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Health and safety risks of working with metalworking fluids

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Metalworking fluids, or MWFs for short, are water-based fluids or neat oils used in the machining and forming of metals to cool and lubricate.

Sometimes MWFs are referred to as soap, suds or coolants.

Exposure to MWFs can cause serious negative health impacts, especially when operations don’t adhere to the Health and Safety Executive’s (HSE) guidance regarding complying with the Control of Substances Hazardous to Health Regulations (COSHH), and when workers fail to use personal protective equipment (PPE).

There are many ways to mitigate the health risks of working with metalworking fluids, and the first step is to understand their properties, followed by a careful assessment of the dangers they present to workers.

With this knowledge, operations can implement strategies to minimise risk during the manufacturing process.

Here, we explore common hazards connected MWFs and study the HSE’s guidance on best practices for safe storage and usage.

Injuries and illnesses caused by metalworking fluids

Many employed in metal manufacturing are unaware of the health and safety issues caused by prolonged exposure to MWFs.

Poor maintenance of MWFs is often a common cause of injury and illness in the metalworking industry. The impact can range from respiratory conditions to skin-related problems, and can differ considerably in severity.

However, they are avoidable when proper safety protocols are observed. Below, we discuss the most common risks associated with MWFs.

Respiratory problems

Mists from MWFs can lead to respiratory problems when workers inhale them. Negative impacts can vary from irritated airways to more severe conditions such as work environment-related asthma. When such contact with mists occurs over an extended time, metalworkers can sometimes develop conditions like chronic bronchitis and even impaired lung function.

Infections

Fungi and bacteria can breed in MWFs, resulting in infections like folliculitis and bacterial dermatitis.

Dermatitis

Extended skin contact with MWFs can cause skin irritation, dermatitis and other topical conditions.

Allergic reactions

Workers may also have underlying allergic sensitivities to the ingredients in MWFs like emulsifying agents and biocides.

MWF splashes

Workers hit by fluid splashes can experience issues of different severity, from eye redness and irritation to chemical burns in more extreme cases.

Fire hazards

Some MWFs are flammable by formulation and can present a fire risk when improperly managed.

Slipping and falling

When MWF spillages occur and are not cleaned up immediately, they represent a slip hazard.

How do you store metalworking fluid to promote health and safety?

Many MWFs purchased will provide explicit storage instructions. These product guidelines should always be adhered to, as they will help make sure that metalworkers remain safe handling take place.

Following manufacturer guidelines can also help optimise the active service life of the stored MWFs and ensure they provide the same level of effectiveness.

However, MWF users should also consider the best practices for general storage that all operations should implement when they are managing a stock of cutting-fluids, quenching fluids and other lubricants designed for metalworking on site.

MWFs must always be stored in an area that is cool and well-ventilated, and safely away from any direct sunlight. The lubricant storage area should also be kept separate from substance such as oxidisers, acids and produce for ingestion.

When required, users should implement secondary containment solutions such as drip trays and bunds to capture accidental spills when they occur. Users can also invest in specially designed storage cabinets engineered to catch any drips and stop spillage.

It is imperative that all flammable MWFs used on site are stored away from sources of potential ignition and using practices that comply with HSE fire safety regulations.

Sites should also place spill kits close to areas where especially hazardous MWFs are stored, and on routes used by them to make sure they can react rapidly when a spill happens that represents a serious health risk.

All MWFs stored must have clear labelling on their containers. Labels should state the type of metalworking fluid, its expiry date and any known associated hazards. This practice is a legal requirement stated by the HSE designed to prevent metalworking accidents. Some sites find that using a colour-coded system can be helpful for visual reference.

MWF users maintaining supplies must ensure that each container is kept tightly sealed to defend against potential contamination and loss of fluid through evaporation. Furthermore, MWF supplies should be stored so that the oldest supplies are always used first, and all products are easily accessible for routine inspection.

Finally, when MWFs are kept on pallets, users must ensure that stock is well balanced and never stacked overly high.

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