JANUARY 2020

Q1: (a) Outline what might cause an agricultural tractor to overturn. (6)

 One of the ways that a tractor could overturn is by travelling too fast round a corner or travelling
across a steep slope.
 If the tractor sinks into soft ground or is working on uneven ground it could topple over.
 If the tractor had uneven tire pressures or a narrow wheelbase that would also make it more unstable.
 Towing trailers can increase the load on the back of the tractor or possibly exert a turning effect on the
tractor which could also increase the risk of it overturning.
 Finally, an untrained or incompetent driver would be more likely to operate the tractor in a way that
might increase the risk of it overturning.
(b) Outline the measures that may be necessary to minimize the risk of a tractor overturning. (4)

 To minimize the risk of overturning, the use of tractors on steep slopes should be restricted.
 There should also be speed restrictions on the vehicle.
 The tractor itself could be selected to have a wider wheelbase and counterbalance weights could be
fitted to improve stability.
 A regular maintenance system and pre-use inspection should identify tire problems.
 and training for drivers would increase their awareness of the factors that could lead to an overturning
incident.
Q2: An organization can help ensure workplace transport safety by having safe vehicles and a safe site.
(a) Outline control measures that should be considered to help ensure safe vehicles. (5)
(b) Outline control measures that should be considered to help ensure a safe site. (5)

(a)

 Ensure that vehicles are compatible with the working environment, e.g. electric or gas powered;

 Ensure vehicles are suitable for the purpose for which they are used.

 Maintain vehicles in good repair, particularly the braking system, steering, tyres, lights, mirrors
and specific safety systems. Make sure safety systems/alarms have not been defeated.

 Remove the need for people to climb up on vehicles where possible, e.g. by providing gauges
and controls that are accessible from ground level.

 Reduce the risk of falling when people have to climb onto a vehicle or trailer by providing well-
constructed ladders, non-slip walkways and guard rails where possible.

 Provide reversing aids such as CCTV where appropriate.

  Fit rollover protective structures and use seat belts where fitted.
(b)

• Plan their workplace so that pedestrians are safe from vehicles.

• Provide a one-way system if they can.

• Provide separate routes for pedestrians and vehicles where possible.

• Avoid reversing where possible.

• Provide appropriate crossing points where pedestrians and traffic meet.

• Use road signs to indicate vehicle routes, speed limits, pedestrian crossings etc.

• Make sure lighting is adequate where people and vehicles are working.

• Make sure road surfaces are firm and even.

• Make sure there are safe areas for loading and unloading.

• Try to provide separate car parking for visitors as they may not know your site.

Question 3: An excavation is required of an existing factory floor to repair a damaged water main.
(a) Outline hazards and corresponding risks that may be created by the excavation work. (5)

(b) Outline control measures that should be considered to help ensure the safety of the work activity. (5)

• (a)
• An influx of water into the excavation could lead to drowning of workers.

• Collapse of excavation.

• Underground utilities such.as electrical can cause electrical burn or fatality.

• High noise exposed from excavator can cause hearing damage to the workers.

• Physical and ergonomic hazards.

(b)

• Collapsing should be avoided by supporting the sides by either battering them or supporting
them with sheets.

• Materials from the excavation should be stored at a safe distance from the excavation, this will
help reduce the risk of them falling onto people.
 • Adding barriers to excavation is an essential precaution to avoid people falling into the
excavation.

• It is safer if vehicles are kept completely out of the excavation area, but if required the use of
barriers and stop-blocks should help mitigate that danger.

• Cable, pipe, and service plans should be used to ensure that underground services are known so
they can be marked on the ground or, ideally, the area avoided entirely.

• Around the areas where there are underground services, mechanical equipment should be
avoided and instead use spades and/or shovels.

• Picks and forks should be avoided as they are more likely to pierce cables and pipes.

• Flooding can be avoided by ensuring that there is appropriate pumping equipment so that any
water that seeps into the excavation can be easily pumped out to a safe area.

Question 4: Car park entry and exit is controlled by an automatic barrier of the rising arm type shown
below.

The barrier has a control system with sensors, actuators and electronic controllers. Maintenance is
occasionally required due to vehicle impact or storm damage.

(a) Outline mechanical hazards associated with automatic rising arm barriers. (4)

(b) Outline control measures that should be considered to help reduce risk before starting any
maintenance activity on the barrier. (6)

(a)

• Crushing between the beam and housing

• Shearing hazards due to movement failure of the beam.

• Risk of impact as the barrier arm lowers. The risk here is that a pedestrian may not be aware that
there is an arm about to lower.

• Risk of being hit by the barrier as it raises up

• Risk of becoming trapped in the skirt of the rising arm barrier as it raises

• Where a counter balance is fitted, as the barrier raises there is a risk of shearing, crushing and
entrapment as the counterweight passes the barrier housing.
(b)

• During repair & maintenance work it is often necessary to isolate the barrier from potential
uncontrolled energy sources by implementing LOTO procedure.

• That only those people designated can undertake the work.

• Released of stored energy

• Protect workers from moving traffic by installing fence to separate pedestrian from vehicles.

• Any road that features an automated barrier should be clearly marked to signify that the route is
suitable for car access only.

• fitting a safety edge to the underside of the boom

• provision of safe access/platforms for replacing/releasing the existing barrier components

• Wearing personal protective equipment and provision of instruction and supervision.

• Safe access, with firm footholds (and handholds where necessary) should be provided. This
should be free of obstruction and any material likely to cause slipping.

Question 5
An electrical installation on a dairy farm need replacing.

(a) Outline what may have caused the deterioration of the existing electrical installation. (5)

(b) Outline what should be considered when designing the replacement electrical installation to help avoid
future deterioration. (5)

(a)

• Mechanical damage and solid bodies this includes abrasion, impact, stress, wear and tear,
vibration, hydraulic and pneumatic pressure.

• Deterioration caused by corrosion due to the presence of moisture that not vented to the
atmosphere.

• Deterioration caused by dust and dirt that accumulations on existing electrical installations.
• Deterioration caused by adverse weather conditions, including temperature, rain, snow, ice and
wind, can create a hazardous environment.

• Deterioration caused by Substandard repair and replacement of existing electrical installations.

(b)

• electrical designs with suitable supply and distribution with appropriate conductors,

• The need for suitable supply and distribution with appropriate conductors, junction boxes and
connections.

• Suitable pumps. heater, coolers, milk equipment and agitators.

• A suitable system capable of withstanding animal contact and the corrosive environment

• Protection the system from overload.

• Electrical shock protection.

Question 6:
Outline what should be considered when developing a planned maintenance programmed for workplace
machinery. (10)

• Importance in the Process

• Any strategy adopted should reflect whether the equipment has a critical and central role. For
example, if all production depends on a conveyor moving components from one stage of
production to the next and if without that conveyor production stops, the maintenance strategy
must ensure the minimum downtime during the production process.

• Failure During the Production Process

• This sort of strategy will normally be a more costly option in terms of time and effort, and will
have to be balanced against the loss due to production breakdown.

• Machine Complexity

• Any piece of machinery will have a number of components, any of which may fail. Some are more
difficult to gain access to than others and the potential time delay in repair must be considered.
Certain components may be so inaccessible that replacement or repair requires total strip-down
 of the machine. Consequently, some of the maintenance strategies available may not be an
appropriate choice. An example is the replacement of an armature within an electric motor, where
the amount of stripping-down justifies that the bearings, etc. are checked at the same time.

• Relationship with Other Machines

• In a production line, failure of one machine may cause total failure of the entire line. The position
and effect of a possible failure has to be considered, so the best option for an individual machine
may not be the best option for the overall production line. In such cases, the production line
should be regarded as a single entity in the first instance, with the individual machines being
considered separately when reviewing implementation within the chosen maintenance strategy.

• Availability of Replacement Equipment

• Maintenance strategy selection is varied when it is possible to replace failed equipment with
functional equipment held ‘in store’ for such an occasion. The availability of the replacement, the
work involved in fitting it and getting operational, are factors which must be taken into account,
along with the availability of maintenance capability to undertake the work, as detailed below.
This is an option frequently used for small machines with low purchase cost, where it is possible
to have replacements available. For example, on construction sites, 110v electric hand tools are
usually available as replacements (either on-site or with quick delivery) for failed units, with the
failed unit normally being returned to a workshop for repair.

• Identification of Critical Components

• Within any machine there is a number of key components which will have a major effect on the
failure mode of the machine. The identification of such components is important when deciding
on the maintenance strategy to be adopted.

• Environmental Factors

• Machine characteristics can be considerably altered by the environment in which the machine is
required to work. Environmental factors can include: heat, cold, dampness, dust, vibration and
vapors. Electrical power supply reliability should be examined, as power fluctuations may
influence machine operation.

• Maintenance Capability Within the Company

• Since any maintenance strategy has to be implemented, the resource requirements – in terms of
time and skill – have to be taken into account. It is inappropriate to consider a strategy if the
resources are not available to implement it.

• Maintainability Within the Design of the Machine

• The manufacturer has to make provision for maintainability, taking into account the following
factors:
 – Accessibility of internal parts.

– Ease of handling and human capabilities.

• Unknown Factors

• People generally believe that they are aware of the factors which affect equipment. In practice,
many rely on information from records or by discussion, making the information second- or
third-hand.

Question 7: A mobile crane is to be used to erect a new telecommunications aerial on the roof of a three-
story office building. Outline precautions that should be taken to help reduce risks to anyone at ground
level who may be affected by the operation. (20)

Procedural Control:

• A lifting plan or method statement should be prepared;

• The selection of the crane with respect to its safe working load and reach

• Checking the existence of current test certificates for cranes and all lifting tackles;

• Ensuring the regular thorough inspection and maintenance of the crane and appointing a
competent person to supervise the lift;

Engineering control: should include,

• Ensuring ground conditions are appropriate for positioning the crane

• The out rigger should be fully extended with spreader plate underneath

• Avoiding contact with overhead services and other buildings or structures;

• Using adequate lifting gear

• Speed limiters, over-hoist limit switch and rated capacity indicator and alarm system

• Visibility can be improved by use of mirrors or CCTV;

• Take account of weather conditions and an anemometer should be ensured to identify the strong
wind

• The need to follow safe roof work practices such as the provision of edge protection or the use of
harnesses.
 Behavioral controls

• such as the competence and training of the driver, slinger, banksman and supervisor

The precautions for others who might be affected by the operation.

 The lifting area should be cordoned off and should be segregated and warning signs should be
displayed.

• Providing sufficient personnel on site to control access of the public to the area;

• The provision of adequate signing and traffic control;

• Liaison with the local police and

• Planning the lift for a time of day when few people would be in the vicinity

Question 8: Workers are required to enter a sewer though a vertical shaft. The sewer and shaft are classed
as a confined space.

(a) Give the meaning of the term ‘confined space’. (2)

(b) Outline hazards that the workers could be exposed to when working in the sewer. (10)

(c) Outline what should be considered when developing emergency arrangements that will be
provided during this activity. (8)

(a)

• Any enclosed o partially enclosed place such as a chamber, tank etc. or other similar space in
which, by virtue of its enclosed nature, there arises a reasonably foreseeable specified risk such
as lack of oxygen or the possibility of drowning in free-flowing solids.

• Confined spaces include: Chambers, Tanks (sealed and open-top), Vessels, Furnaces, Ducts,
Sewers, Manholes, Pits, Flues, Excavations, Boilers, Reactors and Ovens

(b)

The possible risks present include, but are not limited to:

• Those associated with the presence of gases and vapors either toxic and/or flammable;

• An atmosphere that was deficient in oxygen which could lead to asphyxiation and/or suffocation;

• Working on slippery surfaces and the presence of pipes, cables or tools which could result in falls;
• The possibility of the sudden ingress of water with the danger of drowning;

• The presence of chemical or biological contaminants either on the surface water or in the sludge
deposited in the sewer with the risk of contracting illnesses such as Weil’s disease;

• Working in a restricted space with low headroom which might lead to musculoskeletal injuries;

• Thermal issues such as heat exhaustion that might occur when working in high temperatures;

• Coming into contact with sharps with the resultant needle stick injuries;

• The ever-present risk of entrapment which could be caused by the collapse of the sewer
(c)

• The means provided for emergency access / egress,

• The equipment required e.g., Life lines, lifting equipment (Tripod / Hoist), air fed breathing
apparatus,

• Methods for raising the alarm with others outside the confined space e.g. Radio, personal alarms
etc., to initiate rescue procedures

• The availability of first aid assistance until the arrival of professional medical help. o Ensuring
that there are persons present who are competent to undertake (CPR) resuscitation procedures,

• The number and competence of those who would be involved in the rescue operation.

