Employee Injury Risks in Pottery Manufacturing (UK Employers’ Liability Guide)
Introduction
Pottery manufacturing is hands-on, fast-moving work. Clay prep, moulding, glazing, firing and packing all bring different hazards, and many injuries happen during “normal” tasks rather than major incidents. If you employ staff in the UK, you also have legal duties to manage workplace risk and (in most cases) to hold Employers’ Liability (EL) insurance.
This guide breaks down the most common employee injury risks in pottery and ceramics production, what good control looks like, and how EL claims typically arise.
What Employers’ Liability insurance is (and why it matters)
Employers’ Liability insurance covers compensation and legal costs if an employee (or certain labour-only workers) claims they were injured or made ill because of their work for you.
In pottery manufacturing, EL claims often relate to:
- Hand and arm injuries from machinery or sharp tools
- Slips, trips and falls in wet or dusty areas
- Burns from kilns, hot ware, steam and heated equipment
- Respiratory disease from silica and other dusts
- Dermatitis and asthma from glazes, solvents and cleaning chemicals
- Musculoskeletal injuries from lifting, repetitive work and awkward postures
EL doesn’t replace good safety management. In practice, strong risk controls reduce incidents and also make it easier to defend claims.
Who is at risk in a pottery factory?
Injury risk isn’t limited to kiln operators. Consider:
- Production operatives (clay prep, casting, fettling, glazing)
- Kiln and maintenance staff
- Warehouse and dispatch teams
- Apprentices and trainees (often higher risk due to inexperience)
- Agency workers and contractors (risk depends on control and supervision)
- Office staff who enter production areas
A good starting point is mapping tasks by area and shift: where people work, what they handle, and what could realistically go wrong.
The main employee injury risks in pottery manufacturing
1) Silica and ceramic dust exposure (respiratory disease)
Many clay bodies and ceramic materials contain crystalline silica. Dust can be generated during:
- Mixing and weighing dry materials
- Sanding, fettling and finishing greenware
- Handling dry glaze materials
- Cleaning with dry sweeping or compressed air
Potential outcomes include occupational asthma, chronic obstructive pulmonary disease (COPD), and silicosis. These are often long-tail claims: symptoms may appear after years.
Practical controls:
- Use wet methods where possible (wet cutting, wet sanding)
- Local exhaust ventilation (LEV) at dust-generating points
- Enclosed mixing systems and lidded containers
- Good housekeeping: vacuum systems with suitable filtration (avoid dry sweeping)
- Fit testing and correct selection of RPE where needed
- Air monitoring and health surveillance where appropriate
EL claim triggers:
- Inadequate dust control, poor LEV maintenance, or lack of training
- No documented exposure assessment or failure to act on findings
2) Machinery and entanglement injuries
Pottery production can involve mixers, pugmills, slab rollers, jiggering/jollying machines, extruders, conveyors and packaging equipment. Common injuries include crush injuries, amputations, lacerations and entanglement.
Practical controls:
- Guarding and interlocks that are not bypassed
- Lockout/tagout procedures for cleaning and maintenance
- Clear safe systems of work and supervision
- Training for new starters and refreshers for experienced staff
- Preventive maintenance schedules and defect reporting
EL claim triggers:
- Missing or inadequate guarding
- Informal “workarounds” becoming normal practice
- Poor contractor control during maintenance
3) Burns and heat injuries (kilns, hot ware, steam)
Kilns, kiln furniture, hot shelves, and recently-fired ware can cause serious burns. Steam and heated equipment used in drying or cleaning can also injure.
Practical controls:
- Physical barriers and signage around hot zones
- Heat-resistant PPE (gloves, sleeves, aprons) matched to the task
- Tools for handling hot ware (tongs, racks)
- Cooling time rules and clear “hot item” identification
- Training on kiln loading/unloading and emergency response
EL claim triggers:
- Inadequate PPE provision or enforcement
- Poorly marked hot areas or rushed processes
4) Chemical exposure (glazes, solvents, cleaning agents)
Glazes and decorating materials may contain hazardous substances. Even where modern formulations reduce risk, exposure can still occur through skin contact, inhalation of aerosols/dust, or poor storage.
Common outcomes include dermatitis, chemical burns, eye injuries and asthma.
Practical controls:
- COSHH assessments kept current and task-specific
- Substitution to lower-hazard products where possible
- Controlled mixing areas with ventilation
- Proper labelling, storage and spill response
- Suitable gloves and eye/face protection
- Skin care regimes and training (including correct glove use)
EL claim triggers:
- Missing COSHH assessments or poor training
- Inadequate washing facilities or PPE
5) Manual handling and musculoskeletal disorders (MSDs)
Pottery can be deceptively heavy. Bags of clay, moulds, kiln shelves, packed boxes and pallets all create risk. Repetitive tasks (throwing, fettling, glazing) can drive strain injuries.
