Fitness Center & Gym Safety Manual

Fitness Center & Gym Workplace Hazards

Employees may be exposed to hazards involving:

• Exercise equipment
• Free weights
• Moving machine components
• Electrical equipment
• Cleaning and disinfecting chemicals
• Wet floors
• Slips, trips, and falls
• Manual lifting
• Repetitive tasks
• Maintenance activities
• Blood and other potentially infectious materials
• Sharps
• Member medical emergencies
• Fire and evacuation
• Workplace violence
• Working alone
• Pools, spas, saunas, and steam rooms when applicable

Employees should receive training appropriate to their responsibilities and workplace hazards.

Exercise Equipment Safety

Fitness facilities may contain:

• Treadmills
• Elliptical machines
• Stationary bicycles
• Rowing machines
• Stair-climbing machines
• Selectorized strength machines
• Cable machines
• Plate-loaded equipment
• Benches
• Racks
• Free weights
• Functional-training equipment

Exercise equipment should be maintained according to facility procedures and manufacturer recommendations.

Employees should report damaged, unstable, excessively worn, or malfunctioning equipment.

Equipment Inspections

Fitness equipment should be routinely inspected based on the equipment, frequency of use, manufacturer recommendations, and facility procedures.

Inspections may include:

• Cables
• Belts
• Pulleys
• Fasteners
• Adjustment mechanisms
• Pins
• Seats
• Pads
• Handrails
• Pedals
• Foot platforms
• Weight stacks
• Guards and covers
• Electrical cords
• Plugs
• Emergency stops
• Frames
• Welds
• Anchoring
• Flooring around equipment

Defective equipment should be removed from use or otherwise controlled until it can be safely repaired.

Defective Equipment

Employees should know how to identify and report equipment that is unsafe for continued use.

Defective equipment should be clearly marked or otherwise made unavailable to employees and members until appropriate repairs are completed.

Employees should not attempt temporary or improvised repairs that could create additional hazards.

Preventive Maintenance

Preventive maintenance helps reduce unexpected equipment failures and employee exposure during emergency repairs.

Maintenance programs may address:

• Lubrication
• Belt adjustment
• Cable replacement
• Fastener inspection
• Electrical components
• Equipment alignment
• Upholstery
• Moving components
• Safety devices
• Manufacturer service intervals

Maintenance records should be maintained when appropriate.

Treadmill Safety

Treadmills contain powered belts and moving components that can create caught-in and fall hazards.

Employees should:

• Keep areas around treadmills clear.
• Inspect emergency-stop features.
• Report abnormal belt movement or equipment operation.
• Keep electrical cords protected.
• Avoid reaching into moving equipment.
• Follow shutdown procedures before cleaning or servicing hazardous areas.

Employees should be aware that treadmills may continue moving briefly after controls are activated.

Strength-Training Equipment

Strength-training machines may contain weight stacks, cables, pulleys, moving arms, adjustment pins, and pinch points.

Employees should:

• Inspect cables and attachment points.
• Check adjustment mechanisms.
• Maintain guards and covers.
• Keep hands clear of weight stacks and moving components.
• Report frayed cables or damaged equipment.
• Avoid placing body parts beneath unsupported components.

Free Weight Areas

Free-weight areas may expose employees to dropped weights, unstable equipment, manual handling, and trip hazards.

Facility procedures should address:

• Weight storage
• Dumbbell racks
• Plate storage
• Benches
• Barbell racks
• Damaged equipment
• Floor conditions
• Clear walkways

Weights should be returned to designated storage locations rather than left on floors or in walkways.

Weight Racks

Weight racks should be stable and maintained in good condition.

Employees handling weights should:

• Evaluate the weight before lifting.
• Maintain control of the load.
• Avoid overreaching.
• Use mechanical or team assistance when appropriate.
• Keep fingers and feet clear of pinch and drop zones.

Group Exercise Areas

Group exercise rooms may be used for aerobics, cycling, yoga, dance, martial arts, strength training, and other activities.

