HSE has released a practical four-part video series focusing on how to control exposure to metalworking-fluid (MWF) mist during CNC machining. The films demonstrate how effective local exhaust ventilation (LEV), visualisation techniques and straightforward monitoring tools can significantly reduce respiratory and skin risks for operators.

Metalworking fluids are essential for cooling and lubricating cutting operations, but the mist generated can lead to occupational asthma, hypersensitivity pneumonitis and dermatitis if not properly controlled. The new videos give employers concise demonstrations they can replicate on the shop floor to strengthen compliance with COSHH and improve day-to-day operator protection.

What the four new HSE videos cover

HSE’s new series consists of four short films designed for toolbox talks, inductions and refresher training. Each video provides actionable guidance for assessing and improving exposure controls:

1. LEV to control worker exposure to MWF mist

A demonstration of how correctly designed, positioned and commissioned LEV equipment captures mist at source. The video highlights key design principles, the importance of enclosure, the role of filtration and tips for ensuring effective capture.

2. Monitoring methods for MWF mist

Explains simple, practical techniques such as dust lamps, smoke pens and direct-reading aerosol monitors. These tools help you visualise mist behaviour, compare machines and identify priority areas for improvement.

3. Assessing control of MWF mist during CNC machining using monitoring methods

Shows how to run short monitoring sessions during typical CNC cycles. The video illustrates how different machining operations can generate varying mist levels and where additional controls may be needed.

4. Monitoring methods to check LEV for MWF mist

Provides step-by-step practical checks for routine LEV assessment, including airflow indications, dust-lamp checks and clearance-time tests. The video demonstrates how to embed these checks into regular maintenance procedures.

Why this matters for your workshop

MWF mist is a recognised cause of occupational lung disease and remains an area of active HSE attention. Key challenges frequently seen during inspections include:

• Poor LEV design or use
• Operators opening machine doors before mist has cleared
• Ineffective or unmonitored filtration
• Inadequate fluid-quality management
• Limited recording of checks and LEV performance
• Lack of health surveillance where exposure remains possible

These new videos provide clear demonstrations that show what “good” looks like and help employers benchmark their own practices.

A seven-step action plan for employers

Use the videos as part of a structured improvement programme. The following steps are practical, inexpensive and effective:

1. Show the videos to operators and supervisors

Use the films as part of a 10–15 minute toolbox talk or induction module. The visual demonstrations help reinforce safe behaviour and clarify the reasons for engineering controls.

2. Risk-rate your CNC machines

Conduct a walk-through using a dust lamp or aerosol monitor to identify which machines generate the most mist. Prioritise these machines for enclosure improvements, LEV review or process-change considerations.

3. Commission and document LEV

Ensure LEV hoods are correctly sized and positioned, that enclosures are used effectively and that commissioning records — including clearance times — are up-to-date and accessible.

4. Introduce a routine LEV check schedule

Use a standard checklist to record weekly airflow indications, dust-lamp checks, filter condition and enclosure performance. Maintain a simple LEV logbook and ensure responsible persons are clearly identified.

5. Manage fluid quality effectively

Check concentration, pH, odour and bacterial contamination as part of a structured fluid-management programme. Poor coolant condition increases mist production and health risks.

6. Review and update safe working procedures

Avoid compressed-air cleaning, limit door-opening until after clearance times and ensure operators know how to position LEV hoods correctly. Consider interlocks or time-delay systems where appropriate.

7. Apply health surveillance where required

If workers are exposed to MWF mist, health surveillance for skin and respiratory symptoms is required under COSHH. Implement a structured programme and ensure early-reporting systems are in place.

Recommended next steps which Outsource Safety can assist with

• Toolbox talk outline: play one video → run a short Q&A → agree two machine-specific improvements.
• LEV quick-check sheet: hood condition, visual capture check, airflow gauge, filter state, clearance time, required actions.
• Machine-priority register: machine ID, mist-assessment result, action required, target date, assigned person.

Further resources for deeper understanding

• HSE metalworking-fluids main guidance pages
• COSHH Essentials: MW0–MW5 (Machining with metalworking fluids)
• HSE YouTube playlist: “Metalworking fluid mist” – the full four-video series

Final thoughts

HSE’s updated video materials make it easier than ever to demonstrate a clear, evidence-based approach to controlling MWF mist. By combining simple monitoring methods, effective LEV and structured checks, employers can reduce ill-health risks, improve operator confidence and strengthen COSHH compliance.

A practical next step is to run a short session with your CNC operators using the new films, followed by a quick dust-lamp survey on your highest-use machines – or we can do this for you if you are a retained client under Safety~net support. Small, visible improvements can deliver significant gains in both safety and operational reliability.  If you need specific help and you are a retained client (or would like our help on this) please contact Roger Hart or ask for a call back from one of our safety experts

Construction

Key Data & Risks

• In 2024/25, the construction sector recorded 35 worker fatalities, the highest of any sector.
• From HSE’s Labour Force Survey data, construction also has one of the highest self-reported rates of non-fatal injury: 2,388 per 100,000 workers.
• In terms of illness, the construction sector’s rate of self-reported work-related ill health is 3,772 per 100,000 workers, which is below some other sectors but still substantial.
• The most common fatal accident type in construction is falls from height, which matches long-standing trend data.

