Maintenance is a high-risk activity

Maintenance-specific hazards and risks

In addition to the risks associated with any working environment, maintenance operations involve some specific risks. 

These include working alongside a running process and in close contact with machinery. During normal operation, automation typically diminishes the likelihood of human error that can lead to accidents. In maintenance activities, contrary to normal operation, direct contact between the worker and machine cannot be reduced substantially - maintenance is an activity where workers need to be in close contact with processes.

Maintenance often involves unusual work, non-routine tasks and it is often performed in exceptional conditions, such as working in confined spaces.

Maintenance operations typically include both disassembly and reassembly, often involving complicated machinery. This can be associated with a greater risk of human error, increasing the accident risk.

Maintenance involves changing tasks and working environment. This is especially true in case of contract workers. Subcontracting is an aggravating factor in terms of safety and health – numerous accidents and incidents relate to subcontracting maintenance.

Working under time-pressure is also typical for maintenance operations, especially when shutdowns or high-priority repairs are involved.

Hazards, risks and health outcomes

Because maintenance is carried out in all sectors and workplaces and involves a wide range of tasks, it is associated with a great variety of hazards.

Physical hazards

• noise, vibration
• excessive heat and cold
• radiation (ultraviolet radiation, x-rays, electromagnetic fields)
• high physical workload
• ergonomics-related risks: due to poor design of machinery, process and work environment from the point of view of maintenance difficult to reach the objects to be maintained - strenuous movements (bending, kneeling, reaching, pushing and pulling, working in confined spaces)

:: Typical tasks:

• drilling, grinding, filing, sanding
• working outdoors, maintenance of industrial plant (e.g. ovens and furnaces, chilling units)
• welding, inspection of pipes, rail maintenance

:: Potential health outcomes: hearing problems due to noise, musculoskeletal disorders

Chemical hazards

• Asbestos, glass fibre
• Vapours, fumes, dust (e.g. asphalt fumes, diesel exhaust, crystalline silica)
• Solvents

:: Typical tasks

• building maintenance
• electrical arc welding
• carrying out work in confined spaces
• working in car repair shops
• maintenance of industrial installations where hazardous chemicals are present

:: Potential health outcomes: breathing problems, occupational asthma, allergies, asbestosis, cancer

Biological hazards

• Bacteria (e.g. legionella, salmonella)
• Mould and fungi

:: Typical tasks:

• maintenance in waste treatment plants
• maintenance where biological agents are handled such as laboratories
• maintenance in places where bacteria, moulds, and fungi are likely to proliferate, such as air-conditioning systems

:: Potential health outcomes: breathing problems, asthma, allergies, Legionnaires’ disease

Psychosocial risk factors

• Time pressure
• Shift work, weekend work, night work, on-call work and irregular working hours
• Working together with staff from contractors / several contractors – communication issues

:: Potential health outcomes: work-related stress, fatigue, increased accident risk

High risk of all types of accidents

• Many accidents are related to work equipment and machine maintenance, e.g. crushing by moving machinery, unexpected start-up
• Falls from height, accidents involving falling objects
• Electrocution, electrical shocks, burns
• Confined spaces, asphyxiation
• Explosion, fire