Employees should ensure:

• Floors are maintained in safe condition.
• Equipment is properly stored.
• Exits remain clear.
• Cords do not create trip hazards.
• Adequate space is maintained for the activity.
• Damaged equipment is removed from use.

Functional Training Areas

Functional-training areas may contain kettlebells, medicine balls, resistance bands, suspension systems, ropes, sleds, boxes, and other equipment.

Equipment should be inspected and stored to minimize trip, struck-by, and equipment-failure hazards.

Anchored equipment should be installed and maintained according to applicable requirements and manufacturer instructions.

Cleaning & Disinfection

Fitness facilities require frequent cleaning of high-contact surfaces and equipment.

Employees may use:

• Disinfectants
• Cleaners
• Degreasers
• Glass cleaners
• Floor-care products
• Laundry chemicals
• Other cleaning products

Employees should follow product labels, facility procedures, and applicable Safety Data Sheet information.

Chemicals should not be mixed unless specifically permitted by the manufacturer.

Hazard Communication

Employees who work with hazardous cleaning, maintenance, pool, or other chemicals should receive applicable Hazard Communication information and training.

The facility should maintain:

• Proper chemical labels
• Safety Data Sheets
• Employee training
• Appropriate storage
• Procedures for spills and exposures

Secondary containers should be appropriately identified.

Chemical Storage

Cleaning and maintenance chemicals should be stored:

• In designated areas
• In compatible containers
• Away from unauthorized access
• According to label instructions
• Away from incompatible materials

Chemicals should not be stored in beverage containers or other containers that could cause mistaken use.

Personal Protective Equipment

PPE should be selected according to the employee’s assigned tasks and exposures.

Depending on the work, PPE may include:

• Disposable gloves
• Chemical-resistant gloves
• Safety glasses
• Goggles
• Face protection
• Protective footwear
• Protective clothing
• Hearing protection
• Other task-specific equipment

Employees should understand when PPE is required and how to use it properly.

Slips, Trips & Falls

Fitness facilities can have significant slip and trip hazards because of:

• Perspiration
• Water
• Cleaning activities
• Locker rooms
• Showers
• Pool areas
• Entryways
• Exercise mats
• Cords
• Loose equipment
• Weights
• Personal belongings

Spills and wet areas should be addressed promptly.

Temporary warning signs should be used when appropriate, but hazards should be corrected rather than relying solely on signs.

Walking-Working Surfaces

Floors, stairs, aisles, ramps, and other walking-working surfaces should be maintained in a clean and safe condition.

Employees should report:

• Damaged flooring
• Loose mats
• Uneven surfaces
• Damaged stairs
• Missing handrails
• Poor lighting
• Obstructions

Emergency exits and access routes should remain clear.

Locker Room Safety

Locker rooms may expose employees to:

• Wet floors
• Cleaning chemicals
• Biological contamination
• Sharps
• Personal belongings
• Electrical equipment
• Member interactions

Employees should use appropriate cleaning procedures and PPE.

Unknown sharps should never be picked up with bare hands.

Shower Areas

Shower areas should be maintained to reduce slips and other hazards.

Employees should:

• Address standing water.
• Maintain drainage.
• Use appropriate cleaning procedures.
• Control access during maintenance when necessary.
• Report damaged surfaces or fixtures.

Electrical equipment not intended for wet locations should be kept away from shower and other wet areas.

Bloodborne Pathogens

Employees may encounter blood while:

• Providing first aid
• Responding to an injury
• Cleaning exercise equipment
• Cleaning locker rooms
• Handling contaminated materials
• Responding to discarded sharps

Employees with reasonably anticipated occupational exposure should be addressed under the facility’s applicable Bloodborne Pathogens Exposure Control procedures.

Employees should use appropriate precautions when blood or other potentially infectious materials are present.

Blood & Body Fluid Cleanup

Employees assigned to clean blood or other potentially infectious materials should:

• Restrict access to the affected area when appropriate.
• Wear suitable PPE.
• Use appropriate disinfecting procedures.
• Avoid direct contact.
• Dispose of contaminated materials properly.
• Wash hands after completing the task.

Broken glass or other sharp objects should not be picked up directly by hand.

