Engineering
Engineering DSEAR risk assessment expertise
We have provided DSEAR risk assessments for a wide range of engineering businesses, including repair workshops, fabrication facilities, motor and pump service centres, and specialist engineering manufacturers across the UK.
These environments typically involve the use of flammable gases, paints, solvents and varnishes alongside heat processes such as ovens, curing systems and welding activities. Our work focuses on identifying where hazardous atmospheres may arise, assessing ignition risks and ensuring appropriate controls are in place to support safe, compliant operations.
Sulzer Pumps – Ashford
The challengeAs part of the Sulzer Dowding Mills group the site provides a repair service to a range of industries and has both electrical and pumps divisions on the same site. The electrical division has …
Sulzer Dowding – Middlesbrough
The challengeA visit was made to the Sulzer, Dowding & Mills site at Middlesbrough, Cleveland in March 2015 to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). Sulzer have …
Sulzer Dowding – Falkirk
The challengeA visit was made to Sulzer, Dowding & Mills site, Falkirk in February 2015 to consider compliance in respect of the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). The Falkirk site is an …
Skanska Fabrications
The challengeA visit was made to the Skanska Fabrications site at Slough, on 5th January 2016 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). The site’s core business is fabricating …
Twiflex
The challengeAt the Twiflex factory in Bedford, rotating equipment clutch and braking assemblies are manufactured. An internal audit identified a need for DSEAR RA for the manufacturing processes and DSEAR RISK ASSESSMENTS were chosen in …
Newland Engineering
The challengeA visit was made to the Newland Engineering Company, Hyde, in 2020 to consider compliance with the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR), incorporating Amendment 1: June 2015. At the site, Newland …
DSEAR risk assessments for engineering workshops and manufacturing facilities
Engineering environments often present DSEAR risks through a combination of flammable substances and routine processes that introduce ignition sources.
Typical risk areas include:
- Welding, cutting and hot work operations
- Use and storage of flammable gases such as propane and acetylene
- Paint spraying, coating and finishing processes
- Solvent cleaning and degreasing
- Varnish dipping, impregnation and curing operations
- Ovens, furnaces and heat treatment systems
- Storage and handling of gas cylinders and flammable liquids
Flammable gases and vapours are commonly present across engineering sites, often in multiple locations and used by different teams. Even relatively small releases – such as from hoses, cylinders or open containers – can create explosive atmospheres if ignition sources are present.
In addition, processes such as paint spraying, varnish application and solvent use can generate flammable vapours, particularly in enclosed or poorly ventilated areas. When combined with hot surfaces, electrical equipment or static discharge, this creates a clear fire and explosion risk.
DSEAR assessments in this sector focus on how these activities interact in real working conditions. This includes reviewing storage arrangements, ventilation and extraction, control of ignition sources, maintenance procedures and the use of permit-to-work systems for hot work.
Where required, hazardous area classification is applied to define higher-risk areas, and clear, prioritised recommendations are provided to help businesses reduce risk and maintain compliance without disrupting day-to-day operations.
Frequently asked questions
The main risks come from flammable gases, vapours and liquids used in processes such as welding, paint spraying, solvent cleaning and heat treatment.
Yes. Gases such as propane and acetylene can form explosive atmospheres at low concentrations. Storage, handling and use of cylinders must be carefully controlled.
Not always, but it is often needed around specific activities such as paint spraying, gas use, or where flammable vapours may be released in normal operation.
Through a combination of good ventilation, equipment maintenance, segregation of hazardous substances, control of hot work via permit systems, and ensuring equipment is suitable for the environment.