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We can see and observe the world around us through our eyes; the nose allows us to breathe in vital oxygen-containing air and pick out the different smells in our environment; our multi-functional mouths allow us to communicate with others and take in fuel to power our bodies; our ears are our radar, detecting vibrating air molecules to alert us to sounds. All of these functions and more are processed and enabled by one of the most vital parts of our body, the biological computer that is our brain.
Whilst it is an amazing thing, it is unfortunately also a weak spot for us. If someone has organ failure, sometimes we can save that person through surgery and organ replacement. Someone suffering a cardiac arrest can be kept alive by performing CPR (Cardio Pulmonary Resuscitation), manually pumping blood to the victim’s brain until we can get their heart re-started (usually using an AED, or Automatic External Defibrillator). Someone suffering a head injury, however, is usually not so fortunate.
Head injuries are often fatal. We would have to hope that the victim does not even have time to register that they are about to die as many of these injuries kill the victim instantly. For those that do survive major head trauma, we are able to remedy some issues, such as partial or total loss of hearing through the fitting of hearing aids. Unfortunately, major brain damage and severe injuries can permanently alter victim’s lives. They may become totally dependent on others to care for and look after them, as they can no longer function as a human on their own. In extreme cases, the victim does not even know what has happened. They are just… there.
Unfortunately, how the head is harmed, and the amount of harm that can occur, can vary dramatically just like in any other incident in the workplace. So what can we do to protect our heads from these sorts of nightmare scenarios?
Assessing the Risks
Risk assessment is a vital information gathering and decision-making tool, as with any other safety scenario. This will provide us with the key data we need regarding our head protection needs. What are the hazards that we face? Who may be harmed by these hazards, and how would that harm occur? It is also important at this point to take into consideration what we are already doing to protect people against these threats. We can then assess the effectiveness of these current control measures, before we then decide what new/additional controls we would like to implement.
The ubiquitous “hard hat” or safety helmet is something nearly everyone would be familiar with. Whilst PPE (Personal Protective Equipment) is something useful, it should not be our first thought. Remember, the easiest and cheapest solution, is not necessarily the best. For example, hard hats are good for limiting the injury caused by someone accidentally banging their head against something but would be utterly useless if a large object weighing 100 kg dropped onto a worker’s head. An object does not even have to be big or heavy to cause major damage, if it falls far enough. As a DROPS (Dropped Objects Prevention Scheme) approved instructor, I can testify to this. Small items such as nuts, bolts and screws can be killers.
Another weakness of “hard hats” is that while they offer some protection to the top of the worker’s head, they will do nothing to protect the wearer’s ears, eyes, mouth, nose or face. So, what we may need to use depends on if we are protecting a specific part of the head, or the whole head. Indeed, some items of equipment may not be compatible with others, so priorities may need to be in place on what area to look after (for example, some types of ear defenders would not be able to be worn with some hard hats, as the ear defender’s band would not wrap around the hard hat sufficiently to reach the ears). Of course, the best thing to do is to eliminate the hazards on site, as we would then have no risk of injury occurring and there would be no problem. Make use of the Hierarchy of Control, with Elimination being the first thing to look at. If not, think about Substitution, Engineering and Administrative Controls, as well as PPE. Let us take look at some of these other methods of protection, and equipment, that we could use to protect people’s heads.
Head Protection
Objects falling onto people’s heads is a common occurrence, so the use of something called “Drop Zones” is something to consider. These are areas where we prevent all but the essential workers from having access to them. In this scenario, should an object fall, it would land harmlessly on the floor or another surface, rather than a human being. Drop Zones can be marked using barriers and signs warning of the dangers, and are particularly useful for situations involving the use of scaffolding, MEWPs (Mobile Elevated Working Platforms) or cranes.