Sharps

Employees may occasionally discover needles or other sharps in restrooms, locker rooms, parking areas, or other facility locations.

Employees should:

• Avoid handling sharps with bare hands.
• Use appropriate tools or procedures.
• Place sharps in suitable containers when required.
• Report exposures immediately.

Employees assigned to sharps cleanup should receive appropriate training.

First Aid

Fitness facilities should have appropriate procedures for employee and member injuries.

Employees should know:

• How to summon emergency medical services
• Location of first-aid supplies
• How to report an incident
• Their responsibilities during an emergency

Employees should provide first aid only within the scope of their training and assigned responsibilities.

AEDs & Cardiac Emergencies

Because fitness facilities serve individuals engaged in physical exertion, procedures should address potential cardiac emergencies.

Where an Automated External Defibrillator (AED) is provided, the facility should establish procedures for:

• Accessibility
• Inspection
• Maintenance
• Battery and pad replacement
• Employee response
• Emergency medical services activation
• Post-use procedures

Employees assigned emergency-response responsibilities should receive appropriate training.

Medical Emergencies

Fitness facilities may experience emergencies involving:

• Cardiac events
• Breathing difficulties
• Falls
• Head injuries
• Cuts
• Fractures
• Heat-related illness
• Seizures
• Diabetic emergencies
• Other sudden illnesses or injuries

Employees should know how to contact emergency services and provide responders with access to the affected individual.

Emergency Access

Emergency responders should be able to enter the facility and reach an injured or ill person without unnecessary delay.

Employees should know:

• Facility address
• Emergency entrances
• Access procedures
• Elevator locations
• AED locations
• First-aid locations

Someone should be designated to meet emergency responders when appropriate.

Electrical Safety

Fitness centers contain numerous electrically powered machines and appliances.

Employees should:

• Inspect cords and plugs for visible damage.
• Report damaged electrical equipment.
• Keep electrical panels accessible.
• Avoid unauthorized repairs.
• Protect electrical equipment from water.
• Follow manufacturer instructions.
• Remove unsafe equipment from service.

Only appropriately qualified persons should perform electrical repairs.

Electrical Equipment in Wet Areas

Special attention should be given to electrical hazards around:

• Locker rooms
• Showers
• Pools
• Spas
• Cleaning activities
• Other damp or wet areas

Electrical equipment should be appropriate for the location and maintained to prevent employee exposure to electrical hazards.

Equipment Maintenance & Repair

Maintenance may expose employees to:

• Moving components
• Electrical energy
• Stored mechanical energy
• Elevated equipment
• Sharp edges
• Heavy components
• Chemicals

Employees should not perform repairs beyond their training or authorization.

Equipment should be appropriately shut down and hazardous energy controlled before servicing when required.

Lockout/Tagout

Servicing exercise, HVAC, pool, mechanical, and other equipment may expose employees to hazardous energy.

Applicable energy-control procedures should be followed when unexpected startup or release of stored energy could cause injury.

Employees performing covered servicing should be trained and authorized as required.

Hand & Power Tools

Employees may use hand and power tools for maintenance and facility repairs.

Tools should:

• Be appropriate for the task.
• Be inspected before use.
• Have required guards.
• Be maintained in safe condition.
• Be removed from service when defective.

Employees should use appropriate PPE.

Ladders

Employees may use ladders for:

• Lighting
• Decorations
• Cleaning
• Storage
• Maintenance
• Audio/video equipment
• Signs

Ladders should be appropriate for the task and inspected before use.

Employees should not use chairs, exercise equipment, weight benches, boxes, or other makeshift climbing devices.

Manual Lifting

Employees may lift and move:

• Weights
• Exercise equipment
• Supplies
• Cleaning products
• Laundry
• Mats
• Furniture
• Deliveries

Employees should evaluate loads before lifting and use mechanical assistance or team lifting when appropriate.

Moving Exercise Equipment

Exercise machines can be extremely heavy and may have awkward centers of gravity.

Before moving equipment:

• Evaluate its weight and dimensions.
• Review manufacturer instructions when available.
• Clear the travel path.
• Use suitable moving equipment.
• Obtain additional assistance.
• Control moving components.
• Protect hands and feet.

