Steel Mill Safety Manual

Steel Mill Safety Programs

The safety programs needed by a steel mill depend on its processes and equipment. A comprehensive manual may include programs covering:

• Molten Metal Safety
• Furnace Safety
• Machine Guarding
• Lockout/Tagout
• Overhead Crane Safety
• Rigging and Material Handling
• Heat Stress Prevention
• Personal Protective Equipment
• Respiratory Protection
• Hearing Conservation
• Industrial Hygiene
• Confined Space Entry
• Electrical Safety
• Arc Flash Safety
• Welding, Cutting and Hot Work
• Mobile Equipment Safety
• Forklift Safety
• Conveyor Safety
• Hazard Communication
• Job Safety Analysis
• Emergency Action Plan
• Fire Prevention

Additional programs should be included when coke production, blast furnaces, specialty alloys, chemical processes, rail operations, or other specialized activities create additional hazards.

Steel Mill Safety

Steel mill operations should be evaluated systematically to identify hazards associated with production, material movement, maintenance, and employee access.

Potential hazards include:

• Molten steel
• Molten iron
• Slag
• Extreme temperatures
• Steam explosions
• Carbon monoxide
• Metal fumes
• Dust
• Moving machinery
• Hydraulic and pneumatic energy
• Electrical energy
• Overhead loads
• Heavy steel products
• Rail equipment
• Mobile equipment
• Noise
• Confined spaces

Employees should receive training appropriate to their work areas and assigned tasks.

Steelmaking Operations

Steelmaking processes vary considerably between facilities.

Operations may include:

• Raw-material handling
• Scrap handling
• Coke production
• Blast furnaces
• Basic oxygen furnaces
• Electric arc furnaces
• Secondary metallurgy
• Ladle treatment
• Continuous casting
• Ingot casting
• Rolling
• Finishing
• Coil processing

The safety manual should include only the programs applicable to the facility.

Pre-Job Planning

Non-routine and hazardous steel mill work should be planned before it begins.

Planning should consider:

• Work scope
• Process conditions
• Molten-metal exposure
• Hazardous energy
• Electrical hazards
• Confined spaces
• Elevated work
• Rigging
• Mobile equipment
• Hot work
• Required PPE
• Contractor activities
• Emergency procedures

Conditions should be reassessed when the work scope or process changes.

Job Safety Analysis

A Job Safety Analysis (JSA) can help identify hazards and controls before steel mill tasks begin.

JSAs may be appropriate for:

• Furnace maintenance
• Rolling-mill maintenance
• Ladle maintenance
• Caster maintenance
• Conveyor repair
• Crane maintenance
• Coil handling
• Equipment clearing
• Hydraulic repair
• Electrical work
• Refractory work
• Confined-space entry
• Rigging
• Hot work
• Shutdown activities

The JSA should identify task steps, hazards, and required controls.

Molten Metal Safety

Molten iron and steel can cause catastrophic burns, fires, explosions, and equipment damage.

Access to molten-metal areas should be controlled.

Employees should understand hazards associated with:

• Furnaces
• Ladles
• Tundishes
• Tapping
• Teeming
• Casting
• Slag
• Transfer operations
• Water and moisture
• Molten-metal spills

Only trained and authorized employees should perform specialized molten-metal work.

Molten Metal and Water

Water or uncontrolled moisture contacting molten metal can rapidly turn to steam and violently eject molten material.

Steel mill procedures should control water around furnaces, ladles, casting operations, slag, and other molten-metal areas.

Employees should report:

• Water leaks
• Cooling-system problems
• Standing water
• Wet scrap
• Wet tools
• Damaged water-cooled equipment
• Unexpected moisture

Abnormal water conditions around molten metal should be treated as potentially serious hazards.

Wet Scrap and Charge Materials

Scrap and other furnace-charge materials should be evaluated before charging.

Potential hazards include:

• Water
• Ice
• Snow
• Closed containers
• Pressurized components
• Oil
• Unknown substances
• Other contaminants

Procedures should prevent unsuitable or wet material from being introduced into molten metal.

Scrap Inspection

Incoming scrap should be evaluated according to the mill’s procedures before being charged.

Employees should watch for:

• Sealed containers
• Cylinders
• Tanks
• Hollow components
• Hazardous materials
• Excessive moisture
• Unexpected objects

Materials presenting unacceptable hazards should be segregated and addressed according to established procedures.