Implications & Strategies

• Height safety: Given that falls remain a leading cause, ensure rigorous fall-prevention systems: guardrails, harnesses, scaffold inspections, and robust safe-work-at-height training.
• Incident culture: Encourage near-miss reporting and proactive inspections — in construction, small interventions can prevent major accidents.
• Manual handling/injury prevention: Construction workers face a high risk of non-fatal injury, so strong manual-handling training, task review, and use of lifting aids are essential.
• Health monitoring: Though self-reported ill health is moderate relative to some sectors, musculoskeletal disorders may be underreported. Regular health surveillance and ergonomic reviews (e.g., for repetitive tasks) will help.

Agriculture, Forestry & Fishing

Key Data & Risks

• Agriculture, forestry, and fishing recorded 23 worker fatalities over 2024/25.
• This sector has the highest fatal injury rate per 100,000 workers among main industry sectors.
• A large proportion of fatalities in this sector involve self-employed workers. Over recent years, self-employed farm workers make up a much greater share of deaths compared to their proportion of the workforce.
• Non-fatal injuries: According to commentary on HSE data, agriculture has historically had very high non-fatal injury rates, though precise LFS data for 2021/22–2023/24 is less available.

Implications & Strategies

• Self-employed focus: Because many in this sector are self-employed, safety programmes must reach beyond “company culture” — tailor interventions, training, and guidance to farm owners and contractors.
• Machinery risk: Given the high rate of machinery-related incidents, ensure robust maintenance regimes, machine guarding, and operator training (especially on tractors, combines, ATVs).
• Fatigue management: Farming often involves long hours; fatigue contributes to risk. Introduce rest-break policies, rotation, and risk assessments for “after-hours” working.
• Fall prevention: While not as obvious as in construction, elevated tasks (e.g., silos, barns) must be properly managed with fall prevention measures.
• Engagement & safety culture: Promote peer-to-peer safety networks (e.g., farm-safety groups), encouraging reporting, safe practices, and shared learning across small farms.

Manufacturing

Key Data & Risks

• In 2024/25, 11 workers in manufacturing were fatally injured.
• From HSE’s LFS data, the self-reported non-fatal injury rate in manufacturing is 1,936 per 100,000 workers.
• For ill health, manufacturing’s self-reported rate is **3,400 per 100,000 ** — somewhat lower than in “high-ill-health” sectors like health and education, but still significant.
• Regarding the causes of fatal injuries, in manufacturing, there is a higher incidence of being struck by moving machinery or objects, reflecting typical industrial hazards.

Implications & Strategies

• Machine safeguarding: Ensure all machinery has proper guards, interlocks, and isolation procedures. Maintenance schedules and lock-out / tag-out processes must be strictly enforced.
• Hazardous manual tasks: Use risk assessments on handling, lifting, and moving parts. Introduce ergonomic improvements, mechanical aids, and training.
• Safety training & behaviour: Invest in strong safety induction and continuous training (especially for new staff) with a focus on behaviours around moving plant, visibility, and safe working zones.
• Near-miss systems: Encourage reporting of “close calls” around machinery. These insights can help prevent more serious incidents.
• Health surveillance: Depending on processes, monitor workers for noise exposure, vibration, or repetitive strain injury — especially in CNC / manufacturing operations.

Transportation & Storage / Admin / Support / Other High-Risk Sectors

Key Data & Risks

• Transportation & storage saw 15 fatalities in 2024/25.
• Admin and support services recorded 13 fatalities, and wholesale/retail & accommodation/food combined had 12.
• In the non-fatal injury statistics, transportation/storage and construction top the charts for self-reported injury rates.
• For non-fatal injuries overall (2023/24), the most common accident kinds are: slips, trips or falls (31%), handling/lifting (17%), struck by an object (10%), acts of violence (9%), and falls from height (8%).

Implications & Strategies

• Transport risk management: For logistics, warehouses, and storage, focus on vehicle safety, pedestrian-vehicle segregation, and robust traffic management plans.
• Manual handling: Given the high share of handling / lifting incidents, implement regular training, use mechanical lifting aids, and review load handling tasks.
• Slips, trips, falls: Implement housekeeping programs, good housekeeping routines, surface maintenance, and non-slip flooring — especially in admin/support facilities.
• Violence risk: In support services or customer-facing settings, assess risk of violence or aggression, train staff in de-escalation, and provide safe working measures.
• Near-miss & reporting culture: Create simple but effective reporting frameworks, so that non-fatal, “low-consequence” incidents feed into safety improvement programmes.

Why This Matters for Your Business, Outsource Safety (and Your Clients)

When working with clients in these sectors, Outsource Safety can offer tailored, sector-specific health & safety services that reflect the unique risk profiles shown in the HSE data:

• Use industry benchmarking: Compare a client’s safety performance (fatalities, injury rate, near-misses) to HSE-sector averages to prioritise interventions.
• Embed preventative systems: Not just “tick-box” compliance, but proactive risk management (e.g., fall prevention in construction, machine guarding in manufacturing).
• Provide behavioural safety training: Sector-focused programmes (e.g., for drivers, machine operators, farm owners) can target the most frequent incident types.
• Support health and well-being: For sectors with high ill-health risk (e.g., musculoskeletal, mental health), help clients develop health surveillance, fatigue management, and health promotion.
• Facilitate continuous improvement: Using HSE data as a benchmark, run regular reviews, safety audits, and strategy sessions to show progress in reducing injuries and ill health.

