Sawmill Safety Manual

OSHA Sawmill Requirements

Federal OSHA maintains specific safety requirements for sawmill operations under 29 CFR 1910.265 — Sawmills.

The standard addresses sawmill operations including:

• Log and lumber handling.
• Sawing.
• Trimming.
• Planing.
• Waste disposal.
• Dry kilns.
• Finishing.
• Shipping.
• Storage.
• Yard operations.
• Yard equipment.
• Power tools.
• Affiliated equipment.

Other OSHA General Industry requirements may also apply according to the mill’s operations and employee exposures.

Sawmills, Logging, and Woodworking

Sawmill operations should be distinguished from both logging and secondary woodworking.

Logging generally involves harvesting trees and moving logs from the stump toward the point of delivery.

Sawmill operations involve receiving logs and converting them into lumber and other basic wood products.

Woodworking operations generally involve further fabrication of lumber into products such as cabinets, furniture, millwork, fixtures, doors, and similar products.

A sawmill safety program should therefore be built around primary wood-processing hazards rather than simply using a Logging Safety Manual or Woodworking Safety Manual.

What Should a Sawmill Safety Manual Include?

Depending on operations, a Sawmill Safety Manual may address:

• Sawmill safety responsibilities.
• Hazard assessments.
• Job Safety Analysis.
• Log receiving.
• Log unloading.
• Log storage.
• Log decks.
• Log conveyors.
• Debarking.
• Chipping.
• Head saws.
• Band saws.
• Gang saws.
• Edgers.
• Resaws.
• Trimmer saws.
• Planers.
• Machine guarding.
• Lockout/Tagout.
• Lumber handling.
• Dry kilns.
• Wood dust.
• Fire prevention.
• Powered Industrial Trucks.
• Mobile equipment.
• Hearing Conservation.
• Personal Protective Equipment.
• Electrical safety.
• Housekeeping.
• Emergency procedures.

Programs should be selected according to the equipment, materials, processes, and employee exposures at the individual mill.

Sawmill Safety Program

An effective Sawmill Safety Program establishes responsibilities and procedures for controlling log movement, saws, machinery, hazardous energy, material handling, mobile equipment, noise, dust, fire, and other mill hazards.

Management should provide properly guarded equipment, safe work procedures, appropriate PPE, employee training, effective supervision, preventive maintenance, and emergency resources.

Managers, supervisors, and designated safety personnel should:

• Identify and evaluate sawmill hazards.
• Maintain applicable written programs.
• Establish safe operating procedures.
• Maintain machine guards and safety devices.
• Establish hazardous-energy procedures.
• Maintain log- and lumber-handling equipment.
• Control vehicle and pedestrian traffic.
• Evaluate noise and dust exposures.
• Maintain fire-prevention systems.
• Correct unsafe conditions.
• Investigate incidents.
• Provide employee training.
• Maintain applicable records.

Employees should follow established procedures, use required guards and PPE, stay clear of hazardous log and machinery areas, and promptly report unsafe conditions, damaged equipment, missing guards, injuries, and other hazards.

Sawmill Hazard Assessments

Hazard assessments should consider each phase of mill operations.

Potential areas include:

• Log receiving.
• Log yards.
• Log ponds.
• Log decks.
• Debarking.
• Chipping.
• Log breakdown.
• Head rigs.
• Resaws.
• Edgers.
• Trimmers.
• Planing.
• Dry kilns.
• Lumber sorting.
• Lumber stacking.
• Warehousing.
• Shipping.
• Maintenance.

Potential hazards may include:

• Rolling logs.
• Falling lumber.
• Saw blades.
• Kickback.
• Flying debris.
• Pinch points.
• Rotating equipment.
• Hazardous energy.
• Forklifts.
• Loaders.
• Noise.
• Wood dust.
• Fire.
• Heat.
• Falls.

Assessments should be reviewed when equipment, processes, materials, or operating conditions change.

Job Safety Analysis (JSA/JHA)

A JSA/JHA may be used to evaluate higher-risk sawmill activities.

Potential JSAs/JHAs may address:

• Log unloading.
• Log deck operations.
• Debarker operation.
• Chipper operation.
• Head saw operation.
• Band saw blade changes.
• Edger operation.
• Trimmer saw operation.
• Jam clearing.
• Conveyor maintenance.
• Kiln entry.
• Lumber stacking.
• Forklift operations.
• Equipment maintenance.

The analysis should identify job steps, hazards, controls, PPE, and employee responsibilities.

