Prioritising hydraulic health and safety

29 November, 2023

The construction industry is considered to be high risk due to the number of fatal and non-fatal injuries that occur each year. The dynamic nature of the profession along with the operation of heavy machinery in often hazardous environments, means workers are frequently exposed to a wide range of risks. Last year, The Health and Safety Executive (HSE) reported 59,000 cases of non-fatal work-related injury, with RIDDOR identifying that a large portion of accidents were the result of handling equipment; slips, trips, and falls; and being struck by moving objects.

Whilst these figures are still high compared to other industries such as manufacturing and transportation, steps have been taken in recent years to improve health and safety across construction sites. In the UK, for example, the introduction of new health and safety regulations and guidelines enforce all construction projects to have a health and safety plan in place to help manage risks from start to finish. Technology developments including the use of drones, smart vests, and hard hats with location tracking help better protect workers from injury. And more and more companies are making health and safety training a mandatory requirement for all staff in tandem with driving education and encouraging awareness of its importance.

As part of these efforts to improve health and safety, special attention must be paid to hydraulic systems as well as the importance of using trained experts when they breakdown.

Hydraulics in construction

If you walk on a construction site, nearly all of the machinery you will encounter will be powered by modern hydraulics. From bulldozers and excavators through to power shovels, cranes, and graders. Not only do hydraulics deliver power to large onsite equipment but they are also crucial in the manufacture of many of the construction products that are delivered to site. In a nutshell, the world of construction relies on hydraulics to keep operations moving to meet the stringent deadlines of a project.

Whilst the machinery itself will have operations guidance and regulations surrounding how it is used (it must be separated from pedestrians, it can only be operated by trained personnel, and it needs to be inspected regularly to prevent accidents) only competent technicians should carry out repairs and maintenance. If a hydraulic breakdown should occur, it might be tempting for onsite staff to try and fix it themselves in efforts to minimise downtime or save money. However, this is a risky strategy to employ and can lead to life-changing injuries for those carrying out the work without the required expertise.

Dangers of hydraulic hoses

A hydraulic hose allows fluid to flow from one component to another, ensuring it is able to move unimpeded to keep the hydraulic system moving. Constructed from flexible rubber and wire, a hydraulic hose has multiple layers to give it strength and durability but it is not infallible. Without professional maintenance it can naturally sustain damage and degrade over time, causing it to fail before its average five-year life expectancy. Old age, high operating temperatures, abrasions, chemical erosion, poor fittings, and pressure overload are some of the common reasons for hoses needing to be replaced before this time.

In construction, problems will often occur when a hydraulic hose is damaged by the surrounding environment where nicks, cuts, and tears can happen easily – and in extreme cases, the hose can be severed or crushed. No matter the scenario, a hydraulic hose must never be repaired due to the dangers associated with high pressure systems, instead it must be replaced with new, safe components. Yet, there is a naivety and lack of understanding surrounding the dangers of a damaged hose. For example, if a hydraulic hose bursts, the pressure and heat of the fluid can lead to burns and infections and the potential of a fluid injection injury. If not treated quickly, injection injuries can result in amputation and even death.

Taking responsibility

Unfortunately, this lack of awareness in combination with tighter budgets means there is a tendency for hoses to be repaired using a DIY fix or re-ended; the process where the last few inches of the hose is cut off and replaced with new fittings to artificially extend its life. The British Fluid Power Association (BFPA) strongly advice against this practice stating that trade associations, industry experts and safety bodies all agree that the risks are too great; but the problem of re-ending is still prevalent across the industry.

Businesses within the construction and plant hire industries need to keep their people safe by ensuring anyone dealing with hydraulic hoses receives hydraulic safety awareness training to help reduce the risks involved. This should be provided by industry experts who are members of the BFPA to make sure that the training delivered is to a high standard and up to date. This can be complemented by implementing robust inspection and reporting procedures to monitor equipment usage, condition and if any maintenance has taken place.

To further ensure safety and compliance, it is crucial that hydraulic hoses are treated with the same level of attention and importance as other high-risk components. When a failure occurs and an emergency callout is required, the best course of action is to contact a hydraulic hose specialist that understands the potential dangers at a construction site. Partnering with a best-in-class hydraulic hose expert will mean a technician is onsite quickly and a quality service will be delivered. Planned maintenance and servicing can also help reduce the level of risk, and using suppliers accredited by the BFPA’s Approved Hose Assemblies Scheme means that everything from hose manufacturing and assembly through to distribution and fitting will comply with best practice safety procedures.

Hydraulics is just one cog on the health and safety agenda in construction, but it shouldn’t be underestimated as one mistake could have disastrous consequences for the company and individuals involved. Failure of hydraulics can also have serious repercussions for the downtime of equipment so ensuring that any replacements or maintenance is done by experts is vital. Health and safety leaders in the industry have a duty of care to offer training, promote awareness and make sure the right suppliers are being used at all times. Taking responsibility now can help protect tomorrow’s worker.

For further information please visit: https://www.pirtek.co.uk/training-courses/

https://twitter.com/PirtekUKIreland

https://www.linkedin.com/company/pirtek-uk-ltd/