Metal Fabrication Safety Manual

Metal Fabrication Safety Programs

The safety programs needed by a metal fabrication company depend on the processes and equipment used. A comprehensive manual may include programs covering:

• Welding, Cutting and Hot Work
• Machine Guarding
• Lockout/Tagout
• Hand and Power Tool Safety
• Grinding Safety
• Personal Protective Equipment
• Hearing Conservation
• Respiratory Protection
• Hazard Communication
• Compressed Gas Cylinder Safety
• Crane and Rigging Safety
• Overhead Crane Safety
• Forklift and Powered Industrial Truck Safety
• Manual Lifting and Material Handling
• Electrical Safety
• Fire Prevention
• Fall Protection
• Job Safety Analysis
• Emergency Action Plan
• First Aid

Programs that do not apply to the company’s operations can be removed, while additional programs should be included when specialized fabrication processes create additional hazards.

Metal Fabrication Shop Safety

Metal fabrication facilities should be organized and maintained to control hazards created by machinery, materials, welding, grinding, material handling, vehicle movement, and fabrication processes.

Shop planning should consider:

• Equipment layout
• Machine operating zones
• Material storage
• Crane travel
• Forklift routes
• Welding areas
• Hot-work areas
• Grinding areas
• Compressed-gas storage
• Chemical storage
• Ventilation
• Electrical equipment
• Emergency exits
• Fire protection

Employees should receive training appropriate to the equipment and processes they are authorized to use.

Machine Guarding

Metal fabrication equipment may contain points of operation, rotating components, nip points, reciprocating parts, flying material, and other machine hazards.

Machines should be guarded as required to protect employees from hazards created by:

• Points of operation
• Rotating parts
• Flying chips and sparks
• Nip points
• Reciprocating components
• Belts and pulleys
• Gears
• Shafts
• Other moving components

Guards and safety devices should be maintained in place during operation.

Employees should not remove, bypass, disable, or defeat machine guards or safety devices.

Machine Safety

Only trained and authorized employees should operate fabrication machinery.

Before operating equipment, employees should:

• Inspect the machine.
• Verify guards are installed.
• Check controls and safety devices.
• Remove unnecessary tools and materials.
• Secure the workpiece when required.
• Select appropriate tooling.
• Wear required PPE.
• Keep unauthorized employees away.

Employees should understand normal startup, operation, shutdown, and emergency-stop procedures.

Lockout/Tagout

Servicing and maintenance of fabrication equipment can expose employees to hazardous energy.

Energy sources may include:

• Electrical
• Mechanical
• Hydraulic
• Pneumatic
• Gravity
• Thermal
• Stored pressure
• Springs

Authorized employees should follow established energy-control procedures before performing servicing or maintenance where unexpected energization, startup, or release of stored energy could cause injury.

Energy isolation should be verified before work begins.

Stored Energy

Shutting off a machine does not necessarily eliminate hazardous energy.

Before servicing, employees should evaluate stored energy associated with:

• Hydraulic pressure
• Pneumatic pressure
• Flywheels
• Springs
• Elevated components
• Capacitors
• Gravity
• Thermal energy

Stored or residual energy should be relieved, restrained, blocked, disconnected, or otherwise rendered safe before work begins.

Welding Safety

Welding can expose employees to intense light, heat, sparks, molten metal, fumes, gases, electrical hazards, and fire.

Welding operations should address:

• Appropriate PPE
• Welding screens
• Ventilation
• Fire prevention
• Compressed gases
• Electrical safety
• Combustible materials
• Welding fumes
• Hot surfaces

Only trained and authorized employees should operate welding equipment.

Welding Fumes

Welding fumes can contain metals and other contaminants generated by the base metal, coatings, consumables, and welding process.

Exposure controls should be selected based on the materials and work being performed.

Controls may include:

• Local exhaust ventilation
• General ventilation
• Fume-extraction equipment
• Employee positioning
• Process changes
• Respiratory protection when required

Employees should avoid placing their breathing zone directly in the welding-fume plume.

Additional evaluation may be necessary when welding stainless steel, galvanized metal, painted or coated materials, or metals containing substances with specific occupational exposure limits.

Hexavalent Chromium

Welding, cutting, or grinding stainless steel and certain chromium-containing materials can expose employees to hexavalent chromium.

When applicable, the company should evaluate employee exposures and implement required controls.

Controls may include:

• Engineering controls
• Work practices
• Regulated areas where applicable
• Respiratory protection
• Protective clothing
• Hygiene practices
• Exposure monitoring
• Medical surveillance when required

Employees should receive training appropriate to their potential exposure.