Log Receiving

Incoming logs may arrive by:

• Truck.
• Rail.
• Loader.
• Other transport equipment.

Receiving procedures should protect employees from:

• Rolling logs.
• Shifting loads.
• Vehicle movement.
• Unstable log stacks.
• Material-handling equipment.

Employees should remain outside areas where uncontrolled log movement could strike or crush them.

Log Unloading

Before logs are unloaded, employees should evaluate load stability.

Load restraints should be removed using procedures that prevent employees from being struck by shifting or rolling logs.

Employees should avoid:

• Downhill sides of unstable loads.
• Uncontrolled fall zones.
• Pinch points.
• Areas between equipment and logs.

Mechanical equipment should be used to control loads where appropriate.

Log Yards

Log yards should be organized to reduce uncontrolled interaction among:

• Loaders.
• Trucks.
• Pedestrians.
• Log piles.
• Conveyors.
• Rail equipment.

Traffic routes and employee work areas should be clearly established.

Log Storage

Logs should be stored to minimize:

• Rolling.
• Sliding.
• Collapse.
• Uncontrolled movement.

Storage arrangements should reflect:

• Log size.
• Terrain.
• Ground conditions.
• Stack configuration.
• Material-handling methods.

Employees should not climb unstable log piles.

Log Ponds — When Applicable

Some sawmills use log ponds or water-storage areas.

Potential hazards include:

• Drowning.
• Slippery surfaces.
• Moving logs.
• Cold water.
• Equipment movement.

Employees working where drowning hazards exist should receive appropriate protection.

Working Over or Near Water — When Applicable

Where employees work over or adjacent to water and a drowning hazard exists, appropriate lifesaving equipment, personal flotation devices, access, and rescue procedures should be provided as applicable.

Walking surfaces should be maintained to reduce slips and falls.

Log Decks

Log decks can expose employees to severe crushing hazards from logs that:

• Roll.
• Shift.
• Drop.
• Jam.
• Move unexpectedly.

Employees should remain outside hazardous log travel paths.

Decks, stops, controls, and related equipment should be maintained.

Log Stops

Stops and other devices used to control logs should be maintained so logs do not move unexpectedly.

Employees should not enter hazardous areas to manually control logs when mechanical controls can be used.

Log Conveyors

Conveyors transporting logs can expose employees to:

• Nip points.
• Chains.
• Sprockets.
• Rollers.
• Falling logs.
• Unexpected startup.

Required guards should remain installed.

Employees should not ride on conveyors unless specifically designed and authorized for riding.

Conveyor Crossovers

Where employees must cross conveyors, appropriate crossover walkways or other safe means should be provided.

Employees should not climb over or under operating conveyors in unauthorized locations.

Conveyor Jam Clearing

Employees should not enter hazardous conveyor areas to clear jams until applicable hazardous energy has been controlled.

Normal stop buttons should not be treated as substitutes for required energy isolation.

Log Handling Equipment

Sawmills may use:

• Front-end loaders.
• Log loaders.
• Forklifts.
• Cranes.
• Grapples.
• Specialized log-handling vehicles.

Only trained and authorized employees should operate assigned equipment.

Operators should maintain safe clearance from pedestrians.

Debarking Operations

Debarkers can expose employees to:

• Rotating machinery.
• Moving logs.
• Flying bark.
• Pinch points.
• Noise.
• Unexpected startup.

Guards and protective devices should remain installed.

Employees should not manually hold material where mechanical equipment is intended to control it.

Debarker Maintenance

Before employees clean, adjust, inspect, or repair debarking equipment, applicable hazardous energy should be controlled.

Employees should account for:

• Electrical energy.
• Hydraulic pressure.
• Pneumatic pressure.
• Rotating components.
• Stored mechanical energy.

Chipping Operations

Chippers can cause catastrophic injuries.

Potential hazards include:

• Cutting knives.
• Rotating components.
• Feed systems.
• Flying debris.
• Wood dust.
• Noise.

Employees should never reach into chipper feed or cutting areas while hazardous movement is possible.

Chipper Guards

Guards and enclosures should prevent employee contact with hazardous chipper components.

Inspection or access doors should remain closed during operation.

Damaged guards should be repaired before operation continues.

Chipper Jam Clearing

Before clearing a jam:

• Stop the equipment.
• Isolate hazardous energy.
• Control stored energy.
• Verify the equipment cannot start.
• Use appropriate tools and methods.

Employees should recognize that large rotating components may continue moving after power is disconnected.

