Peninsular Acoustics was commissioned to undertake a Noise at Work Assessment for a specialist timber case manufacturing facility in Birmingham. The purpose of the assessment was to quantify employee noise exposure within the warehouse environment and ensure compliance with the Control of Noise at Work Regulations 2005.
Industrial workplaces often contain a range of noise sources including machinery, saws and impact processes. Without proper assessment, these activities can expose workers to levels of noise that may cause long-term hearing damage. This project demonstrates how structured acoustic assessments can help organisations maintain regulatory compliance while protecting the health and wellbeing of their workforce.
The Client
JK Francis & Sons are one of the UK’s leading Export Packers, Dangerous Goods Packers, Case Makers and Freight Forwarders, with over 100 years of trading and experience. Their work involves the construction of large timber crates used to transport goods internationally, including hazardous materials.
The facility comprises several operational areas including timber cutting zones where industrial saws are used, assembly areas where timber cases are constructed and nailed together, and packing areas where finished crates are prepared for shipment. There is also a small office area separate from the manufacturing process where staff are not exposed to significant noise sources.
- Timber cutting zones where industrial saws are used
- Assembly areas where timber cases are constructed and nailed together
- Packing areas where finished crates are prepared for shipment
- A small office area separate from the manufacturing process where staff are not exposed to significant noise sources
Employees working within the warehouse typically move between different workstations depending on production requirements, meaning their exposure to noise varies throughout the working day and week.
Our Approach
We undertook a detailed site survey of the JK Francis & Sons Ltd facility during normal operational conditions, ensuring that the measurements captured were representative of the noise environment experienced by employees on a typical working day.
Noise measurements were taken using professional sound level meters and dosemeters that had been calibrated before and after the survey in accordance with best practice, ensuring the accuracy and reliability of all recorded data. These instruments were configured to capture key acoustic metrics, including equivalent continuous sound levels (LAeq), peak sound pressure levels (LCpeak) and time-averaged exposure levels. All measurements were taken at the ear position of operatives while tasks were actively being performed, ensuring that the results reflected realistic working conditions rather than background noise levels alone. Additional measurements were also taken at various locations across the warehouse to establish the wider ambient noise environment experienced by workers who were not directly operating machinery at that time but remained within the working area.
Activity-Based Exposure Assessment
Through discussions with JK Francis & Sons Ltd and observations made during the site visit, a representative weekly working pattern for warehouse operatives was established. Workers regularly move between a variety of tasks depending on the type of timber case being manufactured at any given time. The key activities assessed during the survey included:
- Unloading and handling timber materials
- Cutting operations using crosscut, Wadkin and Sedgwick saws
- Framing and assembly, including hammering processes
- Nailing timber panels together
- Packaging and preparing finished crates for shipment
Each activity was measured individually to determine the noise levels generated during that specific task. These measurements were then combined with the typical duration workers spend performing each activity throughout the working week, allowing for the calculation of each employee’s overall weekly personal noise exposure (LEP,w). This activity-based approach ensures that the exposure assessments reflect the varied and practical nature of work carried out at JK Francis & Sons Ltd, rather than relying on a single generalised measurement.
Key Findings
The survey found that noise levels varied significantly depending on the task being performed. The highest noise levels were associated with machinery such as crosscut saws and with impact-based assembly processes involving hammering and nailing. Crosscut saw operation generated noise levels in excess of 90 dB(A), while certain assembly tasks involving repetitive hammering also produced relatively high sound levels.
Background noise levels within the warehouse environment were significantly lower, typically ranging between the mid-60s and mid-70s dB(A), although these still contributed to the overall noise exposure experienced by workers throughout the day.
Using the measured noise levels and the typical working pattern identified during the survey, Peninsular Acoustics calculated the weekly personal noise exposure level (LEP,w) for warehouse operatives.
Where does 81.4 dB(A) sit?
The assessment determined that employees were exposed to a weekly noise exposure level of approximately 81.4 dB(A). This level exceeds the Lower Exposure Action Value of 80 dB(A) defined within the Control of Noise at Work Regulations 2005. However, it remains below the Upper Exposure Action Value of 85 dB(A) and well below the Exposure Limit Value of 87 dB(A). Peak noise levels measured during the survey were also found to be significantly below the peak exposure thresholds set by the regulations.
Recommendations
Following the assessment, Peninsular Acoustics provided JK Francis & Sons Ltd with a number of practical recommendations to support effective noise management within the facility.
Hearing protection was already available on site, and it was recommended that suitable options continue to be provided to employees. Hearing protection with a very high attenuation rating can lead to over-protection, reducing a worker’s ability to hear warning signals or communicate with colleagues. For this reason, a moderate Single Number Rating (SNR) of around 20–22 dB was recommended as the most suitable option. The Moldex Mellows earplugs (SNR 22 dB) are one example of a suitable product that could be made available via on-site dispensers.
The condition and maintenance of machinery also plays an important role in managing noise levels. Although some of the saws on site were older models, they were reported to be well maintained. It was recommended that JK Francis & Sons Ltd continue to:
- Carry out regular servicing and maintenance of all machinery
- Monitor older equipment for any increases in noise output over time
- Address mechanical defects promptly to prevent unnecessary noise increases
Where operationally possible, rotating employees between tasks was also recommended to reduce the time any one individual spends on the noisiest activities, without adversely affecting productivity.
Finally, employee training and awareness should form part of the ongoing noise management approach. Workers should be informed of:
- The noise levels present in their workplace and which tasks carry the highest exposure
- The long-term risks associated with excessive noise exposure, including noise-induced hearing loss
- How to correctly fit and use hearing protection
- How to identify and report defects in hearing protection or other safety equipment
The Outcome
The assessment confirmed that JK Francis & Sons Ltd was operating within regulatory limits while also identifying practical steps that could further improve noise management on site. By undertaking a structured Noise at Work Assessment, JK Francis & Sons Ltd was able to demonstrate compliance with the Control of Noise at Work Regulations 2005, gain a clear understanding of employee noise exposure levels, and implement appropriate measures to protect their workforce. The assessment also provides a useful baseline reference for future reviews, particularly if machinery, production processes or working patterns change.
Noise-induced hearing loss remains one of the most common occupational health risks in the UK. Regular noise assessments help organisations such as JK Francis & Sons Ltd identify risks early and implement effective control measures before problems arise. Peninsular Acoustics supports clients across a wide range of industries by providing professional Noise at Work assessments, workplace noise monitoring and expert acoustic advice.
If your organisation requires a Noise at Work Assessment, please do not hesitate to get in touch with Peninsular Acoustics. We would be happy to provide a quotation for a noise survey and technical report tailored to your site and your budget.
