CASA B-07a Occupational Health and Safety in Aviation PDF

MODULE 07 Category B Licence CASA B-07a Occupational Health and Safety in Aviation Copyright © 2020 Aviation Australia All rights reserved. No part of this document may be reproduced, transferred, sold or otherwise disposed of, without the written permission of Aviation Australia. CONTROLLED DOCUMENT 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 2 of 217 Knowledge Levels Category A, B1, B2 and C Aircraft Maintenance Licence Basic knowledge for categories A, B1 and B2 are indicated by the allocation of knowledge levels indicators (1, 2 or 3) against each applicable subject. Category C applicants must meet either the category B1 or the category B2 basic knowledge levels. The knowledge level indicators are defined as follows: LEVEL 1 Objectives: The applicant should be familiar with the basic elements of the subject. The applicant should be able to give a simple description of the whole subject, using common words and examples. The applicant should be able to use typical terms. LEVEL 2 A general knowledge of the theoretical and practical aspects of the subject. An ability to apply that knowledge. Objectives: The applicant should be able to understand the theoretical fundamentals of the subject. The applicant should be able to give a general description of the subject using, as appropriate, typical examples. The applicant should be able to use mathematical formulae in conjunction with physical laws describing the subject. The applicant should be able to read and understand sketches, drawings and schematics describing the subject. The applicant should be able to apply his knowledge in a practical manner using detailed procedures. LEVEL 3 A detailed knowledge of the theoretical and practical aspects of the subject. A capacity to combine and apply the separate elements of knowledge in a logical and comprehensive manner. Objectives: The applicant should know the theory of the subject and interrelationships with other subjects. The applicant should be able to give a detailed description of the subject using theoretical fundamentals and specific examples. The applicant should understand and be able to use mathematical formulae related to the subject. The applicant should be able to read, understand and prepare sketches, simple drawings and schematics describing the subject. The applicant should be able to apply his knowledge in a practical manner using manufacturer's instructions. The applicant should be able to interpret results from various sources and measurements and apply corrective action where appropriate. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 3 of 217 Table of Contents Occupational Health and Safety Responsibilities (7.1.1.1) 9 Learning Objectives 9 Summary 9 Safe Work Practices 10 Workplace Accidents 10 The Victim 10 The Workplace 10 The Supervisor 11 The State 11 Manual Handling 13 Case Study: Improper Manual Handling 13 Manual Handling Demonstration 13 WH&S Obligations for Manual Handling 14 Manual Handling Injuries 16 Safe Lifting and Lifting Limits 18 Handling Loads 21 Responsibilities in the Workplace 24 Responsibility of the Employer 24 Responsibility of the Employee 24 Environmental Responsibilities 25 Basic Workplace Safety Precautions 28 Ways to Make Your Workplace Safer 28 Safety Precautions in Workshops 30 Advanced Composite Materials Hazards and Safety Precautions What Is a Composite Material? 33 Advanced Composite Materials 34 Advanced Composite Hazards 36 Example: Composite Damage 40 Process Material Precautions 41 Waste Disposal 43 Waste Hazards and Disposal 43 Job Knowledge And Training 43 Identification and Reporting of Workplace Hazards (7.1.1.2) Learning Objectives 2024-04-22 33 B-07a Maintenance Practices CASA Part 66 - Training Materials Only 45 45 Page 4 of 217 Workplace Accidents 46 Hazards in the Workplace 46 Cause and Effect of Accidents 46 Inadequate Training and Experience 49 Causes of Accidents 49 Accident Prevention 53 Health and Hygiene 56 Work Health and Safety 58 Workplace Health and Safety Committees 60 Noise Safety and Precautions 63 Workplace Noise 63 Noise Control in the Workplace 64 Hazards in the Workplace 66 Machinery and Equipment 66 Electricity 66 Hazardous Substances 67 Working in the Sun 68 Safety Data Sheets 69 Reporting Hazards and Accidents in Aircraft Maintenance 71 The Hazard Report Form 71 Report of Injury, Illness or Dangerous Event Form 71 Summary Safety Precautions Associated with Aircraft Maintenance Operations (7.1.1.3) Learning Objectives 72 73 73 Safety Signs 74 Signs 74 Standard Symbols and Colour Markings 75 Safety Colours 80 Posting Signs 82 Making Signs 82 Signage in Aircraft Maintenance 2024-04-22 85 Maintenance Signage 85 Cockpit Signage 86 Aircraft Lockout Devices 89 Aircraft Cabin Door Safety 89 Biological Hazards 91 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 5 of 217 Common Aircraft Symbols 92 Aircraft Placards 93 Fluid Line Identification 94 General Safety Precautions in Aircraft Maintenance 96 Aircraft Propellers 96 Maintenance Documentation 97 Foreign Object Damage 97 Tyre Inflation Safety Precautions 101 Aircraft Tyres 101 Compressed Air Hazards 102 Aircraft Oxygen Safety Precautions 104 Aircraft Oxygen Systems 104 Oxygen Safety 105 Aircraft and Oxygen Cart Grounding 106 Importance of Cleanliness 107 Operate an Oxygen Valve Slowly 107 Oil and Grease Precautions Around Oxygen Cylinders 108 Oxygen-Safe Lubricants 109 Aircraft Oxygen Storage Cylinders 110 Oxygen Cart 111 Oxygen Replenishment Cylinders 112 Hydrostatic Testing 113 Oxygen Safety Precautions 115 Electrical Safety 117 Human Functions of Life 117 Electric Shock 117 Chemical Safety 120 Chemicals 120 Solvents 120 Battery Safety 121 Aviation Oils and Fuels Hazards 122 Hydraulic Fluids and Lubricants 124 Aircraft Refuelling and Defuelling Safety 2024-04-22 126 Refuelling and Defuelling 126 Fuel Tank Safety 127 Defuelling Safety 128 Safe Tooling Near Flammable Gases or Liquids 130 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 6 of 217 Safe Task Lighting Near Flammable Gases or Liquids Explosion Hazards and Safety 132 133 Explosion Hazard Definitions 133 Fuel Tank Venting 133 Exposure Limit 135 Fuel Tank Confined Space Entry 136 Fuel Tank Entry 136 Fuel Tank Safety Equipment 137 The Entry Crew Duties 138 Summary 140 Ionising and Non-Ionising Radiation Safety 141 Radiation Spectrum and Types 141 Ionising Radiation 141 Non-ionising Radiation 142 Radiation Sources on Aircraft 146 Radiation and Radar Hazards in Aviation Personal Protective Equipment (7.1.1.4) Learning Objectives Hazardous Substances Safety Precautions 148 152 152 153 Poisonous and Hazardous Substances 153 How Do Hazardous Substances Enter the Body? 154 Inhalation (Breathing) 155 Skin Contact 157 Injection 158 Consumption (Swallowing) 159 Illness and Disease 160 Protective Equipment 163 2024-04-22 Personal Protective Equipment 163 PPE Responsibilities 164 Head Protection 165 Hearing Protection 166 Eye Protection 167 Hand Protection 168 Body Protection 170 Foot Protection 171 Breathing Protection 172 Machinery 172 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 7 of 217 Storage and Care of PPE 174 Summary Emergency Equipment (7.1.2) Learning Objectives 176 177 177 General Emergency Tools 178 First Aid Station 178 Emergency Procedures 178 Fire Safety 181 Fire Emergencies 181 Fire Hazards 181 Fire Risk Assessment 184 Fire Emergency Plan 187 Aircraft Maintenance Fire Hazards 188 Actions to Take on Discovering a Fire 190 Fire Extinguishing Tools 192 Fire Classification 192 Types of Extinguishers 196 Uses of Fire Extinguishers 196 Water Extinguishers 197 Carbon Dioxide Extinguishers 198 Dry Chemical Powder Extinguishers 199 Class D Fire Extinguishers 200 Foam Extinguishers 201 Wet Chemical Extinguishers 202 Vaporising Liquid Extinguishers (Halotron) 203 Fire Blankets 204 Fire Extinguisher Locations and Signage 205 Fire Extinguisher Usage 2024-04-22 208 Pull Aim Squeeze Sweep 208 Using a Foam Fire Extinguisher 211 Using a Carbon Dioxide Fire Extinguisher 212 Using a Dry Powder Fire Extinguisher 213 Rules for Responding to a Fire 214 After Discovering the Fire 214 Deciding to Fight a Fire 215 Evacuations 216 Summary 217 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 8 of 217 Occupational Health and Safety Responsibilities (7.1.1.1) Learning Objectives 7.1.1.1 Examine organisational and individual responsibilities for ensuring safe working practices (Level 3). Summary This lesson will discuss the aspects of safe working practices and safety precautions taken around aircraft and within the workshop. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 9 of 217 Safe Work Practices Workplace Accidents Most workplace accidents are avoidable. If people took time to identify hazards that exist in the workplace and deal with them, workers would enjoy a happier and safer workplace. The cost of workplace accidents is high. For every dollar paid out in workers’ compensation, the employer can pay out many times that amount in hidden or indirect costs. The following sections outline parties that are affected by a workplace accident or injury. Aviation Australia Workplace accidents affect more than just the victim The Victim The victims of accidents can suffer: Death Disability Pain Loss of earnings Reduction of self-esteem. Their families often suffer as well. Aviation Australia Consequences for the victim 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 10 of 217 The Workplace The workplace may: Lose a trained worker and output Suffer damage to plant and machinery Incur fines and prosecutions Be sued by workers or their families. Resultant loss of reputation can ruin a business or organisation. Aviation Australia Consequences for the workplace The Supervisor The supervisor or other workers may: Lose valuable production Have to do extra work Lose time doing reports Feel responsible. Aviation Australia Consequences for the supervisor 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 11 of 217 The State Accidents can also affect the State’s workforce and even upset the balance of trade if exported goods cannot be produced. The community pays dearly for workplace accidents. Enforcing and obeying the law helps to reduce these costs. Aviation Australia Consequences for the state 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 12 of 217 Manual Handling Case Study: Improper Manual Handling Case: Back injuries caused by improper manual handling. Manual handling is an extremely common cause of workplace injuries. Back injuries in the workplace case study Australia has up to 100 000 cases of occupational back injuries a year. Of these, 45% involve 5 or more days off work and almost 10% result in periods of up to 6 months lost from work. Every year, over 13 000 claims are lodged with WorkCover. Compensation costs alone are $22,000,000, and total costs to industry and the community are several times greater. Poor workplace design, poor work practices and inadequate training cause most back injuries. Since these causes can be controlled, the majority of back injuries can be avoided. Manual handling is ‘any activity requiring the use of force exerted by a person to lift, lower, push, pull, carry, or otherwise move, hold, or restrain any animate or inanimate object’. Since 1991, part of employers' and workers' obligations has been the control of risks associated with manual handling injuries. The Work Health and Safety Act 2011 requires all at a workplace to ensure the health and safety of others. The penalty for a breach of the Work Health and Safety Act causing serious injury or death is a fine of up to $300 000 for a body corporate or $60 000 and/or 12 months of imprisonment for an individual. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 13 of 217 Manual Handling Demonstration View the following demonstration video about manual handling in the workplace. Relevant Youtube link: Manual Handling in the Workplace 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 14 of 217 WH&S Obligations for Manual Handling Worker Obligations Workers should follow instructions and act in a way that does not place their own or any other person's health and safety at risk. All workers must make sure that, wherever possible: Methods of work and work procedures are followed. Mechanical aids and any assistive devices made available are used. If mechanical aids are not provided or practical, team lifting procedures are used. Manual handling training sessions are attended and learned principles are applied in the workplace. Employer Obligations Employers should provide a workplace designed to minimise risk of back injury. This includes design of work organisation, workstation layout, plant, equipment and containers used in the workplace. Where manual handling cannot be designed out of work and is necessary to complete a task, employers must provide a combination of the following where applicable: Mechanical lifting devices Enough staff for team lifting procedures Training and supervision for team lifting Adequate information, instruction and training Supervision to enable workers to work safely. © Stanley Hand trolley used for mechanical assistance to lift heavy objects safely 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 15 of 217 Discussions should be held among: The workers carrying out manual handling work Health and safety representatives Employers to set out the workplace's manual handling policy. Aviation Australia Team discussion before manual handling occurs 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 16 of 217 Manual Handling Injuries As mentioned in the case study, manual handling leads to a large number of industrial accidents, including strained backs, damaged spinal discs, strained shoulders, hernias, and injured hands and feet. Many manual handling injuries result in permanent disabilities and thousands of workdays lost. Where manual handling must occur, adopting preferred lifting, moving and handling techniques is strongly recommended. Rhythmic human movements need to be adopted in manual handling of materials. Avoid sudden or jerky movements. Control of manual handling risks not only reduces back injuries but improves productivity and efficiency in the workplace. The most common injuries caused by improper manual handling are back injuries, specifically, spinal injuries. The Spine and Manual Handling Standing is a natural posture for the human spine. The spine is not suited to lifting loads when the upper part of the body is acutely bent or twisted because of the forces exerted on the lower back (lumbar region). When the back is bent, the mere weight of the upper part of the body puts stress on the lumbar discs. It is not surprising that 95% of all disc injuries occur in the three lowest discs, where spinal movement and stress are greatest. The illustration shows the configuration of the spine in a straight back and the configuration of the spine in a bent back. © Aviation Australia The configuration of the spine in a straight-back lift versus a bentback lift. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 17 of 217 Disc compression and rupture If you lift with a bent back as shown, the inter-vertebral discs are compressed on the front of the spine and stretched over the back of the spine. Also, the bones of the spinal column at the back are separated from each other. This means extra pressure is placed on the soft tissues and can result in severe strains or ruptured discs. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 18 of 217 Safe Lifting and Lifting Limits How Much Can a Worker Lift? From a standing position, you should avoid lifting loads that weigh more than 16–20 kg. As weight increases from 16 kg to 55 kg, the percentage of healthy adults who can safely lift, lower or carry the weight decreases sharply. Lifting loads Mechanical assistance should be provided to reduce the risk of injury associated with these heavier weights. Trained and supervised team lifting should be used when mechanical assistance is not practical. Repetitive manual handling, workers with special needs, and lifting from unusual positions require special consideration. For example, while you are seated, you should generally not lift loads over 4.5 kg. Safe Lifting of Low-Lying Objects (7 Steps) Adapting workplace design and using mechanical lifting aids are the best ways to deal with manual handling problems. But when manual lifting is unavoidable, it is essential to follow manual handling principles when lifting low-lying objects to reduce the risk of back injury. The following steps can help you lift objects safely. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 19 of 217 Step 1 Make sure your path of travel is clear. Step 2 Assess the load (weight, size and shape). Consider your physical ability to handle it. If in doubt, get assistance. Avoid lifting loads that weigh more than 16–20 kg. Step 3 Place your feet close to the object to be lifted. Step 4 Adopt a balanced position by bending your knees in a semi-squat to a comfortable degree and get a good handhold. Lift the load, keeping it close to the body. Try to maintain the natural curves in your spine while lifting. Step 5 Use your leg muscles to lift the load and allow it to rest in fully extended arms. Lift smoothly and rhythmically. Avoid sudden accelerations or jerky movements. Step 6 With the load comfortable in your hands and arms, move your feet in the direction of travel. Do not twist at your hips or shoulders. Step 7 Setting the load down safely is just as important as picking it up safely. Using your leg muscles, lower the load by bending your knees in a semi-squat to a comfortable degree. Do not let go of the load until it is secure. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 20 of 217 The 7 Steps (Pictured) © Aviation Australia Safe manual handling procedure 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 21 of 217 Handling Loads You should always assess the load you are to carry and lift it only if it is within your capabilities to do so. If in doubt, use mechanical aids such as a trolley. However, with repetitive manual handling, workers with special needs or those lifting from seated or unusual positions should handle only much smaller loads. If you are not sure, ask your Workplace Health and Safety Officer about this. High-Risk Work Practices Some things to avoid when you are lifting or manual handling include: Handling awkward shapes or big loads. Handling weights which are too heavy and beyond a worker’s capacity. Over-reaching while handling (i.e. lifting from below mid-thigh or above shoulder height). Handling with an unstable work surface underfoot. Repetitive and/or long duration of manual handling. Carrying objects extended away from the body. Awkward twisting movements while handling. Insecure grip and poor lifting position, with feet too close together while handling. High-Risk work practices 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 22 of 217 Avoiding Injury To reinforce procedure, when you do decide to lift a low-lying object remember the seven steps. For general lifting and while you are lifting, to avoid injury always remember: Avoid twisting movements, bending and jumping. Check beforehand to see if your path is obstructed. Do not reach or begin lifting from an unstable work surface. High-risk work practices Summary Workplace health and safety legislation has been developed to protect the safety of all employees in the workplace. However, it has been established that all personnel have certain responsibilities, including a duty to notify and due diligence. This places the onus on all personnel to accept responsibility for their own action or accept the consequences. Accepting responsibility is less debilitating than dealing with the consequences and is also much safer. Not only are you protecting yourself in the workplace, but you are also protecting your co-workers. It is all too easy to injure your back. The spine is a delicate balance of vertebrae held in place with cartilage. It is up to you to protect the long-term health of your back. Do not lift above your capacity. Instead, ask for help or use appropriate equipment. Be sure to follow the correct lifting techniques to avoid minor and major damage to your spine. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 23 of 217 Responsibilities in the Workplace Responsibility of the Employer Ensuring the health and safety of workers is the obligation of the employer. Managers, supervisors or team coordinators are responsible for making sure that you have: Adequate lighting A clean and tidy work area Safe machines and materials Safety signs and safety equipment Chemicals stored separately, safety guards and standard operating procedures (SOPs) Job rotation Safe working practices and facilities for workers First aid equipment, toilets and wash basins Lunchrooms Information, instruction and training. Aviation Australia Aircraft hangar 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 24 of 217 Responsibility of the Employee A worker has the following obligations in a workplace: To comply with the instructions given for workplace health and safety at the workplace by the employer or supervisor. To use Personal Protective Equipment (PPE) if the equipment is provided by the worker's employer and the worker is properly instructed in its use. Not to interfere wilfully or recklessly with or to misuse anything provided for workplace health and safety at the workplace. Not to wilfully place at risk the workplace health and safety of any person at the workplace. Not to wilfully injure oneself. Aviation safety is everyone's responsibility Environmental Responsibilities The following section outlines some of the environmental safety precautions and procedures that are to be observed in the workplace environment. Environmental Management Systems Organisations need to develop environmental management systems to cover all of their activities. The system should meet international standards (ISO 14001) and address environmental issues by integrating the environment into daily business operations. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 25 of 217 Your General Environmental Duty When applied to your workplace, your general environmental duty is to ensure that you take all reasonable and practicable measures to prevent or minimise environmental damage resulting from your work. How can you do that? Be more aware and better informed – know about your environmental responsibilities. Help identify environmental risks and impacts in your work. Help develop and implement reasonable and cost-effective ways to minimise environmental risks. Ask for help if you are not sure. Your Duty to Notify You must tell a supervisor or team leader immediately if you become aware of an activity that is causing or could cause environmental harm (e.g. a gas leak or chemical spill). If your supervisor is unavailable or takes no action, notify your senior manager. Duties of Management Managers, supervisors and team leaders must: Plan and act to minimise environmental risks and impacts as part of your daily operations and emergency procedures. Ensure that staff fully understand and are fulfilling their legal duties. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 26 of 217 Environmental Due Diligence Exercising due diligence means taking all reasonable care by establishing a proper system to prevent an environmental problem occurring and taking responsible steps to ensure the effective operation of that system. Systems used to implement a due diligence program help organisations comply with all environmental legislation, reduce long-term costs and improve their public image. Image from Pixabay on Pexels Chemicals pose an environmental risk 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 27 of 217 Basic Workplace Safety Precautions Ways to Make Your Workplace Safer Adopt Good Housekeeping Practices Good housekeeping often minimises hazards by removing the cause of accidents. Some practices include: Keeping rubbish away from work areas. Ensuring access to fire extinguishers and exits is not obstructed. Keeping passages and stairways clear. Wiping up spilt oil, liquids and grease. Cleaning up areas after working. Using metal containers for greasy or paint-stained rags or waste. Not accumulating waste or scrap. Keeping work areas/benches and machines uncluttered. Not leaving loose tools on running machinery or equipment. Attend Health and Safety Training Wear Personal Protective Equipment (PPE). Typically, office workers do not need PPE, other than footwear which completely covers the foot. However, many occupations within any organisation require office-based workers to go into the field. In this case, you will be given specific PPE. You must be properly trained in the PPE you use and know where to access it. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 28 of 217 Keep Fit and Healthy Drugs and alcohol can cause dependence and prevent people from being able to do a full day’s work properly. They are strictly prohibited at work. Develop good posture at work, whether you spend long periods standing or sitting at a desk. Keep yourself well groomed, clean and neatly attired. Observe hygienic practices such as washing your hands regularly. This is particularly important for employees involved with sewage treatment, transport or maintenance. Ensure that your immunisations, such as for hepatitis, are up to date. Do not ignore medical problems that may be nagging you. See a doctor before they lead to other problems. Maintain a healthy balance between work and your personal life. This will keep you happier and less stressed both at work and at home. If you find work stressful because you have too much or too little work to do, or because work is monotonous or lacking in stimulation, talk to someone about it. This may be a supervisor, team leader or counsellor. Compensation payouts for stress-related illness are substantial and can be reduced if people heed the signs before a major problem occurs. Safety Precautions and Short and Simple Rules No unauthorised access to workshops without supervision. No unauthorised use of equipment. Wear protective equipment (PPE). Wear only closed-toe shoes. No jewellery or loose-fitting clothing. Contain long hair and beards. Walk – do not run. If you do not understand, ask! No food or drink. Read all material Safety Data Sheets and labels. Be aware of emergency procedures, exits and emergency buttons. Read and understand any safety signs, instructions and notices. Think before you act. Clean up as you work to avoid dangerous clutter. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 29 of 217 Accidents Associated with Poor Housekeeping Practices Slips, trips and falls due to debris and greasy floors, especially if lighting is poor. Cuts and lacerations from protruding parts, stores or objects. Fire danger from waste products or poorly stored materials. Health risks from the dusts and fumes of hazardous materials that are badly stored or used. Short and simple consequences: You may lose access privileges to workshops if you violate any safety rule or cause injury or damage to persons or equipment. © Aviation Australia Housekeeping is a simple way to make the workplace safer Safety Precautions in Workshops Construction laboratories and workshops are places to experiment, be creative, and use skills and talents to construct models, furniture and other design prototypes. However, these activities in design and development are often unpredictable. Use of exotic materials, unorthodox use of tools and equipment, and rapid changes in activities as new design ideas develop sometimes make it difficult to respect safety regulations. Safety is Common Sense Stop and think before you act, and ask the technical staff for advice before you start on an unfamiliar process. They have an enormous amount of knowledge and experience and can help guide you to achieve your ideas safely. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 30 of 217 The Wrong Tool for the Job It is sometimes tempting to use available equipment or tools in a way not originally foreseen or for which they have not been adapted or designed. All equipment and tools can be used to undertake a variety of tasks, but if you do not know their limits or use them the right way, trouble is just around the corner! If you have the slightest doubt about the suitability of a tool for the operation, ask for advice from technical staff. They will ensure that the necessary precautions are taken and adequate safety equipment made available, or they may suggest alternative equipment that can be used. Do not think of the safety organisation as being there to stop you from doing interesting things. It is there to help you achieve success. As well as the workshop where you are working, technical staff have access to other resources within the organisation that can usually carry out special processes that cannot be handled in workshops. Consult. Ask for advice and help from technical staff. That is their job, and they want to see how proud you are of the finished project. Clean Up Your Mess Areas around machines and walkways are specially marked to prevent accidents. Do not block them with materials or obstacles that may restrict access or emergency evacuation, or simply clutter up the workspace and make safe and efficient work more difficult. At the end of the session, that magical someone is supposed to wave a magic wand to clean up the mess. Technical staff are not employed to clean up after you. Cleaning equipment is provided, and time is usually allocated at the end of your shift to clean benches and machinery and sweep the floor around your work area. Making a mess, when using a workshop, is a fact of life. You cannot produce a masterpiece without cutting, sanding, sawing or drilling that special creation. However, accidents usually occur when people do silly things, are in a hurry or are surrounded by a huge pile of off-cuts that get in the way of the next stage of the process. Housekeeping 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 31 of 217 Is It Safe? Some materials, solutions and solvents are unsafe when they mix or come into contact with other substances. They must be used in well-ventilated areas and under fume extraction hoods. Any materials or solutions you bring into the laboratory or workshop must be shown to the technical staff to assess if there is any risk in their use in the area. Technical staff have access to Safety Data Sheets (SDSs or ChemAlert) for the common materials used within the laboratory or workshop. Before you decide to try some special type of material, ask what safety hazards may be likely and whether special precautions and processes need to be undertaken. Verify that all safety equipment you need for a particular job is present before starting the activity. When Things Go Wrong Even when all the safety precautions are in place, sometimes things go wrong and emergency procedures must be implemented. Get to know the work environment. In particular, know where to find the: Fire extinguisher First aid kit Emergency stop buttons Telephone and emergency number Emergency exits. Eye wash station A Place For Everything Laboratories and workshops are operated by well-organised technical staff who provide multiple sets of tools and equipment for your use. Leaving tools lying around on the workbench when they are not required is inviting an accident to happen. When you have finished using a tool, put it back in the rack or cupboard for others to use and keep your work area uncluttered. If a tool is broken or blunt, or if you break it, tell the technical staff; they usually will not bite your head off. They understand that these things happen all the time as students are learning and experimenting with new skills. If a tool is damaged or unsafe to use, then it is your responsibility to inform them. Do not just return it to the cupboard, as the next user could be seriously injured. Aviation Australia Sometimes things go wrong 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 32 of 217 Advanced Composite Materials Hazards and Safety Precautions What Is a Composite Material? This topic will take you through the hazards and safety precautions associated with advanced composite materials. But to do this, you need to know what an advanced composite and a composite material is. The term composite is used to describe two or more materials that are combined to form a much stronger structure than either material by itself. Simple composites are composed of two elements: A matrix which serves as a bonding substance (glue) A reinforcing material. Fibreglass is a widely used composite material that is used in sporting equipment, boats, aircraft parts, and even furniture and playground equipment. The reinforcing material is a glass fibre cloth material which can be folded or scrunched up just like a piece of clothing. The matrix or glue is a resin compound, in liquid form, consisting of two liquid parts which, when mixed together, form a solid plastic compound after curing. When the glass fibre is impregnated (or soaked) with the mixed resin, the result of curing is a high-strength reinforced plastic. Glass fibre and resin 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 33 of 217 The concept of composite materials is not new. The oldest man-made building material, adobe (mud brick), is a composite formula. Adobe is produced by combining two dissimilar components (mud and straw) to form building bricks. After the bricks are allowed to cure in the sun, the resulting building block is substantially stronger and more durable than either of the original components. The centuries-old ruins of the Anasazi Indians in south-western Colorado are proof of the durability of this simple composite material. Advanced Composite Materials As technology in aircraft has developed, so has the technology in the materials they are made from. To make an aircraft fly faster, higher and longer, we need to reduce its overall weight while still maintaining airframe strength. The use of expensive, high-performance resin systems and highstrength, high-stiffness fibre reinforcement instead of metal alloy structure has allowed this to happen due to the superior strength-to-weight ratio of advanced composite materials. The much stronger and stiffer fibres of boron, graphite (carbon) and Kevlar have given composite materials structural properties superior in several ways to the metal alloys they have replaced. These are the materials that make up advanced composites. Boron fibre, graphite carbon fibre and kevlar™ 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 34 of 217 Where Are Advanced Composites Used? Advanced composites are used extensively on military and commercial aircraft. Flight controls, landing gear doors, skins, panels, antennas and radar covers are just a few examples of where advanced composites can be used on aircraft to reduce weight while maintaining the required strength. Boeing 737 The Boeing 737 uses approximately 1500 pounds of composite material, providing a weight saving of approximately 600 pounds or 29%, when compared to conventional sheet metal construction. Sikorsky S-76 helicopter 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 35 of 217 The Sikorsky S-76 helicopter airframe is constructed from approximately 60% of composite material. This has made a 30% weight saving compared to a metal alloy equivalent. Advanced Composite Hazards Specific hazards are involved with advanced composite materials, both during and after manufacture. You have not learnt about composite manufacture yet, and indeed may not, depending on which trade stream you take. You still need to be aware of the hazards associated with it as you may be exposed to it while other tradespeople in your workplace work with it. You also need to be aware of the potential health and maintenance hazards that advanced composites present. Hazards During Manufacture During manufacture, four main things can present a hazard: The matrix or resin system The reinforcing or fibre material The solvent or cleaning compound Dusts. Inhalation is a hazard associated