• Training or refresher trainings for emergency personnel.

• List of Contacts at a minimum, ERP should include a list of contact people and phone numbers for
trouble shooting, servicing and assistance.

• Mitigation Measures, as mitigation measures refer to actions taken to eliminate or reduce the
harmful effects of wastewater systems emergencies such as cleaning sewer lines on a regular
basis.
Question 9
The final process in the manufacture of office furniture involves spraying it with solvent-based paint, in a
custom-designed spray room.
The solvent has a flash point of 15°C. Assuming that a risk assessment has been carried out, outline control
measures that could help minimize the associated risk of fire and explosion with this spraying activity. (20)

• Selecting a higher flashpoint product….

• Using equipment suitable for a flammable atmosphere…..

• Safe cleaning of spray-painting nozzles……

• Stop painting operations and immediately evacuate exposed workers when atmospheric testing
indicates that the concentration of solvent vapors reaches or exceeds 10% of the LEL.

• Use exhaust ventilation that is discharged away from working areas and potential ignition
sources to keep concentrations of flammable vapors below 10% of the lower explosive limit and
prevent fires or explosions.

• Continue using ventilation after the completion of paint or coating applications to dissipate
excess vapor concentrations, keeping the compartment or space gas free.

• Retest the atmosphere 10 minutes after ventilation has been discontinued to confirm that
atmospheric conditions remain at an acceptable level.

• Make sure that where paints or coatings in use have flash points below 80°F, all motors and
control equipment are classified as explosion-proof and are properly maintained and grounded.

• Ensure that the metallic parts of air moving devices, such as fans, blowers, and jet-type air
movers, and all duct work are bonded to the vessel’s structure where paints or coatings in use
are mixed with toxic vehicles or solvents.

• Only permit explosion-proof lighting in work areas, approved by a Nationally Recognized Testing
Laboratory for use in Class I, Group D atmospheres, or approved as permissible by the Mine
Safety and Health Administration or the U.S. Coast Guard.

• Check that all power and lighting cables are inspected regularly by a competent person to verify
that the insulation is free of cracks and worn spots, lines are not overloaded, and that cables are
suspended with sufficient slack to prevent undue stress or chafing.

• Prohibit the use of objects or equipment that produce open f lames or sparks, such as matches,
lit cigarettes, cigars or pipes, cartridge-type stud guns, and tools used for hot work. Use only non-
sparking paint buckets, spray guns, and tools.

• Keep electrical connections at least 50 feet or more from paint and tank coating operations.

• The appropriate PPE, such as protective clothing, gloves, goggles, and face shields, that prevent
air sprayed coatings from contacting the worker’s face, eyes, head, hands, feet and other
exposed skin.

• Employers must provide covered metal containers at worksites for the disposal of scrapings and
rags soaked with flammable compounds.
• Provide suitable fire extinguishing equipment for each work area that is immediately available in
a state of readiness for instant use.

• Train workers to recognize unsafe conditions, including significant fire hazards, and procedures
to follow in the event a fire occurs as outlined in the facility’s fire safety plan.

Question 10
A steam boiler is a type of pressure system used in industry where loss of containment can occur through
mechanical failures such as overheating, creep and hydrogen embrittlement.

(a)Outline why a steam is classified as a pressure system. (3)

(b)Identify THREE additional examples of mechanical failure to which a steam boiler is susceptible AND,
in EACH case, outline the mechanism of the identified mechanical failure. (9)
(c)Outline the content of a written scheme of examination form for the boiler. (8)

(a)

• A steam boiler has a boiler drum, relief valves, internal tubes and steam pipework.

(b)

THREE additional examples of mechanical failure to which a steam boiler is susceptible are:

• Mechanical Fatigue and Shock: this is caused by the physical movement of parts of the system,
setting up fatigue failure. An example of this is the bellows failure at Flix borough in that the
bellows eventually could not withstand the movement.

• Brittle Fracture: this is caused by cold changing the characteristics of the material from which the
system is made, e.g., polymer seals need to be selected with care as their use in ‘cold’ systems
makes the material brittle and liable to failure.

• Corrosive Failure: this is caused by substances in the relevant fluid attacking the material from
which the system is made. This is usually because of impurities within the fluid, as the system has
to be designed to take the fluid.
(c)

• Identification of the items of plant or equipment within the system;

• Those parts of the system which are to be examined;

• The nature of the examination required, including the inspection and testing to be carried out on
any protective devices;
 • The preparatory work needed for the item to be examined safely;

• Where appropriate, the nature of any examination needed before the system is first used;

• The maximum interval between examinations;

• The critical parts of the system which, if modified or repaired, should be examined by a
competent person before the system is used again;

• The name of the competent person certifying the written scheme of examination; and

• The date of certification.

Question 11:
An organization operates a multi-story care home.

(a)Outline what should be considered to help ensure an adequate means of escape in the event of a fire. (12)

(b)Outline general requirements for fire doors that should be installed in the care home. (8)

(a)

• The possible number of employees and visitors to be evacuated

• The type of person such as their sensory disabilities and physical disabilities and age (old age,
child) etc. to be considered

• Means of Alerting and evacuating people through public address system

• The distance of fire evacuation routes; and the numbers of such routes

• Ensuring that the escape routes and assembly points are clear from any obstructions.

• The provision of emergency lighting and appropriate sign ages for demarking the exit routes
from super market and restaurants, being sufficiently separated to avoid confusion

• Assembly points - Well defined, Displayed and communicated and always free from any
obstructions

• Liaison with emergency services – such as their access requirements; without obstructing
assembly areas and access to the buildings

• The Appointment of trained Fire Marshals who can ensure clear escape routes and trained in
evacuating people in safe manner.
• Providing door marshals to prevent entry or re-entry to the store.

• Security considerations such as minimizing the opportunity for theft / vandalism/sabotage.

• The procedure, once drawn up, would need to be summarized on prominently displayed fire
notices and tested with regular fire drills.

(b)

• Exits to open outwards

• Easily operated

• Should not be locked

• Provided along escape routes

• Prevent spread of fire & it’s a means of escape

• Not wedged open

• Lead to open air – safety

• May be fitted with a vision panel

 JANUARY 2019

Question 1:
A university has several students with a range of physical and mental disabilities. A fire risk assessment needs
to be completed.
(a) Explain why students with a physical or mental disability may be at increased risk. (4)
(b) Identify other categories of people especially at risk. (2)
(c) Outline control measures that may need to be included in a Personal Emergency Evacuation Plan (PEEP).
(4)

(a)

• Individuals with a hearing impairment may take longer to be alerted.

• the visually impaired may have greater difficulty finding their way out of a building.

• Persons with severe mobility impairment may require assistance during a fire evacuation from
building.

(b)

• young persons

• those with disabilities.

• lone workers.

(c)

• Personal trembler alarms, which “vibrate” at the same time as the alarm.

• Buddy system, where someone is allocated the task of helping the person with a sensory
impairment.

• Visual alarms for the hearing-impaired, such as a flashing beacon.

• Tactile/Braille signs for the visually impaired, providing the person can locate the sign and is able
to read Braille.
Question 2: Car park entry and exit is controlled by an automatic barrier of the rising arm type shown
below.

The barrier has a control system with sensors, actuators and electronic controllers. Maintenance is
occasionally required due to vehicle impact or storm damage.

(a) Outline mechanical hazards associated with automatic rising arm barriers. (4)

(b) Outline control measures that should be considered to help reduce risk before starting any
maintenance activity on the barrier. (6)

(a)

• Crushing between the beam and housing

• Shearing hazards due to movement failure of the beam.

• Risk of impact as the barrier arm lowers. The risk here is that a pedestrian may not be aware that
there is an arm about to lower.

• Risk of being hit by the barrier as it raises up

• Risk of becoming trapped in the skirt of the rising arm barrier as it raises

• Where a counter balance is fitted, as the barrier raises there is a risk of shearing, crushing and
entrapment as the counterweight passes the barrier housing.
(b)

• During repair & maintenance work it is often necessary to isolate the barrier from potential
uncontrolled energy sources by implementing LOTO procedure.

• That only those people designated can undertake the work.

• Released of stored energy

• Protect workers from moving traffic by installing fence to separate pedestrian from vehicles.
 • Any road that features an automated barrier should be clearly marked to signify that the route is
suitable for car access only.

• fitting a safety edge to the underside of the boom

• provision of safe access/platforms for replacing/releasing the existing barrier components

• Wearing personal protective equipment and provision of instruction and supervision.

• Safe access, with firm footholds (and handholds where necessary) should be provided. This
should be free of obstruction and any material likely to cause slipping.

Question 3:
A worker is carrying out a user check on an alternating current (AC) electric drill which is to be used with a
residual current device (RCD).
(a) Outline types of visible defect on the drill that may be found during the check. (8)
(b) Outline the importance of an RCD. (2)

(a)

• Damage, e.g., cuts, abrasion (apart from light scuffing) to the cable covering.

• Damage to the plug, e.g. the casing is cracked or the pins are bent.

• Non-standard joints, including taped joints in the cable.

• The outer covering (sheath) of the cable not being gripped where it enters the plug or the
equipment. Look to see if the colored insulation of the internal wires is showing.

• Use in conditions where it is not suitable, e.g. a wet or dusty workplace.

• Damage to the outer cover of the equipment or obvious loose parts or screws.

• Overheating (burn marks or staining).

• Body of appliance is intact.

(b)

• They are sensitive enough to detect a leakage current which is too small to operate a fuse but
which may be large enough to start a fire.

• Also, the RCD is intended to provide indirect shock protection.

Question 4:
An organization can help ensure workplace transport safety by having safe vehicles and a
safe site.
(a) Outline control measures that should be considered to help ensure safe vehicles. (5)
(b) Outline control measures that should be considered to help ensure a safe site. (5)

(a)

• Ensure that vehicles are compatible with the working environment, e.g. electric or gas powered;

• Ensure vehicles are suitable for the purpose for which they are used.

• Maintain vehicles in good repair, particularly the braking system, steering, tyres, lights, mirrors
and specific safety systems. Make sure safety systems/alarms have not been defeated.

• Remove the need for people to climb up on vehicles where possible, e.g., by providing gauges
and controls that are accessible from ground level.

• Reduce the risk of falling when people have to climb onto a vehicle or trailer by providing well-
constructed ladders, non-slip walkways and guard rails where possible.

• Provide reversing aids such as CCTV where appropriate.

• Fit rollover protective structures and use seat belts where fitted.

(b)

• Plan their workplace so that pedestrians are safe from vehicles.

• Provide a one-way system if they can.

• Provide separate routes for pedestrians and vehicles where possible.

• Avoid reversing where possible.

• Provide appropriate crossing points where pedestrians and traffic meet.

• Use road signs to indicate vehicle routes, speed limits, pedestrian crossings etc.

• Make sure lighting is adequate where people and vehicles are working.

• Make sure road surfaces are firm and even.

• Make sure there are safe areas for loading and unloading.

• Try to provide separate car parking for visitors as they may not know your site.
Question 5: Slips are a common cause of workplace accidents.
(a) Outline what contributes to slip accidents at work. (6)
(b) Explain TWO tests for measuring the slip resistance of surfaces. (4)

(a)

• Wet floors

Wet floors can be caused by a variety of things. Spillages are an obvious culprit. Cleaning activities
can also create wet floor surfaces. When it's raining outside, entrance areas can become wet as rain
travels in off peoples’ shoes and clothing. Poorly maintained buildings may also leak and let the
outside in.

