Machinery Maintenance & Refuelling Risk Assessment Template

Typical hazards & measures

• Compressed air misuse — Limit pressure at the gun; never use for cleaning skin or clothing. Wear eye protection and guard against flying debris. Use safety nozzles with relief ports; check hoses for damage and whip-checks at couplings. Depressurise before disconnecting; secure cylinders upright and cap when stored.
• Hydraulic pressure release — Lower implements to ground, chock and support; apply pressure dump controls. Use rated hose caps and a card-edge test for pinhole leaks—never hands. Replace damaged hoses with like-for-like; torque to spec. Wear face shield and gauntlets when cracking joints; keep a spill tray in place.
• Engine exhaust and carbon monoxide — Avoid indoor testing; if unavoidable, duct exhaust outdoors and monitor CO. Open doors and use fans to create flow-through ventilation. Limit run time; never idle in enclosed vans. Brief on CO symptoms; stop work and evacuate if monitors alarm or symptoms present.
• Stored energy in blades and springs — Block moving parts; fit guards and chocks before work. Release spring tension with approved tools and follow manufacturer sequences. Rotate flywheels to safe positions; remove spark plugs on small engines. Keep hands clear of cutting edges; use blade clamps and sheaths for handling.
• Welding or hot work near fuel — Issue a hot-work permit; move fuel and combustibles 10 m or shield with FR covers. Test atmosphere; provide a fire watch with suitable extinguishers. Ventilate; control sparks and slag. Earth clamps close to the work; check for hidden tanks or residues that could off-gas.