Fire risks in the workshop

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Fire risks in the vehicle body repair shop cover all

classes of fire: class A, i.e. paper, wood and cloth;

class B, i.e. flammable liquids such as oils, spirits,

alcohols, solvents and grease; class C, i.e. flammable

gases such as acetylene, propane, butane;

and also electrical risks. It is essential that fire is

detected and extinguished in the early stages.

Workshop staff must know the risks involved and

should be aware of the procedures necessary to

combat fire. Bodyshop personnel should be aware

of the various classes of fire and how they relate to

common workshop practice.

Class A fires: wood, paper and cloth

Today wood is not used in cars, although there are

exceptions. Cloth materials are used for some main

trim items and are therefore a potential fire hazard.

The paper used for masking purposes is a prime

area of concern. Once it has done its job and is

covered in overspray it is important that it is correctly

disposed of, ideally in a metal container with

a lid, and not scrunched up and thrown on the floor

to form the potential start of a deep seated fire.

Class B fires: flammable liquids

Flammable liquids are the stock materials used in the

trade for all body refinishing processes: gun cleaner

to clear finish coats, cellulose to the more modern

finishes, can all burn and produce acrid smoke.

Class C fires: gases

Not many cars run on liquid propane gas (LPG),

but welding gases or propane space heaters not

only burn but can be the source of ignition for A or

B fires.

Electrical hazards

Electricity is not of itself a class of fire. It is, however,

a potential source of ignition for all of the fire

classes mentioned above.

The Electricity at Work Regulations cover the

care of cables, plugs and wiring. In addition, in

68Repair of Vehicle Bodies

the bodyshop the use of welding and cutting

equipment produces sparks which can, in the

absence of good housekeeping, start a big fire.

Training in how to use fire fighting equipment can

stop a fire in its early stages. Another hazard is the

electrical energy present in all car batteries. A

short-circuit across the terminals of a battery can

produce sufficient energy to form a weld and in

turn heating, a prime source of ignition. When

tackling a car fire a fireman will always try to disconnect

the battery, as otherwise any attempt to

extinguish a fire can result in the reignition of

flammable vapours.

Body filler

A further possible source of ignition to be aware of

in general use in the body repair business is the

mixing of two materials to use as a body filler. The

result of mixing in the wrong proportions can give

rise to an exothermic (heat releasing) reaction; in

extreme cases the mix can ignite.

General precautions to reduce

Fire risk

(a) Good housekeeping means putting rubbish

away rather than letting it accumulate.

(b) Read the manufacturer’s material safety data

sheets so that the dangers of flammable liquids

are known.

material for the job in hand.

(d) Materials left over from a specific job should

be put back into a labelled container so that not

only you but anyone (and this may be a fireman)

can tell what the potential risk may be.

(e) Take care when welding that sparks or burning

underseal do not cause a problem, especially

when working in confined areas of vehicles.

(f ) Be extremely careful when working close to

plastic fuel lines.

(g) Petrol tanks are a potential hazard: supposedly

empty tanks may be full of vapour. To give

some idea of the potential problem, consider

one gallon of petrol: it will evaporate into

33 ft3 of neat vapour, which will mix with air

to form 2140 ft3 of flammable vapour. Thus

the average petrol tank needs only a small

amount of petrol to give a tank full of vapour

waiting to ignite and explode.

The key to fire safety is:

1 Take care.

2 Think.

3 Train staff in the correct procedures before things

go wrong.

4 Ensure that these procedures are written down,

understood and followed by all personnel within

the workshop.

2.2.5 Portable extinguishers: types

And uses

The colour codes for each type of appliance are as

follows:

Red for water.

Cream for foam.

Black for CO2.

Blue for powder.

Green for halon (BCF).

Figures 2.12a–c show various types of extinguisher.

Although older fire extinguishers are colour coded,

new ones are all red in colour with labelling to

identify their contents and applications.

Water

Water is the most widely used extinguisher agent.

With portable extinguishers, a limited quantity of

water can be expelled under pressure and its direction

controlled by a nozzle.

There are basically two types of water extinguishers.