Electric Arc Furnace Safety

Electric arc furnaces can expose employees to extreme heat, electrical energy, molten metal, slag, furnace eruptions, explosions, fumes, and noise.

EAF procedures should address:

• Charging
• Melting
• Oxygen injection
• Furnace controls
• Cooling systems
• Tapping
• Slagging
• Maintenance
• Emergency conditions

Employees should remain outside designated hazardous areas unless their work requires entry.

EAF Water-Cooling Systems

Water-cooled furnace components should be monitored and maintained because uncontrolled water entering a furnace can create severe explosion hazards.

Employees should understand:

• Cooling-system alarms
• Leak indicators
• Emergency procedures
• Restricted areas
• Shutdown requirements

Suspected water leaks should receive immediate attention according to facility procedures.

Carbon Monoxide in Electric Arc Furnaces

Electric arc furnace steelmaking can generate significant quantities of carbon monoxide.

Furnace conditions should be controlled to prevent hazardous accumulation and explosion conditions.

Employees should understand applicable:

• Process controls
• Monitoring
• Ventilation
• Alarm systems
• Restricted areas
• Emergency procedures

Abnormal furnace conditions should be reported promptly.

Basic Oxygen Furnace Safety

Basic oxygen furnace operations can expose employees to molten metal, slag, oxygen, intense heat, fumes, dust, and explosions.

Procedures should address:

• Charging
• Oxygen blowing
• Furnace positioning
• Tapping
• Slag handling
• Additions
• Employee positioning
• Maintenance

Employees should remain clear of hazardous furnace trajectories and splash zones.

Blast Furnace Safety

Where blast furnaces are used, procedures should address hazards associated with:

• Hot metal
• Furnace gas
• Carbon monoxide
• Tapping
• Slag
• Tuyeres
• Cooling systems
• Refractory
• Pressure
• Material charging

Only trained and authorized employees should perform specialized furnace work.

Furnace Tapping

Employees involved in tapping operations should maintain safe positioning and clear escape routes.

Procedures should address:

• Ladle positioning
• Molten-metal flow
• Slag
• Communication
• PPE
• Floor conditions
• Restricted areas

Employees not necessary to the operation should remain clear.

Ladle Safety

Ladles used to contain and transport molten steel should be suitable for the process and maintained in safe condition.

Inspections may include:

• Shell condition
• Refractory
• Trunnions
• Lifting points
• Hooks
• Mechanical systems
• Safety devices

Conditions affecting safe use should be corrected before the ladle is returned to service.

Ladle Refractory

Refractory condition should be monitored to reduce the potential for molten-metal breakout.

Employees involved in inspection and repair should understand:

• Residual heat
• Confined-space hazards
• Dust
• Falling refractory
• Equipment movement
• Hazardous energy

Ladles should be placed in an appropriate safe condition before maintenance begins.

Ladle Transport

Molten steel may be transported using overhead cranes, ladle cars, or other specialized equipment.

Travel routes should be controlled.

Employees should:

• Remain clear of molten-metal movement.
• Avoid unnecessary work beneath transfer routes.
• Follow warning signals.
• Maintain awareness of moving equipment.

Operators should avoid sudden movements that could destabilize the load.

Overhead Molten-Metal Movement

Molten-metal loads require particular precautions because a dropped or spilled load can affect a large area.

Procedures should address:

• Crane condition
• Lifting devices
• Travel routes
• Employee exclusion
• Communication
• Emergency response

Employees should not congregate beneath or immediately adjacent to molten-metal transfer paths.

Tundish Safety

Continuous casting operations may use tundishes to control molten-steel flow between ladles and molds.

Hazards may include:

• Molten steel
• Refractory failure
• Splash
• Heat
• Elevated work
• Moving equipment
• Water

Employees should maintain designated safe positions during casting operations.

Continuous Casting

Continuous casting can expose employees to molten steel, high temperatures, moving machinery, hydraulic equipment, cooling water, pinch points, and heavy material.

Procedures should address:

• Ladle positioning
• Tundish operations
• Mold conditions
• Strand movement
• Cooling systems
• Cutting
• Equipment access
• Maintenance

Employees should remain clear of operating caster machinery unless their assigned work requires access.