Log Breakdown

Log breakdown is a core sawmill operation and may involve:

• Head rigs.
• Carriages.
• Band saws.
• Circular saws.
• Gang saws.
• Feed rolls.

Employees should remain protected from saw blades, carriage movement, flying material, and other machine hazards.

Head Rigs

Head-rig operations may expose the sawyer and other employees to:

• Saw blades.
• Moving logs.
• Carriage movement.
• Flying debris.
• Broken saw components.

Required guards and safety devices should remain functional.

Only authorized employees should occupy designated operator locations.

Log Carriages

Log carriages can move rapidly and create severe crushing hazards.

Carriage areas should be controlled to prevent employees from entering travel paths during operation.

Stops, bumpers, controls, and related safety devices should be maintained.

Carriage Runways

Carriage runways should be kept clear of employees during operation.

Maintenance personnel should control hazardous energy before entering areas where carriage movement could occur.

Band Saws

Band saws can cause severe lacerations and amputations.

Band wheels should be appropriately enclosed or guarded.

Saw catchers and other required protective devices should be maintained.

Employees should not operate band saws with required guards removed.

Band Saw Blades

Band saw blades should be inspected for:

• Cracks.
• Damage.
• Improper tension.
• Excessive wear.
• Other defects.

Blade changes should be performed according to safe procedures and with equipment properly isolated.

Circular Head Saws

Circular head saws should not be operated above manufacturer-recommended speeds.

Required guides, guards, and screens should remain in place.

Employees should be protected from flying particles.

Gang Saws

Gang saws should be equipped with applicable guards and protective devices.

Employees should remain clear of:

• Saw blades.
• Feed systems.
• Moving lumber.
• Kickback paths.

Resaws

Resaws can expose employees to:

• Saw contact.
• Kickback.
• Feed-roll hazards.
• Flying material.

Required antikickback devices, spreaders, guards, and feed-roll protection should be maintained.

Kickback

Kickback can cause material to be propelled toward employees with significant force.

Employees should avoid standing directly in predictable kickback paths.

Equipment designed to control kickback should remain installed and functional.

Edgers

Edgers should be equipped with applicable guards and feed controls.

Employees should avoid placing hands near cutting zones or feed rolls.

Mechanical feeding and handling methods should be used where provided.

Edger Kickback

Irregular lumber, improper feeding, defects, or machine conditions can increase kickback hazards.

Employees should use designated operator positions and maintain clear escape paths where appropriate.

Trimmer Saws

Trimmer saws should be guarded to protect employees from:

• Saw blades.
• Flying debris.
• Moving lumber.

Baffles and other protective devices should remain in place.

Employees should not reach into operating saw areas.

Planers

Planers can expose employees to:

• Rotating cutter heads.
• Feed rolls.
• Kickback.
• Flying chips.
• Noise.

Required guards should be installed.

Employees should remain clear of feed and discharge hazards.

Machine Guarding

Machine guarding is a central component of sawmill safety.

Machinery should be evaluated for:

• Saw blades.
• Rotating shafts.
• Belts.
• Pulleys.
• Chains.
• Sprockets.
• Gears.
• Feed rolls.
• Nip points.
• Cutting heads.
• Reciprocating components.

Guards should prevent employee contact with hazardous moving parts.

Guard Removal

Guards should not be removed or bypassed for routine production.

Where guards must be removed for maintenance, adjustment, or repair, appropriate hazardous-energy procedures should be followed.

Guards should be reinstalled before equipment returns to service.

Interlocks and Safety Devices

Interlocks, emergency stops, pull cords, and other safety devices should be maintained and tested as appropriate.

Employees should not bypass or defeat safety devices.

Emergency stopping devices are not substitutes for required hazardous-energy isolation.

Lockout/Tagout

Sawmill machinery often contains multiple hazardous-energy sources.

Applicable Lockout/Tagout procedures should be followed during covered:

• Maintenance.
• Repair.
• Cleaning.
• Jam clearing.
• Saw changes.
• Blade changes.
• Adjustment.
• Inspection.

Potential energy sources may include:

• Electrical.
• Mechanical.
• Hydraulic.
• Pneumatic.
• Gravity.
• Stored pressure.

Energy Isolation

Employees should identify all hazardous energy sources before servicing equipment.

Isolation may require multiple:

• Disconnects.
• Valves.
• Blocks.
• Locks.
• Other energy-isolating devices.

Employees should verify isolation before work begins.

Stored Energy

Stored energy should be:

• Relieved.
• Restrained.
• Blocked.
• Dissipated.
• Otherwise controlled.