• Slippery floors

Glossy polished floor tiles can be slip hazard if they are used in an unsuitable place, like a bathroom
or entrance, where the floor may become wet. Depending on the type of footwear worn, flooring
may be slippery even in dry conditions.

• Dusty floors

It's not just liquids that can cause slips. Dusty surfaces can also create a slip hazard, preventing
shoes from gripping the floor.

• Loose mats and floor coverings

Some mats can also create a slip hazard if they don't grip well with the surface underneath. Step on
it in the wrong way and it can slide from under you. Temporarily protecting a new floor with sheets
or cardboard? These can also slip and slide underneath you.

• Unsuitable footwear

Ever tried running in slippers, or socks? It's not recommended. Shoes with a slippery sole also aren't
going to help you avoid slip hazards. In fact, they become one.

• Icy conditions

Working outdoors in winter, or in cold environments? Ice is a slippery surface, even for the most
robust footwear. Make sure you consider the possibility of ice forming on surfaces causing a slip
hazard.
(b)

The pendulum Co F (coefficient of friction) test is also known as a Portable Skid Resistance Tester
and is in accordance with British Standards BS 7976: 1- 3 2002.

The instrument itself is a swinging, replica heel made of a standard rubber sole. This swings over a
sample area of flooring in both a dry and contaminated state, and in different directions for profiled
flooring.

The pendulum test values (PTVs) then gives the tester a slip potential classification of:

Surface Microroughness Test

To supplement the pendulum test data, a surface microroughness test can be undertaken to
indicate slip levels in contaminated conditions, this is done by measuring the surface roughness of
the flooring materials used. The instrument measures the total surface roughness (Rz) of the
flooring and can also indicate wear. However, if testing with contaminants other than water,
different levels of roughness will be required.

Generally, a high level of surface roughness is needed to minimize the risk of slips. If a pendulum
test has not been completed, the data should be used together with results from the Slips
Assessment Tool (SAT).

The slip potential classification can then be interpreted as follows:

Rz surface roughness Slip potential

Below 10 µm High

10-20 µm Moderate

20 + µm Low
Question 6:

Outline what should be considered when developing a planned preventive maintenance

program for safety-critical machinery. (10)

• Importance in the Process

Any strategy adopted should reflect whether the equipment has a critical and central role. For
example, if all production depends on a conveyor moving components from one stage of
production to the next and if without that conveyor production stops, the maintenance strategy
must ensure the minimum downtime during the production process.

• Failure During the Production Process

This sort of strategy will normally be a more costly option in terms of time and effort, and will have
to be balanced against the loss due to production breakdown.

• Machine Complexity

Any piece of machinery will have a number of components, any of which may fail. Some are more
difficult to gain access to than others and the potential time delay in repair must be considered.
Certain components may be so inaccessible that replacement or repair requires total strip-down of
the machine. Consequently, some of the maintenance strategies available may not be an
appropriate choice. An example is the replacement of an armature within an electric motor, where
the amount of stripping-down justifies that the bearings, etc. are checked at the same time.

• Relationship with Other Machines

In a production line, failure of one machine may cause total failure of the entire line. The position
and effect of a possible failure has to be considered, so the best option for an individual machine
may not be the best option for the overall production line. In such cases, the production line should
be regarded as a single entity in the first instance, with the individual machines being considered
separately when reviewing implementation within the chosen maintenance strategy.

• Availability of Replacement Equipment

Maintenance strategy selection is varied when it is possible to replace failed equipment with
functional equipment held ‘in store’ for such an occasion. The availability of the replacement, the
work involved in fitting it and getting operational, are factors which must be taken into account,
along with the availability of maintenance capability to undertake the work, as detailed below. This is
an option frequently used for small machines with low purchase cost, where it is possible to have
replacements available. For example, on construction sites, 110v electric hand tools are usually
available as replacements (either on-site or with quick delivery) for failed units, with the failed unit
normally being returned to a workshop for repair.

• Identification of Critical Components

Within any machine there is a number of key components which will have a major effect on the
failure mode of the machine. The identification of such components is important when deciding on
the maintenance strategy to be adopted.

• Environmental Factors

Machine characteristics can be considerably altered by the environment in which the machine is
required to work. Environmental factors can include: heat, cold, dampness, dust, vibration and
vapours. Electrical power supply reliability should be examined, as power fluctuations may
influence machine operation.

• Maintenance Capability Within the Company

Since any maintenance strategy has to be implemented, the resource requirements – in terms of
time and skill – have to be taken into account. It is inappropriate to consider a strategy if the
resources are not available to implement it.

• Maintainability Within the Design of the Machine

The manufacturer has to make provision for maintainability, taking into account the following
factors:

– Accessibility of internal parts.

– Ease of handling and human capabilities.

• Unknown Factors

People generally believe that they are aware of the factors which affect equipment. In practice,
many rely on information from records or by discussion, making the information second- or third-
hand.
Question 7 A rainwater gutter at a height of five meters is leaking.

Explain how you would apply the work at height hierarchy of control to the repair of the
gutter. (20)

• Avoid working at height:

– Design out the need to work at height.

– Erect handrails/edge protection at ground level and crane in.

– Working from the floor below, e.g. by using extending poles, where possible.

• Prevent working at height by using an existing place of work:

– A flat roof with permanent edge protection.

– A tanker roof with fixed edge protection.

• Prevent working at height by using collective work equipment:

Access equipment fitted with guardrails:

– MEWPs.

– Scissor lifts.

– Mast climbers.

– Cradles.

– Tower scaffolds.

– Independent scaffolds.

• Prevent working at height by using personal work equipment:

PPE used in a way that makes it impossible to get to a fall position:

– Work restraint.

• Mitigate by using collective work equipment to minimize the distance and consequences
of a fall:
Nets and soft-landing systems, such as air bags positioned close under work equipment to
minimize distance from work surface.

• Mitigate by using personal work equipment to minimize the distance and consequences
of a fall:
– A personal fall-arrest system with the anchorage point sited above the head.

– Rope access.

– A work-positioning system.

– A personal fall-arrest system with anchorage level at sternum/dorsal attachment point.

– A personal fall-arrest system with an anchorage point sited at the feet.

• Mitigate by using collective work equipment to minimize the consequences of a fall:

– Nets positioned at a lower level.

– Soft landing systems.

• Mitigate by using personal work equipment to minimize the consequences of a fall:

– A personal injury system (life jacket while working next to unguarded water).

• Mitigate through training and instruction or other means:

– Ladders.

– Hop ups
Question 8:

(a) Outline hazards from the use of a scissor lift. (12)

(b) Outline control measures that would help protect members of the public when operating
a scissor lift in a supermarket during opening hours. (8)

• Ejections From the Basket/ Falls, ejections from the basket of falls from elevated heights can as a
result of various hazards.

• Collapses/Tip-Overs, collapses and tip-overs are usually caused by inappropriate handling and
traveling of the lift as well as inadequate mechanical inspections and pre-start vehicle. Tip-overs
may also occur as a result of an exceeded load capacity.

• Electrocutions, electric shocks can also occur if you work in proximity to electric power lines.

• Falling Objects from the Lift, the risk of falling objects is mostly caused by the scissor lift hire
carrying objects that are larger than the platform or carrying unstable objects.

• Scissor lifts present crushing hazards similar to vehicles and other mobile equipment at
worksites.

• Being trapped between the Scissor lift and/. materials or fixed structures.

• Striking or coming into contact with sharp objects.

• Running into bystanders or unexpected movement of Scissor lift.

• Machine not used in a serviceable condition.

• Raising and lowering on uneven ground.

• Electric shock from damaged cords.

• Entanglement.

• Unauthorized use.

• Explosion of gases, dust, vapors, liquids or other, Explosion during battery charging, Explosion
during refueling.

• Shearing or cutting of body or limbs.

• Slipping, tripping or falling out of the machine.

(B)

• Follow the manufacturer’s instructions for safe movement—this usually rules out moving the lift
in an elevated position.
 • Isolate the scissor lift or implement traffic control measures to ensure that other equipment
cannot contact the scissor lift.

• Select work locations with firm, level surfaces away from hazards that can cause instability (e.g.,
drop-offs, holes, slopes, bumps, ground obstructions, or debris).

• Use the scissor lift outside only when weather conditions are good. Scissor lifts rated for outdoor
use are generally limited to wind speeds below 28 miles per hour.

• Ensure that safety systems designed to stop collapsing are maintained and not bypassed.

• Never allow the weight on the work platform to exceed the manufacturer’s load rating.

• Never allow equipment other than the scissor mechanism to be used to raise the work platform
(e.g., using a forklift to lift the work platform).

• Keep the lift from being struck by other moving equipment on the worksite.

• Implement traffic control measures around the scissor lift to prevent other workers or vehicles
from getting too close.

• Use ground guides when operating or moving the scissor lift around the workplace.

• Select work locations that do not approach electrical power sources (e.g., power lines,
transformers) by at least 10 feet and that do not pose other overhead hazards (e.g., other
utilities, branches, overhangs, etc.).

Question 9:
A storeroom is to be built for the storage of bulk stocks of palletized containers of highly
flammable paints and thinners.
(a) Outline what should be considered when designing and constructing the storeroom. (10)
(b) Outline what should be considered in the use of the storeroom. (10)

(a)

• All legal / corporate / insurance company requirements should be met……….

• Construction of store room should be of fire-resistant material……….

• There should be adequate escape routes such as emergency exits, keeping in view number of
personnel and distance between two exits……….

• Automatic fire detection and alarm system should be available……….

• Adequate ventilation should be available……….

 • Fire extinguishers and hydrants should be available keeping in view quantity of flammable
material……….

• Earthing of pallets should be done particularly during dispensing……….

• No hot work should be done in the area……….

• All electrical wiring should be concealed as much as possible……….

• Design structure should be fire resistant until emergency services arrive……….

(b)

• Use a less flammable, solvent-based substitute paint.

• Reduce the quantity of paints and solvents to a minimum.

• Provide an external, fire-resistant storeroom for paints and solvents with adequate ventilation,
located an adequate distance from the workplace.

• Provide local exhaust ventilation.

• Provide dilution ventilation at high and low levels.

• Use intrinsically safe electrical equipment.

• Earth to avoid electrostatic ignition.

• Use conductive footwear and clothing to avoid static build-up.

• Identify the appropriate zone for the work area.

• Use non-spill containers.

• Provide fire-fighting equipment, escape routes and an emergency plan.

Question 10:
(a) Outline the effects of a fire in a workplace on the following structural materials:
(i)steel; (4)
(ii) concrete; (4)
(iii) wood. (4)
(b)Outline precautions that could be taken to prevent failure of these materials in the event
of a fire. (8)

(a)
(i) Steel is affected by fire in such a way that when it is heated the steel expands and twists, and will
break welds/bolted joints, destroying the integrity of the steelwork and building fabric, however
when it cools down some of its strength will remain, but it may have changed in what it can take
with regards to loading and strength.

(ii) Concrete doesn’t expand in a fire but it can suffer some damage, e.g., cracks, but the worst effect
is when steelwork is used as reinforcing, as the metal expands on heating and will badly damage the
concrete.

(iii) Wood – generally burns in small quantities, but when used as large timbers it generally smolders
and then the charring builds up an insulating layer, which can protect the wood

(b)

Precautions used to protect structural steel:

• Sprinkler systems to dose down in the event of fire.

• Heat-resistant / insulating coatings can be applied to protect the steelwork, which includes
concrete and specialist paints.

Precautions used to protect concrete:

• Increase thickness of material around metal reinforcement so that the heat doesn’t reach the
reinforcement and expansion is prevented.

• Surround the concrete in a fire-retardant material to protect it from the heat.

• Use a concrete mix which contains materials which provide fire resistance.
 Precautions used to protect wood:

• Selection of wood with good fire-resistant properties.

• Use of larger timbers which allow an outer layer of charred material to form without affecting
integrity.

• Impregnating the timbers with a coat of fire-retardant material.