Continuous Casting and Water

Water is integral to many continuous-casting cooling systems but can create severe hazards if it contacts molten steel in an uncontrolled manner.

Employees should report:

• Leaks
• Abnormal water flow
• Damaged hoses
• Cooling-system failures
• Standing water

Water-system abnormalities should be evaluated promptly.

Slabs, Billets and Blooms

Steel products leaving the caster may remain extremely hot and can weigh many tons.

Employees should treat recently cast material as hot unless its condition has been established otherwise.

Material handling should address:

• Product temperature
• Weight
• Stability
• Crane movement
• Rolling hazards
• Employee positioning

Employees should not stand in locations where shifting steel could trap or crush them.

Hot Steel Identification

The temperature of steel may not be obvious from appearance.

Facilities should establish procedures for identifying or controlling hot steel.

Employees should not touch or approach recently processed steel based solely on visual appearance.

Slag Safety

Slag can remain extremely hot and may react violently with water or wet materials.

Slag handling procedures should address:

• Transport
• Dumping
• Cooling
• Water
• Restricted areas
• Mobile equipment
• PPE

Employees should remain clear of slag-handling areas unless required for their work.

Slag Pots

Slag pots and their handling equipment should be inspected and maintained.

Operators should consider:

• Pot condition
• Load
• Travel path
• Ground condition
• Dumping location
• Moisture

Employees should remain outside potential splash and dumping zones.

Rolling Mill Safety

Rolling operations involve massive rotating equipment capable of creating crushing, entanglement, and caught-between hazards.

Employees should remain clear of:

• Rolls
• Drive systems
• Pinch points
• Guides
• Transfer equipment
• Moving steel

Appropriate guarding and safeguarding should be maintained.

Hot Rolling

Hot-rolling operations can expose employees to:

• Hot steel
• Scale
• Steam
• Water
• Moving material
• Rolls
• Noise
• Hydraulic equipment

Employees should remain outside established operating zones.

Material should be controlled so employees are not exposed to unexpected movement.

Cold Rolling

Cold-rolling operations can create severe nip-point, entanglement, cutting, and coil hazards.

Procedures should address:

• Roll hazards
• Strip movement
• Coil handling
• Sharp edges
• Machine guarding
• Hazardous energy

Employees should not enter machine danger zones while equipment is capable of unexpected movement.

In-Running Nip Points

Rolling, straightening, leveling, feeding, and processing equipment can create dangerous in-running nip points.

Safeguards should prevent employee contact with hazardous areas during normal operation.

Employees should not reach into moving equipment to guide, adjust, or remove material unless specifically protected by an established safe system.

Steel Bar and Rod Processing

Bar and rod mills may expose employees to rotating, whipping, moving, or unexpectedly displaced material.

Employees should remain outside hazardous material trajectories.

Equipment should be guarded and work practices established to prevent employees from entering danger zones.

Steel Strip Safety

Steel strip can have sharp edges and may move at high speed through processing equipment.

Employees should use appropriate tools rather than hands when positioning material where practical.

Gloves selected for sharp-metal handling should be used when they do not create an entanglement hazard.

Coil Handling

Steel coils can weigh many tons and create crushing hazards if they roll, shift, fall, or become unstable.

Coil-handling procedures should address:

• Storage
• Chocking
• Cradles
• Lifting devices
• Coil cars
• Cranes
• Employee positioning

Employees should not stand in the potential path of a rolling or shifting coil.

Coil Storage

Coils should be stored using systems designed to maintain stability.

Storage areas should consider:

• Coil orientation
• Floor capacity
• Chocks or cradles
• Stacking
• Traffic
• Crane access

Employees should not enter pinch points between coils.

Coil Lifting

Specialized coil grabs, C-hooks, tongs, or other lifting devices should be inspected and used according to their design.

Before lifting:

• Verify load weight.
• Inspect the lifting device.
• Ensure proper engagement.
• Clear the load path.
• Keep employees clear.

Employees should not stand beneath suspended coils.

Steel Plate and Sheet Handling

Plate and sheet products can create sharp-edge, crushing, shifting, and suspended-load hazards.

Mechanical handling should be used when practical.

Employees should keep hands and feet clear when steel is being positioned or landed.