Final Thought

These sector-specific breakdowns underscore that health & safety is not one-size-fits-all. Different industries face very different risks — and a tailored, data-driven approach is essential. For us at Outsource Safety, aligning clients’ safety strategies with the latest HSE data not only helps to reduce risk but also demonstrates value: fewer accidents, lower absence, better compliance, and potentially lower costs.

Contact us for more info on how we support hundreds of clients in construction and industry across the UK, or request a call back, and one of our consultants will call you.

The Health and Safety Executive has published the latest annual statistics covering work-related ill health, injury, and fatalities in Great Britain for 2024/25. HSE Workplace Statistics 2024/25. These figures serve as a vital barometer for the overall health of workplaces across industries — and they underline several key areas that businesses, large and small, must continue to address.

Key headline figures

Here are some of the major data points that stand out for 2024/25:

• An estimated 1.9 million working people suffered from work-related ill-health in 2024/25.
• Of those, 964,000 workers reported stress, depression or anxiety caused or made worse by work.
• A further 511,000 reported a work-related musculoskeletal disorder.
• Non-fatal injuries: An estimated 680,000 working people sustained a non-fatal injury at work.
• Fatal injuries: 124 workers died in work-related incidents during the 2024/25 period (an improvement of 14 fewer deaths compared to the previous year).
• Working days lost due to ill health and workplace injury totalled around 40.1 million.
• The estimated annual cost of workplace injuries and new cases of ill health reached £22.9 billion (based on rolling averages for 2023/24) — broadly consistent with the prior year.

What these numbers tell us

These statistics reflect several critical insights for any business responsible for workplace health and safety:

1. The challenge of ill health remains very significant
While the numbers for fatalities are relatively lower than in many decades past, the fact that nearly two million workers experienced ill health shows how pervasive the problem is. Mental health (stress, depression, anxiety) remains a major driver. The musculoskeletal burden is still high as well.

2. Persistent risk of injury
With 680,000 non-fatal injuries and many more perhaps unreported or self-reported outside the official regulatory system, the message is clear: injury risk remains real. For the construction, agriculture, waste & recycling and other higher-risk sectors, the focus must remain sharp.

3. Fatalities still matter — each one is avoidable
Although 124 deaths might seem a “small” number in the context of 32+ million workers, each one represents a worker, a family, a business scene turned tragic. Importantly, the highest numbers of deaths remain in sectors such as construction and agriculture.

4. Economic-cost pressure remains heavy
40.1 million lost working days and £22.9 billion in estimated cost: For an organisation, large or small, the indirect and direct costs of health and safety failures are material. They affect productivity, staff retention, reputation, compliance risk and business continuity.

Implications for your business & what you should focus on

Given these figures, if your organisation places any reliance on external safety-support (such as outsourced safety services) or has internal H&S teams, it’s worth considering the following action areas:

• Mental health & well-being: Since stress, depression, and anxiety dominate the ill-health figures, businesses must ensure their health & safety strategy includes psychological risks (workload, remote/hybrid working, support mechanisms, bullying/harassment, workplace culture), not just physical hazards.
• Musculoskeletal risks: Whether work is manual (lifting, repetitive actions, awkward postures) or involves significant time at display screens, consider reviewing ergonomic assessments, manual-handling training and DSE processes.
• High-risk sectors/tasks: If your operation includes any of the sectors with elevated fatality or injury rates (construction, agriculture/forestry/fishing, waste/recycling) then proactive risk management of fall-from-height, working with vehicles, machinery/plant, and near-miss reporting is essential.
• Non-fatal injury monitoring & intervention: A robust incident/near-miss reporting culture can catch small issues before they become costly. Use the lost-day figures as a reminder that even non-fatal incidents create a burden.
• Cost awareness: For directors and senior management, translating safety performance into cost metrics (working-days lost, financial impact) helps make the business case for investment in safety resources, training, engagement and monitoring.
• Continuous review: Trends in older data show improvements in some areas (e.g., fatal injuries down when compared to decades ago) but less improvement in some other areas (mental health, musculoskeletal disorders). An outsourced safety partner should be capable of helping you embed continuous improvement, not just compliance.

Why this matters

These statistics highlight both the continuing need for expert health & safety support and the opportunity to add value beyond mere regulatory compliance:

• Partnering with businesses to address latent hazards (not just the obvious ones).
• Supporting clients with mental-health and ergonomic interventions in addition to traditional safety.
• Providing data-driven insights — using industry benchmarks (such as these HSE figures) to help clients measure their performance, set targets, and track improvement.
• Ensuring that safety programmes are embedded in business strategy and culture, not just safety committees or incident response.
• Translating safety outcomes into commercial metrics (reduced days lost, fewer incidents, lower insurance premiums) so that board-level stakeholders engage.

Final thoughts

The 2024/25 HSE statistics provide a clear message: while progress has been made, much remains to be done. The large number of workers suffering ill-health and the ongoing burden of non-fatal injuries show that a safe working environment encompasses more than preventing major accidents — it includes day-to-day risks, psychological hazards, and systematic controls.

For businesses of all sizes, health and safety – when done well – isn’t a cost centre: it’s part of sustainable performance, workforce retention and corporate responsibility. The role of an external safety partner should therefore be positioned not just in terms of compliance, but as a strategic asset.