Question 11:

An external lift on a construction site has an interlocked guard to prevent the lift operating
when the gate is open. With reference to the diagram below:
(a) identify the two types of switches shown (Switch A and Switch B); (2)
(b) identify the functional components associated with BOTH switches; (4)
(c) outline the normal sequence of operation for the electricallyoperated, cam-activated
switch assembly when the gate opens and closes; (6)
(d) outline ways in which electrically-operated, cam-activated switches may fail to operate
as intended. (8)

(a)

Limit switch A is wired normally closed and is a positively operated switch while switch B is wired
normally open and is negatively operated.

(b)

The functional components of the switches are

- The cam follower or plunger, and
- Internal spring compressed from the bottom
- Internal electrical contacts attached to the cam follower with the gate acting as the cam

Functional components are the gate acting as cam, the plunger acts as cam follower, the spring
which compresses and de-compresses, the electrical connections and switch.

(c)

When the gate is closed

- the normal sequence of operations would be

- The depression of the plunger on switch B and
- The compression of the internal spring
- The release of cam follower on switches A This allows electrical contact to the both switches, so
making the circuit and allowing the operation of the lift.

When the gate is open –

- The cam follower on switch A is depressed

- The internal spring compresses while the cam follower in switch B is released causing
decompression of the spring. This electrical contact is broken in both switches thus breaking the
circuit and preventing the operation of the lift.

(d)

There are number of ways in which the type of switch described in the scenario might fail to operate
as intended, these include

- Failure of or damage to the internal spring which prevent the appropriate contact being made
- Damage to the other internal parts of the switch
- The presence of the debris or dirt within the body of the switch
- A contact weld through electrical arcing
- A misalignment between cam and cam follower or a wiring fault
- Wear of or damage to parts such as bent plunger
- Damage due to corrosive atmosphere and sabotage such as deliberate disconnection of wiring
or the taping up parts to simulate activation by the gate.
 JULY 2019
Question 1:
(a) Outline TWO zone classifications for explosive atmospheres with a flammable solvent in air. (4)

(b) Outline control measures to help reduce the risk of an explosion with a flammable solvent in air. (6)

(a)

• Zone 0

A place in which an explosive atmosphere consisting of a mixture with air of dangerous substances
in the form of gas, vapor or mist is present continuously or for long periods or frequently.

• Zone 1

A place in which an explosive atmosphere consisting of a mixture with air of dangerous substances
in the form of gas, vapor or mist is likely to occur in normal operation occasionally.

(b)

- Controlling ignition sources in zoned areas, in particular those from electrical and mechanical
equipment (refer to Selection of Equipment Section in Appendix 2);
- Where necessary, identifying the entrances to zoned areas;
- Providing appropriate anti-static clothing for employees (refer to Control of Ignition Sources
section in Appendix 2);
- Provide local exhaust ventilation /Provide dilution ventilation at high and low levels.
- Use intrinsically safe electrical equipment.
- Earth to avoid electrostatic ignition.
- Use conductive footwear and clothing to avoid static build-up.
- Provide fire-fighting equipment, escape routes and an emergency plan.
- controlling the source of ignition by preventing smoking in the area.
- issuing permits-to-work.
Question 2:
The designers of a large item of machinery are intending to include an access opening in the side of the
machine to allow an operator to reach inside with a single arm to manually open a drain valve.

Outline ergonomic factors that would influence the design of the access opening. (10)

- The layout
- operation of controls
- emergency controls;
- reducing the need for access (automation, remote systems).
- frequency and duration of the task
- designing protection from moving parts within the machine.
- allowance for winter clothing.
- the need to hold tools when accessing the valve through the opening
Question 3:
An office building has a passenger lift to transport office workers between floors.

(a) Outline hazards associated with using passenger lifts in the office building. (5)

(b) Outline control measures to help reduce risks to passengers when using lifts in the office building. (5)

(a)
 (b)
- Lifting equipment for lifting persons must be thoroughly examined every six months, or at
shorter intervals if considered appropriate, or in accordance with the intervals specified in an
examination scheme drawn up by a competent person.
- By providing & installing adequate local lighting.
- Marking of the maximum number of persons and maximum working load.
- Emergency stop devices
- Space and strength corresponding to the maximum number of persons and maximum
working load.
- Emergency arrangements, including first aid
- Signage, don’t use in event of fire.
- Regular maintenance and servicing
- Procedure for reporting door and
- Control faults
- Lift replacement strategy.

Question 4:
A scaffolder is lowering scaffold poles from the third floor of a scaffold tower to a colleague below using a
pulley wheel and rope. Next to the scaffold tower there is a shop entrance. The scaffolder on the ground
floor places the scaffold poles horizontally onto the back of a vehicle parked on a busy road. The
scaffolders have already received information, instruction, training and suitable supervision.

Outline additional control measures that could help reduce the risk of injury to those who may be affected
by this activity. (10)

- The pulley wheel and rope were; -the required statutory inspections of such tools.
- The SWL of pulley was not exceeded;
- Correct slinging techniques and rigging on the scaffold poles and use guide ropes where
necessary.
- Toe-board and handrails would need to be fitted on the upper platform to protect both the
scaffolder on that floor and public below.
- Suitable safety harness should also be worn by the workman on the upper floor as fall protection
- Attention should be given to nearby hazards such as obstruction and power lines
- Signs and barriers to be erected at ground level to prevent public access to the lowering areas.
- There could be a danger of passing traffic and the placing of cones would help to prevent a
collision with the lorry.
- Finally, both workmen should be provided with hi vi clothing, gloves and head protection.
-

Question 5:
Large quantities of aerosol canisters are stored in a warehouse. The canisters contain liquefied highly
flammable gases.

(a) Outline what could cause a fire and explosion in these circumstances. (5)

(b) Outline fire precautions that could be taken to limit the spread of any resulting fire and explosion. (5)

(a)

The canisters may have suffered damage for example to the valve or body of the canister, leading to
loss of containment and the formation of flammable vapors which if between the upper and lower
flammable limits can be ignited by a heat source, perhaps a nearby fire or hot work and even by
direct sunlight. The canisters may then be propelled from their original position as projectiles as the
radiant heat from the initial fire causes boiling of the contents of adjacent canisters. This causes the
release and ignition of additional vapor sources resulting in multiple BLEVEs.

(b)

- Fire precautions that can be taken to limit the spread of any resulting fire and explosion in a
similar type of warehouse include
- The segregation of the canisters from other flammable products;
- The separation of high flammability canisters by physical barriers;
- Using compartmentalization within the warehouse with fire resistant partitions;
- The provision of containment cages to prevent projectiles;
- The installation of automatic fire detection and alarm systems;
- The use of automatic extinguishing systems and venting and explosion reliefs.
- The canisters should be fitted with pressure relief valves
Question 6
A fire protection contractor has recommended the provision of portable water and carbon dioxide fire
extinguishers to be placed in a multi-story office block.

(a) Identify the class of fire that the water extinguisher is designed for AND give an example of a material
that is included in this class. (2)

(b) Outline advantages of a carbon dioxide extinguisher. (2)

(c) Outline what should be considered in siting the extinguishers. (6)

(a)

Water fire extinguishers have a red label and a class A rating. They are suitable for fighting fires
involving solid combustibles such as wood, paper and textiles,

(b)

 smother fires more quickly in draught free conditions

 carbon dioxide is a non-conductor, so can be used on live electrical equipment (so is often
suitable for server rooms)
 leaves no residue and is not as damaging to electrical equipment as powder
 suitable for class B fires – flammable liquids including petrol, diesel, spirits, and paint.

(C)

The fire-fighting equipment should be sited in a position where it is easily seen and reached, usually
by an escape route. The location should be marked and should not be further than 30m from an
alternative equipment location (see the following figure).
The extinguishers should be located so they are:
• Conspicuous.
• Readily visible on escape routes.
• Properly mounted.
• Accessible (less than 30m from any fire).
• Sited to avoid temperatures beyond the operating range and corrosive environments.
Special extinguishers should be sited close (but not too close) to the risk.
Question 7
A number of lights in a storage warehouse have failed and need replacing. The lights are at a height
of 5 meters.

Outline what should be taken into consideration when replacing the lights to help reduce the risk
of work at height. (20)

• Avoid working at height:

– Design out the need to work at height.

– Erect handrails/edge protection at ground level and crane in.

– Working from the floor below, e.g. by using extending poles, where possible.

• Prevent working at height by using an existing place of work:

– A flat roof with permanent edge protection.

– A tanker roof with fixed edge protection.

• Prevent working at height by using collective work equipment:

Access equipment fitted with guardrails:

– MEWPs.

– Scissor lifts.

– Mast climbers.

– Cradles.

– Tower scaffolds.

– Independent scaffolds.

• Prevent working at height by using personal work equipment:

PPE used in a way that makes it impossible to get to a fall position:

– Work restraint.

• Mitigate by using collective work equipment to minimize the distance and consequences of a fall:
Nets and soft-landing systems, such as air bags positioned close under work equipment to minimize
distance from work surface.

• Mitigate by using personal work equipment to minimize the distance and consequences of a fall:

– A personal fall-arrest system with the anchorage point sited above the head.

– Rope access.

– A work-positioning system.

– A personal fall-arrest system with anchorage level at sternum/dorsal attachment point.

– A personal fall-arrest system with an anchorage point sited at the feet.

• Mitigate by using collective work equipment to minimize the consequences of a fall:

– Nets positioned at a lower level.

– Soft landing systems.

• Mitigate by using personal work equipment to minimize the consequences of a fall:

– A personal injury system (life jacket while working next to unguarded water).

• Mitigate through training and instruction or other means:

– Ladders.

– Hop ups

Question 8
During a fire drill exercise at a large multi-storey office premises, the majority of the occupants evacuated
the building in less than three minutes. However, all of the occupants based in one area of the building
failed to leave the building until a further four minutes had elapsed.

(a) Outline what may have contributed to the delay in evacuation. (15)

(b) Outline reasons for conducting regular fire drills in workplaces. (5)

(a)

Fire Alarm: Fire Alarm too quite due to low volume; - number of fire alarm are insufficient; - Alarm
may sound similar to other alarming system creating confusion among people; - Alarm may be
inactive due to maintenance work; - signal of alarm may be weaken due to wall and doors or other
obstruction.

Design of buildings: inadequate escape routes which are greater than recommended travel distance;
- too complex to traverse; - too narrow slowing down the evacuation; less numbers of access
comparing to strength of occupants; even blocked and locked; inadequate lighting or no emergency
lighting in the escape routes; incorrect signs showing emergency exits;

Deficiency in existing Evacuation procedure: FEP too difficult and complex to understand; - - the
procedure may not be communicated adequately; -no or insufficient instructions for staff mentioned
in the procedure; - actions / responsibilities are not well communicated; - fire marshal duties may
not be well defined; - inadequate number of fire marshal deputed; - insufficient training / drills
conducted for the occupants of the building.

Execution / Compliance of Procedure: possible noncompliance of procedure during actual exercise; -

Delay in response to the alarm by finishing work, finishing telephone call, by shutting of PC,
gathering their belonging or may be investigating why alarm sounded; No response at all Assuming
the Alarm as FALSE alarm or a Drill.

Human factors: hearing disabilities; physical disabilities; general apathy; lack of will to participate;
lack of familiarity with the layout of the building.

(b)

- Fire drills allow staff to practice evacuation procedures in a simulated situation to ensure they are
fully aware of how to safely exit the building.
- The more familiar staff are with fire drill procedures, the higher the chance that staff remain safe
and well during an emergency.
- Regular fire drills will help to underpin the correct procedures, removing panic and uncertainty
for all concerned.
- Fire drills are also an important opportunity to analyses how effective the evacuation procedure
is and how effective the exit routes were, so that changes can be made to improve the strategy in
the future.
- Fire drills are a legal requirement for all businesses.
Question 9:
Workers are using lathes to make metal components.

(a) Identify FIVE types of mechanical hazard associated with lathes AND give a practical example of EACH.
(10)

(b) Outline control measures that help reduce risks associated with lathes. (10) Candidates only need to
relate answers to lathes and not computer numerically controlled (CNC) lathes.