Safety nets are great to stop falling items by catching them mid-air, and workers might use tool belts and/or tool boxes for storing tools and equipment, particularly when working at height. Other loose items could also be secured in some way (ropes and netting for example). You could even simply limit how many workers and items of equipment are in the air at any one time, by storing materials at ground level and only taking them up to the work area when needed. Rubber, foam and other soft materials could be used to cover items sticking into walkways, sharp edges and so on. This might limit the damage and injury that occurs should a person strike against them. Bright coloured markings and/or tape could be used to highlights these objects/areas, giving people a chance to take appropriate actions, such as using alternate routes, ducking below items, and so on.
“make use of the Hierarchy of Control, with Elimination being the first thing to look at”
In warehouses, yards, construction sites and other workplaces where materials need to be stacked, the heights of the stacks should be kept to an absolute minimum. They should also be secured in some way, such as using correct stacking techniques, and being secured to floor surfaces. At least if these stacks do fall, they would then hopefully strike a person on the body, arm or leg, rather than the head.
We have already spoken about hard hats before, but we could look at other alternatives, such as bump caps. You can even now buy baseball-cap style hats with composite linings. Depending upon legal requirements, the type of head protection we require may have to be a certain type for a certain task. Other considerations could include the mandatory fitting and use of chin straps on head gear to stop it falling off during use. I know of at least three fatalities in the workplace which could be partially associated with the hard hat coming off the person’s head, before their head struck the object and/or floor surface, leading to the injury that killed them.
Eye Protection
There are various types of eye-wear that could be used in a workplace setting to protect people’s eyes. These include goggles and glasses of various kinds. Be careful! These two terms get mixed up all the time. They are two totally different things. For example, chemical goggles would be perfect for protecting eyes against splashes of chemical or biological substances but would be absolutely useless when trying to shield someone’s eyes from Ultraviolet (UV) Radiation produced by the sun, or the blinding flash produced by an Arc-Welder.
Safety glasses are ideal protection against flying particles, sparks and shrapnel. Whilst this is great, these glasses may still struggle against a large impact from a heavy object, such as a hammer or pipe.
Particular consideration must also be given to workers who may suffer from poor eyesight or other eye related ill-health conditions. This is because they may need to have special lenses made that match their “prescription” eyewear. You can purchase goggles, for example, that come with a special recess built into them. These are specifically for people who wear glasses, who place the glasses into the recess, so they can be protected without actually having to remove their glasses.
What we really need depends upon the specific hazards and types of harm we are trying to protect people against. You can also consider the use of other personal protection measures, such as masks, visors and face-shields.
Ear Protection
In terms of people’s ears, most people think about is protecting a person’s ability to hear. This should not be our only worry though. People can suffer physical trauma to their ears, including cuts, burst ear drums, or even having an ear partially torn, or indeed ripped off their heads altogether. One type of Hearing Protection is soft, foam ear plugs. These are great for protecting people’s hearing, and will act as a barrier to prevent any foreign objects from entering the ear canal. However, there are issues to consider.
Most (but not all) types of ear plugs are designed for “one-use” only. A common occurrence is that people reuse them over and over again. Ear infections and other ill-health can become an issue as a result, due to contaminated or dirty ear plugs being used, or workers “sharing” them, as they do not have enough.
Another common scenario is someone forgetting their ear plugs for a particular shift and asking another co-worker to borrow their pair. Unlike ear plugs sitting in the ear canal, ear defenders cover the whole ear, and therefore offer more protection to the entire ear, which is good for protecting ears against the other injuries we discussed earlier. These are also good for workers who struggle to use ear plugs (their ear canals are either too small or too big), or for working in areas where they are exposed to noise for longer durations.
Again, ear defenders are not infallible. The foam on the rubber ear cups can deteriorate and become hard and uncomfortable, causing painful marks and rashes on the head. This can also occur on the headband. Some ear defenders are also more technical in nature, as they include noise-cancelling technology, batteries, and even communications systems such as radios and microphones. Training of the workforce in their use, and how to correctly maintain and store the equipment, is therefore a key consideration.
