapp/BRL014 86073 01752 586073
Plmouth Hospitals NHS website: In An Emergency
The Cumberland Centre Minor Injury Unit (telephone 01752 434390) is at Dameral Close (satnav PL1 4JZ).
The Royal Eye Infirmary (telephone triage 01752 439330 for accident and emergency advice on eye problems) is now at Derriford Hospital.
In an emergency, call Security first on 333, (Security can than expedite the services once on site), then ring for external services using 9.999.

To go directly to the heading for a specific topic click on the relevant entry in the list below ..

Reference Activity/Task Hazards Persons in Danger Probability (P) Severity (S) Risk Factor (R =P*S) Controls in Place or Action to be Taken Additional Requirements
                 
   Life [JSu] meningitis  all 2 3 6  Awareness  
   Smoking [JSu] now illegal indoors in the UK  all           
                 
   Visitors              
   visitors [JSp] tripping  all 1 1 1  areas kept tidy .. walkways marked .. general good housekeeping  control and guidance by UoP staff
   visitors [JSp] overhead hazards  all 1 1 1  overhead beams signed .. protective padding as required  control and guidance by UoP staff
   visitors [JSp] slipping hazards  all 1 3 3  prevent splashing into walkways .. use signs to warn of danger .. do not run  control and guidance by UoP staff
   visitors [JSp] fire  all 1 2 2  shout fire .. react to bell .. follow evacuation procedures (leave by nearest exit and proceed to assembly point)  control and guidance by UoP staff (fire marshalls)
   hands-on demonstrations/activities [JSp] general  all 1 2 2  avoid potentially dangerous activities .. engage visitors in actions with little or no risk  .. consider the ability of the visitor to actively participate.  control and guidance by UoP staff .. maintain a staff presence at all times and a high staff/student ratio.
                 
 C0  Thermosetting resins              
 C0A     Epoxide resin              
   base resin [JSu]  sensitisation  operator 1 2 2  personal protective equipment (specifically lab coat .. barrier cream .. nitrile gloves .. safety glasses)  is the operator already sensitised?
   curing agents [JSu] skin absorption  operator 1 2 2  personal protective equipment (specifically lab coat .. barrier cream .. gloves)  
   mixing components [JSu] volatile organic compounds  operator/those adjacent 2 1 2  local extraction during both decanting and mixing  
 C0B     Unsaturated polyester              
   base resin/diluent [JSu] solvent (styrene)  operator 2 1 2  vapour extraction ventilation - personal protective equipment (specifically lab coat .. barrier cream .. gloves)  
   peroxide initiator [JSu]  oxidising substance:  burns  operator 2 3 6  dispense with single opening partial vacuum polymer pipettes.
  personal protective equipment (specifically safety glasses .. lab coat .. barrier cream .. gloves)
   cobalt accelerators CMR2 reprotoxic.
possible carcinogenic class 1B.		  operator  1  1  1  cobalt-free accelerator  
   cobalt sulphate lung carcinogenic category 1B.
reproductive toxicant category 1B.
mutagenic category 2.		  operator  1  1  1  cobalt-free accelerator  
 C0C     Other resins              
   Atlas Polymers DI 011 DE 004 [JSp] isocyanate  operator/those adjacent 3 2 6  read MSDS and COSHH assessment .. wear air fed hood .. mix in fume cupboard .. use local extraction  insist others leave the area
 C0B  Thermoplastic polymers              
                 
 C1  Reinforcement fibres              
   all fibres [JSu] nuisance dust  operator/those adjacent 1 1 1  dust mask .. local extraction  
   all fibres sharp cutting tool  operator/those adjacent 1 2 2  use chain mail glove(s) provided.  
   aramid fibres [JSu] respirable dust  operator/those adjacent 2 1 2  dust mask .. local extraction  synthetic fibres are not anticipated to be respirable, but can irritate.
   carbon fibres [JSu] electrical conductor leading to short circuit  electrical equipment 2 1 2  avoid floating fibres .. filtered electrical power supplies  synthetic fibres are not anticipated to be respirable, but can irritate.
                 
