Guest Blog from NFU Mutual – Top 10 Hazards, Controls and Injuries in UK Woodworking

BWF affiliate partner NFU Mutual takes a look at the real-world risks faced by woodworking businesses.  Highlighting the main industry hazards, common injuries, and practical controls to help strengthen claims defensibility.  Drawing on guidance from the UK’s Health and Safety Executive (HSE), NFU Mutual outline the top 10 hazards in woodworking and the controls recommended to keep workers safe.

Woodworking is an inherently high-risk activity, presenting multiple hazards that, if not effectively controlled, can result in severe injuries and complex liability issues. To highlight this, NFU Mutual is running a Mock Trial exclusively for BWF Members on 1st October 2025, focussing on a personal injury case involving machinery in a joinery workshop.

1. Machinery-Related Hazards: Contact with moving parts, such as saw blades, cutters, and rotating tools, can cause severe injuries, including amputations, lacerations, and crushing. 

Controls:

• Use of appropriate guards on all machines.
• Ensuring emergency stop controls are easily accessible.
• Regular maintenance and inspection of machinery.
• Training workers on safe operation procedures.

2. Dust Exposure: Inhalation of wood dust can lead to respiratory issues, including occupational asthma, and in some cases, certain types of cancer. 

Controls:

• Installation of effective Local Exhaust Ventilation (LEV) systems.
• Use of dust extraction systems and vacuum cleaners instead of sweeping.
• Providing appropriate Respiratory Protective Equipment (RPE).
• Regular health monitoring for workers exposed to wood dust.

3. Noise Exposure: Prolonged exposure to high noise levels from machinery can cause hearing loss. 

Controls:

• Implementing engineering controls to reduce noise at the source.
• Providing Personal Protective Equipment (PPE), such as ear defenders or plugs and monitoring its use by workers.
• Regular noise assessments and health surveillance for workers.

4. Manual Handling: Lifting, carrying, or handling heavy or awkward loads can lead to musculoskeletal disorders, including back injuries. 

Controls:

• Providing mechanical aids such as trolleys or hoists.
• Training workers on proper lifting techniques.
• Reducing the need for manual handling by designing work processes.

5. Kickback: Sudden and forceful ejection of wood from machinery, particularly table saws and planers, can cause injuries. 

Controls:

• Properly setting up and adjusting machines to prevent kickback.
• Using push sticks or push blocks to guide wood.
• Training workers on recognizing and preventing kickback scenarios.
• Supervision and monitoring good working practices.

6. Fire and Explosion: Accumulation of wood dust in the air or on surfaces can create a fire or explosion hazard. 

Controls:

• Keeping work areas clean and free of dust accumulation.
• Installing fire detection and suppression systems.
• Storing flammable materials away from ignition sources.
• Regularly emptying dust extraction systems and disposing of dust safely.

7. Vibration Exposure: Prolonged use of vibrating tools (e.g., sanders, saws, drills) can lead to hand-arm vibration syndrome (HAVS). 

Controls:

• Providing tools with lower vibration levels.
• Limiting the duration of exposure through job rotation.
• Regular health surveillance and training on recognizing early symptoms of HAVS.

8. Electrical Hazards: Faulty wiring, poor maintenance, or incorrect use of electrical equipment can lead to electric shock or fire.

Controls:

• Ensuring all electrical installations comply with regulations and are suitable for a dusty environment.
• Regular inspection and maintenance of electrical equipment.
• Training workers on safe use and reporting faults immediately.
• Use of Residual Current Devices (RCDs) for additional protection.

9. Slips, Trips, and Falls: Slippery surfaces, obstacles, or uneven flooring can lead to slips, trips, and falls. 

Controls:

• Keeping walkways and work areas free of obstacles.
• Using non-slip flooring materials.
• Ensuring good housekeeping practices.
• Providing appropriate footwear with slip-resistant soles.

10. Chemical Exposure: Exposure to wood preservatives, adhesives, solvents, and other chemicals can cause skin irritation, respiratory issues, or long-term health effects. 

Controls:

• Using less hazardous substances where possible (substitution).
• Providing adequate ventilation and using LEV systems when working with chemicals.
• Providing appropriate PPE such as gloves, goggles, and respiratory protection.
• Ensuring proper storage, handling, and disposal of chemicals.

Most common 10 injuries

Woodworking can be a hazardous activity, and injuries are common among workers in this field. Below are the top 10 injuries reported in woodworking in the UK:

1. Amputations: The most severe and catastrophic injuries, often resulting from contact with moving machinery parts, such as saw blades or cutters.

Common Causes: Unprotected machinery, lack of safety guards, improper use of equipment, or failure to follow safety procedures.

2. Lacerations and Cuts: Deep cuts or tears in the skin, often requiring stitches or surgery.

Common Causes: Contact with sharp tools, such as saws, chisels, and blades. Mishandling of hand tools or accidents involving powered machinery.

3. Crush Injuries: Injuries where body parts, usually hands or fingers, are crushed between objects or caught in machinery.

Common Causes: Improper use of machinery, getting caught in moving parts, or failure to use safety guards.

4. Eye Injuries: Injuries to the eye, ranging from minor irritation to severe damage, including loss of sight.

Common Causes: Flying wood chips, dust, or debris during cutting, sanding, or drilling without proper eye protection.

5. Respiratory Issues: Long-term respiratory problems, including occupational asthma and, in some cases, chronic obstructive pulmonary disease (COPD) or cancer.

Common Causes: Inhalation of wood dust, especially from hardwoods, and exposure to chemicals used in finishes and adhesives.

6. Hearing Loss: Permanent or temporary hearing damage, often due to prolonged exposure to high levels of noise.

Common Causes: Continuous exposure to loud machinery, such as planers, routers, and saws, without adequate hearing protection.

7. Burns: Thermal or chemical burns affecting the skin.

Common Causes: Contact with hot surfaces, tools, or machinery, or exposure to hazardous chemicals used in woodworking processes.

8. Musculoskeletal Disorders (MSDs): Injuries affecting muscles, joints, and tendons, including strains, sprains, and repetitive strain injuries (RSIs).

Common Causes: Repetitive motions, overexertion, poor posture, and improper lifting techniques.

9. Vibration-Related Conditions: Conditions such as HAVS or carpal tunnel syndrome, resulting from prolonged use of vibrating tools.

Common Causes: Extended use of power tools such as sanders, grinders, or chainsaws without proper breaks or protective measures.

10. Slip, Trip, and Fall Injuries: Injuries resulting from slipping, tripping, or falling in the workplace, leading to fractures, sprains, or bruises.

Common Causes: Poor housekeeping, uneven or slippery floors, or obstructions in walkways.

While woodworking presents significant risks, these hazards can be effectively managed through robust safety measures, proactive training, and a strong culture of compliance. By implementing the right controls and fostering awareness, businesses not only protect their workforce but also strengthen their legal defensibility and reputation. The upcoming NFU Mutual Mock Trial offers an excellent opportunity to deepen understanding, share best practices, and demonstrate leadership in risk management—turning challenges into a platform for continuous improvement and resilience.  BWF members can reserve their free seat at the trial by logging into the Members Area of the website https://www.bwf.org.uk/members/login/