(a)

- Being hit by loose objects on the lathe, such as chuck keys, tools or swarf.
- Entanglement of clothing in moving parts such as drive gears, chucks, lead and feed screws and
the workpiece.
- Being struck by a workpiece that has not been adequately secured in the lathe or is oversized.
- Entanglement from inappropriate tooling and polishing techniques
- Slips, trips & falls due to lose materials or oil spillage existence near the machine.
(b)

- ENCLOSE parts (eg. Chuck keys, tools or swarf) in interlocked guards to avoid being hit.
- USE the appropriate chuck for the workpiece.
- KEEP the headstock free of loose items.
- AVOID wearing loose clothing, jeweler or gloves - they increase the risk of entanglement.
- PLACE lathe controls to AVOID reaching through the work zone.
- Workpieces SHOULD NOT extend beyond the headstock of the lathe. If they do, adequate
support MUST be provided.
- ENSURE that cooling fluids and lubricants are, contained to prevent harm, treated or replaced in
accordance with manufacturer’s instructions.
- Leaking oil, or bulging or abraded hose walls, MUST have faulty parts replaced.
- Apply a program preventive maintenance (hydraulic hoses and hydraulic hose couplings).
- Reduce noise levels by isolating machines or enclosing within noise barriers.
- Keep up-to-date housekeeping procedures and keep the area around lathes clear of slip and trip
hazards.
Question 10:
Construction work is due to take place to repair the footpath of a single carriageway road. The road is near
to a busy school in a residential area. Trucks and buses use the road occasionally.

Outline control measures that should be put in place to help ensure the safety of members of the public.
(20)

- Providing devices to guide the drivers and their movements through construction zones/ lane
closures/ traffic diversions etc.
- Provide adequate measures that control driver behavior through construction zones.
- Maximum width of lane required for construction during various activities.
- A qualified personnel at least average intelligence, be mentally alert and good in physical
condition be selected, since flagmen are responsible for public and workmen safety.
- scheduling the work while the school was closed,
- conducting risk assessments and writing method statements.
- Training and instruction for workers about speed limits were peripheral
- Use personal protective equipment for pedestrians.
- It’s vital that you consider the noise levels on your site and if these are damaging for close
passers-by.
- Contractor should carefully watch the amount of dust that leaves your site and lands in other
areas , so proper control must be provide by damping & wet site traffic roads.
- People can suffer serious injuries if they fall into stairwells, manholes, or excavations from open
floor edges. You must block these areas off with barriers or use a suitable covering.
- If you stack or store materials outside of your boundary, then you increase the likelihood of a
trip. Store all your materials within your site parameter, preferably in secure compounds.
- Visibility - make sure drivers driving out onto public roads can see both ways along the footway
before they move on to it;
- Obstructions – do not block walkways so that pedestrians have to step onto the vehicle route;
- Traffic controllers must know where to stand, how to slow or stop traffic, and how to coordinate
public and construction traffic movements.
- Speed limits should be consistent with safe site operations and traffic movements.
- A systematic preventative maintenance program should be established for all trucks, plant, and
vehicles.
- The public should be notified of all current and upcoming road construction work projects and be
advised on personal safety and how to best avoid accidents and traffic becoming congested.
Question 11:
(a) Outline hazards when excavating near underground electrical cables. (4)

(b) Outline control measures that should be considered when excavating near underground electrical
cables. (12)

(c) Outline the effects of electric shock on the body. (4)

(a)

- Damage to cables usually occurs during excavation work and is caused by the crushing or
penetrating effects of hand or machine tools such as pneumatic drills and mechanical excavators.
- Damage to live cables often results in arcing currents with associated explosive effects, fire and
flames, which usually cause severe (potentially fatal) burns to the hands, face and torso.
- Collapse of excavation side wall if there is no proper excavation protection system is provided
such as (slope, shoring).

(b)

The precautions taken to avoid risk associated taken to avoid risk associated with a cable strike when
excavating near underground.

• The excavation work has to be carried out with proper plan.

• Planning involves seeking advice from the relevant body such as appropriate electrical supply
company or lighting road authority.

• Assessing the electricity cable plan or understanding the symbols.

• The high and low voltage cable can be shown on separate plans.

• The supply should be made dead and investigating the possibility of diversion.

• Providing the use of mechanized excavation utilizing a permit to work system.

• Before the excavation starts it is necessary to locate the produce of cables by use of cable avoidance
tools (CATS) such as Hum or radio frequency.

• When cable which is recorded in a plan cannot be located, assistance and advice should be sought
from appropriate authority with extreme care.

• The excavation should be carried out with trained and competent person in safe digging practice.
• They should be experienced enough to detect cables which are not indicated in the plans.

• They should be aware although the cable is exposed there may be further cables at a lower level.

• When cables joints are discovered, they should be supported not to be moved nor be treated
roughly.  The important precaution during the excavation work includes the need to lookout for
permanent marker posts or other visible indication of buried cables.

• To establish positive location by careful hand digging exposing the cables by digging from the side
and using hand held power tools.

• The use of mechanical excavations helps in avoiding damage to a reasonable way.

• The personnel should be kept well away from the excavation and drivers instructed to stay in the cab
if the cable is struck.

• When the cables are exposed, the damage should be reported to cable owners, no work should be
undertaken.

• Support should be provided if more than on meter of cable is exposed and protection such as use of
planks or sand bags should be provided to prevent damage from ongoing work.

• Cables should not be moved aside unless the work is supervised by the cable owners.

(C)

the effects of electric shock on the body include:

- Flash: A flash injury typically causes superficial burns. These occur due to the heat of an arc flash,
which is a type of electrical explosion. The current does not penetrate the skin.
- Flame: These injuries occur when an arc flash causes a person’s clothes to ignite. The current may
or may not pass through the skin.
- Lightning: These involve short but high voltage electrical energy. The current flows through a
person’s body.
- True: The person becomes part of the circuit, and the electricity enters and exits the body.
 January 2018
Question1:

An organization provides an overnight security guard service. The duties of the security guard include
locking the building at night, patrolling the perimeter, conducting visual checks during the night and
unlocking again in the morning.

(a) Explain why the security guard is at greater risk of harm as a lone worker in these circumstances. (3)

(b) Outline what the organization could provide to minimize the lone working risks of the security guard. (7)

(a)

- violence/physical attack;

- having no assistance in the event of a medical emergency

- in the event of an emergency not having someone to assist or to summon help.

(b)

• Ensuring risk assessments identify lone working tasks on and off site and the potential hazards.
• Eliminating the hazards of working alone by using a buddy system. People should work in pairs
at difficult or outof-the-way sites, including home and community visits.
• Information on high-risk geographical areas or jobs should be given to staff (particularly new
members) and records of staff whereabouts should be kept. Safe completion of jobs should be
reported.
• Good communications at all times: mobile telephones and two-way radios can be useful in some
cases.
• Electronic and visual monitors, which can also offer some protection.
• The introduction of a Personal Alarm Security System (PASS).
• Alarms: many counter, service and care workers have access to panic buttons and a range of
other emergency, personal distress and violent attack alarms are available.
• Reorganize the way jobs are done to provide a safer system of work.
• Review procedures regularly to make sure they are working.
• The necessity for handling cash or dangerous materials should be continually reassessed.
Question 2:

A battery-powered lift truck is being used in a potentially flammable atmosphere.

(a) Outline sources of ignition from the battery-powered lift truck. (4)

(b) Outline the protection that should be applied to the battery powered lift truck to help minimize the risk
of an explosion. (6)

(a)

- sparks arising of Trucks electrical system – sparks arise to static electricity – through over
speeding / over loading – from frictions / surface temperature – Fuel gets hotter than Flash
point
- arcing and sparking of unprotected electrical components, hot surfaces such as brakes and
sparks from friction or the build-up of static electricity.

(b)

- protection of the drive motor in an explosion proof housing

- Reduce static by using electrical conducting material for tyres.
- Speed limit
- Electrical starters wired to plug and socket in a safe area
- Inspect, test and maintain cooling systems
- Perform preventive maintenance properly and in strict accordance with the manufacture
published requirement and to be carried out by trained and experienced personnel.
- Lift truck operator should be trained about fire risk and prevention.
- Lift truck should be cleaned for dirty such as corrugated paper dust and bits of torn paper and
Question 3:

A contractor is working on an electrical distribution board and proposes to carry out live working. Outline
a safe system of work when working on the live electrical distribution board. (10)
The first priority should be to avoid working on or near live electrical parts. If its not possible,
following precautions should be taken:

 All electrical cables and other items should be properly insulated such as class II or double
insulation
 All underground and overhead cables should be properly marked as such for their depth /
clearance, height, route and rating
 Only trained, qualified and experienced electricians should work on or near live electrical parts
such as cables, substations, bus-bars etc
 The workers should wear appropriate PPEs such as insulated footwear, gloves, face shields, head
protection etc taking into account specific hazards such as voltage / current rating of parts they
are working on.
 Residual current devises (RCD) or residual current circuit breakers (RCCB) should be used where
there is danger of contact with live electrical parts as the current leakage can be harmful such as
portable electrical equipment, lab equipment etc
 All the flooring inside areas containing electrical installations such as HT / LT substations should
be covered with rubber pads having specs in accordance with hazards like voltage rating
 All works on electrical parts such as on / near live electrical cable, LT / HT substations etc should
be accompanied by valid permit to work, signed off by competent person after careful risk
assessment, considering avoiding the work first
 Periodic inspection / audit plan of electrical appliances should be performed covering issues like
earthing, identification of damaged electrical cables, sockets, switchboard etc
 Overcurrent protection devices such as circuit breakers, fuses etc should be installed in electrical
system to prevent more current flowing in circuit then it is designed for
 Periodic calibration plan of circuit breakers should be devised to ensure integrity of these
breakers
 All equipment, metallic sockets, machinery and portable equipment should be properly
grounded to prevent causing electrical shocks in case of current leakage. The grounding plan
should be subjected to testing plan
 Physical barriers must be in place between live electrical parts such as cables, bus-bars,
substation equipment and these should be clearly marked via signage.
 Positioning of overhead electrical cables should be considered for areas where cranes are to be
used to avoid contact of crane with overhead cables. Also where pipes and tubes are to be used
manually / vertically such as scaffolding, safe system of work should be ensured such as
minimum distance to be maintained
 Single line diagram for electrical overhead and underground cables should be prepared,
displayed and communicated to all relevant staff
 Ensure that no work on electrical systems should be done in case of adverse weather such as
rain, high wind, storm etc. unless critically necessary and accompanied by safe system of work

Question 4:

A dental surgery uses a small steam sterilizer to disinfect dental instruments.

the sterilizer is labelled with a CE mark, and has a written record with it in the form of a logbook.

(a) Outline why the sterilizer would be considered a pressure system. (3)

(b) Outline the purpose of the CE mark. (2)

(c) Outline what records need to be contained in the logbook. (5)

(a)

• Pressure vessel containing relevant fluid (steam).

• Pipework, with its protective devices, to which a transportable pressure receptacle is connected.
• ancillary safety devices
• presence of steam, in a pressurized vessel

(b)
• The purpose of the CE mark is to ensure that the Responsible Person who affixes the mark takes
responsibility for the conformity of the product.
• CE marking is a visible sign that the product complies with all relevant product supply law.
• CE marking gives companies easier access into the European market to sell their products
without adaptation or rechecking.
• You’ll guarantee your customers safety.
• free movement of the product throughout the EU because the CE Marking is recognized
worldwide.

(c)
  Written scheme of examination or periodic test.
 Installation records.
 Records of routine maintenance and repair.
 competent person responsible for the examinations
 TYPE of maintenance
 Previous maintenance

Question 5:

An organization uses a powered guillotine to trim paper to the correct size.

Outline control measures that can be taken to help minimize risk when operating the guillotine. (10)

• The provision of fixed guards or other safeguarding systems such as photo-electric devices ('light
curtains') or pressure mats;
• Shrouding the foot pedal to ensure the guillotine was not accidentally operated;
• Provision of adequate distance away from the blade when a person is removing cut materials
from the table – this may be achieved by extending the table so that they are standing far
enough away to avoid contact with the blade.
• The possibility of introducing automated or mechanical systems for the handling of the sheet
metal;
• Methods for noise reduction such as hoods or absorbent bin lining;
• Ensuring correct selection, maintenance and adjustment of the blade.
• Training and competence of those working with the equipment.
• Provision of adequate workspace around the equipment so that people can move freely without
trip hazards, etc.
• Provision of adequate heat and lighting.
• Provision of one or more emergency stop devices which are clearly marked.
• Provision of local isolation devices for maintenance.
• Installation of the machine on a firm, level surface.
• Implementation of safe systems of work for safe use of the equipment – this includes training
operators in these systems.
• Development of maintenance procedures, to check the guards are in place and used correctly
and that the machine and LEV are in good working order, together with the training of
maintenance personnel.
• Provision of PPE, e.g., dust masks, hearing protection and goggles if required.