Potential sources include:

• Raised equipment.
• Hydraulic pressure.
• Pneumatic pressure.
• Flywheels.
• Rotating saws.
• Spring tension.
• Gravity.

Jam Clearing

Employees should not reach into operating or energized machinery to remove jammed:

• Logs.
• Lumber.
• Bark.
• Chips.
• Scrap.

Hazardous energy should be controlled where servicing provisions apply.

Preventive Maintenance

Preventive maintenance should address safety-critical sawmill equipment.

Inspections may include:

• Saws.
• Guards.
• Conveyors.
• Emergency stops.
• Log-handling equipment.
• Forklifts.
• Hydraulic systems.
• Brakes.
• Kiln equipment.
• Dust collection.
• Electrical systems.

Defects affecting safe operation should be corrected.

Lumber Handling

Finished and partially processed lumber may be moved by:

• Conveyors.
• Rollers.
• Forklifts.
• Carts.
• Cranes.
• Manual handling.

Employees should remain clear of falling, shifting, and moving lumber.

Lumber Sorting

Sorting operations can expose employees to:

• Moving lumber.
• Pinch points.
• Repetitive motion.
• Splinters.
• Falls.

Workstations and equipment should be designed and maintained to reduce these hazards.

Lumber Stacking

Lumber stacks should be stable.

Stacking should consider:

• Lumber dimensions.
• Stack height.
• Foundation.
• Dunnage.
• Banding.
• Environmental conditions.

Unstable stacks should be corrected before employees work nearby.

Lumber Piles

Employees should not climb unstable lumber piles.

Mechanical equipment should be used for high or heavy stacking where appropriate.

Aisles should be maintained between storage areas where required for safe access.

Forklift Operations

Forklifts may be used to move:

• Lumber bundles.
• Pallets.
• Materials.
• Equipment.

Only trained and authorized employees should operate Powered Industrial Trucks.

Operators should use equipment within rated capacity.

Forklift Load Stability

Long lumber bundles can affect:

• Vehicle stability.
• Turning radius.
• Visibility.
• Load balance.

Operators should travel at safe speeds and consider load length and center of gravity.

Mobile Equipment

Other mobile equipment may include:

• Loaders.
• Yard trucks.
• Skidders used within mill yards.
• Utility vehicles.
• Specialized lumber carriers.

Equipment should be inspected and maintained.

Traffic rules should address pedestrians and equipment interaction.

Yard Traffic

Sawmill yards can contain simultaneous movement of:

• Log trucks.
• Lumber trucks.
• Loaders.
• Forklifts.
• Employees.

Traffic-control measures may include:

• Designated routes.
• Speed limits.
• Signs.
• Mirrors.
• Restricted areas.
• Pedestrian walkways.

Backing

Backing should be minimized where practical.

Where visibility is restricted, controls may include:

• Cameras.
• Mirrors.
• Alarms.
• Spotters.
• Restricted pedestrian zones.

Employees should not stand between backing equipment and fixed objects.

Dry Kilns

Dry kilns introduce hazards involving:

• Heat.
• Steam.
• Lumber movement.
• Kiln cars.
• Tracks.
• Doors.
• Pits.
• Limited clearances.

Kilns should be constructed and maintained for safe operation.

Kiln Foundations

Kiln foundations and tracks should remain stable enough to safely support loaded kiln cars and lumber.

Damaged or sagging systems should be corrected.

Kiln Passageways

Required passageways should provide sufficient clearance for employees.

Passageways should remain free of unnecessary obstructions.

Kiln Doors

Kiln doors can be large and heavy.

Doors, lifting systems, tracks, and securing devices should be inspected and maintained.

Employees should remain clear of potential door travel or fall zones.

Kiln Pits

Pits associated with kiln operations should be guarded or otherwise protected as required.

Safe access should be provided where employees must enter.

Steam Hazards

Kilns and other sawmill operations may involve steam.

Employees should be protected from:

• Burns.
• Hot piping.
• Leaks.
• Pressure releases.

Defective steam systems should be reported and repaired.

Kiln Entry

Before employees enter kilns, conditions should be evaluated for:

• Heat.
• Equipment movement.
• Steam.
• Limited access.
• Atmospheric hazards where applicable.

Equipment should be isolated where unexpected movement or energy release could occur.

Heat Stress

Employees working around dry kilns or in hot outdoor conditions may experience heat stress.

Heat-illness prevention should consider:

• Temperature.
• Humidity.
• Workload.
• Radiant heat.
• Acclimatization.
• Drinking water.
• Rest and cooling.

