Health and Safety

Executive

Example risk assessment for a motor vehicle mechanical repair workshop

Setting the scene
The garage manager did the risk assessment. The
business employed 12 mechanics, including two
apprentices who carried out mechanical repairs.
How was the risk assessment done?
The garage manager first looked at relevant guidance on
the HSE website, including:

The health and safety toolbox: How to control risks

at work (www.hse.gov.uk/toolbox/index.htm)

Health and safety in the motor vehicle repair (MVR)

industry (www.hse.gov.uk/mvr/index.htm)

COSHH essentials sheets for repair workshops

(www.hse.gov.uk/coshh/index.htm)

about health and safety issues. He confirmed what

training had been provided and asked that they
consider particular requirements the two young
apprentices may need
phoning the licensed disposal contractor to discuss
the arrangements for waste disposal
looking at the accident book to learn what had
previously resulted in accidents or near misses.

As he identified the hazards he also thought about who

could be harmed and how. He noted what he was already
doing to control the risks and considered whether he
needed to do anything more. He then recorded any
further actions required.

He also read the manufacturers instructions for chemicals

and equipment.

Putting the risk assessment into practice, the manager set

out what actions needed to be taken. Who would do
them and by when. He placed a copy of the risk
assessment where all workers could see it.

He then identified the hazards in the garage. He did this

by:

The findings of the risk assessment were discussed by the

supervisors and their teams of mechanics.

walking around the repair workshop and noting things

The manager decided to review the risk assessment

whenever there were any significant changes such as new
work equipment, work activities or workers.

that may cause harm

talking to workers to learn from their knowledge and
experience and listen to their concerns and opinions

Example risk assessment: Motor vehicle mechanical repair workshop

How to use this example

This example risk assessment shows a wide range of
hazards that might be present in this type of small
business. It can be used as a guide to help you think
through some of the hazards in your business and the
steps you need to take to control the risks.
However, this is not a generic risk assessment. Every
business is different. To satisfy the law you must
identify and assess the hazards your business poses,
think through the controls required to provide effective
protection to people who may be affected by them, and
record the significant findings from your risk
assessment of your business.

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Health and Safety

Executive

Company name: PQR Motor Vehicle Repair shop (mechanical repairs only)
Date of risk assessment: 01/05/2012

What are the hazards?

Who might be harmed and how?

What are you already doing?

Do you need to do anything else to

control this risk?

Action
Action by Done
by who? when?

Hazardous substances
Skin contact over a long period can lead to
Contact with used engine severe dermatitis and skin cancer.
oil etc during servicing

Nitrile gloves supplied and used

Garage overalls supplied and used
Contract for regular cleaning of overalls
Workers informed to clean hands thoroughly and use skin
creams provided after contact with hazardous substances

Supervisor to start keeping a check that JB

gloves are being used

10/03/12

09/03/12

Risks from dermatitis and skin cancer to JB

be explained to workers

10/03/12

09/03/12

Car engine running

inside, toxic exhaust
fumes, eg carbon
monoxide

The fumes may cause eye irritation and

breathing difficulties.

Car exhaust attached to extractor system when

engine is running
Extractor system maintained and tested to prevent leaks

No further action required

Fire
Petrol and LPG fires

If trapped workers and customers could

suffer fatal injuries from smoke inhalation/
burns.

Fire alarms maintained and tested by manufacturer

Extinguishers provided and inspected under contract
Special fire exits not needed as all work areas have
immediate access to outside
Fuel retriever used to empty vehicle fuel tanks outside
Spillages cleared immediately
Component cleaning in re-circulating paraffin system, not
petrol
LPG fuelled vehicles ported in safe places
Workers trained in hazards of LPG
Fire risk assessment has been done, and any necessary
action taken, see www.gov.uk/workplace-fire-safety-yourresponsibilities

Manager to arrange training on use of

extinguishers for all workers

SP

1/7/12

Annual fire drill to be carried out

RB

11/11/12

Brief workers on safe working with

RB
petrol. Refer to HSEs Safe use of petrol
in garages (INDG331).

02/07/12

Brief workers on safe working with LPG. RB

Refer to HSEs LPG-fuelled motor
vehicles (INDG387)

02/07/12

Proprietary charger, installed by electrician, is used in

accordance with instructions
Acid-resistant gloves and goggles supplied and used

No further action required

Battery charging

Workers could suffer burns from contact

with battery acid while charging,
particularly if battery is overcharged and
explodes.

Example risk assessment: Motor vehicle mechanical repair workshop

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Health and Safety

Executive

What are the hazards?

Who might be harmed and how?

What are you already doing?

Electrical equipment
Portable appliances, eg
hand lamps.

Workers could get electrical shocks or

burns from faulty electrical equipment or
on installation.
Electrical faults can also lead to fires.

