Intelligent Panel Systems
Practical lessons and site safety scenarios for toolbox talks and pre-start briefings.
Use these sheets alongside the project risk assessment, method statement and current manufacturer instructions. Stop work and tell the site supervisor if the planned controls are missing or conditions change.
Safety sheet 01 · Supplied incident learning
The original lessons-learnt report, with its wording and incident photograph retained in the IPS colour scheme.
The original report records incident-specific learning. For current inspection requirements, follow HSE guidance and the manufacturer's instructions; a tower tag does not replace a competent inspection.
Safety sheet 02
Illustrative training scenario — not an actual IPS incident.
Large boards and panels can be awkward, unstable and difficult to grip. Plan delivery, storage and movement before the task.
Training example: two workers begin carrying a large panel across an obstructed route. The load blocks their view and one worker starts to lose their grip.
Strains, trapped fingers and crushing injuries can result. Stop and lower the load safely; do not try to catch a falling panel.
The weight and centre of gravity were not checked. The route was cluttered and the team had no agreed movement plan.
Avoid hazardous manual handling where possible. Use suitable mechanical aids and bring materials close to their point of use. Assess the load, task, people and surroundings. Keep routes clear.
Confirm the handling method, suitable equipment and clear landing area. Brief the team and agree communication. Stop if conditions change; do not rely on a fixed “safe” lifting weight.
Plan the move before lifting.
Safety sheet 03
Illustrative training scenario — not an actual IPS incident.
Cutting paving blocks, kerbs or flags with a cut-off saw can release harmful respirable silica dust.
Training example: a worker starts dry-cutting paving blocks beside an occupied walkway. Dust spreads to nearby trades.
Fine dust can damage lungs even when the job is brief. Stop uncontrolled cutting and keep others away.
Cuts were not planned. Dust suppression was unavailable and nearby workers were not separated from the task.
Reduce cuts or use precut materials or a block splitter. Where sawing is necessary, use suitable water suppression or on-tool extraction. HSE specifies H or M class extraction and APF20 RPE for this task; tight-fitting masks need face-fit testing.
Check controls operate correctly, the exclusion area is clear and RPE fits the wearer. Tight-fitting masks require a clean-shaven seal. Review the COSHH assessment and maintenance arrangements before restarting.
Control dust at its source.
Safety sheet 04
Illustrative training scenario — not an actual IPS incident.
Deliveries and mobile plant can put workers and visitors at risk, especially where routes change during construction.
Training example: a delivery vehicle begins reversing while a worker steps into its route to pass a stack of materials.
A person can be struck or crushed. Stop the movement and clear the area before any manoeuvre resumes.
The walkway was blocked, the reversing area was not segregated and the visiting driver had not received clear instructions.
Separate people and vehicles with suitable routes and barriers. Keep walkways clear and provide visible crossings. Avoid reversing where possible through delivery planning and one-way routes.
Brief drivers and workers on the traffic plan. Check lighting and visibility. Use trained, authorised signallers where required by the plan. Keep pedestrians outside the manoeuvring area; high-visibility clothing alone is not separation.
Keep people out of vehicle routes.
Safety sheet 05
Illustrative training scenario — not an actual IPS incident.
Trenches may collapse or fill with water. People, spoil and vehicles can fall in or overload an edge.
Training example: after heavy rain, a worker prepares to enter a trench with damaged support and spoil stored close to the edge.
Collapse can bury or crush a person. Keep people out, isolate the area and report the unsafe condition.
Changed ground conditions were not reassessed. Edge loading increased and the support arrangement was not checked.
Plan suitable support or battering before digging. Identify services and protect nearby structures. Provide safe access, edge barriers and controls for water. Keep plant and spoil away from edges as determined by the assessment.
A competent person must inspect supports or battering at the start of the shift and after events affecting stability. Record required inspections. Rectify defects before work. No unplanned entry or improvised rescue into an unsafe trench.
No entry until the excavation is safe.
Safety sheet 06
Illustrative training scenario — not an actual IPS incident.
Site tools and temporary supplies face water, dust and mechanical damage. Electrical defects can cause fatal injury.
Training example: a worker finds a cut extension lead taped together beside a wet work area but considers using it to finish the task.
Electric shock, burns and fire are possible. Do not use or touch damaged parts. Keep others away and arrange safe disconnection.
The damaged lead remained available. Checks had not identified the defect and a makeshift repair was accepted.
Use suitable site equipment, preferably cordless tools or a 110V centre-tapped-to-earth supply. Check equipment and remove damaged items from service. Protect cables; do not make makeshift repairs.
Quarantine the faulty equipment and arrange repair or replacement by a competent person. Maintain an appropriate inspection and test programme. An RCD is additional protection, not permission to use damaged equipment. Electrical work requires competent personnel.
Take damaged equipment out of use.
Safety sheet 07
Illustrative training scenario — not an actual IPS incident.
Unprotected stairwells, service openings and floor edges create fall risks during construction and fit-out.
Training example: a temporary cover is moved to pass materials through a floor opening and the area is left accessible to other trades.
A worker may fall through the opening or be struck by falling materials below. Stop access and alert the supervisor.
The cover was removed without a controlled method. Protection was not reinstated and other trades were not informed.
Avoid exposure to the edge where possible. Provide suitable collective protection, such as secured load-appropriate covers or guardrails. Warning tape alone does not prevent a fall. Plan protection during temporary removal.
Confirm the protection is suitable, secure and checked before access. Control work below and brief affected trades. Agree who authorises removal and reinstatement. If personal fall protection is needed, plan competent use and rescue arrangements.
Protect the opening before work continues.
New scenarios are illustrative training examples. Guidance checked against the linked HSE sources on 21 October 2026. These briefing aids do not replace a site-specific safe system of work.
Existing HomePod and IPS reference documents. Complete project-specific details and competent review before use.