Employees should not attempt to manually move equipment beyond their capabilities.

Ergonomics

Employees may perform repetitive tasks involving:

• Cleaning
• Towel handling
• Laundry
• Front-desk work
• Computer use
• Equipment adjustment
• Material handling
• Personal training

Work practices and equipment should be arranged to reduce unnecessary bending, reaching, twisting, and repetitive strain where practical.

Laundry & Towel Handling

Facilities providing towels or laundry services should establish procedures for:

• Collection
• Handling
• Washing
• Drying
• Chemical use
• Storage

Employees should use appropriate precautions when handling visibly contaminated laundry.

Pool & Aquatic Areas

Fitness facilities with swimming pools may have additional hazards involving:

• Wet surfaces
• Pool chemicals
• Electrical equipment
• Pumps and filtration systems
• Biological contamination
• Member emergencies
• Chemical storage

Employees should receive training appropriate to their assigned aquatic-area duties.

Pool Chemical Safety

Pool chemicals can create serious hazards if improperly mixed, stored, or handled.

Employees assigned to handle pool chemicals should:

• Follow manufacturer instructions.
• Review Safety Data Sheets.
• Use required PPE.
• Keep incompatible chemicals separated.
• Maintain appropriate storage conditions.
• Avoid mixing chemicals unless specifically required by established procedures.
• Know emergency procedures for spills and exposures.

Saunas & Steam Rooms

Facilities with saunas or steam rooms should address:

• Heat
• Hot surfaces
• Electrical equipment
• Slippery floors
• Cleaning
• Member medical emergencies

Employees entering these areas for cleaning or maintenance should recognize heat-related hazards.

Hot Tubs & Spas

Employees servicing spas or hot tubs may be exposed to:

• Water-treatment chemicals
• Wet surfaces
• Electrical equipment
• Pumps
• Filters
• Heat
• Biological hazards

Only employees trained for the assigned work should service associated mechanical or chemical systems.

Childcare Areas

Some fitness facilities provide childcare services.

Where employees are assigned to childcare areas, additional procedures may be needed for:

• Infection prevention
• Bloodborne pathogens
• Cleaning and disinfection
• Lifting children
• Emergency evacuation
• Security
• Authorized pickup
• Workplace violence
• Employee exposures

Childcare operations should comply with applicable facility and regulatory requirements.

Food & Beverage Areas

Fitness centers may sell or prepare:

• Beverages
• Smoothies
• Snacks
• Supplements
• Other food products

Employees should follow appropriate sanitation, equipment, electrical, chemical, and housekeeping procedures for these areas.

Front Desk Safety

Front-desk employees interact continuously with members, visitors, delivery personnel, and prospective customers.

Procedures should address:

• Emergency communications
• Security
• Cash handling when applicable
• Member conflicts
• Unauthorized persons
• Suspicious activity
• Medical emergencies
• Facility access

Front-desk employees should know how to summon assistance.

Workplace Violence

Fitness facilities should establish procedures for responding to threatening, aggressive, or violent behavior.

Employees should:

• Report threats and concerning behavior.
• Avoid unnecessarily escalating confrontations.
• Know how to obtain assistance.
• Follow emergency procedures.
• Contact law enforcement when appropriate.

Employees should not be expected to physically intervene in dangerous situations unless specifically trained and assigned to do so.

Facility Security

Security procedures may address:

• Building access
• Keys and access cards
• Restricted areas
• After-hours access
• Parking areas
• Locker rooms
• Cash handling
• Theft
• Suspicious activity
• Closing procedures

Employees should report security concerns promptly.

Working Alone

Employees may work alone during:

• Opening
• Closing
• Overnight shifts
• Cleaning
• Maintenance
• Low-occupancy periods

Facilities should evaluate working-alone situations and establish appropriate communication and emergency procedures.

Member & Public Areas

Employees should recognize that members and visitors may be unfamiliar with workplace hazards.

Service areas, chemical-storage areas, mechanical rooms, maintenance areas, and other hazardous locations should be restricted from unauthorized access.