Lithium-ion batteries are everywhere — powering forklifts, mobile devices, e-bikes, energy storage systems and more. Despite their benefits, they pose a serious fire and explosion hazard when improperly stored or handled. As safety professionals and business owners, we must treat them with the same respect as other hazardous items.

This post outlines what you need to know to store lithium-ion batteries safely in a UK workplace — summarising key risks, regulatory considerations, and practical controls you can implement today.

Why lithium-ion batteries pose a risk

At their best, lithium-ion batteries offer excellent performance. But when things go wrong – overcharge, damage, thermal abuse, or manufacturing defects – the outcome can be dramatic. The process known as thermal runaway is central to the hazard: an overheated cell can release flammable gases, rupture, and ignite adjacent cells.

In the UK, this risk is growing. The number of e-bike fires involving lithium-ion batteries has risen sharply. For organisations, storage (and charging) of these batteries is a significant safety issue, not just a housekeeping matter.

Key UK guidance and regulatory context

You should be aware of the following key resources:

• HSE INDG139 – Using Electric Storage Batteries
• Aviva Risk Solutions – Guidance on lithium-ion battery storage and transit
• Safety Storage Systems – Specialist advice on storage controls
• Lithium-Ion Battery Safety Bill (UK) – Ongoing legislative development
• British Safety Council – Risk assessments, ventilation, and temperature control guidance

There’s no single “lithium battery law,” but the message is clear: treat lithium-ion batteries as hazardous and control the risks accordingly.

Practical controls for safe storage

1. Storage environment

• Keep in a cool, dry, well-ventilated space (ideally 5 °C – 20 °C).
• Avoid direct sunlight and heat sources.
• Use racks or shelving — never stack batteries directly.
• Keep away from combustible materials.

2. Battery condition, charge level and handling

• Store at 40–60% charge for long periods.
• Remove from equipment when not in use.
• Inspect regularly for swelling, leaks or heat.
• Use manufacturer-approved chargers only.

3. Storage containment and suppression

• Use fire-rated storage cabinets built for lithium-ion batteries.
• Install suitable fire detection and suppression.
• Segregate from general storage.

4. Risk assessment and policy

• Carry out a formal risk assessment.
• Document safe systems of work.
• Maintain logs and inspection records.
• Dispose of damaged batteries through authorised waste routes.

5. Transport and movement

• Follow UN 3480/3481 regulations for transport.
• Avoid storing or moving through hot zones.

Common pitfalls

❌ Over-stacking or contact between terminals
❌ Long-term full charge
❌ Poor ventilation
❌ Use of non-OEM chargers
❌ Ignoring small or damaged batteries
❌ Failure to update the fire-risk profile

Integrating into your safety management system

• Add lithium-ion batteries to your fire risk assessment.
• Create a dedicated storage zone with signage and inspection.
• Update charging procedures and train staff.
• Review containment standards and fire controls.
• Coordinate with facilities and fire safety teams.

Final thought

Lithium-ion batteries will only become more common — and so will the risks. With proper storage, handling and control, those risks remain manageable. The key is awareness and proactive management.

P50 service‑free fire extinguishers — what they are and whether they’re right for your site

Service‑free extinguishers are becoming a popular option across UK sites — and the P50 family (manufactured in Great Britain) is one of the better‑known ranges. They’re marketed as lightweight, corrosion‑proof composite extinguishers that are service‑free for the first 10 years, with the aim of simplifying maintenance and lowering lifetime cost.

Below we explain what P50 extinguishers are, the real benefits and limitations, and a clear checklist to help you decide whether they’re a good fit for your premises.

What is a P50 extinguisher?

P50 extinguishers are composite‑bodied portable extinguishers produced in the UK. In short: they use a corrosion‑resistant composite shell, are available in multiple agent types (powder, foam, water‑mist, Class F/kitchen variants, and more), and are designed to be service‑free for the first 10 years — subject to annual visual checks by a competent person. After year 10 the unit can be refurbished/refilled and continue in service for a further period when correctly maintained.

Why organisations consider a P50 extinguisher

• Lower ongoing contractor costs. The service‑free claim removes the need for an annual discharge/refill by a contractor in years 1–10; only an annual visual inspection is required. That can reduce external maintenance spend and disruption.
• Better resistance to corrosion. The composite shell makes a P50 extinguisher a good option in wet, coastal or exposed environments where steel cylinders are at greater risk of rust and failure.
• Lightweight and easier handling. Composite construction often reduces weight compared with comparable steel extinguishers, which can make manual handling easier.
• Environmental and lifecycle advantages. The longer initial service interval, refurbishment option and recyclable components are attractive where organisations are trying to cut embodied carbon and waste.

Key cautions — don’t assume ‘service‑free’ means ‘no responsibility’

• You still have legal duties. The Regulatory Reform (Fire Safety) Order requires that equipment is suitable and maintained; service‑free does not remove your duty to ensure extinguishers are appropriate, sited correctly and inspected by a competent person.
• Annual visual inspections remain essential. A competent person must carry out, record and keep inspection records every year. These records form part of your fire safety management and could be inspected by enforcing authorities.
• Match agent to hazard. Not all P50 extinguisher agents are appropriate for every risk (for example Class F extinguishers for deep fat fryers, or specific requirements for electrical fire coverage). Always check agent suitability against your fire risk assessment.
• Refurbishment after 10 years. The ‘service‑free’ benefit applies to the first 10 years; plan for refurbishment/refill costs and lifecycle replacement beyond that point.

