3. Definition
• A mechanical hazard is any
hazard involving a machine or
process
• Are essentially due to machine,
components of the machine,
moving parts of the machine,
or any other source, which can
injure a person
• Compressed gases or liquids can
also be considered a mechanical
hazard
Mechanical and Handling Hazards
Cut Laceration Bruises
Puncture Crush Bone
Hematomas
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Types of mechanical injuries
4. Machining* operations
• Conventional and CNC machine tools
… but also folding presses, rolling
machines, and cabling machines are
other types
• There are more special machines, e.g.
M-line orbital cutting machines (LS1)
and bus bar surfacing, grinding
machines, sawing, …
• Against metal chips, burrs, powders,
lubricants, cleaning agents, solvents:
• Goggles, gloves
Mechanical and Handling Hazards
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*Or more generally, operations on/with machinery/tools
5. Some materials are more aggressive
• Fiberglass and composite materials
require particular precautions
• Always wear respirator/face mask,
and goggles
• Many resins are inflammable or contain additives
that are inflammable, so be careful with heat sources
• Many materials used in fiberglass work are corrosive, or
have some undesirable effect on the skin (irritant), so
protect your skin/eyes … again goggles and gloves!
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6. Heavy loads may fall on the floor!
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• … and worst, on your foot!
7. Welding, soldering, brazing
• Personal protection (the welder)
• Burns (adapted cloth, gloves), arc flash - “coup d’arc” (protect your face/eyes with
a welding mask)
• Protection of personnel working at the vicinity of a welding area (not
the welder)
• Use curtains to surround the welding area
• Soldering, e.g. when using tin lead alloy (soldering of the shunts)
• Analyses of fumes, in collaboration with HSE, have shown no trace of Pb, i.e. no
need of a specific filter for this. However, a filter was used to prevent other hazards
due to traces of rosin and alcohol
Mechanical and Handling Hazards
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8. Welding press for dipole shells, 1
• On top of obvious welding related hazards
• Mechanical hazards due to the necessity for
the welder to watch carefully the weld pool
during welding, …
in a small space
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9. Welding press for dipole shells, 2
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emergency cable pull switch
Help is recommended in certain
circumstances … allocate sufficient
resources
10. Hydraulic and pneumatic systems, 1
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Collaring press:
Up to 375 MN over 15 m!
High pressure up to 700 bar
Hydraulic group of the
welding press:
Up to 162 MN over 16 m
High pressure up to 550 bar
11. Hydraulic and pneumatic systems, 2
• High pressure fluids hazards, hydraulically and
pneumatically driven tools hazards
• Crushing, high pressure / hot fluid leaks / jets
Mechanical and Handling Hazards
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• High pressure oil easily punctures skin causing
serious injury, gangrene or death
• If injured, seek emergency medical help.
Immediate surgery is required to remove oil
• Do not use finger or skin to check for leaks
• Lower load or relieve hydraulic pressure before
loosening fittings
12. Real case: pressure test
• When: March 2007
• Where: LHC tunnel
• Need: verify/accept triplets after
installation in the tunnel
• Action: carry out pressure test
• Incident: due to movement of one of the
cold masses, rupture of a helium piping with
strong detonation
• Consequence: 2 of the 7 persons who witnessed
the test (even if at 25 m of the incident) presented
signs of hearing loss (that disappeared after some
time). Only one of the seven was wearing hearing
protection
Mechanical and Handling Hazards
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13. • Machine conformity – Mise en conformité des machines
• To be checked with EN-MME, Emmanuel Ravry / Alain Stalder
• Safety Form M-4-0-2 - Workshop machine tool - Authorization of use
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14. For new and special machines
• For example, a 6.5 m long reaction furnace currently in assembly in
B180
• Risk assessment file shall be developed by the manufacturer
• There are guidelines available at:
• https://edms.cern.ch/document/1114042/3: Safety Guideline on risk assessment
• https://edms.cern.ch/document/1114759/3: Safety Tool for risk assessment
• https://edms.cern.ch/document/1218312/1: List of generic hazards typically present in
workshops
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15. Safety form – Risk assessment form
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RISK ASSESSMENT FORM OHS-0-0-5 Template EDMS No.: 1175316
Department/Group: TE/MSC-LMF
Location: Bâtiment180
Assessment done by:
EDMS:
Life Cycle
Description of the equipment: Production
Date: 31 July 2012
Local effect(s) End effect(s) Provision measure(s) Compensating measure(s) People Environment Property Operational
Moteur METABO BE1100 *
Actionne la mise en rotation
de la machine orbitale de
découpe
Le moteur ne fonctionne pas Absence d'alimentation
Pas de mise en rotation de la
machine
Activité stoppée
Contrôler le branchementélectrique
du moteur
Contrôle de l'équipement
avantutilisation
Utiliser le matériel électrique
de réserve
2 A A A A A2
Acceptable risk: no actions need to be
taken.
Fiche d'instructions de la machine de
découpe
* cetéquipementcommerciale
estdoté en origine d'une
certification CE, ici on considère
les risques inhérents à son
utilisation spécifique dans
l'assemblage en objet.