Storage Areas

Equipment and supplies should be stored to prevent:

• Falling objects
• Blocked exits
• Excessive stacking
• Trip hazards
• Difficult manual handling
• Unauthorized chemical access

Frequently used or heavy materials should be positioned to reduce unnecessary lifting hazards where practical.

Housekeeping

Good housekeeping is essential in fitness facilities.

Employees should:

• Clean spills promptly.
• Return equipment to designated locations.
• Maintain clear aisles.
• Keep exits unobstructed.
• Control cords.
• Store cleaning equipment.
• Remove damaged items from use.
• Keep emergency equipment accessible.

Fire Prevention

Fitness centers should maintain appropriate fire-prevention procedures.

Employees should:

• Keep exits clear.
• Maintain access to extinguishers.
• Avoid overloading electrical systems.
• Store combustible materials appropriately.
• Report damaged electrical equipment.
• Control ignition sources during maintenance.

Emergency Action Plan

Employees should know facility procedures for emergencies such as:

• Fire
• Medical emergencies
• Severe weather
• Power failure
• Violence
• Chemical spills
• Gas leaks
• Electrical emergencies
• Other facility-specific events

Employees should know evacuation routes, exits, assembly locations, and emergency communication procedures.

Evacuation

Employees should understand their assigned responsibilities during evacuation.

Procedures should consider:

• Members
• Visitors
• Children when childcare is provided
• Individuals requiring assistance
• Locker rooms
• Pools
• Saunas
• Group exercise rooms
• Other occupied areas

Employees should not unnecessarily delay evacuation to retrieve personal belongings.

Severe Weather

Facilities should establish procedures appropriate to local weather hazards.

Employees should know:

• Where to shelter
• How members will be notified
• How outdoor activities will be handled
• When areas should be closed
• How power outages affect equipment and facility operations

Heat Stress

Employees working outdoors, in mechanical areas, or in poorly conditioned spaces may experience heat exposure.

Facilities should provide appropriate water, rest, cooling, and other controls based on workplace conditions.

Employees should recognize signs and symptoms of heat-related illness.

Incident Reporting

Employees should promptly report:

• Employee injuries
• Member injuries
• Equipment failures
• Near misses
• Chemical exposures
• Blood exposures
• Sharps incidents
• Electrical hazards
• Security incidents
• Fires
• Significant property damage

Prompt reporting allows hazards to be evaluated and corrective action taken.

Incident Investigation

Workplace incidents and significant near misses should be reviewed to identify contributing factors.

Investigations may consider:

• Equipment condition
• Inspection history
• Maintenance
• Housekeeping
• Employee training
• Procedures
• Chemical use
• Facility conditions
• Communication
• Emergency response

Corrective actions should address identified causes where practical.

Fitness Center & Gym Safety Training

Employee training should correspond to assigned duties and may include:

• Exercise equipment safety
• Equipment inspections
• Defective-equipment procedures
• Cleaning and disinfection
• Hazard Communication
• Chemical safety
• PPE
• Slips, trips, and falls
• Bloodborne pathogens
• Sharps
• First aid
• AED and emergency response
• Electrical safety
• Equipment maintenance
• Lockout/Tagout
• Hand and power tools
• Ladder safety
• Manual lifting
• Ergonomics
• Pool and spa safety when applicable
• Workplace violence
• Security
• Working alone
• Fire prevention
• Emergency Action Plan
• Incident reporting

Additional training should be provided when new equipment, chemicals, services, or hazards are introduced.

Customized Fitness Center & Gym Safety Manuals

Fitness facilities vary considerably in size and services. Some operate primarily as exercise gyms, while others include personal training, group fitness, pools, spas, saunas, steam rooms, childcare, food and beverage service, locker rooms, physical-recovery areas, and extensive maintenance operations.

A customized Fitness Center & Gym Safety Manual can be developed around your exercise equipment, employee responsibilities, cleaning procedures, chemicals, maintenance activities, aquatic facilities, emergency-response procedures, member interaction, security concerns, and other workplace hazards.