Practical checklist — before you swap to P50

1. Review your fire risk assessment. Confirm the P50 agent and rating match the hazards identified for each area of the site.
2. Identify your competent person. Ensure someone (internal or contracted) is trained and authorised to perform and record the required annual visual inspections.
3. Check approvals. Verify the exact approvals and standards on the models you plan to buy (manufacturer datasheets will list standards such as EN3/UKCA/other relevant marks).
4. Plan for year‑10 refurbishment. Record lifecycle dates on your maintenance schedule and budget for refurbishment or refill at the 10‑year point.
5. Update training and signage. If a P50 replaces multiple smaller extinguishers or changes extinguisher locations, provide a short refresher to staff and update inspection records and site fire plans.
6. Document everything. Keep inspection records, refurbishment receipts and a log of any incidents or faults. These form the audit trail for compliance.

Where P50 makes the most sense

P50s are a good option where reducing annual contractor costs is a genuine objective, and where corrosion or exposure makes steel cylinders less suitable. They’re particularly attractive to retail, estate managers, warehouses, outdoor sites and organisations aiming to reduce lifecycle waste.

However, P50s are not a universal solution. High‑risk process areas, specialist industrial hazards and sites without a competent person to carry out annual inspections should carefully weigh the pros and cons before switching.

Need help deciding?

If you’d like help assessing whether P50 extinguishers are right for your premises — and ensuring your fire risk assessment, inspection regimes, recordkeeping and staff briefings remain fully compliant — we can help. Contact Outsource Safety to arrange a site review and written recommendation.

The Health and Safety Executive (HSE) has recently announced a new isocyanates awareness and inspection campaign aimed at reducing the health risks posed by isocyanate exposure in UK workplaces.  As the HSE’s attention turns increasingly toward occupational lung disease and chemical safety, this initiative re-emphasises the urgency for duty-holders to review their control strategies, health surveillance, and compliance under COSHH.

In this post, we summarise the key points of the campaign, explore why isocyanates remain a major health hazard, and offer practical steps your organisation can take to stay ahead of regulatory scrutiny

Why is this campaign important?

Isocyanates are widely used chemicals—particularly in spray paints, adhesives, foams, and coatings—that are well-known respiratory sensitisers and irritants.  Even low-level exposure may trigger occupational asthma in sensitised individuals, and once sensitisation occurs, further exposure—even to minute amounts—can provoke severe reactions.

Historically, isocyanates have been a significant contributor to work-related asthma cases in sectors including motor vehicle repair, spray painting and coatings, and polyurethane manufacturing.  Over recent decades, improvements in control and monitoring have driven down incidence in some sectors—but complacency or weak controls allow residual risk to remain. )

Moreover, in its 2025–2026 priorities, HSE has signalled greater focus on occupational lung disease, including exposures to isocyanates, silica dusts, and other chemical hazards. The timing of this campaign suggests inspections and compliance checks will intensify.

What is the HSE campaign focusing on?

From the campaign bulletin, key elements include:

• Awareness-raising: Ensuring duty-holders understand that isocyanate exposure is not just a paint-shop issue.
• Inspection regime: Targeted inspections to verify that control measures, monitoring and health surveillance systems are adequate and effective.
• Guidance and support: HSE is providing resources and references to help businesses comply.

Essentially, HSE wants to push beyond education and move toward enforcement where control is lacking.

What are the regulatory requirements and best practices?

COSHH & legal duties

Under the Control of Substances Hazardous to Health (COSHH) Regulations, duty-holders must:

1. Identify hazardous substances (including isocyanates) in their processes.
2. Assess the risk of exposure.
3. Select and implement proportionate control measures (engineering, administrative, RPE, PPE).
4. Monitor exposure (air monitoring, biological monitoring) where needed.
5. Provide health surveillance where workers are likely exposed.

Importantly, because isocyanates are sensitisers, exposure must be reduced as far as is reasonably practicable (ALARP).

Workplace Exposure Limits (WELs)

UK limits for isocyanates are:

• Long-term (8-hour TWA): 0.02 mg/m³
• Short term (15-minute TWA / STEL): 0.07 mg/m³

Even when exposures remain below these limits, it’s not “safe” per se—because of the risk of sensitisation. Controls must aim for as low as reasonably practicable (ALARP).

Monitoring and health surveillance

• Air monitoring: to check whether control measures keep airborne isocyanate levels within acceptable bounds.
• Biological monitoring: urine sampling to detect isocyanate breakdown products; useful for confirming whether controls are effective.
• Health surveillance: respiratory (spirometry, questionnaires) and skin checks—especially in sectors like vehicle repair, coating, spray painting.

If monitoring indicates exposures exceed guidance, duty-holders must investigate and improve controls, then re-monitor.

Control measures: hierarchy of control

• Elimination / substitution (where possible): use alternative materials or processes with lower hazard.
• Engineering controls: closed systems, local exhaust ventilation (LEV), spray booths with capture, proper mixing enclosures.
• Administrative controls: training, rotation, safe operating procedures, permit-to-work systems when undertaking maintenance or cleaning.
• Respiratory protective equipment (RPE): where airborne levels are significant or unpredictable, an air-fed / supplied air breathing apparatus (not filtering respirators) is required for tasks like spray painting.
• Skin protection: gloves, coveralls, splash protection—because dermal exposure can also contribute to sensitisation.