The gas (CO2) cartridge operated extinguisher,

when pierced by a plunger, pressurizes

the body of the extinguisher, thus expelling the

water and producing a powerful jet capable of rapidly

extinguishing class A fires. In stored pressure

extinguishers the main body is constantly under

pressure from dry air or nitrogen, and the extinguisher

is operated by opening the squeeze grip

discharge valve. These extinguishers are available

with 6 litre or 9 litre capacity bodies and thus provide

alternatives of weight and accessibility.

Foam

Foam is an agent most suitable for dealing with

flammable liquid fires. Foam is produced when a

solution of foam liquid and water is expelled under

pressure through a foam-making branch pipe at

which point air is entrained, converting the solution

into a foam.

Health and safety 69

Figure 2.12(a) Types of portable fire extinguisher (b) Types of fire fighting equipment (UK Fire International

Ltd ) (c) Portable fire extinguishers suitable for a bodyshop (Chubb Fire Ltd )

(b) (c)

(a)

70Repair of Vehicle Bodies

Foam extinguishers can be pressurized either by

a CO2 gas cartridge or by stored pressure. The

standard capacities are 6 and 9 litres.

Spray foam

Unlike conventional foams, aqueous film forming

foam (AFFF) does not require to be fully aspirated

in order to extinguish fires. Spray foam extinguishers

expel an AFFF solution in an atomized form

which is suitable for use on class A and class B

fires. AFFF is a fast and powerful means of tackling

a fire and seals the surfaces of the material, preventing

re-ignition. The capacity can be 6 or 9 litres,

and operation can be by CO2 cartridge or stored

pressure.

Carbon dioxide

Designed specifically to deal with class B, class C

and electrical fire risks, these extinguishers

deliver a powerful concentration of carbon dioxide

gas under great pressure. This not only smothers

the fire very rapidly, but is also non-toxic and

is harmless to most delicate mechanisms and

materials.

Dry powder

This type of extinguisher is highly effective against

flammable gases, open or running fires involving

flammable liquids such as oils, spirits, alcohols,

solvents and waxes, and electrical risks. The powder

is contained in the metal body of the extinguisher

from which it is supplied either by a sealed

gas cartridge, or by dry air or nitrogen stored under

pressure in the body of the extinguisher in contact

with the powder.

Dry powder extinguishers are usually made in

sizes containing 1 to 9 kg of either standard powder

or (preferably and more generally) all-purpose

powder, which is suitable for mixed risk areas.

Vaporizing liquid (halon 1211, BCF)

Portable extinguishers of this type are manufactured

in sizes ranging from 1 to 15 kg. They are

particularly effective for dealing with class B fires

and with fires started by an electrical source.

Halon 1211 (bromochlorodifluoromethane, BCF)

has a low toxicity level, is considered to be noncorrosive

and has a long storage life. It is clean to

use and leaves no residue, thus rendering it harmless

to delicate fabrics and machinery. However,

owing to the contribution of halons to atmospheric

ozone depletion most companies have decided to

cease production of halon 1211.

Choosing and siting portable extinguishers

Because there is such a variety of fire risks in

bodyshops, it is important to analyse these risks

separately and (with the help of experts such as fire

officers) to choose the correct fire fighting medium

to deal with each possible fire situation. It should

be noted that portable fire extinguishers are classified

as first-aid fire fighting and are designed for

ease of operation in an emergency. It is important

to realize that because they are portable they have

only a limited discharge. Therefore their siting,

together with an appreciation of their individual

characteristics, is fundamental to their success in

fighting fire (Figure 2.13).

2.3 Safety signs in the workshop

It is a legal requirement that all safety signs used in

a bodyshop comply with BS 5378: Part 1. Each of

these signs is a combination of colour and design,

within which the symbol is inserted. If additional

information is required, supplementary text may be

used in conjunction with the relevant symbol, provided

that it does not interfere with the symbol.

The text can be in an oblong or square box of the

same colour as the sign, with the text in the relevant

contrasting colour, or the box can be white

and the text black.

BS 5378 divides signs into four categories

(Figure 2.14):

Prohibition Prohibition signs have a red circular

outline and crossbar running from top left to bottom

right on a white background (Figure 2.15a).

The symbol displayed on the sign must be black

and placed centrally on the background, without

obliterating the crossbar. The colour red is associated

with ‘stop’ or ‘do not’.

