Occupational Health & Safety Case Studies

Woodworking in manufacturing environments presents serious respiratory hazards, especially when hardwood dust is involved. Sysco Environmental Ltd conducted a comprehensive exposure assessment at a bespoke conservatory and joinery workshop in Lincolnshire. Air monitoring revealed significant exceedances of COSHH Workplace Exposure Limits, particularly in sanding and timber milling areas. This case study explores the health effects of wood dust, regulatory implications, and practical control measures including LEV upgrades, improved RPE protocols, and cleaner housekeeping methods. Learn how a proactive approach to air monitoring and dust control can help reduce risks and ensure full compliance in wood manufacturing operations.

Wood recycling plays a critical role in the circular economy, but it carries hidden respiratory hazards. Sysco Environmental Ltd conducted an exposure assessment at a high-throughput recycling facility in Birmingham, where hardwood and softwood dust levels exceeded Workplace Exposure Limits by over 900% in some tasks. This case study outlines the health effects of wood dust, especially in the context of engineered and aged timber, and highlights practical control measures including improved ventilation, RPE, and alternative cleaning techniques. Learn how targeted interventions can protect workers and ensure COSHH compliance in one of the UK’s most dynamic and essential recycling sectors.

Welding fumes contain hazardous metals like chromium, nickel, manganese, and iron—all of which pose respiratory and long-term health risks. In this case study, Sysco Environmental Ltd evaluated personal exposure levels among welders at a structural steel facility in Cambridgeshire. Although airborne metal concentrations were found to be well below Workplace Exposure Limits (WELs), the report recommended enhancements to local ventilation, RPE usage, and health surveillance to strengthen long-term protection. This blog explores the risks associated with alloying metals in welding fumes and outlines the practical steps every fabricator should take to remain COSHH-compliant and protect worker health.

Isocyanates are a critical component in two-pack polyurethane paints but pose serious respiratory risks without adequate controls. In this case study, Sysco Environmental Ltd assessed exposure levels during paint mixing and spraying at a fabrication facility in Cambridgeshire. Despite the use of HDI, IPDI, and TDI-based coatings, airborne isocyanate levels were found to be below detection thresholds—thanks to well-maintained extraction and air-fed RPE systems. The study explores how isocyanates function in coatings, their associated health hazards, and the importance of LEV, RPE, and ongoing health surveillance to protect employees and maintain COSHH compliance

Isocyanates are among the most hazardous substances used in industrial manufacturing, posing significant respiratory risks. In this case study, Sysco Environmental Ltd assessed worker exposure to methylenediphenyl diisocyanate (MDI) during potting and mixing operations at a facility in Slough. Although results showed exposure levels well below Workplace Exposure Limits, the assessment identified improvement areas in LEV visibility and staff training. This case study explains the health effects of various isocyanates, outlines our monitoring approach, and presents actionable control strategies to reduce risk and maintain regulatory compliance under COSHH.

Rubber fumes and dust present hidden yet serious health risks in many manufacturing settings. Sysco Environmental Ltd conducted a detailed COSHH-compliant exposure assessment at a precision moulding facility in Hampshire, focusing on press operators working with natural and synthetic rubbers. While exposure levels were below Workplace Exposure Limits (WELs), the assessment revealed the absence of key controls such as LEV and consistent RPE use. This case study outlines the risks associated with rubber processing, our methodology for exposure monitoring, and practical control recommendations to reduce long-term health risks and maintain compliance. A must-read for any business moulding or curing rubber compounds.

Rubber and plastic moulding processes can quietly release hazardous fumes and dust that pose serious health risks to workers. In this case study, Sysco Environmental Ltd shares insights from a recent assessment at a Northampton-based manufacturing facility, where rubber fume exposure was monitored across multiple work areas. Although exposure levels were below legal limits, key vulnerabilities were identified—particularly in the compression moulding zone where ventilation was ineffective. This blog outlines the risks of rubber fume inhalation, discusses the ideal control measures under COSHH, and presents practical recommendations to protect workers and maintain compliance with HSE guidance.

