22 Feb Shop Hazards – Preventing Typical Shop Incidents

Shop Hazards – Preventing Typical Shop Incidents

Shop hazards can lead to serious injuries when employees take shortcuts, bypass safeguards, misuse equipment, or fail to recognize unsafe conditions. Preventing shop incidents requires employees to identify hazards, follow established procedures, and correct or report unsafe conditions before an injury occurs.

Guide for Discussion

Many shop injuries are predictable and preventable. Before beginning a task, consider the equipment, materials, energy sources, and surrounding work area and determine what could go wrong.

Machine Operation and Guarding

Machine tools can cause severe cuts, crushing injuries, amputations, and entanglement.

• Never adjust, clean, lubricate, or service operating machinery when doing so exposes you to hazardous moving parts.
• Follow required lockout/tagout procedures before servicing or maintenance.
• Never remove, bypass, or defeat machine guards or safety devices.
• Keep hands and body parts away from points of operation, rotating equipment, and pinch points.
• Do not wear loose clothing, jewelry, gloves, or other items that could become caught in rotating machinery.
• Secure long hair when working around machinery.

Immediately report missing, damaged, or improperly adjusted guards.

Compressed Air

Compressed air can propel chips and debris at high velocity and can cause serious eye, skin, hearing, and other injuries.

• Never use compressed air to clean your body or clothing.
• Do not direct compressed air toward another person.
• When compressed air is used for cleaning purposes, OSHA generally requires the pressure to be reduced to less than 30 psi and used only with effective chip guarding and appropriate PPE.
• Use safer cleaning methods, such as vacuuming or brushing, whenever practical.
• Wear appropriate eye and face protection when exposure to flying particles exists.

The 30-psi requirement does not mean compressed air below that pressure is safe for cleaning employees.

Personal Protective Equipment

Wear PPE appropriate for the hazards of the work.

Depending on the task, this may include:

• Safety glasses or goggles.
• Face protection.
• Hearing protection.
• Safety footwear.
• Gloves appropriate for the task.
• Protective clothing.

Never wear gloves around rotating machinery when they could become caught or entangled.

Grinder Safety

Bench and pedestal grinders require properly installed and adjusted guards.

Before using a grinder:

• Inspect the wheel for damage.
• Verify that guards are properly installed.
• Keep the work rest adjusted to within 1/8 inch of the wheel.
• Keep the adjustable tongue or upper peripheral guard within 1/4 inch of the wheel.
• Wear appropriate eye and face protection.
• Stand to the side when starting a grinder and allow it to reach operating speed before beginning work.
• Never exceed the wheel’s rated speed.

Remove defective grinders or wheels from service.

Manual Material Handling

Do not attempt to lift or move a load that is beyond your ability to safely control.

• Assess the load before lifting.
• Use mechanical lifting equipment when appropriate.
• Get assistance with heavy, bulky, or awkward loads.
• Keep loads close to your body.
• Avoid twisting while lifting or carrying.
• Make sure the travel path is clear before moving the load.

Electrical Safety

Damaged electrical tools, cords, plugs, and equipment can expose employees to shock, electrocution, and fire.

• Inspect portable electrical equipment before use.
• Do not use equipment with frayed, cracked, exposed, or otherwise damaged cords.
• Never make makeshift repairs with tape when the cord no longer provides the required insulation and integrity.
• Use properly grounded or double-insulated tools as designed.
• Never remove a grounding prong.
• Remove defective electrical equipment from service until properly repaired or replaced.

Flammable and Combustible Materials

Ignition sources must be controlled wherever flammable liquids, gases, or combustible materials could create a fire or explosion hazard.

• Never smoke in prohibited areas.
• Keep flames, sparks, and other ignition sources away from flammable materials.
• Store flammable liquids in approved containers and locations.
• Clean spills promptly using established procedures.
• Maintain good housekeeping around combustible materials.

Compressed-Gas Cylinders

Compressed-gas cylinders must be handled and stored securely.

• Secure cylinders upright to prevent them from falling.
• Keep valve-protection caps in place when cylinders are not connected for use.
• Protect cylinders from damage, heat, and ignition sources.
• Separate oxygen cylinders in storage from fuel-gas cylinders and combustible materials by at least 20 feet, or by an approved noncombustible barrier meeting applicable OSHA requirements.
• Never use damaged cylinders, valves, regulators, or hoses.

Cranes and Hoisting Equipment

Never exceed the rated capacity of cranes, hoists, slings, or other lifting equipment.

• Inspect lifting equipment before use as required.
• Know the weight of the load and equipment capacity.
• Use properly selected and inspected rigging.
• Keep employees clear of suspended loads.
• Never stand or work beneath a suspended load.
• Verify hooks and safety latches are suitable and properly functioning where required.
• Remove damaged rigging or lifting equipment from service.

Before Starting Work

Ask yourself:

• Is the equipment in safe operating condition?
• Are required guards installed?
• Have hazardous energy sources been controlled?
• Am I wearing the correct PPE?
• Are electrical cords and tools in good condition?
• Is the work area clean and organized?
• Are flammable materials properly controlled?
• Can the material be safely lifted or moved?
• Could my clothing, gloves, hair, or jewelry become caught?
• Do I understand the task and its hazards?

If something is unsafe, correct it when authorized or stop and report the condition before proceeding.

Remember

Having performed an unsafe task before without getting hurt does not make the practice safe. Avoid complacency, inspect your work area and equipment, follow established procedures, and never bypass a safeguard simply to save time.