Wood Dust

Sawmill operations may generate wood dust during:

• Sawing.
• Planing.
• Chipping.
• Trimming.
• Material handling.
• Cleanup.

Wood dust can create respiratory, skin, housekeeping, and fire hazards.

Dust should be controlled according to the amount and characteristics generated.

Dust Collection

Dust-collection systems should be inspected and maintained.

Potential concerns include:

• Duct blockage.
• Leaks.
• Accumulation.
• Equipment damage.
• Ignition sources.

Employees should not enter dust-collection equipment without appropriate hazardous-energy and confined-space evaluation where applicable.

Combustible Dust — When Applicable

Fine wood dust can present fire or explosion hazards under certain conditions.

Facilities should evaluate:

• Dust generation.
• Dust particle characteristics.
• Accumulation.
• Enclosure.
• Dust collection.
• Ignition sources.
• Housekeeping.

Combustible-dust controls should reflect the actual processes and material present.

Fire Prevention

Sawmills can contain substantial combustible material including:

• Lumber.
• Bark.
• Sawdust.
• Chips.
• Wood dust.
• Packaging.
• Fuel.

Fire-prevention procedures should address:

• Ignition control.
• Housekeeping.
• Hot Work.
• Electrical hazards.
• Smoking controls.
• Fire protection equipment.

Sawdust and Chip Accumulation

Sawdust, bark, chips, and waste should not be allowed to accumulate excessively around:

• Machines.
• Bearings.
• Motors.
• Electrical equipment.
• Heat sources.
• Access routes.

Waste should be removed using safe methods.

Waste Conveyors

Waste conveyors may transport:

• Sawdust.
• Bark.
• Chips.
• Scrap wood.

Required guards should remain installed.

Employees should control hazardous energy before clearing or servicing conveyor systems where required.

Hot Work

Welding, cutting, brazing, and grinding may be performed during sawmill maintenance.

Hot Work procedures should consider:

• Wood dust.
• Sawdust.
• Lumber.
• Flammable liquids.
• Combustible structures.

Combustible material should be removed or protected before Hot Work begins.

Fire Watch

A fire watch may be appropriate where sparks, slag, or heat can ignite combustible material not otherwise adequately protected.

Fire-watch personnel should have suitable extinguishing equipment and understand their responsibilities.

Flammable and Combustible Liquids

Sawmills may store:

• Fuel.
• Lubricants.
• Solvents.
• Maintenance chemicals.
• Finishing products.

Applicable storage, transfer, ignition-control, and spill procedures should be followed.

Chemical Safety

Chemicals may be used for:

• Maintenance.
• Cleaning.
• Wood treatment.
• Finishing.
• Pest control.
• Equipment servicing.

Employees should understand applicable chemical hazards.

Hazard Communication

A Hazard Communication Program should address hazardous chemicals used or stored at the mill.

Applicable elements may include:

• Chemical inventory.
• Labels.
• Safety Data Sheets.
• Employee training.
• Workplace containers.
• Non-routine tasks.

Employees should know how to obtain hazard information before using chemicals.

Wood Treatment Chemicals — When Applicable

Some mills may use preservatives or other wood-treatment chemicals.

Where such chemicals are present, employees should be protected from applicable:

• Skin exposure.
• Inhalation.
• Eye contact.
• Spills.
• Contamination.

Controls should reflect the actual chemical used.

Respiratory Protection

Where respiratory protection is required, the employer should maintain an appropriate Respiratory Protection Program.

Potential respiratory hazards may include:

• Wood dust.
• Chemical vapors.
• Welding fumes.
• Maintenance exposures.

Respirator use should be based on evaluated hazards and applicable requirements.

Noise

Sawmills can contain high noise levels from:

• Head saws.
• Band saws.
• Chippers.
• Debarkers.
• Planers.
• Conveyors.
• Mobile equipment.

Employee noise exposure should be evaluated.

Hearing Conservation

Where employee noise exposure reaches applicable levels, a Hearing Conservation Program should be implemented.

Applicable elements may include:

• Noise monitoring.
• Audiometric testing.
• Hearing protection.
• Training.
• Recordkeeping.

Engineering and administrative controls should be considered as required.

Personal Protective Equipment

PPE should be selected according to hazard assessments.

Depending on assigned duties, PPE may include:

• Safety glasses.
• Goggles.
• Face shields.
• Hard hats.
• Hearing protection.
• Protective footwear.
• Gloves.
• High-visibility clothing.
• Respiratory protection.
• Fall protection.
• Personal flotation devices.