Question 6:

A fire protection contractor has recommended the provision of portable water and carbon dioxide fire
extinguishers to be placed in a multi-story office block.

(a) Identify the class of fire that the water extinguisher is designed for AND give an example of a material
that is included in this class. (2)

(b) Outline advantages of a carbon dioxide extinguisher. (2)

(c) Outline factors to be considered in siting the extinguishers. (6)

(a)

Water fire extinguishers have a red label and a class A rating. They are suitable for fighting fires
involving solid combustibles such as wood, paper and textiles,

(b)

 smother fires more quickly in draught free conditions

 carbon dioxide is a non-conductor, so can be used on live electrical equipment (so is often
suitable for server rooms)
 leaves no residue and is not as damaging to electrical equipment as powder
 suitable for class B fires – flammable liquids including petrol, diesel, spirits, and paint.

(C)
- Extinguishers should be located in conspicuous positions, available at all times for immediate
use and fitted on brackets or stands where they will be readily seen by any person following an
escape route. Fire extinguishers should be securely hung on wall brackets. Where this is
impractical extinguishers should be located on suitable extinguisher stands so the extinguisher
is not in direct contact with the floor.
- Wherever possible, portable extinguishers should be grouped to form a fire point so employees
can more easily locate them in an emergency.
- If wall mounted the carrying handle of larger, heavier extinguishers should be 1 meter from the
floor but smaller extinguishers with total mass up to and including 4Kg should be mounted so
that the carrying handle is 1.5 meters from the floor. If possible, extinguishers should be sited in
such a way that it is not necessary to travel more than 30 meters from the site of a fire to reach
an extinguisher.

Question 7

A container port handles a wide range of ships’ cargo including dangerous substances that are flammable,
explosive and toxic.

Outline the on-site organizational arrangements that the Port Authorities need to make to prepare for an
emergency. (20)

Organizational measures:

• the provision of equipment in order to ensure their safety,

• staffing levels,
• hours of work,
• definition of responsibilities,
• and controls on outside contractors and temporary workers on the site of the installation.
• Access / egress for emergency services.
• Allocation of role and responsibilities for specific actions in an emergency.
• Emergency phone numbers including out of hours contact numbers.
• People who may require special assistance to evacuate e.g. vulnerable workers or people with
disabilities, visitors or people unfamiliar with the terminal or port.
• Specific procedures for shutting down equipment or power. With crane stoppage during high
winds sufficient time should be factored into procedures to ensure that the crane operator can
safely egress from the crane.  
• Backup communication systems: primary systems can fail and mobile phone networks cannot
always be relied on in emergency situations.
• Maintenance of all emergency plant and equipment.
• Train all employees in the actions to be taken in an emergency.
• Display site plans that illustrate the location of fire protection equipment, emergency and
assembly points and ensure there is clear signposting so emergency services can locate areas.
• Regularly review plans and update as necessary.
• Large scale maps showing evacuation routes and service conduits (such as gas and water lines).
• Detailed lists of emergency response personnel including their cell phone numbers, alternate
contact details, and their duties and responsibilities.
• All possible emergencies, consequences, required actions, written procedures, and the resources
available.

Question 8:

An airport has an automated baggage handling system. A part of the system is a series of large vertical
storage racks, where baggage is placed on to trays. These trays are then put on and taken off the racking
by baggage handling robots.

(a)

(i) Identify FOUR principles of safety integration. (4)

(ii) Outline how principles of safety integration could apply to the robots. (4)

(b) Outline key features for the baggage handling robots to operate safely. (12)

(a)

Principles of safety integration

Eliminate or minimise the risks by (in order of precedence) : design measures. provision of protective
devices. provision of information on residual risks and the precautions needed to deal with them.

( b)

The principles of safety integration set out the following basic principles of safety for any machinery:

“(a) Machinery must be designed and constructed so that it is fitted for its function, and can be
operated, adjusted and maintained without putting persons at risk when these operations are
carried out under the conditions foreseen but also taking into account any reasonably foreseeable
misuse thereof.

The aim of measures taken must be to eliminate any risk throughout the foreseeable lifetime of the
machinery including the phases of transport, assembly, dismantling, disabling and scrapping.

(b) In selecting the most appropriate methods, the responsible person must apply the following
principles, in the order given:
– eliminate or reduce risks as far as possible (inherently safe machinery design and construction),

– take the necessary protective measures in relation to risks that cannot be eliminated,

– inform users of the residual risks due to any shortcomings of the protective measures adopted,
indicate whether any particular training is required and specify any need to provide personal
protective equipment.

(c) When designing and constructing machinery and when drafting the instructions, the responsible
person should envisage not only the intended use of the machinery but also any reasonably
foreseeable misuse thereof. The machinery should be designed and constructed in such a way as to
prevent abnormal use if such use would engender a risk. Where appropriate, the instructions should
draw the user’s attention to ways – which experience has shown might occur – in which the
machinery should not be used.

(d) Machinery should be designed and constructed to take account of the constraints to which the
operator is subject as a result of the necessary or foreseeable use of personal protective equipment.

Machinery should be supplied with all the special equipment and accessories essential to enable it to
be adjusted, maintained and used safely.”

(C )

The following are factors that should be considered:

• Shape of the moving part has a major effect. It will include the effect of having sharp edges,
angular parts, etc. which may be a hazard even if not moving.
• Relative motion is concerned with the motion of one piece of the machine in relation to another.
It is this form of motion which gives rise to crushing, shearing, etc.
• Mass and stability is concerned with the possibility of motion of the machine under the effect of
gravity (i.e. will it fall down?).
• Acceleration is concerned with the increasing speed of motion of the machine. It is possible that
the operator may guess at the travel time and take action accordingly, when in fact the machine
is accelerating and less time is taken for it to travel, putting the operator in danger. This is
analogous to crossing the road where cars are accelerating away from a stop position.
• Inadequate mechanical strength is concerned with the possible break-up or bursting of the
machine. Abrasive wheels have poor mechanical strength, which is why they are designed to run
at a specific speed which should not be exceeded.
 • Potential energy of elastic components is concerned with the hazards from stored-up energy,
e.g., springs or a bandsaw blade.
• Operation
• Task
• Electricity
• Foreseeable misuse.

Question 9:
(a) Outline conditions that must be present for a primary dust explosion to occur. (5)
(b) Outline additional conditions necessary for secondary explosions to occur. (5)
(c) Outline design features that would minimize the likelihood and effect of a dust explosion. (10)

(a)

 The dust must be combustible and release enough heat when it burns to sustain the fire.
 The dust must be capable of being suspended in air.
 The dust must have a particle size capable of spreading the flame.
 The concentration of the dust suspension must be within the explosible range.
 An ignition source must be in contact with the dust suspension.
 The atmosphere must contain sufficient oxygen to support and sustain combustion.
 There is a form of confinement or enclosure that allows pressure to build
 The Dust Pentagon, In the case of a combustible dust explosion, two more elements are
required to be added to the fire triangle, creating the Dust Explosion Pentagon.

(b)

 Dislodgement / Force removal of accumulated dust from horizontal surface within the affected
building by the pressure wave and consequent air turbulence.
 Ignition: When lying dust is distributed by the primary explosion and form a second dust cloud ,
the dust cloud then can be ignited –
 By the combustion of products from primary explosion –
 By the heat released through the primary explosion - Any other source of ignition within the
area with sufficient heat energy

(c)
  Ensuring that the ducting was dust tight,
 Providing local exhaust ventilation at point of transfer,
 Installing explosion relief or suppression systems together with systems for suppressing fire,
 Using screw conveyors instead of pneumatic systems for moving materials Providing a
magnetic extraction system for removing metal from product fed to the plant,
 Interlocking equipment to prevent overfilling of vessels and over pressurization,
 Using instrument systems with integral emergency shutdown
 Using intrinsically safe electrical equipment and bonding all metal work to earth,
 Preventing dust build up in the plant by the use of sloping surfaces and introducing a
mechanized system for humidification of the air
 The initial design of ducting and equipment to withstand the effects of an explosion,
 Control fugitive dust releases using enclosures, collection systems, or equipment design.
 Locate dust-producing operations in areas separated from other occupancies.
 Minimize chances for dust accumulation in buildings.
 If fugitive dusts will exist, design the structure to vent safely potential explosions using
damage-limiting construction techniques.
 Locate the highest hazard equipment—dust collectors—outside, away from important buildings
and utilities.
 Construct equipment that process or transfers combustible particles to contain or safely vent a
potential explosion.
 Where explosion containment or venting of equipment is not possible, eliminate the oxygen in
the system with inert, or install an explosion-suppression system.

Question 10:

Construction work is due to take place to repair the footpath of a single carriageway road. The road is near
to a busy school in a residential area. Trucks and buses use the road occasionally. Outline control
measures that should be put in place to help ensure the safety of members of the public. (20)

- Providing devices to guide the drivers and their movements through construction zones/ lane
closures/ traffic diversions etc.
- Provide adequate measures that control driver behavior through construction zones.
- Maximum width of lane required for construction during various activities.
- A qualified personnel at least average intelligence, be mentally alert and good in physical
condition be selected, since flagmen are responsible for public and workmen safety.
- scheduling the work while the school was closed,
- conducting risk assessments and writing method statements.
- Training and instruction for workers about speed limits were peripheral
- Use personal protective equipment for pedestrians.
- It’s vital that you consider the noise levels on your site and if these are damaging for close
passers-by.
- Contractor should carefully watch the amount of dust that leaves your site and lands in other
areas , so proper control must be provide by damping & wet site traffic roads.
- People can suffer serious injuries if they fall into stairwells, manholes, or excavations from open
floor edges. You must block these areas off with barriers or use a suitable covering.
- If you stack or store materials outside of your boundary, then you increase the likelihood of a
trip. Store all your materials within your site parameter, preferably in secure compounds.
- Visibility - make sure drivers driving out onto public roads can see both ways along the footway
before they move on to it;
- Obstructions – do not block walkways so that pedestrians have to step onto the vehicle route;
- Traffic controllers must know where to stand, how to slow or stop traffic, and how to coordinate
public and construction traffic movements.
- Speed limits should be consistent with safe site operations and traffic movements.
- A systematic preventative maintenance program should be established for all trucks, plant, and
vehicles.
- The public should be notified of all current and upcoming road construction work projects and be
advised on personal safety and how to best avoid accidents and traffic becoming congested.

Question 11:

A truck-mounted crane delivers bulk materials to a construction site. The materials are stored in flexible
one-tone bags. The crane is operated from the ground with a pendant controller. Outline control measures
for safe delivery of bulk materials using this crane. (20)

- It is vital that a competent/responsible person correctly plans all crane lifting operations
concerning this safety procedure.
- The plan prepared by a qualified/reliable person or a team is to be followed by everyone involved
in the process.
- lifting permit be provided & display at work area before starting of job.
- Crane third party certificate, validity one year (plate number, validity, any remarks and number of
falls)
 - Operator & Rigger third party certificate & license must be provided and be valid.
- Provision of appropriate risk assessment & job safe procedure arranges and communicated to
teamwork prior to start work.
- Lifting appliance like (wire rope sling, webbing sling, D shackle, chain block) third party certificate
(validity 6 months) and don’t use beyond its SWL.
- Safety latch of a main and auxiliary hook be on place and make sure in good conditions.
- Make sure the materials stacked properly before lifting.
- The cabin of crane shall be free from blind spot and no hydraulic leak of oil.
- Soil or ground condition shall be checked and should be leveled and in good condition.
- Outrigger shall be fully extended and at least 1 meter away from manholes and trenches.
- Minimum two tag lines shall be used to control the swinging of load.
- The only rigger can give signal to the crane operators and rigger should wear a jacket.
- Safe Working Load (SWL) of the crane shall be mentioned on both side of the crane, and it should be
properly visible.
- Proper wooden blocks should be used under the crane outriggers to distribute and transfer the
load.
- Lifting equipment shall be jointly inspected by plant and safety personnel before the start of work.
This inspection shall be done daily, and a checklist for the same shall be followed and maintain all
record.
- Always provide barricades and proper signage to prevent unauthorized movement.
- Gather information about weather from the authorized agency and perform the job accordingly.
- Material lifting bag must be the third party certified with a valid inspection certificate

JULY 2018
Question 1:
A plastics manufacturer stores plastic beads in a tower silo. The plastic beads are considered to be a free
flowing solid. Workers need to enter the silo to carry out essential maintenance.