Warning Warning signs have a yellow triangle

with a black outline (Figure 2.15b). The symbol or

text used on the sign must be black and placed centrally

on the background. This combination of

black and yellow identifies caution.

Mandatory Mandatory signs have a blue circular

background (Figure 2.15c). The symbol or text

used must be white and placed centrally on the

background. Mandatory signs indicate that a specific

course of action is to be taken.

Health and safety 71

Safe condition The safe condition signs provide

information for a particular facility (Figure 2.15d)

and have a green square or rectangular background

to accommodate the symbol or text, which must be

in white. The safety colour green indicates ‘access’

or ‘permission’.

Fire safety signs are specified by BS 5499, which

gives the characteristics of signs for fire equipment,

precautions and means of escape in case of

fire (Figure 2.16). It uses the basic framework

concerning safety colours and design adopted by

BS 5378.

Figure 2.13Which extinguisher to use (Chubb Fire Ltd )

Figure 2.14Standard safety signs

72Repair of Vehicle Bodies

2.4 General safety precautions in the

workshop

The Health and Safety at Work Act imposes on

employers a statutory duty to ensure safe working

conditions and an absence of risk in the use of equipment

and the handling of materials, and to comply

with Regulations regarding safe working practices in

order to reduce to a minimum the hazards to health

and safety associated with vehicle body repair work.

To skilled and experienced operators this does not

mean that any additional restrictions are imposed on

their activities, but merely that they should carry out

their tasks with constant regard for the health and

safety of themselves and their fellow workers.

Figure 2.15(a) Prohibition signs (b) Warning signs

Figure 2.15(c) Mandatory signs (d) Safe condition signs

74Repair of Vehicle Bodies

Particular hazards may be encountered in the

bodyshop, and safety precautions associated with

them are as follows:

1 Do wash before eating, drinking or using toilet

facilities to avoid transferring the residues of

sealers, pigments, solvents, filings of steel, lead

and other metals from the hands to the inner

parts and other sensitive areas of the body.

2 Do not use kerosene, thinners or solvents to

wash the skin. They remove the skin’s natural

protective oils and can cause dryness and irritation

or have serious toxic effects.

3 Do not overuse waterless hand cleaners, soaps

or detergents, as they can remove the skin’s

protective barrier oils.

4 Always use barrier cream to protect the hands,

especially against fuels, oils, greases, hydrocarbon

solvents and solvent-based sealers.

5 Do follow work practices that minimize the

contact of exposed skin and the length of time

liquids or substances stay on the skin.

6 Do thoroughly wash contaminants such as used

engine oil from the skin as soon as possible

with soap and water. A waterless hand cleaner

can be used when soap and water are not available.

Always apply skin cream after using

waterless hand cleaner.

7 Do not put contaminated or oily rags in pockets

or tuck them under a belt, as this can cause

continuous skin contact.

8 Do not dispose of dangerous fluids by pouring

them on the ground, or down drains or sewers.

9 Do not continue to wear overalls which have

become badly soiled or which have acid, oil,

grease, fuel or toxic solvents spilt over them.

The effect of prolonged contact from heavily

soiled overalls with the skin can be cumulative

and life threatening. If the soilants are or

become flammable from the effect of body

temperature, a spark from welding or grinding

could envelop the wearer in flames with disastrous

consequences.

10 Do not clean dusty overalls with an air line: it

is more likely to blow the dust into the skin,

with possible serious or even fatal results.

11 Do wash contaminated or oily clothing before

wearing it again.

12 Do disguard contaminated shoes.

13 Wear only shoes which afford adequate protection

to the feet from the effect of dropping

tools and sharp and/or heavy objects on them,

and also from red hot and burning materials.

Sharp or hot objects could easily penetrate

unsuitable footwear such as canvas plimsolls

or trainers. The soles of the shoes should also

be maintained in good condition to guard

against upward penetration by sharp or hot

pieces of metal.

14 Ensure gloves are free from holes and are

clean on the inside. Always wear them when

handling materials of a hazardous or toxic

nature.

15 Keep goggles clean and in good condition. The

front of the glasses or eyepieces can become

obscured by welding spatter adhering to them.