Both types of ear protection can also cause problems with communication between workers, or even worse, totally eliminate noise. Well, what is the problem? I hear you ask. The problem is now we cannot hear vehicles approaching us, or a shout from colleagues warning us of danger. This is something we should be looking at more and more, as we move into an age of “electrification” for vehicles and equipment. I myself have used Electric Forklifts in the past, for example. If I am sat directly on the 4-ton machine, and can barely hear it, people 30ft away from me, with ear defenders on their ears, have no chance of hearing me coming.
Respiratory Protection
Finally, we should not ignore our mouth and nose. If we have issues here, people are in for a bad time, as this is our “Breathing Zone”. I am sure you can agree, if we cannot breathe, that is quite the problem! Breathing in some type of hazard or contaminant is one of the main dangers that needs to be looked at. There are two main types of protection for this, respirators and breathing apparatus.
Respirators are often, but not always, fairly simple masks that are placed onto the face to cover the nose, mouth and chin. Whilst wearing one these, when we breath in, the air passes through a filter to get rid of any contaminants and so on. The filters are often designed to stop specific sizes of contaminant from reaching us. So, if we use the wrong filter, the contaminant can still pass through. The filter could also be become blocked with large amounts of contaminant. Like ear plugs, most respirators are also one time use only. Fitting them incorrectly renders them useless. We have all seen this over the past year or so, as the general public has struggled to come to grips with masks, specifically different types, how to use them, and so on.
Breathing apparatus offers several advantages compared to respirators, depending upon the type that is used. Total coverage of the face/head provides a barrier between the worker and the hazard. For example, a SCUBA diver’s face mask keeps the salt water out of their eyes and nose, with fresh air being breathed through a regulator that is fitted into their mouth.
However, self-contained breathing apparatus only provide protection as long as there is air in the tank. Being a technical piece of equipment, it also requires proper maintenance and storage, and a high-level of skill and training in order for it to be used effectively. Supplied-air breathing apparatus can give an unlimited supply of air (in theory), but then the worker is connected to the air source via a hose. This causes issues with how far they can move, potential damage to hoses and connection points causing leaks, and so on. As the air is fed in, the sudden loss of air may not only pose an asphyxiation hazard, but also allow contaminants to enter the mask.
With all types of breathing apparatus, contaminants may also enter the mask if it is not sealed against the workers face (for example, a beard or long hair gets caught between the worker’s head and the mask). So, whether you are using respirators or breathing apparatus, face-fit testing will solve a lot of issues down the line as workers can test them for effectiveness and comfort, and give their thoughts on what would be more suitable. It is pointless buying 1000s of pieces of equipment that people will not wear, or that will not be effective.
“competent personnel will reduce the risks of errors and mistakes, and give people key knowledge and skills to be safe”
In Summary
As always there are so many factors to consider when it comes to protecting people in the workplace. My advice is always to eliminate the hazards first. If this cannot be done, follow the rest of the Hierarchy of Controls (Substitute, Engineering, Administration) before you rely on PPE (Personal Protective Equipment). As with any safety issue, the best approach is multi-layered. Competent personnel will go a long way to reducing the risks of errors and mistakes, and give people key knowledge and skills to be safe. Regular servicing and maintenance of equipment will keep it in the best shape possible.
Consultants, suppliers and others will gladly offer advice and assistance, so do not be afraid to reach out to them for help. Consulting your workforce is also key. They are on the ground, doing the work day in and day out, and are a wealth of information just waiting for you to use. Indeed, the workforce may suggest something that you would never have even considered. Consider all the options, and work together, so everyone can “Head to Safety”.
Author
James Pretty (CMIOSH), is a Chartered HSE and Training and Development Professional. James has experience working globally in Europe, Australia, The Middle East and Far East Asia.
He has experience working in multiple high-risk industries, including recycling plants, freight and rail yards, mining/quarrying and oil and gas.
James has held many varied roles, progressing from multi-skilled operator, to supervisory, instructor and management levels.