Employees should understand PPE use and limitations.

Eye and Face Protection

Eye and face hazards may result from:

• Flying wood.
• Sawdust.
• Chipping.
• Grinding.
• Maintenance.
• Chemical use.

Appropriate protection should be worn.

Hand Protection

Gloves may be appropriate for:

• Rough lumber.
• Splinters.
• Chemical handling.
• Maintenance.
• Manual material handling.

Employees should not wear gloves where they create an increased entanglement hazard around exposed rotating machinery.

Protective Footwear

Protective footwear may be necessary where employees are exposed to:

• Falling logs.
• Lumber.
• Mobile equipment.
• Heavy materials.
• Puncture hazards.

Footwear should be appropriate for terrain and work conditions.

High-Visibility Clothing

High-visibility clothing may help employees remain visible around:

• Log trucks.
• Loaders.
• Forklifts.
• Yard equipment.

High-visibility clothing does not replace effective traffic controls.

Electrical Safety

Electrical systems may power:

• Saws.
• Conveyors.
• Chippers.
• Kilns.
• Dust systems.
• Lighting.
• Maintenance equipment.

Electrical equipment should be maintained in safe condition.

Qualified employees should perform electrical work as required.

Electrical Maintenance

Electrical maintenance should address:

• De-energization.
• Hazardous-energy control.
• Verification.
• Appropriate PPE.
• Safe work practices.

Damaged electrical equipment should be repaired before continued use.

Machine Electrical Controls

Control stations and disconnects should be clearly identifiable and accessible as appropriate.

Employees should know the difference between:

• Normal stop controls.
• Emergency stops.
• Energy-isolating devices.

Walking-Working Surfaces

Sawmills may contain:

• Elevated walkways.
• Platforms.
• Ramps.
• Catwalks.
• Docks.
• Machine-access areas.

Walking-working surfaces should be maintained in safe condition.

Floors and Walkways

Floors, ramps, docks, and walkways should:

• Support anticipated loads.
• Be maintained in good repair.
• Be kept as free as practical from trip hazards.
• Provide measures to minimize slipping.

Hazardous areas that cannot be immediately repaired should be protected.

Floor Openings

Floor openings should be guarded or otherwise protected as required.

Areas below openings should be protected from falling materials where appropriate.

Slips, Trips and Falls

Common hazards may include:

• Bark.
• Sawdust.
• Wood scraps.
• Oil.
• Ice.
• Water.
• Uneven surfaces.

Housekeeping and maintenance should address these hazards promptly.

Ladders and Stairways

Ladders and stairways should be:

• Appropriate for the location.
• Maintained.
• Inspected.
• Safely accessed.

Damaged ladders should be removed from service.

Fall Protection

Where employees are exposed to applicable fall hazards, appropriate fall-protection systems should be used.

Potential areas may include:

• Elevated machinery.
• Kilns.
• Platforms.
• Storage areas.
• Maintenance locations.

Structural Safety

Buildings, docks, tramways, walkways, log dumps, and other structures should be designed, constructed, and maintained to support imposed loads.

Employees should report structural deterioration.

Areas affected by unsafe structural conditions should be controlled until repaired.

Housekeeping

Housekeeping is particularly important in sawmills because wood waste can contribute to both employee injuries and fire hazards.

Employees should control:

• Sawdust.
• Bark.
• Scrap wood.
• Strapping.
• Oil.
• Waste.
• Tools.

Aisles and emergency exits should remain accessible.

Manual Material Handling

Employees may manually handle:

• Lumber.
• Tools.
• Parts.
• Materials.

Procedures should reduce unnecessary:

• Heavy lifting.
• Twisting.
• Overreaching.
• Repetitive handling.

Mechanical assistance should be used where practical.

Ergonomics

Some sawmill jobs involve repetitive:

• Sorting.
• Stacking.
• Pulling.
• Lifting.
• Reaching.

Ergonomic evaluations may identify opportunities to reduce strain through:

• Workstation changes.
• Mechanical handling.
• Job rotation.
• Work-practice changes.

Cranes and Hoists

Cranes and hoists may be used for:

• Equipment maintenance.
• Saw components.
• Motors.
• Lumber.
• Other heavy materials.

Lifting equipment should be inspected and operated within rated capacity.

Employees should remain clear of suspended loads.

Rigging

Rigging equipment should be appropriate for the load.

Slings, hooks, chains, wire rope, and other devices should be inspected and maintained.

Damaged rigging should be removed from service.

Compressed Air

Compressed air should not be used in ways that expose employees to unnecessary hazards.