Cutting Operations

Metal may be cut using:

• Oxy-fuel torches
• Plasma cutters
• Saws
• Shears
• Abrasive cutting equipment
• Other mechanical or thermal methods

Employees should understand the hazards of the specific cutting process.

Cutting areas should be controlled to protect other employees from sparks, hot metal, flying particles, radiation, fumes, and fire hazards.

Hot Work

Welding, cutting, brazing, soldering, grinding, and other spark- or heat-producing activities may qualify as hot work.

Before hot work begins:

• Evaluate combustible materials.
• Inspect the work area.
• Protect openings and penetrations.
• Provide appropriate fire extinguishing equipment.
• Control flammable materials.
• Establish a fire watch when required.
• Evaluate adjacent and opposite-side areas.

Hot work permits should be used when required by the company’s program, facility, customer, or applicable procedures.

Fire Watch

A fire watch should be assigned when required by the hazards and applicable hot-work procedures.

The fire watch should:

• Understand the hazards.
• Have appropriate fire-extinguishing equipment.
• Maintain an unobstructed view of the work when practical.
• Monitor areas where sparks or heat could ignite materials.
• Know how to summon emergency assistance.

Fire-watch responsibilities should continue for the required period after hot work is completed.

Grinding Safety

Grinding is common in metal fabrication and can expose employees to wheel failures, sparks, flying particles, noise, dust, and contact with rotating equipment.

Before using a grinder:

• Inspect the tool.
• Inspect the wheel or disc.
• Verify the wheel is appropriate for the grinder.
• Check the rated speed.
• Verify the guard is properly installed.
• Inspect the power cord or air hose.
• Wear required PPE.

Employees should position themselves appropriately during startup and keep other employees away from the path of sparks and debris.

Bench and Pedestal Grinders

Bench and pedestal grinders should be properly guarded and maintained.

Work rests and tongue guards should be adjusted as required for safe operation.

Employees should:

• Inspect wheels before use.
• Use wheels appropriate for the machine.
• Maintain required guarding.
• Avoid excessive pressure.
• Grind only on surfaces designed for grinding.
• Wear appropriate eye and face protection.

Damaged grinding wheels should not be used.

Portable Grinders

Portable grinders should have appropriate guards and handles installed when required.

Employees should maintain control of the grinder and keep the wheel clear of clothing, cords, hoses, and other materials.

The workpiece should be secured when necessary.

Employees should not remove grinder guards merely to gain access to difficult locations.

Abrasive Wheels

Abrasive wheels should be selected for the tool, material, and intended operation.

Employees should verify:

• Wheel type
• Wheel condition
• Maximum operating speed
• Tool speed
• Mounting
• Guarding
• Compatibility

A wheel should never be operated above its rated maximum speed.

Metal Saws

Fabrication shops may use:

• Band saws
• Cold saws
• Chop saws
• Circular saws
• Reciprocating saws
• Abrasive saws

Machine guards should be maintained.

Employees should keep hands away from blades and cutting areas, secure materials appropriately, and allow equipment to stop before reaching into hazardous areas.

Employees should not attempt to clear chips or scraps from moving machinery.

Shears

Power shears can cause severe crushing and amputation injuries.

Shears should have appropriate point-of-operation guarding or safeguarding.

Employees should:

• Keep hands away from cutting areas.
• Use material supports when appropriate.
• Avoid reaching beneath guards.
• Follow safe operating procedures.
• Use lockout/tagout before servicing or clearing hazardous jams when required.

Foot controls should be protected from unintended activation when necessary.

Press Brakes

Press brakes create significant point-of-operation hazards.

Appropriate safeguarding should be provided based on the machine and operation.

Controls may include:

• Light curtains
• Presence-sensing devices
• Restraints
• Two-hand controls
• Guards
• Safe-distance methods
• Other appropriate safeguarding systems

Employees should never place hands in the die area unless hazardous energy has been appropriately controlled.

Mechanical Power Presses

Mechanical power presses can cause severe crushing and amputation injuries.

Machines should be operated with required guards, safeguarding devices, controls, and inspection procedures.

Employees should not bypass safety devices or reach into the point of operation while the press is cycling.

Maintenance and die-setting activities should be performed using appropriate energy-control procedures.

Punch Press Safety

Punching operations should be performed with appropriate point-of-operation protection.

Employees should be trained on:

• Machine controls
• Safeguarding
• Material positioning
• Tooling
• Emergency stops
• Jam clearing
• Lockout/tagout

Hands and fingers should be kept out of hazardous operating areas.

Ironworkers

Ironworker machines may combine punching, shearing, notching, and other metalworking operations.

