Ensuring Safety. Best Practices for Compressed Air Use

12 February, 2025

Compressed air is a versatile energy source and must be handled with care. From cleaning and painting to operating pneumatic tools and lines, to transportation and injection moulding, the applications for compressed air are extensive.

Although the incidence of injuries related to compressed air systems is relatively low in the UK, these systems can pose significant hazards if not properly maintained or the correct precautions are not taken. Components such as compressors, hoses, pneumatic tools, and electrical connections all have associated risks, and the high pressure within these systems can cause serious injuries. Continuous efforts to enhance safety standards and reduce complacency are therefore essential.

Recent statistics from the Health and Safety Executive (HSE) highlight the broader context of workplace safety in the UK. In the 2023/24 period, there were 138 work-related fatalities and an estimated 604,000 workers sustained non-fatal injuries. Additionally, approximately 1.7 million workers suffered from work-related ill health, with stress, depression, or anxiety accounting for 776,000 of these cases.

These health issues and injuries led to an estimated 33.7 million working days lost during the same period. These figures underscore the critical importance of adhering to safety protocols and ensuring regular maintenance of compressed air systems to prevent accidents and protect worker health.

Barriers to safety

One challenge in promoting a culture of safety is the generational gap in safety perceptions. While younger workers often view new safety measures as standard practice, older employees that have been carrying out their duties for some years may regard them as unnecessary. Bridging this gap is vital for the successful implementation and acceptance of safety protocols.

The importance of compressed air safety

Training and education

Comprehensive training is crucial for all operators working with compressed air systems. Training programs should include detailed instructions on the safe and efficient operation of compressors, awareness of potential hazards, and strategies for risk mitigation.

Air compressor safety tips

Training: BCAS recommends comprehensive training for all operators, including an understanding of relevant safety standards before operating any equipment.

Equipment and workspace setup: Operators should follow the manufacturer’s guidelines, including the installation of safety devices such as pressure relief valves.

Sites should standardise regular pre-start safety checks for all compressor system components to ensure safe and efficient operation

Maintenance: Regular maintenance, including checks of filters, dryers, air receivers, and pipework is vital for extending the life of the system and maintaining air quality.

Good housekeeping and staff involvement: Compressed air is a valuable resource, and leaks should be addressed promptly. Common sources of wastage also include leaving air-consuming equipment running during breaks and using compressed air unnecessarily for cleaning benches and equipment. Encouraging staff to report and identify instances of wasted air usage is critical.

Working safely with compressed air

The British Compressed Air Society’s Certificate in Working Safely with Compressed Air workshop provides a simple and efficient way to train staff that regularly use compressed air in their daily routines.

The one-hour, online workshop helps to fulfil employers’ health and safety obligations and provides evidence that each participant has understood safe working practices and their responsibilities.

Straightforward and easy to follow, the course covers the hazards of compressed air as an energy source, the use of personal protective equipment, employer and employee responsibilities with respect to health and safety when using compressed air and a list of safe working practices to be followed.

To find out more about the Certificate in Working Safely with Compressed Air course from BCAS, please visit

https://elearning.bcas.org.uk/our-courses/fully-online/working-safely-with-compressed-air/

For more information, enquiries@bcas.org.uk or call 0207 935 2464 or visit:  www.bcas.org.uk

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