







This project was all about taking a practical, real-world look at how hazardous substances are handled in a busy industrial workplace in Coventry. Instead of diving into heavy technical jargon, the aim was simple: understand what workers are breathing in day-to-day, how substances behave around the shop floor, and whether the current controls are doing their job.
Over a couple of site days, the assessment focused on areas where chemical baths, metal processing, and manual handling come together — the places where airborne contaminants are most likely to appear. Personal exposure monitoring was carried out alongside static checks placed near the busier process lines. Together, these gave a clear picture of how substances move, settle, and disperse in normal working conditions.
The reassuring news? All measured exposure levels were comfortably below the recognised Workplace Exposure Limits (WELs). That doesn’t mean the job is done, though. The report highlights that even when exposure is low, good habits and sensible controls make all the difference — especially when dealing with substances that can irritate the skin, affect breathing, or cause long-term health issues if left unmanaged.
A few simple improvements were suggested, such as tightening up how chemical bath lids are managed, ensuring the right type of respiratory protection is available for vapour-producing tasks, and keeping food and drink off the shop floor. These aren’t major overhauls, just everyday tweaks that help reinforce a safer working culture.
Overall, the assessment paints a positive picture: controls are working, exposure is low, and with a bit of ongoing housekeeping and awareness, the workplace can continue operating safely and confidently.
This project looked at day-to-day work activities on a busy development site in Baginton, focusing on how workers might come into contact with hazardous substances during normal tasks. The whole idea behind the assessment was really just to get a clear, honest picture of what people were breathing in and being exposed to, and whether anything needed tightening up to keep everyone safe.
A big part of the job involved watching how tasks were carried out — especially cutting and handling materials that naturally generate dust. Even though the site was open-air and pretty well-ventilated, some activities still created noticeable dust levels around workers. The assessment picked up patterns in how exposure varied, mostly depending on the tools being used and whether extraction systems or respiratory protection were actually worn at the right times.
What stood out most is that the risks weren’t out of control, but they were definitely significant enough to take seriously. The report highlighted a few simple things that could make a real difference: reminding teams to use the on-tool extraction systems consistently, rotating tasks so the same people aren’t always doing the dust-heavy work, and keeping respiratory protective equipment in proper use. None of this is complicated — it’s more about small behaviours adding up.
Another important part was recognising that even when exposure levels look “low,” you can’t assume everything is fine forever. Work patterns change, tools age, and conditions shift, so the site needs to keep checking in on these risks regularly. Overall, it’s a project that shows how everyday tasks can quietly create hazardous exposures, but also how manageable the situation is when people stay aware, use the right kit, and keep improving controls bit by bit.
Sysco Environmental Ltd recently conducted a hazardous substances assessment at an industrial facility in Coventry. The objective was to evaluate employee exposure to various hazardous substances and recommend control measures to ensure a safe working environment.
Our assessment focused on measuring atmospheric concentrations of hazardous contaminants, specifically targeting inhalable and respirable dust, volatile organic compounds (VOCs), and other specific chemicals like xylene and limonene. We monitored different operational areas including the picking station, JCB cabs, and the plant operator’s station.
Results showed that inhalable dust levels for cleaning operatives and plant operators exceeded Workplace Exposure Limits (WELs). Picking station and banksman operatives had significant exposure levels, but below the WELs. Operatives in all areas were found to have exposures below WELs for respirable dust and VOCs.
To mitigate these levels, several recommendations were made. Improved housekeeping practices, such as avoiding dry sweeping and using HEPA-filtered vacuum cleaners, are crucial. It is advised to minimise the use of compressed air guns for cleaning and to rotate operatives between high and low exposure tasks to reduce individual exposure. Additionally, the installation of mechanical ventilation in the warehouse and enclosing conveyor systems can help manage dust levels.