Each operating station should be appropriately guarded.

Employees should be aware that operation at one station may cause movement at another part of the machine.

Unused operating stations should be protected against employee exposure to hazardous movement.

Lathes

Employees operating lathes should control hazards associated with rotating workpieces, chucks, tooling, and flying chips.

Employees should:

• Secure workpieces.
• Remove chuck keys before startup.
• Keep loose clothing and jewelry away.
• Keep long hair controlled.
• Use appropriate chip-control methods.
• Avoid reaching across rotating work.

Employees should not use hands to stop rotating workpieces or remove string-like chips.

Drill Presses

Workpieces should be secured when necessary to prevent rotation.

Employees should:

• Remove chuck keys before operation.
• Keep hands away from rotating bits.
• Use appropriate speeds.
• Control loose clothing and hair.
• Remove chips with appropriate tools.

Employees should not hold small or irregular workpieces by hand when doing so creates a rotation or entanglement hazard.

CNC and Automated Equipment

CNC machines, robotic systems, automated cutting tables, and other computer-controlled equipment may start or move unexpectedly.

Employees should not enter safeguarded operating areas while equipment is capable of hazardous movement.

Interlocks and safeguarding systems should not be bypassed.

Maintenance, setup, troubleshooting, and jam clearing should be evaluated for hazardous-energy exposure.

Sheet Metal Handling

Sheet metal can create severe cut, pinch, and handling hazards.

Employees should:

• Wear appropriate gloves.
• Control sharp edges.
• Use mechanical assistance for large sheets.
• Coordinate team handling.
• Store sheets securely.
• Avoid unstable leaning stacks.

Large sheets may also be affected by wind during outdoor handling.

Sharp Edges and Burrs

Fabricated parts, scrap metal, cut stock, and unfinished components may have sharp edges and burrs.

Employees should use appropriate gloves, handling techniques, and deburring methods.

Sharp scrap should be placed in designated containers rather than left on floors, workbenches, or material racks.

Material Storage

Metal stock should be stored to prevent shifting, rolling, falling, or collapse.

Storage systems may include:

• Racks
• Shelving
• Cradles
• Chocks
• Bins
• Designated floor-storage areas

Round stock should be restrained from rolling.

Long materials should not protrude into aisles or work areas where they can create struck-by or trip hazards.

Cranes and Hoists

Fabrication facilities may use overhead cranes, gantry cranes, jib cranes, mobile cranes, and hoists to move materials and fabricated assemblies.

Employees involved in lifting operations should understand:

• Equipment capacity
• Load weight
• Rigging
• Signals
• Load control
• Suspended-load hazards

Loads should not be moved over employees when avoidable.

Only authorized personnel should operate lifting equipment.

Rigging

Slings, shackles, hooks, lifting beams, clamps, and other rigging equipment should be selected for the intended load and inspected as required.

Employees should consider:

• Load weight
• Center of gravity
• Sling angles
• Hitch configuration
• Sharp edges
• Rigging capacity
• Load stability

Damaged rigging should be removed from service.

Employees should remain clear of suspended loads and pinch points.

Overhead Crane Safety

Overhead crane operators should inspect and operate equipment according to applicable requirements and company procedures.

Operators should:

• Verify the travel path.
• Avoid sudden movements.
• Keep loads under control.
• Avoid side pulling unless specifically permitted.
• Maintain awareness of employees.
• Follow signaling procedures.
• Observe rated capacity.

Pendant and radio controls should be protected against unintended operation.

Forklift Safety

Forklifts may be used to move steel, sheet metal, fabricated assemblies, pallets, cylinders, and other materials.

Only trained and authorized employees should operate powered industrial trucks.

Operators should:

• Inspect equipment.
• Wear seat belts when provided.
• Maintain safe speeds.
• Keep loads stable.
• Observe rated capacity.
• Maintain visibility.
• Use caution around pedestrians.

Long, wide, or irregular metal loads require additional consideration.

Loading and Unloading

Metal fabrication companies may load and unload raw materials, fabricated products, machinery, and structural components.

Planning should consider:

• Load stability
• Vehicle positioning
• Rigging
• Forklift capacity
• Crane capacity
• Employee positioning
• Material restraints

Employees should anticipate that materials may shift when straps, chains, binders, or other restraints are released.

Manual Material Handling

Employees may manually handle steel, sheet metal, fabricated parts, tools, cylinders, and other heavy or awkward materials.

Employees should evaluate the load before lifting.

Mechanical assistance, carts, hoists, cranes, forklifts, or team lifting should be used when appropriate.

Employees should avoid placing hands beneath suspended or unsupported materials.

