Hielaman was appointed to carry out a DSEAR risk assessment and hazardous area classification for Rising Sun Campers, a campervan conversion business operating from three light industrial units in Coventry. The site included a spray room, mechanical workshop and wood workshop, each with different dangerous substances and ignition risks, including solvent-based adhesive spraying, diesel storage, LPG canisters, flammable aerosols and combustible wood dust.
The assessment reviewed how flammable vapours, mists and combustible dusts could arise during normal work activities, and whether existing controls were sufficient to protect staff, customers, contractors and lone workers. Particular attention was given to the spray application of highly flammable adhesive, the condition and effectiveness of the wood dust extraction system, diesel storage arrangements and the suitability of equipment used within potentially hazardous areas.
What We Assessed
The project considered the following processes and risk areas across the site:
- Solvent-based adhesive spraying within a dedicated spray room
- Wood cutting, sanding and dust extraction
- Diesel storage and handling in the mechanical workshop
- LPG canisters stored within converted vans
- Flammable aerosol use during maintenance activities
- Hot works, grinding and fabrication
- Existing ventilation, extraction, signage, training and maintenance arrangements
Key Findings
The assessment identified that the spray room presented a credible Zone 1 hazardous area during active spraying, due to atomised flammable adhesive mist and vapour. The wood workshop also required improvement due to combustible dust accumulation, damaged extraction ducting and a lack of recent LEV verification records.
Diesel storage arrangements were assessed as primarily a fire risk rather than an explosion risk under normal UK ambient conditions, with improvements recommended for separation, signage and storage control.
The overall site risk was assessed as Moderate, mainly due to flammable adhesive spraying, combustible wood dust accumulation and incomplete maintenance records. With the recommended controls implemented, the residual risk could be reduced to Low.
Our Recommendations
Hielaman provided a clear, practical action plan, including:
- Verifying the spray room ventilation performance and clearance time
- Reviewing equipment suitability within the spray room Zone 1 area
- Arranging LEV thorough examination and performance testing
- Removing excessive wood dust deposits using suitable industrial vacuum equipment
- Repairing damaged dust extraction ductwork
- Installing bonding and earthing to the extraction system
- Improving flammable liquid storage, waste controls and signage
- Introducing DSEAR-specific staff briefings and training
- Formalising hot work, engine isolation and inspection procedures
Outcome
The completed DSEAR assessment gave Rising Sun Campers a clear understanding of where fire and explosion risks existed, which areas required hazardous area classification, and what actions were needed to improve compliance. The report provided a proportionate, workshop-specific basis of safety, helping the business prioritise practical improvements without unnecessary over-zoning or disruption to operations.