Employees should not use compressed air to clean themselves or coworkers.

Compressed-air equipment should be maintained.

Pneumatic Systems

Pneumatic systems can retain hazardous stored energy.

Pressure should be controlled before employees disconnect or service components.

Hoses and fittings should be inspected.

Maintenance Shops

Sawmill maintenance shops may involve:

• Welding.
• Grinding.
• Machine repair.
• Electrical work.
• Compressed gases.
• Chemicals.
• Lifting equipment.

Maintenance activities should follow applicable safety programs.

Contractor Safety

Contractors may perform:

• Equipment installation.
• Electrical work.
• Maintenance.
• Kiln work.
• Construction.
• Specialized repairs.

Facility and contractor responsibilities should be coordinated.

Contractors should be informed of hazards relevant to their work.

Emergency Action Plan

The sawmill should maintain emergency procedures appropriate to its operations.

Potential emergencies may include:

• Fire.
• Explosion.
• Serious machine injury.
• Log-handling incident.
• Chemical release.
• Severe weather.
• Medical emergency.

Employees should understand alarms, evacuation routes, assembly areas, and reporting procedures.

Fire Emergency

Because sawmills contain significant combustible materials, fire-response planning is particularly important.

Employees should know:

• How to report a fire.
• When to evacuate.
• Which extinguishers they are authorized to use.
• Assembly locations.
• Emergency access requirements.

Severe Weather

Sawmill yards and outdoor operations may be affected by:

• High winds.
• Lightning.
• Heavy rain.
• Snow.
• Ice.
• Extreme heat.
• Extreme cold.

Operations should be modified where weather creates unacceptable hazards.

Cold Stress

Outdoor log-yard employees may be exposed to cold conditions.

Cold-stress procedures may address:

• Protective clothing.
• Warming areas.
• Work scheduling.
• Wet clothing.
• Wind chill.

First Aid

First-aid resources should reflect sawmill hazards.

Potential injuries include:

• Amputations.
• Severe lacerations.
• Crushing.
• Eye injuries.
• Burns.
• Falls.
• Strains.

Employees should know how to summon emergency medical assistance.

Remote Locations

Some sawmills may operate in locations where emergency medical services are not immediately accessible.

Emergency planning should consider:

• Communication.
• First-aid capability.
• Transportation.
• Response time.
• Severe-injury scenarios.

Incident Reporting

Employees should promptly report:

• Injuries.
• Near misses.
• Machine contacts.
• Kickback incidents.
• Log movement incidents.
• Guard failures.
• Equipment defects.
• Fires.
• Unsafe conditions.

Prompt reporting helps identify hazards before similar incidents occur.

Incident Investigation

Significant incidents should be investigated to identify:

• Immediate causes.
• Contributing factors.
• Root causes.
• Corrective actions.

Investigations may consider:

• Machine guarding.
• Log handling.
• Lockout/Tagout.
• Equipment condition.
• Traffic control.
• Training.
• Procedures.
• Supervision.

Root Cause Analysis

Root Cause Analysis may identify underlying factors involving:

• Equipment design.
• Guarding.
• Preventive maintenance.
• Procedures.
• Training.
• Staffing.
• Supervision.
• Work planning.
• Corrective-action systems.

Corrective actions should address identified causes rather than simply assigning blame.

Sawmill Safety Inspections

Periodic inspections should evaluate applicable:

• Log yards.
• Log decks.
• Conveyors.
• Debarkers.
• Chippers.
• Saws.
• Machine guards.
• Lumber storage.
• Dry kilns.
• Forklifts.
• Mobile equipment.
• Electrical systems.
• Fire protection.
• Walking surfaces.
• PPE.

Identified deficiencies should be corrected promptly.

Sawmill Safety Training

Employee training should reflect assigned work and hazards.

Depending on duties, training may address:

• Log handling.
• Saw operation.
• Machine guarding.
• Lockout/Tagout.
• Conveyor safety.
• Mobile equipment.
• Forklifts.
• Kilns.
• Wood dust.
• Hearing protection.
• PPE.
• Emergency procedures.

Employees should not independently operate specialized machinery until they have received appropriate instruction.

Machine-Specific Training

Employees should receive instruction for each machine they are authorized to operate.

Training should address:

• Controls.
• Guards.
• Emergency stops.
• Feed systems.
• Kickback.
• Jam clearing.
• Safe operating positions.
• Hazardous-energy procedures.

Training on one saw or machine should not automatically be considered sufficient for substantially different equipment.