Renew the glass or goggles as necessary. Never

use goggles with cracked glasses.

16 Always wear goggles when using a bench

grindstone or portable grinders, disc sanders,

power saws and chisels.

17 When welding, always wear adequate eye protection

for the process being used. MIG/MAG

welding is particularly high in ultraviolet radiation

which can seriously affect the eyes.

18 Glasses, when worn, should have ‘safety’ or

‘splinter-proof’ glass or plastic lenses.

Figure 2.16Fire signs

Health and safety 75

19 Always keep a suitable mask for use when

dry flatting or working in dusty environments

and when spraying adhesive, sealers, solvent

carried waxes, and paints.

20 In particularly hostile environments such as

when using volatile solvents or isocyanate

materials, respirators or fresh air fed masks

must be worn.

21 Electric shock can result from the use of faulty

and poorly maintained electrical equipment or

misuse of equipment. All electrical equipment

must be frequently checked and maintained in

good condition. Flexes, cables and plugs must

not be frayed, cracked, cut or damaged in any

way. Equipment must be protected by the

correctly rated fuse.

22 Use low-voltage equipment wherever possible

(110 volts).

23 In case of electric shock:

(a) Avoid physical contact with the victim.

(b) Switch off the electricity.

victim away from the source of the electricity

using non-conductive material.

(d) Commence resuscitation if trained to

do so.

(e) Summon medical assistance as soon as

possible.

2.5 Electrical hazards

The Electricity at Work Act 1989 fully covers the

responsibilities of both the employee and the

employer. As a body repairer you are obliged to

follow these regulations for the protection of yourself

and your colleagues. Some of the important

points to be aware of are given below.

Voltages

The normal mains electricity voltage via a three-pin

socket outlet is 240 volts; heavy duty equipment

such as vehicle hoists use 415 volts in the form of a

three-phase supply. Both 240 volt and 415 volt supplies

are likely to kill anybody who touches them.

Supplies of 415 volts must be used through a professionally

installed system. If 240 volts is used for

power tools, then a safety circuit breaker should be

used. A safer supply for power tools is 110 volts;

this may be wired into the workshop as a separate

circuit or provided through a safety transformer.

Inspection hand-lamps are safest with a 12 volt supply;

but for reduced current flow 50 volt hand-lamp

systems are frequently used.

Check list

Before using electrical equipment the body repairer

is advised to check the following:

1 Cable condition – check for fraying, cuts or

bare wires.

2 Fuse rating – the fuse rating should be correct

for the purpose as recommended by the equipment

manufacturer.

3 Earth connection – all power tools must have

sound earth connections.

4 Plugs and sockets – do not overload plugs and

sockets, ensure that only one plug is used in

one socket.

5 Water – do not use any electrical equipment in

any wet conditions.

6 PAT testing – it is a requirement of the

Electricity at Work Regulations that all portable

electrical appliances are tested regularly, they

should be marked with approved stickers and

the inspection recorded in a log.

2.6 COSHH

The Control of Substances Hazardous to Health

regulations require that assessments are made of all

substances used in the body repair shop, for

instance paint and body filler. This assessment must

state the hazards of using the materials and how to

deal with accidents arising from misuse. Your

wholesale supplier will provide you with this information

as set out by the manufacturer in the form of

either single sheets on individual substances, or a

small booklet covering all the products in a range.

2.7 RIDDOR

The Reporting of Injuries, Diseases and Dangerous

Occurrences Regulations 1995 require that certain

information is reported to the Health and Safety

Executive (HSE). This includes the following:

1 Death or major injury – if an employee or

member of the public is killed or suffers major

injury the HSE must be notified immediately

by telephone.

2 Over-three-day injury – if as the result of an

accident connected with work an employee is

76Repair of Vehicle Bodies

absent for more than three days an accident

form must be sent to the HSE.

3 Disease – if a doctor notifies an employer that

an employee suffers from a reportable workrelated

disease then this must be reported to

the HSE.

4 Dangerous occurrence – if an explosion or

other dangerous occurrence happens, this must

be reported to the HSE, it does not need to

involve a personal injury.

2.8 Maintain the health, safety and

security of the work environment

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