Notably, HSE warns that raising the visor during spraying—even briefly—can dramatically increase operator exposure, undermining protection.

What should you do now?

Given the renewed regulatory focus, we suggest the following action plan:

1. Review your substance inventory and SDSs
   Identify all products containing isocyanates, including those labelled as “waterborne” that may still use isocyanate components.
2. Update COSHH risk assessments
   Reassess tasks (especially spraying) using the “Assess–Control–Review” model. Pay attention to the increased risks of mist, enclosed spaces, proximity, and maintenance tasks.
3. Audit engineering and ventilation systems
   Ensure LEV or capture systems are correctly specified, maintained, and effective. For spray booths and high-risk operations, confirm airflow rates, filtration, and exhaust arrangements.
4. Implement or strengthen monitoring programmes
   • Air sampling at operator breathing heights.
   • Biological monitoring (urine sampling) per HSE guidance.
   • Conduct trend analysis and use results to drive improvements.
5. Ensure robust health surveillance
   Initiate baseline and periodic respiratory testing (spirometry) and questionnaires. Monitor for early signs of asthma or dermatitis.
6. Train and empower workers
   Provide training on hazards, safe procedures, correct use of RPE, posture regarding spraying behaviour (no lifting visor), cleaning protocols, and emergency response.
7. Plan for inspections
   With HSE increasingly inspecting chemical and lung disease risks, be ready to demonstrate your control regime, monitoring records, surveillance records, and risk management approach.

Final thoughts

HSE’s new isocyanates awareness campaign is a clear signal: chemical health hazards cannot be relegated to “secondary” concerns. Organisations that underestimate or neglect isocyanate risks may find themselves under closer regulatory scrutiny—or worse, causing serious harm to your workers and facing significant liability.

If your operations involve coatings, spray painting, adhesives, or foam systems, now is the time to audit your control measures, refresh your assessments, and ensure monitoring and health surveillance are robust. Outsource Safety can assist with reviewing risk assessments, designing monitoring regimes, or advising on compliance strategies—please feel free to contact us to discuss your options for support under Safety~net, our Competent Person Scheme.

Health Surveillance for Occupational Asthma: What You Need to Know (G402)

Why this matters

Occupational asthma (OA) remains a serious and preventable work-related disease. Exposure to sensitising agents in the workplace — even at low levels — may trigger asthma symptoms in susceptible individuals. Early detection and intervention are vital to prevent long-term harm. The HSE’s guidance sheet G402 provides clear, practical advice on setting up health surveillance for OA under COSHH.

For businesses across a wide spectrum — spray painters, woodworkers, lab staff, bakers, cleaners, and more — understanding G402 is a key part of meeting your legal obligations and protecting your workforce.

Key points from G402

1. What is occupational asthma and when is surveillance needed

• Occupational asthma (OA) is defined as asthma caused by exposure to substances in the work environment.
• Once sensitisation develops, even very low levels of exposure can provoke symptoms.
• Health surveillance is appropriate when:
    • Workers are exposed to known asthmogens (e.g. isocyanates, wood dust, flour dust, glues)
    • Substances carry a hazard label like H334 (“may cause allergy or asthma symptoms if inhaled”)
    • Control relies on respirators (i.e. PPE is the main barrier)
    • A confirmed OA case arises in the workforce

2. What a suitable health surveillance scheme should involve

• The scheme should be designed and overseen by a competent occupational health professional (doctor or nurse) familiar with respiratory risks.
• It must include:
    • A baseline assessment before or soon after exposure begins (ideally within six weeks)
    • Ongoing surveillance, typically annually (though more frequent for new or high-risk roles)
    • Use of a respiratory questionnaire plus spirometry testing (lung function)
    • Interpretation of results both at the individual and group (exposed workforce) level, to spot trends and triggers
• Employers should appoint a responsible person (trained, supported by the occupational health expert) to help administer questionnaires and manage records.

3. Raising awareness & capturing symptom reports

• Workers should be informed of typical symptoms (e.g. wheezing, recurring cough, chest tightness, shortness of breath, runny/blocked nose) and encouraged to report them promptly — ideally via a clear reporting protocol.
• Surveillance should never replace a risk assessment or control measures; it complements them.

4. Reviewing controls in light of findings

• If any case of OA is suspected or confirmed, your risk assessment must be revisited, and controls improved (or worker moved to lower exposure role) where necessary.
• Health surveillance outcomes are an important feedback loop into your overall risk management.

5. Record keeping

• A health record must be maintained for each worker under surveillance, containing:
    • Personal identifiers & exposure details
    • Dates, durations, and frequency of exposure
    • PPE used
    • Results of questionnaire and spirometry
    • Recommendations and any action taken
• Records must be stored securely for at least 40 years from the last entry.

What your business should do now

1. Check your processes: Do you use or handle substances known to cause OA (paints, wood dusts, enzyme cleaners, etc.)? Are you relying heavily on respirators?
2. Engage an occupational health professional: If you don’t already have one, bring on board someone qualified to set up the surveillance scheme.
3. Baseline your workforce: Establish a starting point for existing staff and set timelines for new starters.
4. Inform & train workers: Make sure they know the symptoms, the reporting route, and why health surveillance matters.
5. Review and improve controls: Use the surveillance data to feed back into risk assessments and control strategies.
6. Record rigorously: Ensure health records are complete, kept secure, and retained for the legally required period.