 C2A  Reinforcement fabrics              
   lifting reinforcement [JSu] back injury  operator 2 2 4  use appropriate lifting strategies (hoists or request assistance from others)  
   cutting [JSu] sharp tools  operator 2 2 4  chain mail gloves .. shielded roller cutter if practical  
C2B  prepreg (see C8A below)               
C2C  Sandwich core materials              
   cutting and shaping [JSu] sharp tools  operator 2 2 4  chain mail gloves  
   cutting and shaping [JSu] dust  operator/those adjacent 3 1 3  dust mask ..local extraction  
                 
                 
C2D  Fine powder fillers              
   handling fine powders  skin irritation  operator 1 1 1  use appropriate gloves  
   handling fine powders  respiratory hazard if <3 μm  operator 1 2 2  use fume cupboard, wear dust maks and PPE  
   handling fine powders  fire  operator/those adjacent 1 3 3  avoid ignition sources  fire extinguisher available
   handling fine powders  toxicity  operator ? ? ?  COSHH assessment  dependent on chemical nature of powder
   mixed powder and resin  toxicity and irritation dominated by matrix resin  operator 1 1 1  observe precautions for resin system in use  risk may be increased with certain resins
   nanomaterials  see A16 below          see A16 below  
                 
 C5  Hand lamination              
   See C0A, C0B, C1 and C2 above
 and C10B below as appropriate 		             
   oven curing [JSu] burns during insertion/removal of part from oven  operator 2 2 4  oven gloves  
   releasing panel from mould tool  see C10A            
                 
 C6  Resin transfer moulding              
   See C0A, C0B, C1 and C2 above
 and C10B below as appropriate 		             
   lifting mould tools [JSu] back injury  operator 2 2 4  use appropriate lifting strategies (hoists or request assistance from others)  
   Hypaject: drawing resin into the machine using vacuum [WR] pipe or valve failure could cause spraying of resin leading to resin contact with eyes, skin and/or clothes  operator/those adjacent 2 2 4  full personal protective equipment and splash screen  
   Hypaject: removal of airline from autosprue [WR] airline whipping when pressure turned on  operator/those adjacent 2 2 4  safety glasses - splash screen - maintain airline/autosprue connection until gel  
   Hypaject: injecting resin into mould using pressure [WR] pipe, valve or mould failure could cause spraying of resin leading to resin contact with eyes, skin and/or clothes  operator/those adjacent 2 2 4  full personal protective equipment and splash screen  
   Hypaject: extracting resin under pressure [WR] resin contact with eyes, skin and/or clothes  operator/those adjacent 2 2 4  full personal protective equipment and splash screen. reduce pressure and allow time for it to drop.  
   Hypaject: machine and pipe cleaning - drawing solvent into injection machine using vacuum [WR] pipe, valve or mould failure could cause spraying of solvent leading to solvent contact with skin and eyes  operator/those adjacent 2 2 4  full personal protective equipment and splash screen  
   Hypaject: machine and pipe cleaning - ejecting solvent from machine using pressure [WR] risk of solvent contact with skin and eyes  operator/those adjacent 2 2 4  full personal protective equipment and splash screen. reduce pressure and allow time for it to drop particularly at end of ejection when air is blown into cup.  
   Hypaject: spills of resin or solvent from containers [WR] slipping hazard.
risk of contact with skin and eyes.		  operator/those adjacent 2 2 4  full personal protective equipment and splash screen. put receiving container in a bucket. protect floor with sheeting. clean up spillage immediately  
   releasing panel from mould tool  see C10A            
                 
 C7  Resin infusion              
   See C0A, C0B, C1 and C2 above
 and C10B below as appropriate 		             
   lifting mould tools [JSu] back injury  operator 2 2 4  use appropriate lifting strategies (hoists or request assistance from others)  
   releasing panel from mould tool  see C10A            
                 
 C8A  Vacuum bagging              
   See C0A, C0B, C1 and C2 above
 and C10B below as appropriate 		             
   cutting prepreg [JSu] exposure to incompletely cured resin operator 2 1 2  personal protective equipment (specifically safety glasses .. lab coat .. barrier cream .. gloves)  
   cutting prepreg [JSu] sharp tools operator 2 2 4  chain mail gloves  
   lifting mould tools [JSu] back injury  operator 2 2 4  use appropriate lifting strategies (hoists or request assistance from others)  
   releasing panel from mould tool see C10A            
 C8B  Autoclave curing              
   lifting [JSu] back injury  operator 2 2 4  use appropriate lifting strategies (hoists or request assistance from others)  
   inert gas atmosphere [JSu] suffocation  operator 2 3 6  check oxygen content of autoclave  
                 
 C8C  Compression moulding      
   lifting mould tools [JSu] back injury  operator 2 2 4  use appropriate lifting strategies (hoists or request assistance from others)  
   oven curing [JSu] burns during insertion/removal of part from oven  operator 2 2 4  oven gloves  
   releasing panel from mould tool  see C10A            
                 