This case study covers a comprehensive assessment of wood dust exposure at a construction training facility, focusing on particle size, suspension time, and worker health risks. The assessment identifies the aerodynamic characteristics of dust particles, highlighting how long different sizes remain airborne and the associated risks of inhalation. Key recommendations include improvements in Local Exhaust Ventilation (LEV), consistent use of Respiratory Protective Equipment (RPE), and adopting safer cleaning practices. By implementing these strategies, the facility can manage dust exposure effectively, reducing the risk of respiratory conditions and ensuring compliance with COSHH regulations.

Wood dust exposure in manufacturing settings poses serious health risks, from respiratory irritation and asthma to increased cancer risk with hardwood dust. Understanding the mechanisms and risks associated with wood dust inhalation is crucial for ensuring a safe and compliant workplace. This article explores the health implications of both hardwood and softwood dust, standard assessment methodologies, and practical control measures. With insights into Local Exhaust Ventilation (LEV), Respiratory Protective Equipment (RPE), housekeeping, and training, businesses can mitigate these risks effectively. Implementing these measures not only protects workers but also helps companies meet COSHH and international safety standards.

Sysco Environmental Ltd conducted a thorough indoor air quality assessment in the historic crypts of Northwood Cemetery, London. This evaluation targeted various contaminants, including VOCs, formaldehyde, hydrogen sulphide, carbon dioxide, carbon monoxide, asbestos, heavy metals, ionising radiation, radon gas, and fungal spores. Our findings confirmed that all contaminant levels were within safe limits, ensuring a safe environment for entry and work. The project highlights our expertise in handling unique and challenging environments, emphasising our commitment to maintaining health and safety standards.

Sysco Environmental Ltd conducted a hazardous substances assessment at a fabrication workshop in Northwich. Welding operations, whether at small fabricators or large engineering firms, expose individuals to significant hazards such as burns, electric shocks, and harmful fumes. Our mission was to ensure that welding operations were safe and compliant with health regulations. By implementing robust safety practices and proper use of Personal Protective Equipment (PPE), we aim to protect welders from potential risks. The assessment revealed varying levels of airborne contaminants, highlighting the need for immediate action in some areas. Our recommendations include training in the use of Local Exhaust Ventilation (LEV) systems, regular health surveillance, and maintaining a tidy and well-ventilated workspace to ensure the well-being of all workers.

Sysco Environmental Ltd performed a hand-arm vibration assessment at a Sheffield manufacturing facility. The assessment measured employees' exposure to vibrations from various tools and machinery, identifying high-risk areas and recommending control measures. By adhering to HSE guidelines and ISO standards, we aim to mitigate health risks associated with hand-arm vibration syndrome (HAVS) and ensure regulatory compliance.

Sysco Environmental Ltd conducted an indoor air quality assessment at a historic library in Leeds, focusing on the basement used for book storage. The library, with its extensive collection of rare books, has faced long-standing issues with dampness and mould growth. Using spore trap sampling, culturable methods, and moisture mapping, the assessment identified high concentrations of Aspergillus/Penicillium spores, particularly in hotspots like Book Store 4 Centre. Surface samples confirmed the presence of Aspergillus brasiliensis, indicating active mould growth. Recommendations included improving ventilation, using respiratory protection, implementing health precautions, and regular monitoring to maintain stable environmental conditions. These measures aim to prevent microbial decay of sensitive materials and ensure a safer environment for staff and visitors.

Sysco Environmental Ltd recently conducted an extensive historic plaster anthrax survey at Lansdowne Primary School in Cardiff. Our aim was to locate and identify any animal hair plaster that could potentially contain Bacillus anthracis spores, ensuring the safety of both workers and occupants during essential roof repairs. The survey, which covered Blocks 1, 3, 5, 6, and 7, revealed the presence of animal hair plaster but no anthrax contamination. Despite this, we recommended that all non-accessed areas be presumed contaminated until verified. Our report underscores the importance of continuous monitoring and proper management of hazardous materials, advising the recording of any discovered animal hair plaster in a register and the implementation of a re-inspection regime. This case study exemplifies our commitment to rigorous environmental risk assessment and the meticulous planning required to manage potential hazards in historical buildings, ensuring the safety and preservation of these structures.