(a) Outline the risks to workers from the free flowing solid when entering the confined space. (4)

(b) Outline reasons that the silo atmosphere may be, or could become, oxygen deficient. (3)

(c) Outline possible effects that oxygen deficiency may have on a confined space worker. (3)

(a)

 Oxygen Deficiency
Oxygen can be lacking a silo for the following reasons:
-    displacement of air by another gas
-    various biological processes or chemical reactions (such as rotting of organic matter, rusting
of metals, burning, etc.)
-    absorption of air onto steel surfaces, especially where these are damp
 Flammable or Explosive Atmospheres
A flammable atmosphere presents a risk of fire or explosion. Such an atmosphere can arise from
the presence in the silo of a suspension of combustible dust in air. If a flammable atmosphere
inside a silo ignites, an explosion may occur, resulting in the expulsion of hot gases and the
disintegration of the structure.
 Flowing Solids
solids can flow into the silo causing drowning, suffocation, burns and other injuries.  Solids in
powder form may also be disturbed in a confined space resulting in an asphyxiating atmosphere.
 Excessive Heat
The enclosed nature of a silo can increase the risk of heat stroke or collapse from heat stress, if
conditions are excessively hot. The risk may be exacerbated by the wearing of personal
protective equipment or by lack of ventilation

(b)

oxygen deficient for the following reasons:

- It might be caused by microbial activity (such as the process of fermentation).

- it could be due to the oxidization (rusting) of the internal surface of a tank or pipe.
- it might be that the oxygen has been displaced by another gas such as nitrogen or argon.
- absorption of air onto steel surfaces, especially where these are damp.

( C)
 - At an oxygen level of 16%, individuals are likely to experience an increased pulse rate, more
rapid breathing, compromised thought processes, reduced attention span and impaired
coordination.
- At an oxygen level of 12.5%, respiration will likely be affected, there may be nausea or
vomiting and there is also a risk of permanent heart damage.
- At an oxygen level of 10% or less an individual may well experience convulsions, an inability to
move, loss of consciousness or even loss of life.

Question 2:

An employer provides a multi-story car park for its workers. The car park is made of steel-reinforced
concrete. Following several major fires at similar car parks, a review is being conducted of the fire safety
arrangements.

(a) Outline ignition sources that could be present from the cars. (3)

(b) Outline combustible materials that could be present from the cars. (3)

(c) In the event of a serious fire, outline possible effects of fire on the building structure. (4)

 (a)

- Lamp Filaments of Broken Bulbs: as Lamp filaments of broken bulbs are also a source of ignition
energy especially for gases, vapors, or liquid fuels in a spray or mist form.
- Hot Surfaces: as exhaust manifolds and components can generate sufficient temperatures to
ignite diesel spray and to vaporize gasoline.
- Mechanical Sparks: as Metal (e.g., steel and magnesium) to pavement sparking can generate
enough energy to ignite liquid fuel vapors or gaseous fuels.

(b)

First are the combustible materials which include fluids such as engine fuels and oils, transmission
oils, power steering fluids, brake fluids and lubricants; upholsteries; tyres; plastic materials such as
in dashboards and bumpers; possibly the body work of the vehicle itself.

(c)
The effects of fire in a workplace on structural materials:

Fire resistant and does not conduct heat, acts as an insulator at lower temperatures, will spall and
disintegrate as the temperature rises, reinforcing rods will act as conductors and expand increasing
any spalling & loses structural strength on cooling.

Question 3:

Large goods vehicles are loaded and unloaded at a distribution depot. Outline hazards associated with
these vehicles during this loading and unloading process that should be considered in a workplace
transport risk assessment. (10)

• Sprains and strains from improper lifting or handling of cargo

• Crushing injuries caused by colliding with a forklift, truck, falls from loading docks, or falling
stacked materials
• Bruises and cuts
• Spinal injuries from improper loading, unloading, falls or being crushed
• Head trauma from falling cargo.
• Toppling of improperly stacked or secured cargo;
• Breaking or failure of lashing and dunnage equipment;
• Unsafe access to and egress from the lorry or trailer bed; and
• Falling off the loading platform.
• moving tailgates
• climbing while sheeting over loads
• access to the cabs.

Question 4:
A disused chemical process plant is to be demolished to allow for the development of a large sports
stadium.

Outline what should be considered in a pre-demolition survey for the site. (10)
• planning,
• security of site boundaries
• use of method statements and permits-to-work.
• The construction details of the structures or buildings to be demolished (including the materials
used, fragile roofs, rot and extent of any dilapidation, significance and extent of any dilapidation
of the structure, the presence of cantilevered structures and any general weaknesses) and those
of neighboring structures or buildings;
• The identification of key structures elements including pre-and post-tensioned components 
• A review of drawings, structure calculations, health and safety file, etc. related to the structure.
• The previous use of the premises 
• The load-carrying capacity of adjoining land including the presence of underground culverts;
• The need for possible temporary support structures for the building being demolished and
adjoining buildings;
• The location of any dangerous machinery;
• The presence of asbestos, lead or other hazardous or radioactive substances and any associated
health risks;
• Environmental issues, such as dust, water pollution and noise;
• Public safety including the provision of high fencing or hoarding;
• Manual handling issues;
• The location of any underground or overhead services (water, electricity, gas and sewage)
• The location of any underground cellars, storage tanks, chimneys, balconies or bunkers
particularly if flammable or explosive substances where previously stored;
• The means of access to the site;
• The removal of waste;
• The details of any traffic or pedestrian routes through the site;
• The provision of welfare facilities;
• The proximity of neighbors;
• The location of any public thoroughfares adjacent to the structure or building;
• The age of the structure;
• Its previous use;
• The type of construction;
• Nearby buildings or structures; and the weight of removed materials or machinery on floors above ground
level

Question 5:
The control of risk when using work equipment relies on having trained and competent workers who are
appropriately supervised.

(a) Explain the differences between training and competence. (4)

(b) A worker is being transferred to an unfamiliar machine. Outline training that might be required. (3)

(c) Explain the relationship between competence and supervision. (3)

(a)

• Competence can be defined as the ability to undertake responsibilities and perform activities to
a recognized standard on a regular basis. It is a combination of skills, experience and
knowledge.
• Training is an important component of establishing competence but is not sufficient on its own.
For example, consolidation of knowledge and skills through training is a key part of developing
competence.

(b)

 Workers need to be familiar with the safe system of work.

 Hazards and risk associated with the machines and the required control measures.
 Basic training in how to operate the machine safely.
 How to deal with machine in case of emergency.

(c)

 Where an activity is carried out by highly competent staff and the degree of risk is low, then
self-supervision will be adequate.
 However, where competence levels are low and the work activity involves a significant level of
risk, then close supervision will be required to ensure that the work is carried out safely.
 Some supervision of fully competent individuals will always be needed to ensure that standards
are being met consistently.

Question 6:
An electrical installation on a dairy farm need replacing.

(a) Outline what may have caused the deterioration of the existing electrical installation. (5)

(b) Outline what should be considered when designing the replacement electrical installation to help
avoid future deterioration. (5)
(a)

• Mechanical damage and solid bodies this includes abrasion, impact, stress, wear and tear,
vibration, hydraulic and pneumatic pressure.

• Deterioration caused by corrosion due to the presence of moisture that not vented to the
atmosphere.

• Deterioration caused by dust and dirt that accumulations on existing electrical installations.

• Deterioration caused by adverse weather conditions, including temperature, rain, snow, ice and
wind, can create a hazardous environment.

• Deterioration caused by Substandard repair and replacement of existing electrical installations.

(b)

• electrical designs with suitable supply and distribution with appropriate conductors,

• The need for suitable supply and distribution with appropriate conductors, junction boxes and
connections.

• Suitable pumps. heater, coolers, milk equipment and agitators.

• A suitable system capable of withstanding animal contact and the corrosive environment

• Protection the system from overload.

• Electrical shock protection.

Question 7:
For a large supermarket with restaurant facilities:

(a) outline automatic fire protection systems that should be in place. (6)

(b) outline what should be considered when developing a safe means of escape for the supermarket. (14)

(a)

• Fire Detection System:

- might include Heat sensors in the restaurant & super market areas, Smoke Detectors in general
areas, Flame Sensors in furnishing areas and CCTV – closed circuit television to monitor
throughout.

• Fire Suppression System:

- Fire sprinklers are the most common fire protection systems in supermarket because they
extinguish fires rapidly and effectively. Sprinkler systems offer versatility and compatibility
within a variety of supermarket areas.
- Kitchen fire suppression systems are required in any restaurant & kitchen area. these systems
use non-water agents to “suffocate” the fire and stop the spread of grease fires fast

• Fire Alarm System:

- Loud, flashing fire alarms and fire alarm monitoring ensure all restaurant and supermarket to
help occupants evacuate immediately, saving lives and potentially many thousands of dollars in
property damage.
- The alarm itself could be bells, sirens or verbal instructions over public addressing system.
Consideration might be taken for zoning and a staged alarm system. Automatic Fire service calls
out through auto dialer or similar techniques.

(b)

Factors to be considered when developing a safe means of escape for the supermarket.

- The possible number of employees and visitors to be evacuated

- The type of person such as their sensory disabilities and physical disabilities and age (old age,
child) etc. to be considered
- Means of Alerting and evacuating people through public address system.
- The distance of fire evacuation routes; and the numbers of such routes
- Ensuring that the escape routes and assembly points are clear from any obstructions.
- The provision of emergency lighting and appropriate sign ages for demarking the exit routes
from super market and restaurants, being sufficiently separated to avoid confusion
- Assembly points - Well defined, Displayed and communicated and always free from any
obstructions
- Liaison with emergency services – such as their access requirements; without obstructing
assembly areas and access to the buildings
- The Appointment of trained Fire Marshals who can ensure clear escape routes and trained in
evacuating people in safe manner.
- Providing door marshals to prevent entry or re-entry to the store.
- Security considerations such as minimizing the opportunity for theft / vandalism/sabotage.
- The procedure, once drawn up, would need to be summarized on prominently displayed fire
notices and tested with regular fire drills.

Question 8
Construction work is to take place in a rural area where electrical power for the site is to be gained from
an existing 11kV overhead supply that cuts across the site on wooden poles.

Outline control measures that should be taken to help reduce risks associated with the:

(a) overhead supply; (8)

(b) supply of electricity on the site. (12)

(a)

• induct and train your workers and contractors in safe work procedures, emergency procedures,
and exclusion zones;
• carefully plan the tasks to be completed near powerlines and work away from them whenever
possible, not towards or underneath them;
• show your workers the safe distance from a powerline by using clear and resilient markings at
ground and driver eye level; and
• ensure people are aware that powerlines sag or sway in hot or windy weather.
• make powerlines and poles visible (ask your electrical entity for permission to paint power poles,
mark pole stays and/or have them install markers or flags on the powerlines);
• operators should use a safety observer when working near powerlines; and
• follow the safety advice you obtain from your electrical entity.
• ensure no person, plant or object at the workplace comes within an unsafe distance of an
overhead or underground electric line;
• identify overhead and underground powerlines by consulting the electrical entity, maps and
talking to the property owner;
(c)

control measures that should be taken to help reduce risks associated with the of an electrical
supply would include the following:

• Prevent contact by isolation of supply, by locking-off and proving the supply is dead before work
is allowed to progress.
• Insulation of live parts to prevent contact.
• Set up physical barriers to prevent contact.
• Interlock panels to prevent access to live parts.
• Protect circuits by provision of earth trips.
• Fusing circuits with correct sized fuse to ensure quick operation if contact occurs.
• Set up procedures for working on electrical circuits/systems to ensure work is conducted safely.
• Use of suitable test equipment, that is insulated, fused and shrouded.
• Provide insulated tools and equipment.
 • Insulated matting where risk of shock is increased.
• Restrict use of conduction materials.