How Outsource Safety can help

At Outsource Safety, we understand that implementing health surveillance — especially for respiratory risk — can be complex and resource-intensive. We support organisations by:

• Advising on appropriate surveillance schemes tailored to your industry and risk profile
• Liaising with occupational health professionals to deliver questionnaire + spirometry packages
• Auditing existing surveillance records and recommending improvements
• Integrating surveillance data into your broader COSHH and risk management systems

If you’d like support to review or set up an occupational asthma surveillance programme in your business, get in touch — we’d be happy to guide you through the process.

A huge number of workers are exposed to respirable crystalline silica every day.  We have been working with clients and delivering training for many years to help our clients and the industry understand the risks.  The image to the right shows you the maximum you can be exposed to in a whole day and still remain below the Workplace Exposure Level (WEL) of 0.1 mg/m³

Silica is everywhere — in stone, concrete, bricks, clay, engineered stone, and more. But when materials containing crystalline silica are cut, ground, or disturbed, they can generate respirable crystalline silica (RCS): an extremely fine dust that can penetrate deep into the lungs.

What many don’t realise is that lung damage from RCS exposure often develops before symptoms appear. That’s why health surveillance is a vital tool — not instead of risk control, but to complement it. The HSE’s COSHH Essentials guidance G404 gives clear direction on how employers should plan, perform, record, and act on health surveillance for workers exposed to RCS.

The Health Risks from RCS

The G404 guidance highlights the key diseases linked to RCS exposure:

• Silicosis — irreversible scarring of lung tissue, in severe cases progressing even after exposure stops.
• Chronic Obstructive Pulmonary Disease (COPD) — a long-term condition that gradually impairs breathing.
• Lung cancer and other diseases — RCS is classified as a carcinogen.

Typical early symptoms include shortness of breath, persistent cough (with or without phlegm), frequent chest infections, and wheezing. Because symptoms can be subtle or develop slowly, letting them go unreported or undetected may allow irreversible damage to advance.

When Should Health Surveillance Be Considered?

According to G404, health surveillance should be considered (and sometimes required) when:

1. Workers are regularly exposed to RCS dust and silicosis is a plausible outcome.
2. There have been prior cases of ill health in the workplace or industry.
3. Respiratory protective equipment (RPE) is a relied-upon control measure.
4. Industry or process evidence indicates a risk.

High‐risk sectors include stone and concrete work, construction (cutting, drilling, breaking masonry), quarrying, foundries, ceramic and slate processing, and worktop installation.

Health surveillance must not replace risk assessment or control measures; rather, it is a safety net to detect ill health early and feed back into improving controls.

What Should a Proper Health Surveillance Scheme Include?

A robust scheme — designed in conjunction with a suitably competent occupational health professional — should contain:

• Baseline assessment as soon as possible after exposure begins (ideally within six weeks) to establish a “before exposure” reference.
• Ongoing periodic assessments at intervals advised by the occupational health professional.
• Questionnaires focused on respiratory symptoms and history.
• Lung function tests (spirometry) to measure breathing capacity.
• Chest X-rays or further imaging, when recommended (particularly in cases of suspected overexposure).
• Interpretation of results at both individual and group levels to spot trends or common issues.

If any signs of work-related lung disease are identified, the employer must act — review the risk assessment, revise controls, and possibly redeploy affected workers to less hazardous roles.

Record Keeping & Reporting

To ensure accountability and long-term traceability, G404 mandates that health records be kept for at least 40 years from the last entry.

Records should include:

• Worker identity (name, address, NI number)
• The processes/products the worker handles
• Date exposure began, frequency, and duration
• The PPE used, if any
• Results of health surveillance tests

Workers should also be encouraged to retain their own copies of their health results in case they change jobs.

Key Takeaways for Employers & Safety Practitioners

1. Don’t wait for symptoms — lung damage can progress before workers notice issues.
2. Implement health surveillance only alongside strong controls (like dust suppression, ventilation, proper PPE).
3. Work with competent occupational health professionals to design suitable surveillance schedules.
4. Regularly review and act on surveillance findings — they should inform your risk assessments and control measures.
5. Maintain detailed and long-lasting records, and allow worker access to their own data.

Recent inspections by the Health and Safety Executive (HSE) have uncovered alarming shortcomings in how businesses are protecting their workers from excessive noise. The findings reveal a widespread lack of understanding and implementation of basic hearing protection measures, putting a significant portion of the workforce at risk of permanent hearing damage.

Key Findings from HSE Inspections

The HSE’s inspections painted a concerning picture:

• Widespread High Noise Levels: A quarter of all workplaces inspected had noise levels high enough to necessitate mandatory hearing protection.
• Lack of Training: A staggering 80% of employees had not been properly instructed on how to wear their hearing protection correctly. This includes crucial details like ensuring a proper fit, avoiding interference from clothing or hair, and checking for compatibility with other personal protective equipment (PPE).
• Poor Maintenance Knowledge: 75% of employees in high-noise environments were unaware of the correct procedures for storing, checking, and reporting damage to their hearing protection.
• Inadequate Emphasis on Continuous Wear: Nearly two-thirds (63%) of workers had not been trained on the critical importance of wearing their hearing protection for the entire duration of their exposure to loud noise.
• Failure to Check for Audibility of Alarms: An overwhelming 95% of employers had not verified whether workers could still hear essential safety warnings, such as fire alarms or reversing vehicle alerts, while wearing their hearing protection.