Walking on Steel Products

Employees should avoid walking on steel coils, bundles, plate stacks, or other stored products unless the work has been evaluated and suitable protection provided.

Surfaces may be:

• Slippery
• Rounded
• Unstable
• Hot
• Contaminated with oil or scale

Designated access should be used where available.

Overhead Crane Safety

Steel mills rely extensively on overhead and gantry cranes.

Cranes may handle:

• Scrap
• Ladles
• Slabs
• Billets
• Blooms
• Coils
• Rolls
• Equipment
• Maintenance components

Only trained and authorized employees should operate cranes as required.

Crane Inspections

Cranes and lifting equipment should be inspected and maintained according to applicable requirements and facility procedures.

Inspection items may include:

• Brakes
• Hooks
• Wire rope
• Controls
• Limit devices
• Warning devices
• Lifting attachments

Defects affecting safe operation should be corrected.

Rigging

Rigging should be selected according to the load and environment.

Employees should inspect:

• Slings
• Chains
• Hooks
• Shackles
• Lifting beams
• Specialized lifting devices

Rigging exposed to high temperatures or harsh environments should be suitable for those conditions.

Suspended Loads

Employees should remain clear of suspended loads and load paths.

When work requires employees to guide a load, positioning should minimize exposure to:

• Crushing
• Pinch points
• Unexpected swing
• Dropped loads

Tag lines or other load-control methods should be used where appropriate.

Machine Guarding

Steel mills contain extensive machinery capable of causing amputations, crushing, entanglement, and fatal caught-in injuries.

Hazards may involve:

• Rolls
• Shafts
• Couplings
• Gears
• Chains
• Sprockets
• Conveyors
• Straighteners
• Shears
• Sawing equipment
• Finishing lines

Required guards and safeguarding devices should remain in place during normal operation.

Automated Equipment

Automated steelmaking and processing equipment can move without obvious warning.

Safeguarding may include:

• Barriers
• Interlocked gates
• Presence-sensing devices
• Light curtains
• Restricted zones
• Warning systems

Employees should not bypass safeguards to enter automated operating zones.

Clearing Jams

Jams and misfeeds should be cleared using established procedures.

Before employees enter hazardous areas:

• Stop equipment.
• Control hazardous energy.
• Secure moving components.
• Control stored material.
• Verify safe conditions.

Employees should not use hands or improvised methods in operating machine danger zones.

Lockout/Tagout

Steel mill equipment can contain multiple hazardous-energy sources.

These may include:

• Electrical
• Mechanical
• Hydraulic
• Pneumatic
• Gravity
• Thermal
• Pressure
• Stored tension

Energy-control procedures should identify the sources that must be isolated before servicing and maintenance.

Complex Lockout/Tagout

Large steel mill equipment may require isolation of multiple energy sources and coordination among several employees or work groups.

Procedures should address:

• Equipment-specific isolation
• Verification
• Group lockout
• Shift changes
• Stored energy
• Contractors
• Return to service

Employees should understand their individual responsibilities within group energy-control activities.

Stored Energy

Energy can remain after equipment is shut down.

Examples include:

• Hydraulic accumulators
• Pneumatic systems
• Elevated components
• Springs
• Rotating equipment
• Thermal energy
• Pressurized piping
• Stored tension

Stored energy should be relieved, blocked, restrained, dissipated, or otherwise controlled.

Hydraulic Systems

Steel mill machinery often operates at high hydraulic pressures.

Employees should not use their hands to search for hydraulic leaks.

Before maintenance:

• Isolate pressure.
• Relieve stored energy.
• Secure movable equipment.
• Verify isolation.

Damaged hoses and fittings should be corrected promptly.

Pneumatic Systems

Compressed-air and pneumatic equipment can store significant energy.

Employees should:

• Isolate pressure before servicing.
• Inspect hoses and connections.
• Control hose movement.
• Use appropriate fittings.
• Avoid directing compressed air toward employees.

Stored pneumatic energy should be relieved before work begins.

Blocking Against Motion

Employees should not work beneath or within the path of equipment capable of hazardous movement unless it has been securely blocked or otherwise controlled.

Potential equipment includes:

• Rolls
• Furnace components
• Hydraulic assemblies
• Transfer tables
• Crane components
• Raised equipment

Hydraulic pressure alone should not be relied upon to support equipment during maintenance.