Sysco Environmental Ltd conducted an indoor air quality assessment at aPrimary School in Rugeley due to complaints of unusual odours, stuffiness, and headaches. Following WHO and HSE guidelines, we assessed airborne moulds, VOCs, carbon monoxide, particulates, temperature, and humidity. Findings showed indoor mould concentrations were lower than outdoors, with minimal health risks from VOCs and zero carbon monoxide levels. However, temperature and humidity levels often exceeded recommendations, causing discomfort. We recommended improving fresh air supply, using humidifiers, and adding house plants. Our detailed assessment and tailored recommendations ensure a healthier environment for the school's occupants.

Sysco Environmental Ltd conducted a historic plaster anthrax risk survey at the Grade 2 listed Old Bank Building in Manchester. The survey aimed to identify animal hair in the plaster and assess health risks associated with Bacillus anthracis. Our team inspected all accessible areas, collecting bulk samples with stringent safety protocols. Animal hair plaster was found in various parts, but no Bacillus anthracis spores were detected. This ensures safe redevelopment while preserving the building's historical integrity. Sysco Environmental Ltd is committed to managing potential risks and ensuring health and safety compliance in refurbishment projects.

This case study presents a detailed hazardous substances assessment conducted at a copper manufacturing facility specialising in high conductivity copper castings. The study identifies significant inhalation hazards, particularly respirable crystalline silica, copper fume, and inhalable dust, encountered during various stages of the smelting and casting processes. Results indicate multiple instances where exposure limits were exceeded, necessitating immediate and routine interventions. The recommendations include enhanced respiratory protective equipment, effective local exhaust ventilation systems, comprehensive health surveillance programs, and regular training sessions. These measures aim to mitigate risks and ensure a safe working environment for all employees.

This case study details a comprehensive mercury vapour survey conducted in a large hospital setting. Utilizing direct reading instruments, the survey targeted areas likely to contain mercury contamination, such as patient examination rooms, laboratories, and maintenance workshops. Over several days, real-time measurements provided immediate feedback on mercury vapour concentrations. The findings revealed no significantly elevated mercury levels, allowing the client to proceed with the demolition project on schedule and without extra decontamination expenses. The survey ensured a safe, efficient, and cost-effective approach to managing hazardous materials in the hospital environment.

Sysco Environmental Ltd conducted a mercury survey at School, assessing contamination levels in various locations. Results indicated that mercury levels were below the limit of detection (LOD), confirming minimal health risks. This case study highlights the effectiveness of safety measures and the thorough evaluation provided by Sysco Environmental Ltd.

Sysco Environmental Ltd performed a comprehensive occupational exposure assessment at a semiconductor manufacturing facility. The study focused on measuring atmospheric concentrations of solder rosin, aldehydes, and volatile organic compounds, determining employees' daily personal exposure levels, and advising on suitable risk control measures. While heavy metals were not the primary focus, the findings provided valuable insights into broader health and safety risks, highlighting the importance of robust ventilation systems, personal protective equipment, and regular training. The results confirmed that exposure levels were within safe limits, ensuring a safer working environment.

Sysco Environmental Ltd conducted an in-depth mercury exposure monitoring survey at a former hospital development site. The study aimed to identify chemical contaminants in the underground ductwork, assess health risks, and recommend safety measures. Using personal samplers, portable meters, and chemical analysis, the team detected significant mercury vapour levels, necessitating immediate decontamination. Other contaminants, including carbon dioxide, carbon monoxide, sulphur dioxide, hydrogen sulphide, ammonia, and volatile organic compounds, were found within safe limits. The project underscored the importance of thorough environmental assessments and stringent safety protocols to protect workers and residents in historically contaminated areas.