New Employee Orientation

New employees should receive safety orientation before independently performing assigned work.

Orientation may address:

• Log-yard hazards.
• Machine areas.
• Traffic.
• PPE.
• Emergency procedures.
• Hazard reporting.
• Restricted areas.

Refresher Training

Refresher or remedial training may be appropriate following:

• Unsafe equipment operation.
• Guarding violations.
• Lockout/Tagout violations.
• Vehicle incidents.
• Machine changes.
• Incidents or near misses.
• Identified knowledge gaps.

Safety Meetings

Periodic safety meetings may reinforce safe work practices.

Potential topics include:

• Log handling.
• Kickback.
• Machine guarding.
• Lockout/Tagout.
• Chipper safety.
• Forklifts.
• Wood dust.
• Housekeeping.
• Fire prevention.
• Recent incidents.

Recordkeeping

Sawmill employers should maintain occupational safety and health records required for their operations.

Records may include:

• Employee training.
• Injury and illness records.
• Equipment inspections.
• Preventive maintenance.
• Lockout/Tagout inspections.
• Powered Industrial Truck training.
• Hearing Conservation records.
• Exposure monitoring.
• Respiratory Protection records.
• Incident investigations.

Records should be retained according to applicable requirements.

Additional Safety Programs

Depending on sawmill operations and employee exposures, additional programs may be necessary for:

• Sawmill Safety.
• Log Handling.
• Log Deck Safety.
• Conveyor Safety.
• Debarker Safety.
• Chipper Safety.
• Head Saw Safety.
• Band Saw Safety.
• Circular Saw Safety.
• Resaw Safety.
• Edger Safety.
• Trimmer Saw Safety.
• Planer Safety.
• Machine Guarding.
• Lockout/Tagout.
• Preventive Maintenance.
• Lumber Handling.
• Lumber Storage.
• Dry Kiln Safety.
• Wood Dust.
• Combustible Dust.
• Fire Prevention.
• Hot Work.
• Powered Industrial Trucks.
• Mobile Equipment.
• Traffic Control.
• Cranes & Hoists.
• Rigging & Material Handling.
• Hearing Conservation.
• Respiratory Protection.
• Hazard Communication.
• Personal Protective Equipment.
• Electrical Safety.
• Walking-Working Surfaces.
• Fall Protection.
• Ladders & Stairways.
• Working Over or Near Water.
• Heat Stress Prevention.
• Cold Stress.
• Housekeeping.
• Emergency Action Plan.
• First Aid.
• Contractor Safety.
• Incident Reporting & Investigation.
• Root Cause Analysis.

Programs should be included when the mill’s equipment, processes, materials, and employee exposures make them applicable.

Building a Sawmill Safety Manual

A useful Sawmill Safety Manual should reflect the actual processes performed at the facility.

A large lumber mill may require extensive procedures for log receiving, log storage, log decks, debarking, chipping, head rigs, saw carriages, band and circular saws, gang saws, edgers, trimmers, planers, dry kilns, lumber storage, forklifts, loaders, dust systems, and shipping.

A smaller sawmill may perform many of the same processes using fewer machines and employees but still require strong controls for log movement, saws, machine guarding, hazardous energy, lumber handling, and mobile equipment.

A mill with extensive dry-kiln operations may require greater emphasis on kiln structures, steam, heat stress, kiln cars, access, and maintenance.

A facility that produces large quantities of sawdust, chips, and fine wood particles may require more extensive dust-control, housekeeping, fire-prevention, and combustible-dust procedures.

A sawmill with significant yard and log-handling operations may require additional programs for loaders, log trucks, traffic control, working around heavy equipment, and outdoor environmental hazards.

The safety manual should therefore be based on the mill’s actual operations rather than automatically assigning every sawmill-related program to every facility.

Customized Sawmill Safety Manuals

A Sawmill Safety Manual can be developed around the mill’s log receiving, log handling, saws, conveyors, debarkers, chippers, kilns, lumber-handling equipment, forklifts, loaders, maintenance activities, employees, and other occupational hazards.

The finished manual may incorporate applicable programs for Machine Guarding, Lockout/Tagout, Log Handling, Conveyor Safety, Chipper Safety, Sawmill Machinery, Dry Kilns, Wood Dust, Fire Prevention, Powered Industrial Trucks, Hearing Conservation, Respiratory Protection, PPE, Emergency Planning, Incident Investigation, and other hazards associated with lumber production.

This provides sawmills, lumber mills, primary wood-processing facilities, and related employers with a practical safety manual organized around the work their employees actually perform.