with composite manufacture 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 36 of 217 Matrix or Resin Hazards A number of different resin types are used in advanced composites manufacturing, and they present similar hazards. If you treat them all the same, you will no doubt experience the problems they can cause. Uncured resins can present a significant dermal (skin) exposure hazard. In many workplaces, manual handling results in potential skin exposure, leading to skin irritation, rashes and subsequent dermatitis if contact is prolonged. Skin sensitisation to the resins can also develop and may require a change of work assignment. Exposure to vapours emitted from resins may irritate the eyes, nose, throat and respiratory tract. Irritation may be severe enough to cause bronchitis and pulmonary oedema. If exposure is prolonged, respiratory sensitisation (an allergic, asthmatic-type reaction) may occur. Analysis has suggested that some elements of certain resins may cause irreversible liver toxicity and damage to the retina when absorbed through ingestion and inhalation. These are also classified as suspected human carcinogens. © Aviation Australia Full PPE for mixing resins 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 37 of 217 Reinforcing Fibre Hazards Most of the reinforcing materials used in industry have the potential to cause eye, skin and upper respiratory tract irritation as a result of the mechanical-irritant properties of the fibres. Skin rashes are common with fibre contact. Carbon-fibre may be associated with an increased risk of skin cancer. Skin irritation from composite materials 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 38 of 217 Solvents Like resins, a number of different kinds of solvents are used in advanced composites manufacturing, and they present similar hazards. If you treat them all the same, you will no doubt experience the problems they can cause. Many of the solvents used in advanced composites processes are volatile and flammable. Most are skin and eye irritants, and some may be readily absorbed through the skin. They may cause eye, nose and throat irritation, and prolonged contact with the liquid may result in defatting of the skin and resultant dermatitis. In high concentrations, narcosis is produced, with symptoms of headache, nausea, light-headedness, vomiting, dizziness, poor coordination and unconsciousness. Some solvents have the ability to depress the central nervous system. SDS Due to the fact that paper-based SDSs may not contain the latest information, aviation companies have moved to the computer-based ChemAlert system. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 39 of 217 Dusts Dusts may be generated in several ways in advanced composite processes. The most common dustgenerating processes are machining and finishing of cured parts and repair of damaged parts. Much of the dust generated in these processes is very fine and can be readily inhaled. Dusts may irritate the eyes, nose, throat and respiratory tract. Irritation may be severe enough to cause bronchitis and pulmonary oedema. If exposure is prolonged, respiratory sensitisation (an allergic, asthmatic-type reaction) may occur. Contact with the skin may cause skin irritation, rashes and subsequent dermatitis if it is prolonged. Dust hazards 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 40 of 217 Example: Composite Damage You need to be aware of hazards associated with composite aircraft components when working on and around these types of materials. Here is an example of how delicate composite components can be: Suppose you are working on an aircraft and drop a tool on a metal alloy panel. The result is a small dent, 0.002 in. deep. The probable outcome is that the damage would be classed as negligible and would remain as is without repair. While working on that same aircraft, you drop that same tool on a composite panel. The size of the dent is also the same. As you do not want to get into trouble for damaging the panel, you think the damage will be OK, so you neglect to tell your supervisor about it. But because of the delicate nature of composites, the extent of the damage does not stop there even though it is all you can see. The sudden impact of the tool has also cracked the resin between the fibre plies, which greatly reduces the strength of the panel. The aircraft takes flight, and the panel breaks off and hits the vertical stabiliser. The aircraft only just makes it back and is found to need a new stabiliser and of course a new panel at a cost of over $100 000. An investigation is launched into the incident which finds that it was all caused by you dropping your tool on the composite panel. The moral of this example is to be extra careful while working around aircraft. If you cause some damage, report it to your supervisor no matter how small you may think it is. If you had reported this damage when it happened, it would have been fully investigated and repaired at a fraction of the cost, and you would more than likely have gotten a pat on the back for not keeping it to yourself. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 41 of 217 Process Material Precautions Good workplace controls are essential in controlling exposure to process materials. Many of the materials, particularly resins and fibres, present a potential dermal exposure hazard. Many of the solvents and some of the resins present a potential inhalation hazard. Some materials present both a dermal and inhalation hazard. Ingestion may be a potential exposure hazard, but usually involves poor personal hygiene or contamination of dining facilities. With this knowledge, when working with or around composites manufacture or repair processes, always keep your health at the forefront of your mind. If you can smell the resins, solvents, or generated dust waste, they are getting into your system. You must either wear your PPE or vacate the area until all airborne contaminants have dissipated. These contaminants might not affect you immediately, but it is more than likely you will suffer health problems in the future. Most advanced composites manufacturing and repair procedures (especially those that involve grinding, routing, machining and the use of solvents) should be performed under an extraction unit. Where it is not practical to do this, they should be performed in a well-ventilated area at a time when the fewest employees are present. Use of an extraction unit and sanding composites in a well ventilated area If you are unsure of the hazards a particular substance presents, request from your employer or WH&S representative a copy of the SDSs. These will tell you exactly what hazards are associated with the substance and what precautions you need to take. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 42 of 217 Waste Disposal Waste Hazards and Disposal The hazards associated with the product may also apply to the waste. Therefore, it is important to dispose of any waste in an appropriate and safe manner. Items that require disposal include the following: All substances collected as spills or leaks. Containers that have been emptied after a leak or spill, including broken bags, fibre-board drums, and any objects such as pallets that may have absorbed the spillage. Heavily contaminated equipment and clothing. Surplus or redundant product. Non-returnable containers that contain residue. Methods Of Disposal The local waste disposal authority should be consulted regarding the suitability of the proposed disposal method. The suppliers of the products may also provide advice. Waste hazard sign 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 43 of 217 Job Knowledge And Training All personnel working with chemicals must be familiar with the hazards these chemicals pose. They should understand the SDSs for the chemicals being stored/used and be familiar with remedial actions in case of poisoning by these chemicals. Operators need to be trained in dealing with spillage and firefighting and should be familiar with the PPE and clothing requirements for these operations. Other employees should, at a minimum, be aware of the relevant handling hazards, including fire risk and symptoms of poisoning, and have knowledge of the action required in an emergency. All people using chemicals or employed in storage areas should receive training appropriate to their duties and responsibilities, which should include: The nature of the work and safe use of equipment The properties of and hazards associated with the substances being kept for use The location of first aid equipment and fire protection equipment The correct use of PPE, its care and maintenance, and actions to be taken in various emergencies, including spills and fire. Note: Regular simulated emergency exercises, including fire drills and spillage-handling procedures, should be included in the training. Such exercises should be conducted at least annually. © Aviation Australia Fire extinguisher use 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 44 of 217 Identification and Reporting of Workplace Hazards (7.1.1.2) Learning Objectives 7.1.1.2 Examine the identification and reporting of workplace hazards to support safe working practices (Level 3). 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 45 of 217 Workplace Accidents Hazards in the Workplace Most workplace accidents are avoidable. If people took time to identify hazards that exist in their work areas and deal with them, workers would enjoy a happier and safer workplace. How do you know if something in your workplace is a hazard? Hazards are dangers at work. You might have a hazard related to noise, machinery and equipment, electricity, manual handling, hazardous substances, working in confined spaces, working in the sun or working in public places. Workplace health and safety This topic will look at some of these areas. On completion of this topic, you will be able to: Explain the causes and effects of accidents. Explain personal and institutional responsibilities with regard to behaviour, practices and hygiene in the workplace. Explain the major functions of safety committees and representatives. Explain the major danger areas applicable to the workplace environment. Illustrate conditions that constitute a fire hazard in the workplace environment. Explain material Safety Data Sheets (SDSs). Create a workplace hazard/accident report. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 46 of 217 Cause and Effect of Accidents Although there are many definitions of an accident, we chose this one as a starting point: An accident is any unplanned or unintentional event, no matter how serious, that stops or interrupts your work and results in personnel injury and/or property damage. There are three basic elements of an accident: An unplanned or unintentional event. Interruption of work. Injury or property damage. Property damage Here is an example that illustrates the three basic elements of an accident: Suppose you are trying to loosen a large nut with a wrench. The nut is rusted tight. As you apply extra pressure to the wrench, the wrench slips. You stagger backwards and strike your head on a stanchion behind you. In this example, there are three distinct happenings: The wrench slipped. You staggered backwards. You hit your head on a stanchion behind you. This example fits the definition of an accident. It was unexpected; it interrupted your work; and, as you would agree, you made contact that caused personal injury or property damage. Accidents are a pain! This is especially true when, after an accident has occurred, you look back and say, ‘If only I’ and finish with a ‘had’, ‘had not’ or ‘did not’. With that in mind, it is important to understand that you are both the number one cause and the number one cure for accidents. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 47 of 217 Identifying Causation and Prevention The two facts that form the basis of accident prevention are: All accidents are caused. Therefore, the only way to stop them is to prevent or eliminate the causes. The more you know about the causes of accidents, the better equipped you will be to prevent them. In any accident the you may be involved in, the cause can always be simplified into two factors, either: You (or your team), or Your environment. These two causes could include: Your unsafe actions or the unsafe actions of your co-workers. An impaired physical or mental condition of the people who caused or influenced the unsafe actions. Any defective or otherwise unsafe tools, equipment, machines, materials, buildings, compartments or other aspects of the work environment. At least two of every three workplace accidents are caused by either a worker’s failure to do (or not to do) something, or a worker taking shortcuts when performing a task. This is known as human error. The following are some of the many factors that can lead you to accidents: Inadequate training and lack of job experience. Inadequate or outdated procedures in technical publications. Inadequate posting or listing of the safety precautions you should observe when performing a task. Behavioural factors, especially negative types of motivation. Medically related factors that reduce your ability to work safely. Communication problems caused by a breakdown in passing, receiving or understanding information. Poorly designed equipment, such as improperly placed controls. Aviation Australia Accidents and causation 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 48 of 217 Most accidents are preventable. However, through ignorance or misunderstanding, there is a common belief that they are the inevitable result of unchangeable circumstances or fate. This belief is false because it fails to consider the basic law of cause and effect, to which accidents are subject. In other words, accidents do not occur without a cause; most are the direct result of some deviation from prescribed safe operating procedures. One purpose of safety rules is to remind the individual of the dangers inherent in the work. Training in the observance of safety precautions can be instrumental in avoiding preventable accidents and in maintaining a work environment which is conducive to accident-free operation. Operating procedures and work methods adopted with hazard prevention as a specific criterion do not expose personnel necessarily to injury or occupational health hazards. Accidents which are about to happen can be prevented if the cause is detected and appropriate remedial action is taken. Inadequate Training and Experience Many accidents occur because of inadequate training and lack of job experience. You may find yourself assigned a task that is clearly beyond your skill level. This may be because of an operational requirement or an emergency that requires prompt action, or your supervisor may not be aware of your limitations. These situations may cause you to misread instructions, take shortcuts or make other errors that could result in an accident. Also, your chances of an accident increase when you are not aware of the hazards associated with a particular task. This lack of awareness can keep you from taking the necessary precautions. In simple English: 1. Do not take shortcuts. 2. Ask for help. If you think a task is too hazardous, it probably is, so before you attempt to do it, seek guidance and become familiar with its associated hazards. Causes of Accidents Inadequate or Outdated Procedures When an accident occurs, examine the procedures you followed just before it happened. They may be in error, or they may not provide enough detailed how-to information; perhaps the technical manual was not updated when a piece of equipment was upgraded or replaced. As a result, you could inadvertently be using the wrong procedures for a particular task. If this is the case, take the initiative to complete the required paperwork to update the technical manual. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 49 of 217 Inadequate Safety Precautions You must be aware of the safety precautions associated with the job or task you are performing. They must be either posted in your work area or listed in the technical manual you are using. If they are not available, you could be attempting something hazardous and not even know it. Make sure you read all applicable precautions. Even if you have performed the task before and are familiar with it, new or revised precautions may exist. Behavioural Factors That Cause Accidents Your behaviour is much more complex than the equipment you operate and maintain. Equipment, regardless of how it is designed and powered, is predictable in its response to certain cues or signals. If a piece of equipment quits working, you can isolate the fault to a specific part with the use of test equipment and schematics. This is not true for you. Your behaviour while performing a task is based on a combination of factors related to your unique experiences, knowledge, attitude and motivation. Each of the above factors can affect your behaviour regarding safety. Behaviour that leads to an accident is usually caused by undesirable attitudes and motivations. Attitudes Attitudes are complex mental states that affect your reaction towards some object, event or state of affairs. They cause you to form opinions and act in certain predictable ways, some favourable and others unfavourable. Attitudes that do not support safe behaviour hamper accident prevention. They can also cause accidents. Motivations Motivations are incentives for specific acts. Your behaviour is based on your motivation, and your motivation is shaped by your attitudes. Ensuring that you have positive motivations towards job safety is clearly a very complex problem. It is complicated because you do not simply react to the basic needs of comfort, security, affiliation and self-fulfilment. Your motivations on and off the job are also greatly affected by attitudes, feeling, tensions and emotions in the world around you. The following are some undesirable motivations that can lead you to accidents in the workplace: Motivation to save time and effort. Motivation to maintain personal comfort. Motivation to gain approval and attract attention. Motivation to express resentment. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 50 of 217 Medical Factors That Cause Accidents Medical factors such as illness, physical impairment, alcohol abuse, fatigue and motion sickness can cause accidents. These factors are frequently associated either with a high tempo of operations that prevents proper rest and nourishment or with events carried over from a recent return from leave or liberty. Illness Your ability to work safely is sometimes affected by illness or the side effects of medicine. Temporary illnesses like colds, flu, dizziness, heat stress and nausea can weaken your physical abilities. They can either reduce your strength, stamina and coordination or disrupt your concentration, mental alertness, memory and reasoning ability. These side effects of medication, such as drowsiness, sluggishness and lack of coordination, can sometimes lead to accidents. Physical Impairments Any pre-existing physical impairment, such as a lower back injury, a slipped disc or a hernia, may make you more susceptible to accidents. Accidents can also stem from visual and hearing defects. Common visual problems include colour blindness, faulty depth perception, far-sightedness and nearsightedness. Hearing defects can cause accidents if they prevent you from hearing instructions or a warning signal. Alcohol Abuse Some people think alcohol is a stimulant. Nothing is further from the truth. Alcohol is a chemical depressant. It acts as a general anaesthetic for the parts of the brain that suppress, control and inhibit thoughts, feelings and actions. Alcohol typically impairs your judgement, gives you unrealistic confidence, slows your coordination and degrades your performance. These effects are present whether you feel them or not. These effects cause risk-taking behaviour that can lead you to unsafe acts and potentially to accidents. Fatigue Fatigue is not an all-or-nothing factor. It begins when you start a task, and it increases as you continue to perform the task. At some point during the task, fatigue can become great enough to impair your performance. It can decrease your work output, change your attitude and reduce your motivation to observe safety precautions. But long before this happens, fatigue decreases your awareness and reflex actions. At this point, accidents can occur. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 51 of 217 The following are some symptoms of fatigue: Lower quality of performance Irritability Impatience Forgetfulness Confusion A higher number of errors. The following are some frequent causes of fatigue: Hard work, long hours and lack of sleep Environmental stress, such as heat, cold or noise Vibration and inadequate lighting Boredom and monotony A change in routine. Suppose, for example, you are accustomed to working days and sleeping nights. If you switch to working nights and sleeping days, you will probably experience fatigue. The results of fatigue vary from person to person, but fatigue always reduces your mental alertness, increasing the chances of an accident occurring. Workplace accidents 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 52 of 217 Communication Problems That Cause Accidents Accidents can occur when there is a breakdown in the passing, receiving or understanding of information. The most common communication problem is misunderstanding the message being sent to you. Your brain reacts to what it thinks it hears, not necessarily to what it hears. Accidents can also stem from language barriers. You cannot understand a message if the person sending the message does not speak clearly enough. Equipment Design Factors That Cause Accidents Poorly designed equipment and improperly placed controls can cause accidents. Controls that cannot be reached quickly and easily, emergency controls protected by cumbersome interlocks, and displays that are difficult to read are examples of design problems that can cause accidents. Aviation Australia You must be aware of the safety precautions associated with the job or task you are performing Accident Prevention Why is accident prevention necessary? The aviation business is deadly serious. It is conducted by professionals, is restricted to limited resources and allows no room for error. Errors produce accidents. Therefore, when errors are reduced, accidents are reduced and readiness is improved. The aviation industry also considers your safety to be as important as productivity. Unlike most civilian businesses whose safety efforts are directed at reducing on-the-job accidents, aviation industry accident prevention efforts give you complete coverage both on and off the job, regardless of your duty status, location or mission. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 53 of 217 Accident prevention is a vital part of your job. By preventing accidents, you avoid injury to yourself and damage to your equipment. When you think of accidents, you probably think of deaths. But for every death, there are many more accidents that result in equipment damage or personal injury. Accident prevention is the process of eliminating accident-producing causes. The goal of the aviation industry’s accident prevention program is to prevent accidents from occurring or, once they have occurred, to prevent them from recurring. The aviation industry’s accident prevention program consists of activities directed to eliminate: Unsafe acts of persons Unsafe mechanical, physical or chemical working conditions. The best way to prevent accidents is to eliminate the factors that lead to them. This can involve anything, from a minute of extra effort that costs nothing, to lengthy planning and work by many people at considerable cost. It all depends on the nature of the unsafe condition. The authority to correct an unsafe condition may involve any level of the chain of command. The following four avenues are available to you: Order correction where authority permits. If you have the authority to do so, do not delay ordering unsafe conditions corrected. Delay means exposing other people to the unsafe condition. If you are uncertain about the best correction method, talk to your supervisor immediately. Report conditions to higher authority. If you do not have the authority to correct the unsafe condition, then promptly report the hazard or potential hazard to your supervisor. Be ready to offer some suggestions about how to correct the unsafe condition. Your ideas may help to speed the correction. Correct the problem at the source. Do not stop with just correcting the unsafe condition. Find its source and begin your corrective actions there. If you have the authority to correct the problem at the source, then do so. If the problem involves people, then point out the unsafe condition and correct the workers causing it. Hold on-the-spot training if needed. If you do not, you are inviting repetition of the unsafe practice. Take temporary precautions. You may need to delay correcting an unsafe condition because of a shortage of funds, personnel or equipment. If this happens, take all temporary precautions needed to protect both yourself and your co-workers from the unsafe condition until it can be corrected. These precautions may include securing the hazardous areas, disconnecting power sources, posting warning signs and giving verbal warning to workers. Whatever precautions are necessary, take them promptly to reduce the exposure of any hazardous condition to all personnel. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 54 of 217 Ground incident 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 55 of 217 Summary Accidents in the workplace cause millions of dollars to be paid out in compensation, not to mention significant grief and pain, especially in severe cases. It is therefore extremely important that personnel are trained correctly and are aware of their responsibilities with regard to themselves and co-workers. Up-to-date processes always need to be in place, and safety precautions must be highlighted to workers and clearly visible in the workplace to avoid unnecessary accidents. Behaviour related to accidents in the workplace is usually related to poor attitudes and motivation. Therefore, employers should always ensure the well-being of the worker. A happy worker is usually a safe worker. However, accidents can be prevented by taking a proactive approach: reporting dangerous situations or faulty machinery in the workplace and accepting responsibility for them. There is no point in saying, ‘Someone else will fix it’. This may be the cause of an accident involving yourself and/or a coworker, so report it. We have safety committees and representatives in the workplace to encourage safe working practices. They provide a channel for you to report any faults or other problems to your representative, on a hazard report form or both. You need to take immediate corrective action. This is especially true in situations that pose an immediate hazard to life or health. Do not delay because you may not have the authority to correct such an unsafe condition. In emergencies, you will always have the right to take corrective action. Just be sure you do not put yourself or others in danger of being hurt. And if you cannot safely correct the problem, inform your supervisor about it immediately. Reporting 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 56 of 217 Health and Hygiene It is important that you think about your actions at home and in the workplace and how they affect your health. The general hygiene principles you use from day to day at home are a good start to keeping you safe in your workplace. At work there are hazards, including biological hazards. You need to identify those hazards and learn how to look after yourself during your workday. Employers should provide: A documented workplace health and safety policy, including guidelines for infection control when workers and first aid personnel are exposed to infection Up-to-date instructions about appropriate safe work practices Ongoing training and supervision Personal protective clothing and equipment, where required An effective system of injury and illness reporting and follow-up. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 57 of 217 Keeping Fit and Healthy Keeping yourself fit and mentally alert by eating a good diet, doing regular exercise, attending to medical problems and getting enough sleep will help reduce accidents and absenteeism brought about by carelessness, stress and fatigue. Heeding the following advice can improve your well-being. Drugs and alcohol can cause dependence and prevent people from being able to do a full day’s work properly. Employees must inform their employer if they are taking any medication that may impair their ability to do tasks. Develop good posture at work, whether you spend long periods standing or sitting at a desk. Keep yourself well groomed, clean and neatly attired. Observe hygienic practices such as washing your hands regularly. This is particularly important for aerospace technologies employees involved with sewage treatment, transport or maintenance. Ensure that your immunisations, such as for hepatitis, are up to date. Do not ignore medical problems that may be nagging you. See a doctor before they lead to other problems. Maintain a healthy balance between work and your personal life. This will keep you happier and less stressed both at work and at home. If you find work stressful because you have too much or too little work to do, or because work is monotonous or lacking in stimulation, talk to someone about it. This may be a supervisor, team leader or counsellor. Compensation payouts for stress-related illness are substantial and can be reduced if people heed the signs before a breakdown occurs. Image by skeeze from Pixabay Keeping fit and healthy 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 58 of 217 Work Health and Safety To comply with the Work Health and Safety (WH&S) Act, risks of injury at all workplaces need to be identified, assessed and controlled. Regulations – prohibit exposure to a risk or prescribe ways to minimise exposure to a risk. Advisory standards – state ways to manage exposure to risks common to the industry. Industry codes of practice – state ways to manage exposure to risks typical in a part of the industry. Where there is no regulation, standard or code, you must exercise due diligence. The WH&S Act is governed by the Australian Commonwealth Government, and each state and territory has established a local Health and Safety Committee. In Queensland, WH&S is regulated by the state government under the Queensland Work Health and Safety Act 2011 (WH&S). Aviation Australia Work health and safety 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 59 of 217 Health and Safety Representatives Who is your Health and Safety Representative (HSR)? What do they do? Go to safety training. Help fix safety problems. Know the safety law. Participate in WH&S committee meetings with managers and supervisors or team coordinators. Exercise authority under the law to raise safety problems with your employer. Your occupational HSR can communicate with managers and supervisors or team coordinators about health and safety problems. This is called consultation. Consultation is about giving everyone the chance to talk about how to fix safety problems in the workplace. Consultation can happen through: Workgroup and team meetings Occupational health and safety committee meetings Discussions with supervisors or team coordinators Discussions with your supervisor or team coordinator and the HSR Workplace audits and inspections. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 60 of 217 Workplace Health and Safety Committees Health and safety committees assist in developing health and safety policies and consult with the employer about changes to policies or procedures. At least half of the committee members must be workers. The committee must meet at least once every 3 months. Members of the committee who represent workers are elected by the workers. They are usually HSRs. If your supervisor, team coordinator or HSR cannot fix a safety problem, it should go to the committee to be discussed. Rock drum, CC BY-SA 3.0 , via Wikimedia Commons Workplace health and safety committee meeting 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 61 of 217 Remember Under the WH&S Act, both employers and employees are obligated to ensure people’s health and safety in the workplace. Standards, regulations or industry codes of practice are in place to help reduce the incidence of workplace accidents. Under the Act, penalties will be incurred for breaches. Employers must instruct workers in safety measures and employ measures to ensure the safety of anyone in or near the workplace. One way to ensure this happens is to implement safety committees. Therefore, most industries have safety officers and committee members in place. Employees have a duty to conduct themselves in a manner that will not harm themselves or others, to carry out certain safety measures, and to use any protective clothing and equipment provided. They must be constantly on the lookout for hazards and notify employers of problems. Training in standard work and emergency procedures, such as evacuations, is the best way to keep the workplace accident-free. The WH&S Act tells you what you must do to work safely. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 62 of 217 Noise Safety and Precautions Workplace Noise Noise can be a major hazard The first is associated with the outer or middle ear, with some type of damage occurring to the eardrum or bones of the middle ear. The second is associated with damage to the nerves and cells of the inner ear, which convert vibrations into messages to the brain. Hearing loss can happen gradually, and the worker may not realise the loss is occurring. Noise is a major hazard. It can damage your hearing and affect your health in many ways. For example, it can cause: Headaches Constant ringing in the ears Stress High blood pressure Increased heart rate. Noise can reach unacceptably high levels in many jobs. Irreparable damage to hearing can be caused by exposure to loud noise for short periods of time or by lower noise levels for extended periods. The table below provides an example of various sound sources, the sound levels produced by these sources and their effects on human hearing. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 63 of 217 Effect on People Sound level in dB(a) Sound Source Highly injurious 140 Pain threshold 130 Jet engine 120 Rivet hammer 110 Chainsaw 100 Sheet-metal workshop 85 General standard in Australia for 8 hours 80 Heavy traffic 60 Normal conversation 50 Low conversation 40 Quiet radio music 30 Whispering 20 Quiet urban room 10 Rustling leaves 0 Hearing threshold Injurious Irritating 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 64 of 217 Noise Control in the Workplace Noise Control Getting rid of noise completely is impossible. What we can do in the workplace is reduce noise emissions and protect ourselves from what remains. Once a noise problem is discovered, action needs to be taken to get rid of it or control it. Remember to use the hierarchy of controls when dealing with noise. Aviation Australia General Hazard Hierarchy of controls applies to noise Personal Protective Equipment Workers who are exposed to unacceptable levels of noise will be provided with suitable work instructions and personal protective equipment (PPE) to reduce their exposure to harmful levels. If you have any concerns, contact your supervisor or Workplace Health and Safety Officer. After assessing noise levels, you should select appropriate hearing protection, such as earplugs or earmuffs. A comfortable fit is an important consideration when choosing hearing protection. In Australia, all approved hearing protection should comply with the appropriate Australian Standard (AS). 