Sysco Environmental Ltd performed a comprehensive diesel fumes air quality assessment for Fire and Rescue Services. The study aimed to measure diesel fume levels during various vehicle operations and assess potential health risks to firefighters. The assessment utilised personal samplers, portable meters, and dataloggers over five days, providing a robust data set. Findings indicated minimal risk, with concentrations of elemental carbon, total carbon, and carbon monoxide not exceeding workplace exposure limits. Recommendations included regular maintenance, effective ventilation, and reducing engine idling. This proactive approach ensured firefighter safety, regulatory compliance, and operational efficiency.

In February 2024, Sysco Environmental Ltd conducted a comprehensive air quality assessment in a confined Sprinkler Plant Room to evaluate diesel exhaust emissions from an emergency generator. Using personal samplers, portable meters, and dataloggers, the study measured gases and particulates, ensuring safe operation levels. The findings verified that emissions were within permissible limits, safeguarding employees and the public. This assessment supports regulatory compliance, enhances safety protocols, and provides a solid foundation for health and safety audits, verifying the safe operation of critical equipment.

Dive into the intricacies of Sysco Environmental Ltd's pioneering dust monitoring initiatives amidst the bustling construction activities in the esteemed Holland Park, London. Our comprehensive case study unveils the meticulous methodologies and advanced equipment employed to uphold stringent environmental standards. With a keen focus on continuous monitoring and timely intervention, our tailored solutions ensure the protection of both the local community and the delicate ecosystem. Join us on a journey of environmental stewardship as we navigate the complexities of construction while prioritizing health, compliance, and sustainability in this iconic development project.

In this case study, we delve into a large commercial development project in central London, focusing on the indoor air quality assessment carried out to satisfy the requirements of the BREEAM scheme, particularly the HEA02 part. The importance of building sustainable structures, understanding the role of Total Volatile Organic Compounds (TVOC), and formaldehyde in indoor air quality are explored in-depth. With meticulous adherence to our recommended sampling methodologies and stringent reference limits, the project was awarded the coveted BREEAM credit, validating the indoor air quality measures implemented.

This case study presents our work in monitoring and controlling occupational exposure to metalworking fluids in a manufacturing setting. We provide an in-depth analysis of workplace conditions, operative tasks, and exposure levels of harmful substances. Our actionable recommendations, focused on preventive measures, engineering controls, and health surveillance, aim to ensure regulatory compliance and worker safety. Our expertise in occupational exposure monitoring can help businesses identify and mitigate risks, leading to a safer and more productive work environment.

n the field of lithium-ion battery recycling, our expertise in occupational exposure monitoring has allowed us to identify and mitigate the health risks associated with handling various contaminants. Through comprehensive monitoring, we have assessed exposure to dust, volatile organic compounds, and microbiological agents, providing valuable insights to our client. By recommending engineering controls, implementing health surveillance programs, and delivering tailored solutions, we have helped improve the management of health and safety in this evolving industry.

This compelling case study delves into our extensive experience in the field of electroplating safety and showcases our expertise in mitigating health risks and ensuring compliance. We partnered with a prominent company in the electroplating industry, committed to prioritizing worker safety and adhering to stringent regulatory standards. By thoroughly assessing the health hazards associated with electroplating chemicals, we implemented effective control measures to protect workers from inhalation of acid aerosols, chemical splashes, burns, skin exposure risks, eye irritation, and irritating fumes. Our approach included implementing robust engineering controls, providing appropriate personal protective equipment, conducting comprehensive training programs, and fostering a culture of safety. Through our collaborative efforts, we enabled the company to create a safer work environment, minimize occupational health risks, and demonstrate their commitment to the well-being of their workforce.

In our latest case study, we examine the issue of hand-arm vibration (HAV) among ground maintenance operatives. By leveraging our expertise in occupational exposure monitoring, we were able to assess and address potential risks in a proactive manner. The study discusses our methodology, observations, and the strategic recommendations we provided to our client, enabling them to ensure compliance with the Control of Vibration at Work Regulations 2005, while significantly enhancing the health and safety of their ground maintenance operatives.

