HSE and surface engineering

What is surface engineering?

Surface engineering refers to a wide range of technologies designed to modify the surface properties of metallic and non-metallic components for decorative and/or functional purposes. Examples include improving corrosion and wear resistance to extend component life; making items more visually attractive; and giving special properties such as lubricity enhancement, non-stick surfaces, etc. Surface engineering processes can classified as follows:

  • Aqueous electrolytic, normally consisting of electroplating of metal coatings, anodising of aluminium and titanium, as well as the electropolishing of stainless steel.
  • Electroless processes for those metals, notably copper, nickel, gold and tin that can be applied by chemical reduction methods and avoid the use of electrolytic energy.
  • Aqueous non-electrolytic typically cleaning, pickling, phosphating, passivation, mechanical plating and a variety of other colouring processes, eg "blacking" of steel.
  • Organic (liquid) which can be solvent or water based but applies pigmented or metal containing coatings by dipping, dip-spinning, flow coating, conventional spraying, or in the case of water based paints, by electrophoretic or auto-catalytic means.
  • Organic (powder), the application of dry powders, usually by the process of electrostatic spraying or by fluidised bed techniques.
  • Heat treatment. The use of heat, sometimes with specific gases, to metallurgically alter the structure and mechanical properties of a component. The component may be stress relieved, softened or hardened or even changed in composition especially where unique surface properties are desired.
  • Galvanizing. A process where ferrous articles are dipped into molten zinc (or an alloy of zinc) to produce a relatively thick surface layer giving protection against corrosion.
  • Tinning. A process where ferrous articles are dipped into molten tin (or an alloy of tin) to produce a relatively thick layer of tin (or tin alloy).
  • Metal spraying. A technique for uniquely transferring metals by the use of heat, plasma, or arc to the surfaces of prepared components.
  • Vitreous enamelling. The application of metallic glass containing liquids by dipping or spraying techniques on to ferrous components eg kitchen hobs.

Health & safety in surface engineering

A significant feature of the surface engineering industry is the diversity of the technology.

Most of the approximately 2000 companies in the UK industry operate in the sub-contract sector; ie offering processing techniques to the original equipment manufacturer (OEM). The majority are small companies employing less than 50 people and specialize in specific processes.

A number of larger companies have their own 'in-house' processes finishing their own manufactured components. In total the industry is a big business accounting for over £1 billion of sales per annum and employing over 10,000 people in the UK.

HSE's contact with the industry is mainly through the Surface Engineering Association's Health Safety and Environment Committee which, for over 10 years, has co-ordinated the interests and activities of all those involved with health and safety in the industry.

The industry has significantly higher accident rates (for fatal, major and 3-day injuries) than manufacturing as a whole. Indeed, whilst accident rates for manufacturing have dropped over the last 6 year period, in Surface Engineering industries they have increased. For example, the major injury rate for surface engineering has increased from 270 (per 100,000 employees) in 1996/7 to 445 in 2002/3 whereas the manufacturing industry rates have fallen from 206 to 196 over the same period.

Detailed statistics

The actual figures for serious and less serious injuries will be much higher than those quoted due to considerable under reporting to the enforcing authorities.

The main causes of injuries

  • Manual handling - eg through lifting/carrying heavy and/or awkward objects and account for 1/3 of all 3-day injuries.
  • Struck by - eg falling objects; moving vehicles
  • Slips and trips - eg on uneven floors or due to poor housekeeping; failure to promptly clear up spillages
  • Contact with a harmful substance (which has also caused the greatest number of fatalities over the period)
  • Falls from height - eg from ladder, elevated walkways.
  • Contact with moving machinery - eg movement of jig transporters

Over the past 6 years these causes have accounted for over 85% of all reported injuries.

Main causes of ill health

There is also considerable underreporting of cases of occupational ill health.

However, available evidence suggests that the main causes are:-

Case studies of typical injuries and ill-health

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Updated: 2025-07-17