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 65 of 217 Hazards in the Workplace Machinery and Equipment Check your plant and machinery regularly, possibly using a checklist, so that it will stay in safe working order. If faults are discovered, do not use the faulty machine. Submit a report to have it serviced immediately. Take care when working with moving vehicles, such as trucks and cranes, or near power lines. High-visibility clothing may be useful in these areas. Aviation Australia High-visibility clothing may be useful 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 66 of 217 Electricity The human body is an excellent conductor of electricity, so it is important that safe work processes are adopted when you use electricity. Electrical hazards may be due to: Cracked or faulty insulation Overheating equipment Damp conditions. Ways to ensure safety around electricity include the following: Wear correct clothing, such as non-conductive footwear, and remove metal watches, jewellery and belts with metal buckles. Keep power cords away from heat and water. Protect and run your power cords at heights where they will not be damaged, for example, away from sharp objects and traffic. Have earth leakage devices installed so that current is cut immediately if power is shortcircuited. Use wooden or fibreglass ladders when you are working near power lines or performing electrical work, as they are non-conductive. Attend to faulty tools and equipment by having them checked regularly and ensure that cords are not frayed. Turn off all power sources after use. Aviation Australia - GL It is important that safe work processes are adopted when you use electricity 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 67 of 217 Hazardous Substances If you handle hazardous substances, make sure you are aware of the special regulations which apply to them. Employers must train workers to use hazardous substances properly when it is part of their job. A worker’s primary protection is the label. Storage containers of hazardous substances must be correctly labelled in English, but do not assume all people can read and understand the labels. Discuss best practices with the person in detail before use or storage. Check frequently that storage containers are not damaged and have not deteriorated over time. Users must also be able to refer to the relevant SDS. These sheets provide information about: The dangers involved in using chemicals and substances Precautions for use Health effects and relevant first aid procedures. Hazardous substances 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 68 of 217 Working in the Sun Many aircraft maintenance employees carry out their daily work in full sunshine. Working in the sun without adequate protection can cause dehydration, headaches, sunstroke and skin cancer. To reduce the effects of the sun, you can: Drink water (keep up your fluid intake) to prevent dehydration. Wear a broad-brimmed hat. Apply sunscreen with at least a 15+ protection factor. Wear long-sleeved, close-weave shirts and trousers. Wear neck protectors under hard hats. Avoid working unprotected for long periods between 11:00 a.m. and 3:00 p.m. Airport workers in the sun 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 69 of 217 Safety Data Sheets To maintain a safe working environment, all substances, compounds and materials used in the workplace must be identified. Information to include in Safety Data Sheets (SDSs) must provide information about the: Hazards of the chemical and how to handle it safely, including storage and disposal. Physical and chemical properties of the chemical, as well as potential health and emergency response measures. Environmental effects of the chemical. This data must be readily available for user reference, either by hard copy or electronic versions like ChemAlert. ChemAlert online safety manual 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 70 of 217 Reporting Hazards and Accidents in Aircraft Maintenance The Hazard Report Form If you notice anything hazardous in your workplace, you should report it to your supervisor or Workplace Health and Safety Officer. However, if action is not taken to rectify the matter, you should fill out the Hazard Report form. A copy should be given to your supervisor and additional copies sent to your Workplace Health and Safety Officer and the Workplace Health and Safety Coordinator for your business. If more people reported hazards, the accident rate might be reduced and fewer people would be seriously injured at work. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 71 of 217 Report of Injury, Illness or Dangerous Event Form The Report of Injury, Illness or Dangerous Event form is used to record all work injuries, work-caused illnesses and dangerous events. It can be completed and transmitted either: Manually (This form is blue and in triplicate. It is sent to the places detailed in its bottom left corner.) Electronically (Copies are sent to the same addressees as detailed above.) Form description: 1. The front page of the form explains how to use the form. 2. The second page lists codes you can use to describe the: Type of injury. Part of the body injured. Incident. Major cause. Action to rectify. 3. The third page is where you record your details. Note: Organisations require that all work injuries, work-caused illnesses and dangerous events are recorded within 3 days. Summary If you notice any hazards in the workplace, you must report them to your supervisor and/or safety committee. However, a Hazard Report Form should be filled out if action is not taken. Always remember that hazards in an aircraft environment can become a FOD hazard and cause severe damage to aircraft. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 72 of 217 Safety Precautions Associated with Aircraft Maintenance Operations (7.1.1.3) Learning Objectives 7.1.1.3 Examine safety precautions that form part of safe working practices in aircraft maintenance, including those associated with electricity, gases, oils and chemicals (Level 3). 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 73 of 217 Safety Signs Signs The operations carried out in the aircraft maintenance industry are unique to this industry. Therefore, the dangers to personnel and equipment are also quite unique. Signs surround us in everyday life. They inform us to turn left, slow down, stop and follow a multitude of other instructions. In workshops, picture safety signs use universal symbols to: Prevent accidents Signal health hazards Indicate the location of safety, first aid and fire protection equipment Give clear guidance and instruction in emergency procedures Form part of the total safety information system of the area. Colour attracts attention and can be used extensively for safety purposes. For example, it can be used as an additional safety measure to indicate the contents of pipes and the nature of a hazard. The choice of colour also draws attention to the severity of the hazard. For example, a dangerous hazard is communicated by the colour red. When employees are aware of the hazards around them and take the necessary precautions, the possibility of an accident or injury is minimised. However, while safety signs and colours are valuable in warning of hazards, they are not a substitute for eliminating or reducing hazards whenever possible. This guideline will help you to effectively use safety signs and colour in your workplace. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 74 of 217 Examples of signs 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 75 of 217 Standard Symbols and Colour Markings Sign Categories There are three basic sign categories: regulatory information warning. Each category is distinguished by its shape and is divided into sub-categories that can be recognised by their colour. Sign categories - regulatory 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 76 of 217 Sign categories - information Sign categories - warning 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 77 of 217 Signs and Symbols The signs and symbols that you see in the workplace are to help remind you or tell you about something. Safety signs can be different types: pictures only, words only or both pictures and words. They fall into four general categories and they are colour coded for easy recognition. Informational Signs (Green and White) These signs give you information about the area you are in. They are usually rectangular or diamondshaped and can also be a tag system. They are numerous and their types vary according to the workplace. Informational signs (green and white) Prohibition Signs (Red and Black) These signs inform you of things you must not do. They usually have a red circle with a line through it from the top left to the bottom right. Some other examples are No Eating, No Flames and No Drinking. Prohibition signs Warning Signs (Yellow and Black) These signs advise you of potential hazards. In a variety of conditions, the law requires certain signs to be used. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 78 of 217 Warning signs Mandatory Signs (Blue and White) Mandatory signs inform you of things you must do to ensure your personal safety. There is no suggestion here – these are ‘must do’ instructions. Mandatory signs (blue and white) A sign usually consists of a symbol, which is a letter or picture surrounded by a border of a definite shape and colour, as shown in the examples below. The symbols used are simple, and they are easy to learn and recognise. They may include simple wording to help reinforce the message or to provide additional information. Recent studies indicate that the most effective signs are those that combine a symbol with a brief verbal message. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 79 of 217 Other common safety signs Symbols for Hazardous Materials By law, hazardous materials received in the workplace must be identified by special symbols on container labels. These symbols indicate the nature of the hazardous material, such as compressed gas, oxidising material or toxic material. For information about the symbols to use and their colour restrictions, consult the Controlled Products Regulation under the federal Hazardous Products Act. You may know these special symbols as the Workplace Hazardous Materials Information System (WHMIS) symbols. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 80 of 217 Safety Colours While no legislation requires the use of colour in the workplace, colour can be used to indicate hazards or point out safety equipment. For example, colour can be applied on: Indicator lights or buttons Pipes Separate work areas Machinery Vehicles Aisles, floors and stairs. Indicator Lights or Buttons With the extensive use of colour in our daily lives, we have learned to associate certain colours with specific meanings. For example, red on a traffic light means stop. These associations should be taken advantage of in the workplace to help employees easily recognise the message associated with colours and respond quickly, as in the case of indicator lights and control buttons. Colour Indicator Light Bu on or Control Red Danger / Alarm Stop / Emergency Stop Yellow / Amber Cau on Interven on Green Safe Condi on Start/On Ⓒ Aviation Australia Indicator light or button colours 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 81 of 217 Other Uses of Colour in the Workplace Colour may also be used to indicate other hazards in the workplace as follows: Colour Orange Yellow Meaning Bu on or Control Warning Steps, guardrails, low beams, storage cabinets for ﬂammable materials, containers for corrosives or unstable materials Cau on Hazardous parts of machines which may cut, crush or injure a worker inside of movable guards or the inside of transmission guards for gears, pulleys, chains, etc. Exposed parts (edges only) of pulleys, gears, rollers, cu ng devices, power jaws, etc. Ⓒ Aviation Australia Orange and yellow can also be used for workplace warning and caution signs Posting Signs The following points should be considered when posting signs: Signs should be clearly visible, positioned in the line of sight, and free from any obstructions or clutter. Keep signs well lit. Observers should be able to read a sign easily and recognise its safety colour. Lighting should also be sufficient to make any hazard being pointed out clearly visible. A sign should be posted within an appropriate distance to the hazard it is meant to highlight. An observer must have enough time to read the message and do whatever is necessary to keep safe. Related signs should be placed side by side, but no more than four signs should appear in the same area. Unrelated signs should be posted far apart to eliminate confusion. Directional signs should be visible from all directions. Include arrows on exit signs wherever the direction is not obvious. Directional signs should be posted at intervals so that the correct route is always clear. Signs hung from ceilings should be at least 2.2 m above the floor. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 82 of 217 Making Signs Using Easy-to-Read and Easy-to-Understand language in signs: To help employees and visitors understand them quickly, signs should display plain English and easily learned or recognised symbols. Symbols should be kept as simple as possible; details that do not make the message clear should be eliminated. Avoid using signs that contain only verbal messages, as these are the least likely to be complied with. When compliance is critical because of a hazard, a sign is most effective and most likely to be complied with when it contains the following information: 1. A signal word, such as danger or warning 2. A hazard symbol 3. Information about the consequences if the hazard is not avoided 4. Instructions for how to avoid the hazard. Multilingual signs may be used to help employees whose first language is not English. Uppercase letters should be used for the first letter of the first word, and lowercase letters for the rest. Commands or cautionary words should be uppercased. The lettering style should be clear and easy to read. Signs should always have clear wording 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 83 of 217 Wording Use appropriate cautionary words. For example: DANGER: To warn of an immediate or grave hazard that will definitely cause serious, irreversible injury or death. WARNING: To draw attention to a potential risk that could result in serious injury or death. CAUTION: To alert people to a potential risk that can cause minor or moderate injury. It may also be used to warn against unsafe practices. Set a limit of one message per sign. To convey more than one message, use separate signs or a multipurpose sign. Cautionary words in signs 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 84 of 217 Signage in Aircraft Maintenance Maintenance Signage Signage in the workplace must be appropriate, clearly visible and well maintained. Caution sign in the workplace Aircraft paints containing isocyanides are carcinogenic. Caution sign 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 85 of 217 Ingestion Hazards An exterior placard on an aircraft warns of the engine intake danger zone. Example of an exterior placard warning of the engine intake danger zone 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 86 of 217 Cockpit Signage Warning Tags in the Cockpit The image shows examples of safety precautions used during aircraft maintenance. Warning tags are attached to controls to alert others that a system is inoperative or dangerous to operate. Warning tags 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 87 of 217 Switches in the Cockpit Switch guard with a tell-tale copper safety wire which must be broken to activate the switch. Safety-wired switches are for emergency operation only. Covered switch 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 88 of 217 Handles in the Cockpit Red handles or levers indicate emergency operation or release. Emergency handles Aircraft Lockout Devices View these demonstration videos about lockout devices in aviation: Relevant Youtube link: Supplementary: S2029 Aircraft Power Receptacle Lockout Device Application (Video) Relevant Youtube link: Supplementary: S2329 Aircraft Circuit Breaker Lockout (Video) 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 89 of 217 Aircraft Cabin Door Safety Aircraft door and emergency exit internal operating handles are painted red. The handle pictured has one end painted red for quick identification of a latched or unlatched door and for emergency use. Door and emergency slide arming levers are painted yellow to distinguish them from the normal door-operating handle. Aircraft door handles Aircraft door-open stowing latches and other hold-open devices are typically painted yellow. Yellow paint allows easy identification. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 90 of 217 Aircraft door-open stowing latches Aircraft door-open stowing latches 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 91 of 217 Biological Hazards Hazardous material is any material that, because of its quantity, concentration, or physical or chemical characteristics, may pose a substantial hazard to human health or to the environment when purposefully released or accidentally spilled. Hazardous waste is any discarded material (liquid, solid or gas) which meets the definition of hazardous material. Safe and healthy working conditions, when using hazardous materials and its waste, are everyone’s responsibility. Biohazard sign Biological hazards include human specimens, viruses, bacteria and human organs destined for transplant patients. These are packed in specific containers and clearly marked with their contents. Great care must be taken in handling, using and storing hazardous materials and in the accumulation of hazardous waste for disposal in order to prevent injury to personnel and the environment. Common Aircraft Symbols The following symbols have been borrowed from NATO (North Atlantic Treaty Organization) and may be found on commercial transport aircraft and on military aircraft and helicopters. A mooring or tie-down point is indicated by an anchor symbol painted on the aircraft structure adjacent to the tie-down attachment location. Mooring points are used to secure a parked aircraft against strong winds. Tie-down point 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 92 of 217 A jacking and shoring point is indicated by this symbol painted on the aircraft structure adjacent to the jacking location. © Aviation Australia Jacking point A ground point or earth point is indicated by this symbol painted on the aircraft structure adjacent to the ground connection. Ground points are used during fuelling operations and whenever an aircraft is in the hangar. © Aviation Australia Earth point A lifting point is indicated by this symbol painted on the aircraft structure adjacent to the lifting attachment location. Lifting points are commonly located on heavy components such as flaps, flight control surfaces, doors and engine transport stands. © Aviation Australia Lifting point 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 93 of 217 Aircraft Placards Normally, aircraft fairing access panels are identified by the aircraft manufacturer’s alphanumeric code, while servicing panels are placarded with their description. Panel identification codes and locations can be found in the Aircraft Maintenance Manuals. Water service panel Fuel panel - jet fuel (see AMM), max pressure 50 psig, max auction 4 psig 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 94 of 217 Fluid Line Identification Aircraft fluid hoses, pipes and tubing are identified by colour-coded decal strips. The name of the fluid is printed across the decal, followed by a standardised symbol. Normally, the symbol identifies the direction of flow. Common fluid line decals 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 95 of 217 General Safety Precautions in Aircraft Maintenance Aircraft Propellers One very important safety precaution associated with propellers is: Treat all propellers as ‘live’ at all times. This is particularly important with piston-engine aircraft which have magneto grounding switches which are not always reliable. The following article outlines a real-life close call when propeller safety is not adhered to. View the article here. Image taken from article at Flight Safety Australia Dangerous - Stay properly clear of the prop! At night, be aware that rotating propellers may appear stationary under the effect of strobe lighting. Propellers can kill 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 96 of 217 On 24 July 1983, during the height of his professional career, Australian golfer Jack Newton had a near-fatal accident when he walked into the spinning propeller of a Cessna 421 Golden Eagle aircraft he was about to board at Sydney Airport following a Sydney Swans AFL game. He lost his right arm and eye and sustained severe abdominal injuries. A severe rainstorm was in progress at the time and safety aspects near the aircraft were deficient. Maintenance Documentation Always check the aircraft paperwork first! When working on aircraft, as a safety precaution and a requirement, you should always check the aircraft paperwork (maintenance documentation) to ensure it is safe to work on. Extract from an aircraft maintenance log 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 97 of 217 Foreign Object Damage The ingestion of foreign objects and debris into jet engines accounts for a large percentage of unscheduled engine changes. Foreign object damage (FOD) is often caused by poor housekeeping and everyday carelessness. The use of protective covers, FOD walk-arounds and a positive Tool Control Program can eliminate the problem. If you see FOD, pick it up and dispose of it properly. FOD disposal bins are strategically placed around airport terminal areas and inside hangars. FOD collected in one day at Brisbane Airport The bags and piles of FOD in the illustration above were collected from Qantas, Ansett, Flight West and Pacific Aviation ramps in Brisbane, Queensland, in June 1995 to illustrate the amount of waste material that was being discarded carelessly during routine ramp and line maintenance. It starts with the odd split-pin and ends of lockwire and just progresses from there. FOD can come in all shapes and sizes. The following picture was taken by an airline in America when a Lockheed L1011 Tri-Star number 3 engine was started while an empty container was on the ground nearby. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 98 of 217 Engine FOD damage The following picture was a result of a China Southern Airlines aircraft that was involved in a birdstrike which damaged several turbine blades. It made an emergency landing at a regional airport. The maintenance crew decided that a few tie-down straps would fix the problem. Although it experienced quite alarming levels of vibration, the aircraft flew to a major base where an engine change was carried out. Damaged fan blades The following picture shows the damage as a result of a bolt that was left in a careless position. The bolt caused the damage illustrated and necessitated an engine change due to the torque shock on the fan. 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 99 of 217 Fan blade damage 2024-04-22 B-07a Maintenance Practices CASA Part 66 - Training Materials Only Page 100 of 217 Tyre Inflation Safety Precautions Aircraft Tyres Aircraft tyres can be a lethal store of energy, with some inflation pressures exceed 250 psig. When working on aircraft wheels and tyres, always ensure the following: Inflate to the Maintenance Manual recommended pressure. Use the gas recommended in the Maintenance Manual – typically nitrogen. Use a regulated supply, not high-pressure shop air. Deflate the tyre before attempting to split the wheel. Always deflate the tyre before attempting to remove the valve core as pressure can eject the valve at very high velocity. Place the wheel assembly inside a safety cage before inflating a new tyre for the first time or inflating a tyre when the wheel assembly is not

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