This case study delves into our robust methodology for the identification, monitoring, and mitigation of exposure to diesel exhaust fumes in the railway depot maintenance sector. Using a blend of specific indicators and rigorous analytical methods, we captured precise exposure data, compared it against recognized workplace exposure limits, and provided evidence-based recommendations to enhance health and safety. The study illuminates our commitment to creating safer working environments and our competency in handling complex occupational health challenges.

Our case study outlines a detailed noise exposure assessment we conducted for a client's workshop. With potential health risks due to excessive noise exposure, we provided clear, actionable steps to control the situation, ensuring compliance with relevant regulations and contributing to a safer working environment.

Our comprehensive hand and arm vibration exposure assessments deliver tailored solutions to mitigate risks and protect workers' health. With our expert guidance, you can effectively manage vibration-related hazards and create a safer working environment.

This case study provides a detailed examination of a commercial bakery where workers were being exposed to hazardous levels of flour dust. A thorough investigation and assessment were conducted to understand the extent of exposure and its associated risks. Practical and cost-effective strategies were recommended, leading to significant improvements in the working conditions. Flour dust levels were successfully reduced to 2mg/m3, in compliance with HSE good practice guidelines, which resulted in enhanced worker safety, increased productivity, and minimized legal risks for the bakery. The case study showcases our expertise in managing occupational health risks and fostering safer workplaces.

In this case study, we present our experience in effectively managing health and safety concerns during the refurbishment of a historic building. Initially, our mission was to identify potential Bacillus anthracis exposure due to the presence of animal hair plaster, a common material in historic constructions. While no Bacillus anthracis was found, we identified other health risks and recommended crucial protective measures. Our approach underscores the importance of comprehensive risk assessments in ensuring safe and responsible refurbishment projects.

This case study offers a deep-dive into a challenging mould contamination situation in a school environment. Faced with significant mould spore concentrations and potential health risks, our team employed a comprehensive methodology to identify the root cause, manage the situation, and ensure successful remediation. Discover the value of swift, expert response to environmental concerns in educational settings.

This case study showcases our comprehensive assessment and strategic mitigation plan for managing lead exposure at an indoor shooting range. Our intervention led to a substantial reduction in workplace exposure limits, elimination of lead from employees' blood, and establishment of robust health surveillance.

This case study outlines our comprehensive evaluation of a rubber production facility, focusing on the exposure of operatives to rubber dust and fumes. By employing methods such as MDHS 14/4, MDHS 47/3, and MDHS 104, we were able to pinpoint gaps in the facility's safety protocols, including underutilized or absent local exhaust ventilation systems, inadequate respiratory protective equipment, and a lack of regular health surveillance. Our actionable insights provided the client with a roadmap to enhance the safety and health of their employees, demonstrating our competence and commitment in the field of industrial hygiene.

This case study delves into the assessment of isocyanate exposure in an art studio, a unique and ever-changing creative setting. We highlight the challenges posed by the continuously evolving processes, materials, paints, and adhesives, as opposed to established and fixed procedures in typical industrial environments. Our expert team employed the MDHS 25/4 method to evaluate isocyanate levels accurately. The assessment revealed insights into the potential exposure risks and health effects associated with isocyanates. The conclusions emphasize the need for proactive measures to maintain exposure levels below the workplace exposure limits. Our recommendations focus on elimination strategies, personal exposure monitoring, inspection and maintenance protocols, instruction and training enhancements, and the implementation of an in-house health surveillance program. By following these recommendations, the art studio can ensure a safe working environment and safeguard the health of its employees.

This case study focuses on a large-scale steel fabrication company, where welding plays a crucial role in the production process. The inherent difficulties in controlling welding fume exposure, due to the need for movement and large distances to cover, pose generic risks to the workforce. Our assessment aimed to evaluate the exposure levels of various metallic components in welding fumes, including manganese, chromium, and nickel. We followed recognized methods and guidelines to measure personal exposure and compared the results against relevant Workplace Exposure Limits (WELs). Our findings highlight the potential health effects of prolonged exposure to these metals and provide recommendations to mitigate risks and enhance the safety of workers in the industry.