 C10A  Machining composites              
   demoulding composites [JSu] sharp edges  operator 2 2 4  protective gloves .. trim at earliest opportunity  
 C10B  Machining all materials              
   angle grinder [BDL] abrasive wheel  operator  2  2 4  guard .. protective gloves .. restricted use.  training
   angle grinder [BDL] abrasive particles  operator 2 2 4  eye protection .. dust mask  training
   angle grinder [BDL] broken wheel   operator/others 1 2 2  only qualified staff to change wheel  training
   angle grinder [BDL] electricity  operator 1 3 3  regular maintenance .. PAT testing  
   pillar drill [BDL] broken tool/swarf  operator 2 2 4 eye protection .. guards  training .. safe systems of work
    pillar drill [BDL] rotating machinery  operator 2 2 4   guards .. emergency stops  training .. safe systems of work
   pillar drill [BDL] loose tool ..loose key  operator/others 2 2 4  guards  training .. safe systems of work
   pillar drill [BDL] loose work-piece  operator/others 2 2 4  drill vice .. clamps  training .. safe systems of work
   pillar drill [BDL] dust  operator 2 1 2  extraction .. dust mask  training .. safe systems of work
   sawing [BDL] blade  operator 2 2 4  guard .. tools  training
   sawing [BDL] loose particles  operator 2 2 4  guard .. eye protection  training
   sawing [BDL] rotating machinery  operator 2 2 4  guard .. emergency stop  training
   sawing [BDL] loose work-piece  operator/others 2 1 2   guard .. emergency stop   training
   sawing [BDL]  dust  operator/others 2 1 2  extraction .. dust mask  training .. COSHH
   sawing [BDL]  electricity  operator 1 3 3   regular maintenance .. PAT testing  
   diamond slitting saw rotating blade  operator 2 2 4   guard .. face mask/eye protection   training, leather gloves, due caution.
   diamond slitting saw dust  operator 1 1 1  cut wet to trap dust  training
                 
 C10B  Bonding              
   cyanoacrylate adhesives [RKC] adhesive  operator/those adjacent 2 1 2  personal protective equipment (specifically safety glasses .. lab coat .. barrier cream .. gloves)  
   soldering [RGB]  hot iron or object being soldered  operator/those adjacent 2 1 2  students receive safety lecture and are instructed to read laboratory guidelines, student handbook and safety policy  
   soldering [RGB] splash by molten solder  operator/those adjacent 1 2 2  students receive safety lecture and are instructed to read laboratory guidelines, student handbook and safety policy  
   soldering [RGB] lead content of solder  operator 1 1 1  students receive safety lecture and are instructed to read laboratory guidelines, student handbook and safety policy.  NB: RoHS directive.  
   soldering [RGB] fume  operator 1 1 1  students receive safety lecture and are instructed to read laboratory guidelines, student handbook and safety policy. colophony free solder.  COSHH assessed (Dept ID 104)  
   soldering [RGB] changing soldering iron bit  operator 1 1 1  normally restricted to competent staff  
   soldering [RGB] burn and fume hazard  operator/those adjacent 1 2 2  operator training .. use soldering station .. use eye protection .. use recognised fume extraction  
   soldering [RGB] shock hazard  operator/those adjacent 1 2 2 operator training .. fault protection .. first aid .. seek medical attention  
                 