Practical controls:
- Manual handling assessments for regular lifts and awkward items
- Mechanical aids: hoists, lift tables, pallet trucks, vacuum lifters
- Job rotation and micro-breaks for repetitive tasks
- Workstation design to reduce bending, reaching and twisting
- Training that matches real tasks (not generic slides)
EL claim triggers:
- No assessment for known heavy/repetitive work
- Understaffing leading to rushed lifting
6) Slips, trips and falls
Wet clay, glaze spills, water from cleaning, uneven floors, trailing hoses and cluttered walkways are common contributors.
Practical controls:
- Defined walkways and good storage discipline
- Non-slip flooring where feasible
- Spill response procedures and accessible cleaning kits
- Cable/hoses management (reels, hooks, covers)
- Lighting and regular inspections
EL claim triggers:
- Poor housekeeping becoming routine
- No evidence of inspection or maintenance
7) Cuts, punctures and eye injuries
Fettling knives, trimming tools, broken bisque/ware, sharp kiln furniture edges and packaging tools can cause lacerations. Dust and glaze splashes can injure eyes.
Practical controls:
- Tool control and safe blade handling
- Cut-resistant gloves where appropriate
- Eye protection for grinding, mixing and cleaning tasks
- Safe disposal of broken ware and sharps
- First aid provision and reporting culture
EL claim triggers:
- Lack of PPE or inconsistent enforcement
- Poor incident reporting leading to repeat events
8) Noise and vibration
Some equipment (compressors, grinders, extraction systems) can create harmful noise. Hand-held tools may contribute to vibration exposure.
Practical controls:
- Noise assessments and hearing protection zones where needed
- Maintenance to reduce noise at source
- Selection of lower-vibration tools and time limits
- Health surveillance when risk thresholds are approached
EL claim triggers:
- No assessment or failure to act on results
9) Fire, fumes and confined/poorly ventilated areas
Kilns and electrical equipment increase fire risk. Certain processes can generate fumes; poor ventilation can worsen exposure.
Practical controls:
- Fire risk assessment and clear evacuation routes
- Electrical safety checks and kiln maintenance
- Suitable extraction and general ventilation
- Training and drills
EL claim triggers:
- Inadequate maintenance or poor emergency planning
How EL claims typically happen in pottery manufacturing
Most EL claims follow a similar pattern:
- An incident occurs (or symptoms develop over time).
- The employee reports injury/illness and seeks medical help.
- A claim alleges the employer failed to provide a safe workplace, training, PPE, supervision, or adequate risk controls.
- Evidence is reviewed: risk assessments, training records, maintenance logs, inspection checklists, CCTV, witness statements.
- Insurers/solicitors negotiate settlement or defend.
The strongest defences usually come from consistent documentation and a safety culture that matches what’s written on paper.
Practical risk management checklist (quick reference)
- Up-to-date risk assessments for each production area
- COSHH assessments for glazes, solvents and cleaning agents
- Dust control plan (LEV, housekeeping, RPE, monitoring)
- Machinery guarding checks and lockout/tagout
- Manual handling controls and mechanical aids
- Slip prevention: floors, walkways, spill response
- PPE issue records and training refreshers
- Maintenance schedules for kilns, extraction and machinery
- Incident reporting and near-miss tracking
- Induction and supervision for apprentices and new starters
What to tell your insurance broker (to get EL right)
When arranging Employers’ Liability for a pottery manufacturer, be ready to explain:
- Your processes (mixing, casting, glazing, firing, packing)
- Materials used (including any hazardous glaze components)
- Dust controls (LEV, wet methods, RPE)
- Any subcontracted work or labour-only contractors
- Claims history (if any) and improvements made
- Headcount, turnover, and split of clerical vs manual staff
Clear, accurate information helps avoid coverage issues and can improve terms.
When to review your cover
Review EL cover when you:
- Add new processes (e.g., spray glazing, new kiln types)
- Increase production volume or headcount
- Change premises or layout
- Introduce new chemicals or suppliers
- Take on more apprentices or agency labour
Need help arranging Employers’ Liability for a pottery manufacturer?
If you run a pottery or ceramics manufacturing business, we can help you review your injury risks, explain the cover you need, and arrange Employers’ Liability that fits how you actually operate.
Call 0330 127 2333 or visit insure24.co.uk to speak to a specialist.
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