This case study details our comprehensive dust exposure assessment conducted for a construction company. Despite adherence to safety regulations, our specialized approach identified specific areas and tasks where dust and Respirable Crystalline Silica (RCS) exposure exceeded acceptable levels. We provided actionable recommendations to reduce exposure and enhance overall workplace safety, emphasizing the value of regular monitoring and proactive risk management in the construction industry.

This case study delves into the crucial aspect of occupational health risks in the kitchen worktop industry, focusing particularly on exposure to respirable crystalline silica. By adopting rigorous methodologies compliant with the MDHS guidelines, we unravel the risks inherent in everyday operations and provide pragmatic, safety-enhancing solutions. This case study emphasizes the need for regular risk assessments and proactive safety measures, underscoring our commitment to safeguarding employee health.

As industry-leading professionals, we deliver comprehensive radon assessment services for commercial properties. Utilizing state-of-the-art technology and methodologies, our expert team meticulously measures radon levels and interprets the findings. We assess potential risks, provide actionable insights, and offer guidance on measures to maintain radon concentrations within safe and legal limits. Our commitment to safety goes beyond mere compliance with regulations. We proactively partner with our clients to promote a healthier, cleaner, and safer working environment, highlighting potential areas of concern, and suggesting remedial actions. Trust us to ensure the wellbeing of your workforce and the ongoing health and safety of your commercial space.

Sysco Environmental Ltd excels in conducting comprehensive lead surveys and hazard identification for large-scale sites. With our advanced technologies and expertise, we ensure the thorough assessment of lead-based paint presence, guaranteeing the safety of workers and future occupants. Our meticulous inspections cover both interior and exterior surfaces, delivering immediate and accurate results. We pride ourselves on providing unparalleled service to the industry, utilizing cutting-edge methods that allow us to survey extensive areas efficiently. Trust Sysco Environmental Ltd for reliable lead survey solutions that meet regulatory standards and safeguard the health and well-being of all stakeholders.

In lead removal projects, ensuring site safety is crucial. Sysco Environmental specializes in managing lead removal projects to protect workers and maintain compliance. Our comprehensive approach involves rigorous monitoring, on-site analysis, and immediate action to address any issues. With our expertise and commitment to safety, we can effectively manage lead removal, prevent the escape of lead contaminants, and safeguard the well-being of workers and the environment. Trust Sysco Environmental for reliable and compliant lead removal solutions.

This case study presents a comprehensive lead-based paint survey conducted by Sysco Environmental Ltd on a residential property. The assessment involved an exhaustive XRF analysis and a visual inspection of interior and exterior surfaces, revealing varying lead concentrations in the paint. Despite the generally good condition of the lead-based paint, friction on surfaces such as doors and window frames can create lead-containing dust. The primary exposure risk was identified during refurbishment and redecoration activities, highlighting the need for proper safety precautions and controls. The study underscores the necessity for such surveys to safeguard the health of occupants and workers, while also complying with regulatory requirements.

This case study explores a proactive approach to manage dust exposure at a wood products company, focusing on robust risk assessments, effective control measures, and specialized training

This case study investigates mould infestation in a large residential hotel. Initially, air quality issues were linked to dampness and high airborne fungal spore concentrations. Sampling, conducted in compliance with ISO 16000-20 Indoor Air standards, utilised Sysco Environmental Ltd's analysis process. After targeted mould remediation efforts, a significant decrease in airborne spores was recorded, indicating improved indoor air quality. The findings confirmed the safety of the rooms for occupancy, demonstrating the effectiveness of strategic interventions in ensuring a healthy environment in large-scale accommodation establishments.

Sysco Environmental effectively assessed and managed extensive mould contamination at a large masonry and brick manufacturing facility, safeguarding the health of the facility's operatives and maintaining indoor air quality.