Compressed Gas Cylinders

Metal fabrication shops commonly use compressed gases for welding, cutting, and other processes.

Cylinders should be:

• Properly identified
• Secured
• Protected from damage
• Stored appropriately
• Kept away from excessive heat
• Handled with suitable equipment

Valve-protection caps should be installed when required during storage and transport.

Employees should not lift cylinders by their caps.

Oxygen and Fuel Gas Systems

Oxygen and fuel-gas equipment should be inspected before use.

Employees should check:

• Regulators
• Hoses
• Torches
• Connections
• Valves
• Flashback protection when applicable

Oil and grease should be kept away from oxygen equipment.

Leaking or damaged equipment should be removed from service.

Personal Protective Equipment

PPE should be selected according to the hazards of each fabrication operation.

Common PPE may include:

• Safety glasses
• Goggles
• Face shields
• Welding helmets
• Welding gloves
• Work gloves
• Protective clothing
• Safety-toe footwear
• Hearing protection
• Respiratory protection
• Hard hats

Eye protection should be appropriate for flying particles, sparks, radiation, chemicals, and other exposures.

A face shield should supplement rather than replace required primary eye protection when both are needed.

Eye and Face Protection

Grinding, cutting, drilling, machining, welding, and other fabrication operations can produce flying particles, sparks, molten metal, and optical radiation.

Employees should wear eye and face protection appropriate to the hazard.

Welding filter lenses should provide appropriate protection for the welding or cutting operation.

Nearby employees should also be protected from welding arcs and flying particles.

Hearing Conservation

Grinding, hammering, cutting, presses, machinery, compressed air, and other fabrication processes can generate hazardous noise.

The company should evaluate employee noise exposures and implement a Hearing Conservation Program when required.

Controls may include:

• Quieter equipment
• Equipment maintenance
• Isolation
• Enclosures
• Distance
• Hearing protection

Employees should receive required training and audiometric testing when applicable.

Respiratory Protection

Welding fumes, metal dust, coatings, grinding dust, and other fabrication contaminants may create respiratory hazards.

Engineering and work-practice controls should be used as required.

When respirators are necessary, the company should maintain a Respiratory Protection Program addressing:

• Respirator selection
• Medical evaluations
• Fit testing
• Training
• Inspection
• Cleaning
• Storage
• Cartridge or filter replacement
• Program evaluation

Employees should not wear required respirators unless applicable program requirements have been satisfied.

Hazard Communication

Metal fabrication companies may use:

• Welding consumables
• Solvents
• Paints
• Coatings
• Degreasers
• Lubricants
• Metal-treatment chemicals
• Adhesives
• Fuels
• Cleaning products

The Hazard Communication Program should address chemical inventory, labeling, Safety Data Sheets, employee training, protective measures, and non-routine tasks.

Employees should review chemical hazards before using unfamiliar products.

Metal Cleaning and Degreasing

Solvents and cleaning chemicals may create inhalation, skin, eye, fire, and chemical-reaction hazards.

Employees should:

• Follow product instructions.
• Review Safety Data Sheets.
• Use required PPE.
• Maintain adequate ventilation.
• Control ignition sources.
• Store chemicals appropriately.

Employees should not weld or perform hot work on containers or materials contaminated with unknown or hazardous substances without appropriate evaluation and preparation.

Painting and Coating

Fabrication shops performing painting or coating operations should evaluate hazards associated with solvents, flammable materials, overspray, ventilation, and respiratory exposure.

Controls may include:

• Spray areas or booths
• Ventilation
• Ignition-source control
• PPE
• Respiratory protection
• Flammable-liquid storage

Employees should receive training appropriate to the products and processes used.

Electrical Safety

Welders, grinders, power tools, machinery, extension cords, temporary wiring, and electrical panels can expose employees to electrical hazards.

Employees should:

• Inspect electrical equipment.
• Keep panels accessible.
• Avoid damaged cords.
• Use equipment appropriate for the environment.
• Report damaged electrical components.

Only qualified employees should perform electrical work requiring specialized knowledge.

Hand and Power Tools

Employees should inspect tools before use.

Tools should be:

• Appropriate for the task
• Properly guarded
• Maintained
• Used according to manufacturer instructions

Damaged tools should be removed from service.

Employees should not modify tools or defeat safety features.

Compressed Air

Compressed air should be used carefully.

Employees should never direct compressed air toward themselves or another person.

Compressed air used for cleaning should comply with applicable requirements and should not create additional hazards from flying particles or contaminants.

Safer cleaning methods should be used when practical.

