MM4GDM Group 9 Close The Loop To Get Fit Supervisor Dr

A. Campbell-Ritchie

Risk Assessment
This is a student project based around a new take on resistance-based exercise.
For the purpose of this risk assessment, the key features are that it is a large
piece of gym equipment, based around a pull-down machine, and is very
modular in nature. Its overall maximum dimensions (when assembled) are ~
1.1m wide x 2.3m tall x 1.6m deep and it has a total weight of ~80-90Kg.

In Workshop Manufacture

All manufacturing operatives wear the correct safety gear at all times (steel
capped boots, lab coat and safety glasses). All specialist operations are carried
out by qualified technicians (welding, plasma cutting etc.) All materials are
deburred before assembly. Supports (clamps etc.) are used to secure machine
when being worked on. When stored at end of day care is taken to ensure that
the large items are balanced and will not fall, nor pose a trip hazard.

Transportation

For movement and ease of assembly the system naturally separates into 4
detachable pieces whose movement could potentially cause risks that should be
considered:

1) Main framework of approx. dimensions 2.3m x 1.6m x 0.06m and weight

40kg. Although the weight is fine for 2 people to carry comfortably, due to
its size this is a relatively cumbersome item and great care will need to be
taken when moving and lifting it. The people carrying it will need to be
wearing workshop safety gear, in particular safety shoes. The 2 people
carrying should also be accompanied at all times by a 3 rd person to ensure
door openings, obstacle avoidance and to ensure others nearby are aware
of it. When set down, care should be taken to ensure that this piece is
stable (balanced), not damaging anything it is in contact with, and doesnt
pose any kind of trip hazard / obstacle to others.
2) Motor and control box approx. dimensions 0.6m x 0.6m x 0.3m and
weight 30kg. Again, due to its weight, this will require 2 people to move
taking the same precautions as before. However, this is much more
compact and therefore doesnt have the same issues with balancing /
carrying.
3) & 4) End pieces 1 & 2 approx. dimensions 1.1m x 0.6 x 0.4 and weight
5-10Kg. These are both easily portable by one person in terms of weight,
but care should be taken around corners / doorways etc. due to their size.
The same precautions as part 1 should be taken.

Assembly
Initially, the main framework will have to be held vertically and attached to its
bottom stabilisers. This will require 2 people to support the framework while
another attaches the supports. Once the end pieces are securely in place, the
system is very stable and is safe for one person to work on at a time. There are

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MM4GDM Group 9 Close The Loop To Get Fit Supervisor Dr
A. Campbell-Ritchie

no specialist tools required for assembly, other than nuts, bolts and spanners.
Safety gear should still be worn until the system is completely assembled.

Use
In operation the system is almost identical to the user to a lat pull-down
machine. The user sits on an adjustable seat and then secures an adjustable
knee-pad. (Care should be taken to ensure that these are fully locked in position
prior to use) They then reach up and grasp a gripped bar, and pull this down to
shoulder level (resisted by a brake / motor system housed away from the user)
they then allow the bar to raise back up again (resisting the brake / motor
system).
As this piece of equipment would be gym-based, each new user would be given
supervised instruction when first using it to ensure knowledge of safe operating
procedure (and from the point of view of this being a student project the
machine will be supervised at all times when in use).
This machine incorporates moving cables traveling through holes and pulleys
and transmitting large forces, and great care should be taken to avoid these
points. The pulleys are located at a minimum of 2m above the ground and
therefore shouldnt be encountered accidentally. They are also fitted with guards
to ensure that the cable cannot jump out. There is a point where the cable
goes through a hole to get to the motor / brake system, which is potentially
hazardous, but this area is on the opposite side of the machine to the user, and
separated by a large upright. However, other people could come near this area if
they were to walk behind the machine, and during its operation a danger area
should be clearly marked and the supervisors should ensure that no one enters
this area when it is in use.