How to reduce hearing damage risk by 90% at negligible cost by improving risk management programmes

hearing protection PPE does not work well...

There is also an article on using these changes to reduce Noise Induced Hearing Loss (NIHL) published by the British Safety Council and a BOHS noise risk management webinar video that brings together 3 leading experts and innovators in the key fields of noise control, PPE and health surveillance.

I'd like more information on the new approach to noise risk reduction

Hearing protector performance - 3dB attenuation when you expected 30dB

It has been known for decades that it is virtually impossible to guarantee adequate protection from hearing protectors at noise levels above c 95dB(A). Consequently, it should not have been news that research by the Health and Safety Laboratory (report RR720) proved that the common assumption that PPE is a reliable “solution” to hearing damage risk problems is false. This assumption has left many personnel at risk and companies are open to claims if their hearing conservation policy is based on PPE use. Some of the key findings of the research are:-

PPE in 25% of the companies visited was so ineffective that it provided negligible or no protection for most
even in companies with effective PPE use, 14% of workers did not wear protectors when and where required
40% of the workers who should have been wearing protectors got no protection at all

It is almost impossible to guarantee adequate PPE protection above 90dB(A)…

The inadequacy of PPE performance in many real-world situations is also born out by the continuing tidal wave of hearing damage claims of £400 million in one year (2014 - IFA UK deafness working party), despite (or even because of) the over-reliance on PPE without understanding the performance limitations away from the lab. This also brings into sharp focus the need to reduce noise levels to reduce risk, even when the levels cannot be reduced to below 85dB(A).

As a rule of thumb, provided effective management systems are in place, most good quality PPE can be made to work up to noise exposure levels of around 90dB(A) to reduce operator exposure to below 80dB(A). Above this level, as an attenuation of more than 10dB is required, it becomes seriously difficult to guarantee adequate protection. At noise levels above c 95dB(A) - 100dB(A), it is virtually impossible without introducing very stringent, time-consuming controls - and even then it may not be practical...https://www.britsafe.org/publications/safety-management-magazine/safety-management-magazine/2022/noise-at-work-time-for-a-new-approach/https://www.britsafe.org/publications/safety-management-magazine/safety-management-magazine/2022/noise-at-work-time-for-a-new-approach/

Most organisations have hearing conservation programmes that are not based on this information. Consequently, millions of workers have suffered unnecessary hearing damage. The key issues are:-

earplugs are rarely correctly fitted. This can can cut the attenuation from 30dB down to as little as 2dB
earmuffs should be assumed to provide a maximum workplace use attenuation of c 10dB - 17dB, whatever the protector
wear rate should be 100%, but virtually never is - and could you prove it is? Every day? No PPE for a total of 10 minutes a day limits the attenuation to < 17dB

Manufacturers' PPE data says assumed protection of 27dB. Assumption: we're good for 107dB(A). Reality: they may be providing only 3dB - 10dB of attenuation as used which means adequate protection up to only 83dB(A) - 90dB(A)...

The key (and very often missing) factors necessary to improve real-world hearing protection are:-

you must have a system in place to audit wear rate. It is unbelievable that most organisations do not log wear rates and consequently have no idea of the effectiveness of their PPE.
you must train staff in the correct fitting and use of PPE (fit testing). This is particularly critical for earplugs where the assumed protection of 30dB (manufacturer) can often drop as low as 3dB in use
consider using the new generation of intelligent PPE that continuously logs wear rate and attenuation to the cloud automatically. This provides automated verifiable evidence that users are sufficiently protected that can be used to monitor the efficacy of programme and to guide improvements

Don't repeat placebo noise risk assessments

Don't repeat these assessments - or repeat these assessments. Update elements if noise levels have changed significantly. Bear in mind that the HSE says you do not even need to measure with a meter and that you should start to implement noise exposure risk reduction measures as soon as you know the levels are likely to be above 80dB(A). Reports without practical information on noise control are, by definition, inadequate.