Fire Prevention

Metal fabrication facilities often contain numerous ignition sources.

Fire-prevention procedures should address:

• Hot work
• Flammable liquids
• Combustible materials
• Compressed gases
• Electrical equipment
• Waste accumulation
• Fire extinguishers
• Emergency exits

Combustible materials should be controlled around welding, cutting, and grinding operations.

Housekeeping

Good housekeeping is particularly important in fabrication shops.

Employees should control:

• Metal scrap
• Sharp cutoffs
• Welding rod stubs
• Cords
• Hoses
• Tools
• Packaging
• Oil
• Grease
• Grinding debris
• Combustible waste

Aisles, exits, electrical panels, emergency equipment, and machine operating areas should remain accessible.

Slips, Trips and Falls

Oil, coolant, metal scrap, cords, hoses, uneven floors, and stored materials can create walking-working-surface hazards.

Spills should be cleaned promptly.

Hoses and cords should be routed to minimize trip hazards.

Employees should report damaged flooring, stairs, railings, or walking surfaces.

Fall Protection

Field fabrication, structural assembly, loading operations, elevated platforms, mezzanines, roofs, and equipment maintenance may expose employees to falls.

Fall hazards should be evaluated and appropriate protection provided.

Protection may include:

• Guardrails
• Personal fall arrest systems
• Covers
• Work platforms
• Aerial lifts
• Other appropriate systems

Employees should receive training before using personal fall-protection equipment.

Field Fabrication

Metal fabrication employees may perform installation, modification, welding, cutting, and assembly at customer or construction sites.

Before field work begins, employees should evaluate:

• Site-specific hazards
• Fall exposures
• Traffic
• Heavy equipment
• Power lines
• Hot-work restrictions
• Fire hazards
• Confined spaces
• Customer requirements
• Emergency procedures

Company procedures should be coordinated with applicable site or host-employer requirements.

Job Safety Analysis

A Job Safety Analysis (JSA) can help metal fabrication companies identify hazards and required controls before higher-risk or non-routine work begins.

JSAs may be appropriate for:

• Welding
• Torch cutting
• Plasma cutting
• Grinding
• Press-brake operation
• Shearing
• Saw operation
• Punch-press operation
• Overhead crane operations
• Rigging and hoisting
• Loading and unloading
• Equipment maintenance
• Lockout/tagout
• Field fabrication
• Hot work at customer locations

The JSA should identify the steps of the task, associated hazards, and controls needed to perform the work safely.

Emergency Procedures

Metal fabrication facilities should plan for foreseeable emergencies.

Emergency planning may address:

• Fires
• Employee injuries
• Chemical exposures
• Gas-cylinder incidents
• Equipment incidents
• Electrical emergencies
• Dropped loads
• Severe weather
• Medical emergencies

Employees should understand alarms, evacuation procedures, assembly locations, emergency contacts, and their assigned responsibilities.

Metal Fabrication Safety Training

Employees should receive training appropriate to their assigned equipment and work.

Training may include:

• Machine guarding
• Lockout/tagout
• Welding and cutting
• Hot work
• Grinding
• Fabrication machinery
• Hand and power tools
• Crane and rigging safety
• Forklift safety
• Compressed gas cylinders
• PPE
• Hearing conservation
• Respiratory protection
• Hazard communication
• Fire prevention
• Emergency procedures

Training should be documented and updated when equipment, processes, materials, employee responsibilities, or regulatory requirements change.

Building a Metal Fabrication Safety Manual

A Metal Fabrication Safety Manual should be customized to the company’s actual fabrication processes rather than relying solely on a generic manufacturing or construction safety manual.

A small custom welding and fabrication shop may require a different combination of programs than a structural steel fabrication facility operating overhead cranes, CNC equipment, press brakes, shears, saws, forklifts, and multiple welding stations.

A company performing both shop fabrication and field installation may need additional programs addressing construction-site hazards, fall protection, aerial lifts, cranes, customer requirements, and field hot work.

The manual should reflect the company’s machinery, welding and cutting processes, metalworking equipment, materials, chemicals, lifting equipment, employees, maintenance activities, and field operations.

The completed safety manual should provide practical procedures employees and supervisors can use while supporting OSHA compliance, employee training, hazard assessments, JSAs, inspections, incident investigations, customer requirements, and the company’s overall safety-management system.

Customized Metal Fabrication Safety Manuals

Get a Metal Fabrication Safety Manual customized for your welding and cutting operations, grinders, press brakes, shears, saws, CNC equipment, machine tools, cranes and hoists, forklifts, compressed gases, metal handling, field fabrication, chemicals, and other metal fabrication hazards.