Conveyor Safety

Conveyors may transport raw materials, scrap, coke, scale, finished products, and other materials.

Employees should remain clear of:

• Nip points
• Pulleys
• Rollers
• Belts
• Chains
• Drives
• Moving material

Required guards should remain installed.

Conveyor Maintenance

Before conveyor maintenance:

• Stop equipment.
• Isolate hazardous energy.
• Control stored tension.
• Secure elevated components.
• Control material.
• Verify isolation.

Emergency stops should not be used as a substitute for required energy isolation.

Steel Mill Maintenance

Maintenance activities often expose employees to hazards not encountered during normal production.

Maintenance planning should consider:

• LOTO
• Hot equipment
• Electrical hazards
• Confined spaces
• Rigging
• Elevated work
• Chemicals
• Process gases
• Heavy components

Non-routine work should receive additional hazard evaluation.

Shutdowns and Turnarounds

Major steel mill shutdowns can involve hundreds of simultaneous maintenance tasks and multiple contractors.

Planning should address:

• Energy isolation
• Work sequencing
• Contractor coordination
• Confined spaces
• Hot work
• Rigging
• Electrical work
• Temporary access
• Startup

Hazards should be reassessed as shutdown conditions change.

Startup After Maintenance

Before equipment is returned to service:

• Verify work is complete.
• Restore required guards.
• Remove tools and materials.
• Confirm employees are clear.
• Follow energy-control release procedures.
• Communicate startup.

Equipment should not be restarted until it is ready for normal operation.

Refractory Work

Furnaces, ladles, tundishes, and other high-temperature equipment may require refractory inspection, removal, and replacement.

Hazards may include:

• Heat
• Dust
• Silica-containing materials
• Falling material
• Confined spaces
• Equipment movement
• Hazardous energy

The refractory material and work method should be evaluated before work begins.

Silica and Refractory Dust

Removal, cutting, demolition, or handling of certain refractory materials may generate respirable crystalline silica or other hazardous dust.

Controls may include:

• Wet methods
• Local exhaust ventilation
• HEPA-filtered equipment
• Isolation
• Respiratory protection

Employees should be trained regarding the materials they handle.

Industrial Hygiene

Steel mill industrial-hygiene evaluations should reflect actual processes and materials.

Potential exposures may include:

• Metal fumes
• Metal dust
• Carbon monoxide
• Silica
• Hexavalent chromium
• Welding fumes
• Coke-oven emissions where applicable
• Process chemicals
• Noise
• Heat

Monitoring results should be used to determine appropriate controls and employee-protection measures.

Metal Fumes and Dust

Steelmaking, casting, cutting, grinding, welding, and finishing can generate metal-containing fumes and dust.

Potential contaminants depend on the steel and alloys being processed.

The facility should evaluate exposures to metals such as:

• Iron
• Manganese
• Chromium
• Nickel
• Lead
• Other alloying elements

Controls should reflect actual employee exposures.

Hexavalent Chromium

Certain steelmaking, stainless-steel, welding, furnace, and surface-conditioning operations may create hexavalent chromium exposure.

Operations involving chromium-containing alloys should be evaluated.

Where applicable, controls may include:

• Local exhaust ventilation
• Process enclosure
• Work-practice controls
• Respiratory protection
• Protective clothing
• Hygiene practices

Employees should receive appropriate hazard information and training.

Carbon Monoxide

Carbon monoxide may be generated by furnace, combustion, coke, and other steelmaking processes.

Areas with potential exposure should be evaluated.

Controls may include:

• Process controls
• Ventilation
• Fixed monitoring
• Portable monitoring
• Alarms
• Restricted access

Employees should understand carbon-monoxide alarms and emergency procedures.

Coke Ovens

Where coke ovens are present, the safety manual should address the hazards associated with coke production and coke-oven emissions.

Potential hazards include:

• Heat
• Fire
• Combustion products
• Carbon monoxide
• Coke-oven emissions
• Mobile equipment
• Material handling

Only programs applicable to facilities with coke operations should be included.

Dust Collection Systems

Dust collectors and ventilation systems should be maintained in effective condition.

Employees should report:

• Loss of airflow
• Damaged ductwork
• Visible emissions
• Unusual dust accumulation
• Filter problems
• System alarms

Maintenance should be performed under appropriate hazardous-energy controls.