Investing in a Noise Control Audit (NCA) is best practice. This is an engineering evaluation that generates a cost/benefit analysis of the noise control options for plant or areas.to provide the information needed to plan the most cost-effective risk reduction programme. This analysis allows you to balance the reduced risk against costs (capital, reduced PPE, audiometry and management costs, improved working conditions, productivity...).

Anyone can make a basic evaluation of the likely control options from online information or by using of our free email analysis service. The regulations state that PPE cannot be used for long-term risk management unless you can prove that noise control is impractical.

Noise control made simple

General knowledge about modern noise control best practice (even amongst noise specialists ) is abysmal. As a result, good, costed control advice in noise reports is conspicuous by its absence.

The following is the relationship between reduction in noise (dB) and reduction in risk (%).

-3dB - 50% risk reduction
-5dB - 67% risk reduction
-7dB - 80% risk reduction
-10dB - 90% risk reduction

This means, for example, reducing noise from 97dB(A) to 90dB(A) cuts employee risk by 80%. Whilst personal hearing protection is still required, the risk has been reduced by 80% and it is much easier to guarantee adequate PPE performance. Most organisations can cut risk 50%-90% at little cost (or even at a profit) by using the latest noise control technology. The question is...

Q: "How do I find the best noise control options?"

A: consult freely available online engineering noise control case study databases e.g. HSE, INVC

A: use our free online noise control option analysis service (email smartphone video clip and photos) for a cost/benefit analysis of the options based on current best technology

Many noise problems have simple solutions that can be found online and implemented by any competent engineer e.g. "Detailed solutions to the 10 most common industrial noise problems"

Health surveillance

Tradition audiometry is essentially a check-box exercise. Discuss...

Conventional audiometry provides data that is of little use in risk management as it just catalogues failures in risk reduction strategy years later. Whilst it can be useful as a motivational tool, traditional audiometric testing is essentially a check-box exercise to comply with regulatory stipulations.

The newer Otoacoustic Emission (OAE) hearing tests, however, can detect the early stages of damage, making it an effective tool to assess the efficacy of hearing damage risk management programmes. This allows you to monitor how well the hearing protection programme is working and provides a valuable educational and motivational tool. How much motivation would the statement "You had 12% damage last year, this year it is 18%" provide?

Combining NIHL risk reduction measure examples

By combining the techniques described above, it is possible to reduce the risks to hearing by 75%-90% or more in virtually every case and at zero, or negligible, cost. Taking typical examples:-

Food processing plant: 35 staff in area

Before

Noise level = 91dB(A)

PPE attenuation as used was 3dB to 5dB, so operator exposures = 86dB(A)-88dB(A)

After

Noise level = 84dB(A) via hygienic noise control £3k costing £86/head

PPE attenuation improved to 6dB - 10dB (@ no cost), so operator exposures = 75dB(A)-79dB(A)

Profitable within c 3 months

Heavy industry (power press): 12 staff in area

Before

Noise level = 1 op.@ 102dB(A), 11 ops. > 94dB(A)

PPE attenuation as used was 5dB - 10dB, so operator exposures = 1 @ 92dB(A)-97dB(A), 11 @ 84dB(A)-89dB(A)

After

Noise level = 1 op.@ 87dB(A), 11 ops.< 83dB(A) (noise control £4k costing £333/head)

PPE attenuation improved to 10dB (@ no cost), so operator exposures = < 77dB(A)

Profitable within c 1 year

Bakery: c 40 staff in area

Before

Noise level = 86dB(A)-96dB(A)

PPE attenuation as used = c 5dB, so operator exposures = 81dB(A)-91dB(A)

After

Noise level = < 80dB(A) (hygienic noise control £13k costing £325/head)

No PPE required saving c £13k with operator exposures < 80dB(A)

Profitable within 1 year

Noise risk management - It's Time to Change

Current noise risk management procedures have failed to protect staff sufficiently from avoidable noise-induced hearing loss. As a result, millions have suffered unnecessary damage including hearing loss and tinnitus. The damage caused by noise exposure also includes a 9% - 27% increased risk of dementia, making noise the dominant modifiable dementia risk factor.

The improvements detailed here can reduce these risks by 75% - 90% at zero or negligible cost compared with current practices.