L'outil tourne dans le mauvais sens
Non respectde la procédure de changementdes
outils
Mauvais réglage du moteur Risque de casse de l'outil Contrôle visuel
Contrôle du sens de
rotation avantutilisation
Procédure etformation 3 B A B A B3
Moderate risk: actions are recommended
to reduce the risk.
Formation; procédures LS1. 3.1
découpe des manchettes M
Vitesse de rotation trop importante Mauvais réglage du moteur Mauvais réglage du moteur Risque de casse de l'outil Contrôle visuel
Contrôle du réglage de la
vitesse avantutilisation
Procédure etformation 3 B A B A B3
Moderate risk: actions are recommended
to reduce the risk.
Utilisation d'un nouveau moteur à sa
vitessse maximale.
Ne pas utiliser la protection auditive (Niveau sonore
85 à 90 dB)
Non respectde la procédure durant le
fonctionnementde la machine
Dommage auditif Dommage auditif Contrôle médical
Utilisation EPI, respectdes
procédures
Procédure etformation 3 B A A A B3
Moderate risk: actions are recommended
to reduce the risk.
Utilisation de protections auditives
Procédures LS1. 3.1 Découpe
manchette M
Coquille de découpe etcage
d'entrainement
Permettentla mise en rotation
etl'avance de l'outil de
découpe
Chute pendantla manipulation Mauvaise manutention par l'opérateur dommage corporel Activité stoppée, dommage corporel Contrôle visuel
Utilisation EPI, respectdes
procédures
Procédure etformation 3 B A B B B3
Moderate risk: actions are recommended
to reduce the risk.
Utilisation de Chaussures de sécurité
Procédures LS1. 3.1 Découpe
manchette M
Blessure d'un personne extérieure à l'activité
Intrusion d'un personne extérieuredans la zone de
découpe.
dommage corporel Activité stoppée, dommage corporel Contrôle médical
L'opérateur doitfaire
respecter sa zone de
travail
Procédure etformation 3 B A A A B3
Moderate risk: actions are recommended
to reduce the risk.
Formation; procédures LS1. 3.1
découpe des manchettes M
Projection de copeaux Risque inhérente à la l'activité coupure dommage corporel Activité stoppée, dommage corporel Contrôle médical
Utilisation EPI, respectdes
procédures
Procédure etformation 3 B A A A B3
Moderate risk: actions are recommended
to reduce the risk.
Utilisation de lunette de protection
Procédures LS1. 3.1 Découpe
manchette M
La plaquette casse Risque inhérentà la l'activité Plaquette à changer Activité stoppée, dommage corporel Contrôle médical
Utilisation EPI, respectdes
procédures
Procédure etformation 3 B A A A B3
Moderate risk: actions are recommended
to reduce the risk.
Utilisation de lunette de protection
Procédures LS1. 3.1 Découpe
manchette M
La machine se bloque L'outil se bloque dans la piéce
Rotation le l'ensemble de la
machine
Activité stoppéee, dommage
corporel
Contrôle médical Procédure etformation Procédure etformation 3 B A B B B3
Moderate risk: actions are recommended
to reduce the risk.
Insister sur la mise en place du bras de
maintientde la machine
Procédures LS1. 3.1 Découpe
manchette M
Non respectde la procédure de la partde
l'opérateur
L'outil se bloque dans la piéce
Rotation le l'ensemble de la
machine
Activité stoppée, dommage corporel Contrôle médical Procédure etformation Procédure etformation 3 B A B A B3
Moderate risk: actions are recommended
to reduce the risk.
Insister sur la mise en place du bras de
maintientde la machine
Procédures LS1. 3.1 Découpe
manchette M
Entrainementde la main de l'opérateur par le porte
outil
L'opérateur pose la main sur l'outil opposé à la
coupe
coupure dommage corporel
définitif
Activité stoppée, dommage corporel
definitif
Contrôle médical
Controle de la mise en
place du capotde
protection
Procédure etformation 3 C A B B C3
Unacceptable risk: immediate actions are
necessary to reduce the risk promptly.
Un carter de protection de l'outil opposé
doitêtre fabriqué
Procédures LS1. 3.1 Découpe
manchette M
Usinage des deux soudures d'une même
manchette en même temps
Non respectde la procédure durant le
fonctionnementde la machine
L'Attention de l'opérateur est
portée sur deux endroits
Dommage sur la machine,
dommage corporel
Contrôle médical Procédure etformation Procédure etformation 3 B A B B B3
Moderate risk: actions are recommended
to reduce the risk.
Un carter de protection de l'outil opposé
doitêtre fabriqué
Procédures LS1. 3.1 Découpe
manchette M
Vibration de la machine de découpe
Mauvais serrage des demi coquilles, pignon ou
engrenage défectueux
Risque de casse de la
machine
Activité stoppée, dommage corporel Contrôle visuel Procédure etformation Procédure etformation 2 B A B A B2
Moderate risk: actions are recommended
to reduce the risk.
Relacher la commande du moteurdés
les premières vibrations.
