Working safely with metalworking fluids – what you need to know

In December 2023, The Health and Safety Executive warned that anyone working in the metalworking industry may be at increased risk of skin and lung conditions, and should get a health check.¹

If you run a manufacturing business, prioritising the safety of your people from potential health risks associated with fluid exposure should be one of your most important health and safety considerations. These risks can include skin irritation, respiratory issues and other long-term health effects that can impact the lives of your employees and your business.

In a significant move to safeguard workers' health, HSE has been intensifying inspections across manufacturing businesses that utilise metalworking fluids in their machining processes. This initiative, which ran at the beginning of this year, underscores the critical need for rigorous health surveillance in the industry.²

In this article, we explore our essential tips for working safely with metalworking fluids, and what you need to know regarding your legal requirements to your employees.

Key takeaways

1. Personal Protective Equipment (PPE): Choose the right PPE to ensure you minimise exposure to potentially harmful chemicals present in metalworking fluids.
2. Local Exhaust Ventilation Systems: Implement adequate mist extraction systems and engineering controls to minimise exposure to airborne contaminants generated during machining processes.
3. Monitoring and maintenance: ensure metalworking fluid quality alongside maintenance like filtration and skimming to prolong fluid lifespan and effectiveness. Dispose of spent fluids responsibly according to local regulations to minimise environmental impact and maintain equipment efficiency and longevity.

What are metalworking fluids?

Metalworking fluids (or MWFs) are neat oils or water-based fluids used during the machining and shaping of metals, providing lubrication and cooling during the metalworking process. They are sometimes referred to as suds, coolants, slurry or soap.³

What are the main health risks associated with metalworking fluids?

Exposure to metalworking fluids can cause:

• Severe skin irritation or dermatitis
• Lung diseases, such as occupational asthma, occupational hypersensitivity pneumonitis, bronchitis, irritation of the upper respiratory tract and other breathing difficulties.

What does the law require?

Health surveillance is a scheme of repeated health checks which are used to identify ill health caused by work.

Where there is exposure to fluid or mist, it is a legal requirement to carry out health surveillance even when preventative controls, such as fluid quality checks and local exhaust ventilation (LEV), are in place.⁴  

Consider proper handling and protection for your employees

How improper handling of metalworking fluids can lead to harm:

• Inhaling mist generated during machining/shaping operations can lead to breathing difficulties
• Direct contact with unprotected skin and broken skin/abrasions can lead to irritation of the skin
• Accidental ingestion of metalworking fluids through poor personal hygiene e.g. not washing hands properly

MWFs should be handled with care to prevent exposure to skin, eyes, and inhalation. Always wear appropriate personal protective equipment (PPE), including gloves, safety goggles, and respiratory protection, when handling these fluids.

Additionally, store MWFs in designated areas away from heat sources and direct sunlight to prevent degradation. Proper labelling of containers is essential to avoid confusion and accidental misuse.

Implement appropriate local exhaust ventilation and engineering controls

Enclosures, ventilation systems, and local exhaust systems help capture and remove airborne contaminants generated during machining processes. Proper machine guarding also prevents accidental contact with moving parts and reduces the risk of fluid splashes.

Ensure fluid quality is maintained

Regular maintenance of metalworking fluids is essential for preserving their effectiveness and preventing microbial growth. Develop a routine schedule for fluid monitoring, which includes testing for pH levels, concentration, and microbial contamination.

Implement proper filtration and skimming systems to remove contaminants and extend fluid life. Dispose of spent fluids responsibly according to local regulations to minimise environmental impact. As a manufacturing business, you may unintentionally have a negative impact on the natural ecosystem in which you operate, be it suddenly or gradually over time.

Environmental impairment liability insurance can protect your business and provide cover for these types of liabilities, as well as other costs – such as legal fees - that could be involved.

Working safely with metalworking fluids is essential to protect the health and well-being of workers and maintain a productive machining environment. By understanding the different types of fluids, implementing proper handling and storage practices, maintaining fluid quality, implementing engineering controls, and providing comprehensive training, you can minimise risks and ensure a safe working environment for all. Remember, safety is everyone's responsibility.

Visit HSE’s Workright ‘Working with Metalworking Fluid’ campaign website for further information and resources.