Question 9:

Workers are using lathes to make metal components.

(a) Identify FIVE types of mechanical hazard associated with lathes AND give a practical example of
EACH. (10)

(b) Outline control measures that help reduce risks associated with lathes. (10)

Candidates only need to relate answers to lathes and not computer numerically controlled (CNC) lathes
(a)

- Being hit by loose objects on the lathe, such as chuck keys, tools or swarf.
- Entanglement of clothing in moving parts such as drive gears, chucks, lead and feed screws and
the workpiece.
- Being struck by a workpiece that has not been adequately secured in the lathe or is oversized.
- Entanglement from inappropriate tooling and polishing techniques
- Slips, trips & falls due to lose materials or oil spillage existence near the machine.
(b)

- ENCLOSE parts (eg. Chuck keys, tools or swarf) in interlocked guards to avoid being hit.
- USE the appropriate chuck for the workpiece.
- KEEP the headstock free of loose items.
- AVOID wearing loose clothing, jeweler or gloves - they increase the risk of entanglement.
- PLACE lathe controls to AVOID reaching through the work zone.
- Workpieces SHOULD NOT extend beyond the headstock of the lathe. If they do, adequate
support MUST be provided.
- ENSURE that cooling fluids and lubricants are, contained to prevent harm, treated or replaced in
accordance with manufacturer’s instructions.
- Leaking oil, or bulging or abraded hose walls, MUST have faulty parts replaced.
- Apply a program preventive maintenance (hydraulic hoses and hydraulic hose couplings).
- Reduce noise levels by isolating machines or enclosing within noise barriers.
- Keep up-to-date housekeeping procedures and keep the area around lathes clear of slip and trip
hazards.

Question 10:

A mobile crane is to be used to erect a new telecommunications aerial on the roof of a three-story office
building.

Outline precautions that should be taken to help reduce risks to anyone at ground level who may be
affected by the operation. (20)
Procedural Control:
 A lifting plan or method statement should be prepared;
 The selection of the crane with respect to its safe working load and reach
 Checking the existence of current test certificates for cranes and all lifting tackles;
 Ensuring the regular thorough inspection and maintenance of the crane and appointing a
competent person to supervise the lift;

Engineering control: should include,

 Ensuring ground conditions are appropriate for positioning the crane
 The out rigger should be fully extended with spreader plate underneath
 Avoiding contact with overhead services and other buildings or structures;
 Using adequate lifting gear
 Speed limiters, over-hoist limit switch and rated capacity indicator and alarm system
 Visibility can be improved by use of mirrors or CCTV;
 Take account of weather conditions and an anemometer should be ensured to identify the
strong wind
 The need to follow safe roof work practices such as the provision of edge protection or the use
of harnesses.
Behavioral controls
such as the competence and training of the driver, slinger, banksman and supervisor

The precautions for others who might be affected by the operation.

 The lifting area should be cordoned off and should be segregated and warning signs should be
displayed
 Providing sufficient personnel on site to control access of the public to the area;
 The provision of adequate signing and traffic control;
 Liaison with the local police and
 Planning the lift for a time of day when few people would be in the vicinity

Question 11:

On construction sites, outline the roles and responsibilities of the:

(a) principal contractor; 6(
(b) designer; (4)
(c) contractors; (5)
(d) client. (5)

(a) Principal contractor responsibilities would include the following:

• Take account of health and safety issues when submitting the tender.
• Prepare and review the construction phase plan that identifies the risks to health and safety
arising from the work and the measures to address them.
• Co-ordinate the activities of all contractors to ensure that each complies with the construction
phase plan. To this end, the principal contractor may give information, instructions, etc.
• Liaise with other contractors and the coordinator on the content of the health and safety file.
• Liaise with the principal designer for the remainder of their appointment for the purposes of
planning, managing, monitoring and coordinating the pre-construction phase.
• Using pre-qualification assessment services from third party assessors, such as those who are
members of Safety Schemes in Procurement Forum.
• work with the client for the duration of their appointment.

(b) Principal designer responsibilities would include the following:

• Avoid, when preparing a construction design, foreseeable risks to the health and safety of
anyone who may:

– Carry out construction work.

– Be affected by it

– Be involved in maintenance or cleaning work.

– Use a structure that has been designed as a workplace

• Eliminate hazards/reduce remaining risks and provide information about any aspect of the
design, construction or maintenance of the structure to fully assist other parties in complying
with their duties

(C) Principal contractor responsibilities would include the following:

• Plan, manage and monitor their own work so that risks to health and safety are minimized.
• Take reasonable steps to ensure that work is carried out in accordance with the construction
phase plan.
• Provide information for the health and safety file.
• Tell the principal contractor about any injuries or incidents.
• Provide information for the construction phase plan on risk assessments and control measures.
• Comply with site rules and emergency procedures.

(d) Principal contractor responsibilities would include the following:

• Allocate adequate time and resources.
• Consider appointing a coordinator for the project.
• Should ensure that competent people are appointed.
• Provide information to other parties on the following:
– Issues affecting the site.
– Construction work.
– Proposed use of the structure.
– Time available for planning and preparation.
– Any relevant information from an existing building health and safety file.
• Should ensure that construction does not start until the construction phase plan is prepared.
 January 2017
Question 1:
(a) Outline specific occasions when the operation of safety interlock switches should be tested. (5)
(b) Outline suitable features of safety interlock switches that would help to ensure effective operation. (5)
Question 2:

Outline suitable control measures that could help reduce electrical risks from portable electrical
equipment associated with tungsten inert gas (TIG) welding. (10)
Question 3:

An organization can help ensure workplace transport safety by having safe vehicles and a safe site.

(a) Outline control measures that should be considered to help ensure safe vehicles. (5)

(b) Outline control measures that should be considered to help ensure a safe site. (5)
Question 4:

(a) Outline hazards associated with using passenger lifts in the workplace. (5)

(a) Outline control measures to help reduce risks to passengers when using lifts in the workplace. (5)
Question 5:

A scaffolder is lowering scaffold poles from the third floor of a scaffold tower to a colleague below using a
pulley wheel and rope. Next to the scaffold tower there is a shop entrance. The scaffolder on the ground
floor places the scaffold poles horizontally onto the back of a vehicle parked on a busy road. The
scaffolders have already received information, instruction, training and suitable supervision. Outline the
additional practical measures that could minimise the risk of injury to the scaffolders and others who may
be affected by this activity. (10)
Question 6

(a) Explain how features of floor design can help reduce the risk of slipping. (5)

(b) Explain how the coefficient of friction (CoF) is used in workplace floor design. (5)
Question 7:

A golf course management team proposes to store 3.6 tons of a chemical fertilizer, which is an oxidizing
substance, in a single-story building. The chemical fertilizer is delivered to the golf course in bags known as
flexible intermediate bulk containers (FIBCs). Each bag contains 600kg of chemical fertilizer.

(a) Outline properties of an oxidizing substance. (3)

(b) Outline the effects of oxidizing substances on fire and explosion mechanisms. (4)

(c) Other than fire and explosion, outline risks when storing the chemical fertilizer. (3) (

d) Outline principles of safe intermediate storage of chemical fertilizer in the single-story building. (10)
Question 8:

(a) Outline hazards when excavating near underground electrical cables. (4)

(b) Outline control measures that should be considered when excavating near underground electrical cables.
(12)

(c) Outline the effects of electric shock on the body. (4)

Question 9

You have been asked to plan an emergency evacuation drill for a large office building. Outline factors that
should be considered before, during and after the drill to help ensure that the emergency evacuation is
conducted safely. (20)
Question 10:

A wood turning lathe is used to machine components.

(a) Identify mechanical and non-mechanical hazards of wood turning lathes AND, in EACH case, give an
example of the identified hazard. (12)

(b) The lathe is to be upgraded to a Computer Numerical Control (CNC) machine. The new CNC machine
has an enclosure to prevent access to the machining area.

(i) Outline the key features of the enclosure of the CNC machine. (5)

(ii) Outline why access to the machining area might be required. (3)
Question 11:

Construction workers need to use a range of unpowered hand tools.

(a) Outline the criteria for the selection of hand tools for construction tasks. (10)

(b) Outline how risks to health and safety in construction, from the use of hand tools, are controlled. (10)
 July 2017
Question 1:

(a) Outline structural features that protect a building from the spread of fire. (8)
(b) Outline the behavior of plastics in the event of a fire. (2)
Question 2:

A lone worker is using a pallet truck to move pallets of frozen food products in a low temperature store.
The temperature of the store is controlled at -5˚ Celsius. Outline control measures to help the worker
escape if they are accidentally locked into this low temperature store. (10)
Question 3:

Large diameter concrete water pipes are being installed in a trench 2.5 metres deep during excavation
works. Temporary shoring is provided by the use of drag boxes.

(a) Outline workplace control measures that are necessary when drag boxes are used to provide
temporary shoring. (4)

(b) Other than temporary shoring, explain workplace control measures that could help reduce the risk of
collapse of the trench. (6)
Question 4:

Mobile telescopic lighting towers are to be used on a busy highway to illuminate roadworks. The towers
extend to a height of 9 meters. 22kV electrical power cables cross the highway and are as low as 7.5
meters above ground in some places.

(a) Outline specific training requirements for workers who are required to move telescopic lighting
towers in the vicinity of the live overhead cables. (3)

(b) Other than training, outline control measures that should be considered when moving telescopic
lighting towers in the vicinity of the live overhead cables. (7)
Question 5:
Car park entry and exit is controlled by an automatic barrier of the rising arm type shown below. The barrier
has a control system with sensors, actuators and electronic controllers. Maintenance is occasionally required
due to vehicle impact or storm damage.
(a) Outline mechanical hazards associated with automatic rising arm barriers. (4)
(b) Outline control measures that should be considered to help reduce risk before starting any maintenance
activity on the barrier. (6)
Question 6:
Outline what should be considered when developing a planned preventive maintenance programme for
safety-critical machinery. (10)
Question 7:
Vehicles are repaired for the public in a motor vehicle repair workshop. The process involves mechanical
repair, preparation, spray painting and curing. The workshop is situated in a single-storey building with
only one means of escape. Following a serious fire, the organization needs to review the fire prevention
and fire protection measures in the workshop.
(a) Outline what should be considered when assessing the adequacy of the existing means of escape. (12)
(b) Outline what should be considered when assessing the adequacy of the existing fire detection and
alarm systems. (8)
Question 8:
Following a number of driving at work incidents, an organization decides to implement driver assessment
and training.
(a) Outline what may help determine which workers need training. (8)
(b) Outline contents of a typical driver training program. (12)
Question 9:
A road tanker is to be filled with petroleum (gasoline) at an installation.
(a) Identify hazards associated with this operation. (4)
(b) Outline how a vapor cloud explosion could be generated in this situation. (8)
(c) Outline control measures that could reduce risks with road tanker filling. (8)
Question 10:
(a) Outline the causes of instability in a forklift truck (FLT). (8)
(b) Outline the content of a training program for FLT drivers who are to operate a variety of forklift trucks.
(9)
(c) Identify THREE situations in which refresher training for FLT drivers would be appropriate. (3)
Question 11
A steam boiler is a type of pressure system used in industry where loss of containment can occur through
mechanical failures such as overheating, creep and hydrogen embrittlement.
(a) Outline why a steam boiler is classified as a pressure system. (3)
(b) Identify THREE additional examples of mechanical failure to which a steam boiler is susceptible AND,
in EACH case, outline the mechanism of the identified mechanical failure. (9)
(c) Outline the content of a written scheme of examination form for the boiler. (8)