The Health and Safety Risks of Metalworking Fluids

There are a number of occupational safety hazards that workers face in the metalworking industry. These range from serious accidents caused by equipment to slips, trips and falls, which are among the most common types of accidents in any UK workplace. Because of the presence of heavy machinery that poses obvious dangers, many people overlook the health and safety hazards posed by metalworking fluids when carrying out a risk assessment.

However, exposure to these fluids can lead to serious adverse health effects, particularly if workers have not been provided the appropriate personal protective equipment (PPE), or if management has failed to follow the Health and Safety Executive's (HSE) detailed guidance on providing sufficient arrangements to manage health and safety and ensure they comply with the Control of Substances Hazardous to Health Regulations 2002 (COSHH).

There are several ways to anticipate and mitigate the increased risk to health posed by metalworking fluids, but these require a thorough understanding of the properties of these fluids, a careful risk assessment to determine the dangers that workers may be facing, and the implementation of strategies at all stages of the manufacturing process to minimise risk.

Here, the experts in metalworking fluid experts at Broughton Lubricants break down some of the most common hazards associated with these substances, review HSE guidance on how to store them safely, and offer some best practices for keeping your working environment as safe as possible.

What are the most common causes of illness and injury in metalworking?

Many people who work in metal manufacturing do not realise how many health and safety risks prolonged exposure to metalworking fluids can pose. In fact, poor maintenance of metalworking fluids are among the most common causes of illness and injury in metalworking. The effects range from skin problems to respiratory conditions and differ in severity, but they can often be avoided if correct safety procedures are followed.

Below are some of the most common health and safety risks associated with metalworking fluids:

• Dermatitis: Prolonged skin exposure and contact with fluids used in metalworking can irritate the skin and cause dermatitis or other conditions.
• Infection: Bacteria and fungi can grow in tramp oils and other substances, leading to infections like bacterial dermatitis and folliculitis.
• Respiratory issues: Mists from fluids can cause respiratory problems when they are inhaled. These can range from irritation of the airways to more serious conditions like work-related asthma. Over time, workers can develop chronic bronchitis and impaired lung function as a result of exposure to these mists.
• Allergic reactions: Some people may have allergic sensitivities to components of metalworking fluids, such as biocides or emulsifiers.
• Splashes: Fluids splashing can cause eye irritation or, in extreme cases, chemical burns when using chemical additives such as biocides.
• Slips, trips, and falls: Spillages of fluids can lead to slippery floors and heighten the risk of these common accidents.
• Fire hazard: Some metalworking products are flammable and can pose a fire risk if not properly managed.
• Machinery malfunction: Improper use or maintenance of metalworking fluids can affect the performance of equipment, which can result in an increased risk of accidents and injuries.

It is important to remember that, as an employer, you may be found responsible for an accident that causes injury to an employee. All employees have the right to a safe working environment, and it is vital to follow HSE guidance to ensure the working conditions you provide are as safe as possible.

What can businesses do to avoid the health and safety hazards of metalworking fluids?

The most important step that every business should take is to follow HSE guidelines and implement the risk mitigation strategies the authority recommends. This includes:

• Perform a risk assessment - this may be necessary each time you purchase a new product if there are different risks associated with it.
• Monitor for bacterial contamination and clean fluids and machines when necessary.
• Conduct regular health surveillance to make sure the existing measures are working effectively.
• Implement exposure control measures, such as ensuring there is adequate Local Exhaust Extraction (LEV) in areas where there is a risk of airborne contaminants, in order to dissipate harmful fumes or mists.
• Deliver health and safety training for any employees whose responsibilities include handling hazardous substances.
• Provide appropriate protective equipment like gloves, masks and eye protection to prevent skin contact with metalworking fluids.

Thoroughly reviewing HSE's regulations on the control of hazardous substances and implementing the measures that are relevant to each metalworking fluid you are using is a legal requirement, and will also help to mitigate the risk of workplace accidents.

How should metalworking fluids be stored safely?

Many fluids used in metalworking will offer specific storage instructions when you purchase them, and you should adhere to these recommendations in all cases to ensure that workers are safe when handling products. This will also maximise the lifespan of each product and help it to maintain its efficacy over time.

However, there are also general storage practices that all businesses should implement when managing quenching fluids, cutting fluids and other metalworking lubricants.

• Store in a cool, well-ventilated area away from direct sunlight. The storage area should be isolated from incompatible materials like acids, oxidisers, and food items.
• If necessary, use secondary containment methods like bunds or drip trays to capture any accidental spillages. You can invest in cabinets that are designed to catch drips and prevent spills in this way.
• Any fluids that are flammable should be stored away from sources of ignition and in compliance with fire safety regulations.
• Keep spill kits nearby for any particularly hazardous substances to ensure you can react quickly if a spill poses a risk to health.
• Clearly label all containers with the type of fluid, associated hazards, and expiry date, if applicable. This is a legal requirement for preventing accidents in metalworking.
• Ensure that all containers are tightly sealed to prevent contamination and evaporation.
• If fluids are stored on pallets, make sure that they are stable and not stacked too high. If they tip over, this could have disastrous consequences.
• Arrange containers so that older stock is used first and keep products easily accessible for regular inspection.

By following these best practices, along with any specific legal requirements that apply, you can meet accidents at work regulations and minimise the risk of workers being injured or falling ill.

Specific guidelines for different types of fluids

As well as these general guidelines, there are also considerations that are specific to particular types of metalworking fluids.

• Water-miscible fluids: These fluids can degrade over time, especially if exposed to temperature extremes or contamination. You should also make sure to follow the manufacturer's instructions on the correct operating conditions such as concentration.
• Neat oils: These are generally less sensitive to environmental conditions but should still be sealed to avoid contamination.
• Aerosols: If fluids are in aerosol form, additional storage precautions might be required, such as ensuring adequate ventilation and prohibiting any storage practices that could result in high pressure.

You can consult HSE guidance for specific substances when performing a risk assessment or purchasing metalworking fluids, as well as the specific safety data sheets that accompany each product. This will help you to ensure you can store any fluids you purchase in the safest manner possible.

Are some types of metalworking fluid better than others?

When it comes to choosing lubricants, there are also some factors you can consider that may help you to meet the relevant workplace safety regulations. Choosing the right product for the application and one that suits your operating environment is important in ensuring the longevity of the product in use. Remember that sometimes, choosing a higher quality product can result in longer term benefits for operating conditions and can save on costs in the long term.

Castrol's range of metalworking fluids can help to keep all of the moving parts in your manufacturing process in good working order, and deliver the cutting edge in performance for metalworking equipment.

If you need support with buying, storing or using metalworking fluids in your workplace, you can speak to the technical experts at Broughton Lubricants for advice. Our team has a wealth of experience in these applications and can help you to select the appropriate fluids to deliver the performance you need for any metalworking process. Get in touch with us today to learn more about how we can help by calling us on 03300 555 655 or using our online enquiry form to request a call back at your convenience.