Procédures LS1. 3.1 Découpe
manchette M
Mise en rotation de l'engrenage ou des outils lors de
la mise en place de la cage d'entrainement
Non respectde la procédure durant le
fonctionnementde la machine
coupure dommage corporel
définitif
Activité stoppée, dommage corporel
definitif
Contrôle médical
Contrôle du
débranchementdu moteur
avantmise en place
Procédure etformation 3 B A B A B3
Moderate risk: actions are recommended
to reduce the risk.
Insister sur le faitque le moteur doitêtre
débranché lors du changementdes
plaquettes.
Fiche d'instructions de la machine de
découpe
Procédures LS1. 3.1 Découpe
manchette M
Item 2:
Control measure(s)
Item 1:
S
R
Risk with current control measures and/or detection means
FAILURE MODE, EFFECTS AND CRITICALITY ANALYSIS (FMECA)
ID Component Function(s) Potential failure mode(s)
Potential effect(s)
Potential cause(s) P Risk Level Further measure(s) required
Detection mean(s)
17. Part II: Handling hazards
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18. Definition
• Manual handling of loads (MHL) and manual
material handling (MMH) involve the use of the
human body to lift, lower, fill, empty, or carry loads
• When performed incorrectly or excessively, these tasks may expose
workers to physical risk factors, fatigue, and injury
• A variety of MMH techniques and tools
exist to alleviate these potential problems
• Forklifts, overhead cranes, lifting girders,
SpanSet® slings, …
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19. Manual handling and lifting
• There are legal limits, depending on the age/sex, but also the
distance and the characteristics of the task (articles R. 4541-1 à
R. 4541-9 du code du travail, norme AFNOR X35-109 et décret
n° 92-958 du 3 septembre 1992)
• Boys
• From age 14 to 15: 15 kg
• From age 16 to 17: 20 kg
• Men
• Max 55 kg
• May be allowed to carry loads above 55 kg, if recognized able to do so by
the occupational physician
• In any case the load shall not exceed 105 kg. Article R. 231-72 of «code du
travail» says:
«Lorsque le recours à la manutention manuelle est inévitable, et que les
aides mécaniques ne peuvent pas être mises en oeuvre, un travailleur ne
peut être admis à porter d’une façon habituelle des charges supérieures à
55 kgs, qu’à condition d’y avoir été reconnu apte par le médecin du travail,
sans que ces charges puissent être supérieures à 105 kgs»
Mechanical and Handling Hazards
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21. Real case: bus bars in ISR
• When: March 2012
• Need: remove 16-m long bus bars from storage in
the ISR (B181)
• Action: 3 persons intervene, one of
them climb on wooden crates to
reach the bb stored in height
• Accident: a person falls down
between crates
• Safety rules for work in height were
somehow neglected
• Consequence: the person was absent for 7 weeks
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23. Heavy Handling Section – EN-HE-HH
• http://en-dep.web.cern.ch/en-
dep/Groups/HE/Sections/HH/he_hh_mandate.ht
m
• In principle, any overhead crane is driven by a
professional from EN-HE-HH
• However, a specific training course “pontier-
élingueur” is available and allows using
overhead cranes of up to 20 t
• Authorizations to operate a crane are given
exclusively by the EN-HE Group Leader, CERN-
wide, for a specific crane (we do not get
authorization for any crane on the CERN site)
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24. Design/use of handling tools/girders
• May not be used if not formally approved by
HSE
• CE conformity required
• Load test needed
• Design work may be done
on our side; however, one
needs to follow codes and
norms in force for
handling/lifting equipment
• Again, support from HSE is possible
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27. Put priorities in the right order!
• No room for procrastination* in safety
• Safety first, remember the ranking put in
force for LS1:
1. SAFETY
2. QUALITY
3. SCHEDULE
4. COST
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• *Procrastination:
• The action of delaying or postponing something
• The practice of carrying out less urgent tasks in preference to more
urgent ones, or doing more pleasurable things in place of less
pleasurable ones, and thus putting off impending tasks to a later time
28. Things to remember
• Act as a professional, qualification and training
are essential to ensure safety at the workplace
• Do not improvise if you are not sure of what
you do (or are asked to do), always ask to
experienced staff in case of doubt
• Safety is the matter of all
• You can always talk to your supervisor, section
leader, group leader, Territorial Safety Officer,
Departmental Safety Officer (Thomas Otto)
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29. Useful links
• HSE: Occupational Health and Safety and
Environmental Protection Unit
• https://espace.cern.ch/hse-
unit/en/Pages/SafetyinDepartments.aspx
• In particular safety rules https://espace.cern.ch/Safety-
Rules-Regulations/en/Pages/default.aspx, and
• Regulatory watch that provides you with a list of referenced
documents (laws, standards, guides, ...) applicable in
matters of Safety: https://espace.cern.ch/Safety-Rules-
Regulations/en/regulatorywatch/Pages/regulWatch.aspx
• Call them in case of doubt
• Departmental safety plan – TE
• http://safety-commission.web.cern.ch/safety-
commission/SafetyPlan/te/e_index.htm
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