Getting Personal Hearing Protection Right: The “CUFF” System

In response to these findings, the HSE is promoting a simple yet effective system called CUFF to help employers and employees ensure that hearing protection is being used correctly and effectively. CUFF is an acronym that stands for:

• C – Condition: Is the hearing protection in good condition and free from damage?
• U – Use: Is it being used correctly and at all times when required?
• F – Fit the ear: Is it being worn properly to provide a good seal and adequate protection?
• F – Fit for purpose: Is the hearing protection suitable for the level of noise in the workplace?

The HSE emphasizes that hearing protection is the last line of defense against noise-induced hearing loss and must be actively managed to be effective.

Common Mistakes and How to Avoid Them

The HSE’s press release also highlighted several common mistakes that can render hearing protection ineffective:

• Using damaged or old equipment: Hearing protection, like any other PPE, has a limited lifespan and should be replaced when it shows signs of wear and tear.
• Incorrect use: Removing hearing protection, even for a short time, in a noisy environment can significantly reduce its effectiveness.
• Improper fit: Earmuffs worn over hats or hoods, or earplugs that are not inserted correctly, will not provide the intended level of protection.
• Wrong performance: Selecting hearing protection based on factors like comfort or appearance, rather than its technical specifications (such as the Single Number Rating, or SNR), can lead to either under-protection or over-protection, both of which can be dangerous.

How We Can Help

At Outsource Safety, we can provide you with the expert advice and support you need to ensure that your business is fully compliant with the Control of Noise at Work Regulations 2005. Our Safety~net competent person service can help you with:

• Noise risk assessments to identify areas of concern in your workplace.
• Advice on the selection and use of appropriate hearing protection.
• Training for your employees on the importance of hearing protection and how to use it correctly.

Don’t wait until it’s too late. Contact us today to find out how we can help you protect your workers from the life-altering effects of hearing loss.

We all expect other businesses to operate to the same high standards as we do.  You invest in your people and pride yourself on completing jobs on time and to exacting standards of quality and safety.  However, not all businesses, or people, are the same, and sadly, sometimes we can get caught out by a subcontractor who seems to talk the talk but doesn’t deliver on the standards which we should be able to expect.

We work with hundreds of businesses to get them through contractor approval schemes SSIP approval and other accreditations, including PQQ’s (pre qualification questionnaires).  From major bluechips to councils and the public sector, we continue to support scores of clients with SafetyContractor, Constructionline, SMAS, CHAS and other SSIP approval schemes.  Contact us today or request a call back and see how we can take away the burden of SSIP approval from you and your internal teams so you can get compliant and concentrate on winning new business.

Rogue Gas Fitter Jailed for Carrying Out Unsafe Work

Date: 16 July 2025
Case: Antony Clifton of CS Appliance Repairs Ltd – sentenced at Great Yarmouth Magistrates’ Court
Sentence: 46 weeks in prison + £1,000 costs
Incident date: January 2022
Location: Drayton, Norwich, Norfolk

Suspended engineer presses on — and homeowners suffer

Despite being suspended from the Gas Safe Register, 52-year-old Antony Clifton continued carrying out gas installations at domestic properties. In January 2022, he fitted a cooker in a residential home in Drayton, Norwich—but left the inlet pipe leaking gas. The fault was discovered shortly after his visit, prompting emergency repair work (HSE Media Centre).

Clifton had previously received a prohibition notice from HSE preventing him from performing gas work. Despite this, he falsely claimed registration, putting homeowners in significant danger (HSE Media Centre).

Probe reveals serious regulatory breaches

An investigation by the Health and Safety Executive found that the faulty installation created a gas escape risk. Proper checks and protections were not applied—a clear contravention of safety regulations and best practice. This was especially alarming given that Clifton was already known to be suspended from Gas Safe Register duties (HSE Media Centre).

Clifton pleaded guilty to breaches of Regulations 3(7) and 5(3) of the Gas Safety (Installation and Use) Regulations 1998. On 14 July 2025, he was sentenced to 46 weeks in prison and ordered to pay £1,000 in prosecution costs (HSE Media Centre).

Inspector’s strong warning

HSE inspector Martyn Webb emphasised:

“Antony Clifton knew that he was not registered and should not carry out any gas work. However, he showed a blatant disregard… his illegal actions meant the people living in that house could have been killed.” (HSE Media Centre)

He encouraged homeowners and tenants to always verify Gas Safe registration before allowing anyone to carry out gas-related servicing or installations.

Key lessons for stakeholders

Final thoughts

This case underscores the severity of unlicensed gas work and the serious consequences for professionals who flout regulations. Even routine installations become life-threatening when performed without valid registration and oversight.

Gas safety regulation exists for a reason—protecting lives. For anyone involved in domestic or commercial gas work, verifying credentials, adhering to regulations, and never cutting corners are essential. Likewise, homeowners and tenants should be empowered to check credentials before allowing anyone onto their property.