Low voltage 24 V hand lamps used

Residual current device (RCD) built into main switchboard.
A few 240 V tools are used. All have industrial plugs and
leads
Testing carried out annually on all portable 240 V tools
and workers are trained to carry out pre-use visual
checks and report defects
Safety checks of the electrical equipment and installations
are carried out to ensure that equipment continues to be
safe. Where necessary this is done by a competent
electrician

Manager to assess suitability of

replacing 240 V tools with air-powered
or 110 V alternatives

All mechanical equipment checked before use and faults

reported to supervisor
Equipment not to be left running unattended
Guarding provided
Ear defenders and safety goggles provided and worn.
Grinding wheels changed by trained person

No further action required

No further action required

Car lifts and jacks serviced by supplier and inspected by

insurers every 6 months
Jacks only used where ground conditions are firm, stable
and level. Once vehicle lifted, axle stands used
Axle stands regularly maintained and inspected
Safe working loads not exceeded

Workers are trained in correct procedures

Brief workers on safe working with airconditioning systems (from HSEs Safe
working with vehicle air-conditioning
systems INDG349).

Mechanical equipment
Use of grinding
equipment

Workers may suffer serious injury from

unguarded moving parts of machinery.
Workers can also get cut on sharp edges
or scald themselves on hot parts.

Falling objects
Failure of a car lift, jack or other lifting
Car lift failure or car jack equipment may cause severe crush injuries
failure
to an employee.

Work involving air

conditioning systems

Workers could suffer:

frostbite through skin or eye contact
with refrigerant liquid or gas
asphyxiation if sufficient quantities of
gas escape into confined space
exposure to harmful gases through
thermal decomposition of refrigerant if
exposed to a naked flame.

Example risk assessment: Motor vehicle mechanical repair workshop

Do you need to do anything else to

control this risk?

Action
Action by Done
by who? when?
SP

15/06/12

RB

05/11/12

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Health and Safety

Executive

What are the hazards?

Who might be harmed and how?

What are you already doing?

Compressed air
Explosion of equipment
tyres

Workers could suffer blast injuries from

tyre or equipment explosion. Workers could
suffer damage to internal organs if air is
introduced into the body.

Do you need to do anything else to

control this risk?

Action
Action by Done
by who? when?

No further action required

All workers trained in safe working procedures and

dangers of horseplay
Airline has deadmans handle
System inspected and serviced every year by insurers

Handling vehicle air bags Air bags could explode when not fitted,
causing injury.

Units are stored in suitable cabinet of their own

Workers are trained in correct handling and fitting
Faulty units are returned to supplier for disposal

Brief workers on safe handling of air

bags (from HSEs A guide to the
handling and storage of airbags and
seat belt pretensioners at garages and
motor vehicle repair workshops
(INDG280)

RB

02/07/12

Manual handling
Movement of
components

Workers are trained in safe manual handling and to

ensure contractors follow safe manual handling
techniques
Manual handling aids are available, eg lift truck

Manager to arrange manual handling

training for the workers in the store.

SP

10/07/12

15/05/12

Brief workers on handling tyres, refer to RB

HSE publication Collection and delivery
of tyres - Tackling the risk of manual
handling injuries: a practical guide

15/05/12

15/05/12

A detailed assessment to be done using JB

HSE publication Manual handling
assessment charts (INDG383)

15/08/12

15/05/12

No further action required

18/05/12

20/05/12

Workers risk injuries or back pain or pain

elsewhere from handling heavy and/or
bulky objects.

Vehicle movements

Workers and customers risk potentially

serious injury if struck by a moving vehicle

Example risk assessment: Motor vehicle mechanical repair workshop

Safe parking provided for customers without need for

reversing
Marked walkways for pedestrians
Vehicles driven slowly around premises
Workers ensure that cars being manually pushed always
have a person seated at the wheel, to keep the vehicle
under control

JB

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Health and Safety

Executive

What are the hazards?

Who might be harmed and how?

What are you already doing?

Slips and trips

Doorways (rain),
spillages, uneven
surfaces

Workers and customers may be injured if

they trip over objects or slip on spillages,
eg oil or water.

Working at height

Falls from any height can cause bruising

and fractures and potentially serious
injuries.

Public access to
workshop

Customers could suffer various injuries if

they wander into the workshop.

Do you need to do anything else to

control this risk?

Action
Action by Done
by who? when?

Good housekeeping standards maintained through

training and monitoring
Floors degreased weekly
Absorbent granules and sawdust put on spills as soon as
possible
Entrances and exits maintained

Walkways and storage areas to be

designated by yellow lines

JB

09/06/12

07/06/12

Weekly housekeeping check to be

started

JB

09/05/12

12/05/12

Appropriate access equipment is provided for work on

trailers and tops of commercial vehicles
Handrails fitted at edges of raised storage areas and
access stairway provided
Workers are competent to use ladders where appropriate
Vehicle inspection pits clearly marked and covered when
not in use

Supervisor to monitor use of portable

JB
ladders, access equipment for working
on vehicles, and safety at inspection pits

03/06/12

03/06/12

Signs banning customers from the workshop and viewing

window provided in reception

Workers to be reminded to challenge

anyone entering the workshop without
permission

15/07/12

SP

Assessment review date: 01/04/13

Example risk assessment: Motor vehicle mechanical repair workshop

Published by the Health and Safety Executive

04/13

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