 C10C  Repair              
                 
 C4  Health and safety              
   Hot polyurethane including foam: thermal decomposition products may include carbon dioxide, hydrocarbons, carbon monoxide, nitrogen oxides, hydrogen cyanide, isocyanates, isocyanic acid, amines and other potentially hazardous decomposition products [A, B]. thermally extreme conditions including fire  operator/those adjacent 2 3 6 avoid exposing materials to high temperatures.  Exposure to such chemicals may cause irritation of the eyes and respiratory tract with symptoms of running nose, watering eyes, coughing, headaches, dizziness, nausea and breathlessness. Isocyanates and amines can also cause allergic reactions (sensitisation) of the skin and lungs. Workers exposed to thermal degradation chemicals may experience immediate or delayed effects. Obtain medical attention if any symptoms occur.
 A16  Nanomaterials [SP]              
   Awareness of appropriate literature preparation  operator 1 1 1
  • read BSI PD6699-1 [1]
  • read BSI PD6677-2 [2]
  • read PAS 130:2007 [3]
  • read appropriate MSDS
  • read process method sheet [4]
    for the safe handling of nanoclays
   Handling, weighing and
 mixing of nanoclays into matrix		 inhalation  operator 2 2 4 Positive pressure headgear to be worn.
If inhaled, move person to fresh air.
Seek medical attention if required.		 Use ventilated cabinet with airflow from operator to cabinet and with front closure as low as is practical.
   Handling, weighing and
 mixing of nanoclays into matrix		 inhalation  those adjacent 1 2 2 Suitable filtering respirator to be worn.
If inhaled, move person to fresh air.
Seek medical attention if required.
   Handling, weighing and
 mixing of nanoclays into matrix		 ingestion  operator 1 2 2 If large quantities are ingested,
seek medical attention.		  
   Handling, weighing and
 mixing of nanoclays into matrix		 skin contact  operator 2 2 4 Wear lab coat.
Wear protective nitrile and leather gloves.
After contact, flush skin with water.
If irritation persists, seek medical attention		  
   Handling, weighing and
 mixing of nanoclays into matrix		  eye contact  operator 1 2 2 Wear safety glasses with side-shields.
Flush eyes for 15 minutes.
If irritation persists, seek medical attention		  
   Handling, weighing and
 mixing of nanoclays into matrix		 spill procedure  operator 2 2 4 Contain spillage.
Collect nanoclays using damp paper towel,
Place towels in sealed plastic bag then dispose.
Avoid dusting.
Disposal considerations - not regulated		  
   Wet lay-up sample production contact with nanoclay/resin mixture  operator/those adjacent 1 1 1 Use local exhaust trunking  
                 
   Acid digestion              
   adding specimen to acid in beaker  irritation and burns to eyes, nose, throat and skin  operator 2 2 4  use fume cupboard and full PPE  
   heating acid to boiling point  liquid and/or vapour cause damage to eyes, nose, throat and skin  operator 3 2 6  use fume cupboard and full PPE  
   glass beakers and crucibles  breaking glass  operator 2 1 1  handle with care  thorough check of area for broken fragments if faliure occurs
   neutralising and filtering digested materials  liquid contact with skin  operator 2 2 4  use fume cupboard and full PPE  
   Burn-off furnace              
   inserting/removing crucible from oven  burns  operator 2 2 2  use tongs and heat resistant gloves.
 beware hot surfaces adjacent to body.		  
   inserting/removing crucible from oven  fume inhalation operator and others in close proxity 1 3 3  close all outlets not in use.
  use dedicated extraction.		  
                 
                 
                 
   Universal test machines ~ quasi-static tension ~ compression ~ flexure [Sam Thorpe]              
  Moving parts Injuries to the user Operator and others in close proximity 1 2 2 Training will be provided prior to action.  Operation in controlled area. Restricted use with close supervision by staff. Personal protective equipment (PPE) and safety guards are provided.  Only one user can operate the test machine.
  Ejection of material Damage to eyes Operator and others in close proximity 2 2 4 Guidance will be provided to students and others on good practice. Use of personal protective equipment (PPE) or safety guards where applicable.
                 
   Optical microscopes [Sam Thorpe]              
  Moving objectives trapped fingers Operator 2 1 2 Training will be provided prior to action.  
 

Moving objectives

 

 damaged sample or lens None 1 1 1 Training will be provided prior to action.  
  Glass slides cut fingers if glass broken Operator 2 1 2 Guidance provided to students and others on good practice and information on broken glass disposal.  
Reference Activity/Task Hazards Persons in Danger Probability (P) Severity (S) Risk Factor (R =P*S) Controls in Place or Action to be Taken Additional Requirements

References

  1. Nanotechnologies – Part 1: Good practice guide for specifying manufactured nanomaterials, PD 6699-1:2007, British Standards Institution (free download)
  2. Nanotechnologies – Part 2: Guide to safe handling and disposal of manufactured nanomaterials, PD 6699-2:2007 British Standards Institution (free download)
  3. Guidance on the labelling of manufactured nanoparticles and products containing manufactured nanoparticles, PAS 130:2007 British Standards Institution (free download)
  4. Samuel Pickard, Process Method Sheet for Safe Handling of Nanoclays, Appendix B in Investigation of Nanoclay Reinforced Polymers, BSc (honours) Marine and Composites Technology final year project, University of Plymouth, May 2009.

From 01 October 2006, all owners/occupiers of UK business premises have to carry out a Fire Risk Assessment on their buildings under the new Regulatory Reform (Fire Safety) Order 2005.

URLs for Risk Assessment:

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Updated by John Summerscales on 12-May-2022 12:00. Terms and conditions. Errors and omissions. Corrections.