Respiratory Protection

Respiratory protection may be required for metal fumes, silica, dust, gases, vapors, or other airborne contaminants.

When respirators are required, the Respiratory Protection Program should address:

• Medical evaluation
• Respirator selection
• Fit testing
• Training
• Inspection
• Cleaning
• Storage
• Filter and cartridge replacement
• Program evaluation

Respirators should be selected according to the actual hazard.

Heat Stress

Steel mill employees may experience substantial radiant and environmental heat exposure.

High-heat areas may include:

• Furnaces
• Casting operations
• Ladle areas
• Rolling mills
• Refractory work
• Hot-product handling

Heat-stress procedures should address hydration, acclimatization, rest, cooling, employee monitoring, and emergency response.

Radiant Heat

Molten metal, furnaces, slabs, billets, blooms, and hot-rolling processes can create intense radiant heat.

Controls may include:

• Heat shields
• Barriers
• Increased distance
• Remote operation
• Mechanical handling
• Cooling areas
• Work-rest practices

PPE should supplement rather than unnecessarily replace feasible engineering controls.

Personal Protective Equipment

PPE should be selected through a hazard assessment and matched to the work area and task.

PPE may include:

• Hard hats
• Safety glasses
• Goggles
• Face shields
• Heat-resistant clothing
• Flame-resistant clothing
• Molten-metal protective clothing
• Gloves
• Protective footwear
• Hearing protection
• Respiratory protection
• Fall protection

Specialized PPE may be required for electrical, chemical, welding, or molten-metal hazards.

Molten-Metal PPE

Employees exposed to molten-metal splash should use protective equipment suitable for the metal and exposure.

Selection should consider:

• Heat resistance
• Flame resistance
• Molten-metal shedding
• Face and eye protection
• Hand protection
• Foot and leg protection
• Clothing design

PPE should be worn in a manner that minimizes the potential for molten metal to become trapped against the body.

Hearing Conservation

Potential high-noise sources include:

• Furnaces
• Rolling mills
• Straighteners
• Shears
• Fans
• Blowers
• Material handling
• Grinding
• Pneumatic tools

Employee noise exposures should be evaluated and controlled.

A Hearing Conservation Program should be implemented when required.

Electrical Safety

Steel mills use extensive high-energy electrical systems.

Potential equipment includes:

• Furnaces
• Motors
• Drives
• Cranes
• Substations
• Motor-control centers
• Panels
• Processing lines

Only qualified employees should perform electrical work requiring specialized knowledge.

Arc Flash Safety

Electrical maintenance and troubleshooting may expose qualified employees to arc-flash and shock hazards.

Procedures should address:

• De-energization
• Electrical safe-work conditions
• Shock boundaries
• Arc-flash hazards
• Appropriate PPE
• Energized work when justified
• Testing and verification

Applicable electrical-safety practices should be incorporated into maintenance procedures.

Electrical Troubleshooting

Troubleshooting may sometimes require energized diagnostic testing.

Only qualified employees should perform work involving exposure to energized electrical parts.

Once troubleshooting is complete, equipment should be placed in an appropriate electrically safe condition before repair when required.

Confined Space Entry

Steel mills may contain confined spaces such as:

• Furnaces
• Ladles
• Tundishes
• Tanks
• Pits
• Bins
• Hoppers
• Ductwork
• Dust collectors
• Process vessels

Spaces should be identified and evaluated before entry.

Permit-required confined spaces should be entered according to applicable procedures.

Furnace Entry

Furnace entry may involve residual heat, hazardous atmospheres, refractory hazards, electrical systems, fuel systems, and restricted access.

Before entry:

• Shut down equipment.
• Isolate hazardous energy.
• Control fuel and gases.
• Allow adequate cooling.
• Evaluate atmospheric conditions.
• Establish required entry controls.

Rescue provisions should be established when required.

Pits and Below-Grade Areas

Steel mills may contain caster pits, scale pits, furnace pits, maintenance pits, and other below-grade spaces.

Hazards may include:

• Water
• Heat
• gases
• Machinery
• Restricted access
• Falling material

These areas should be evaluated for both physical and atmospheric hazards.

Welding, Cutting and Hot Work

Maintenance and fabrication may involve welding, cutting, brazing, gouging, and grinding.

Hot-work procedures should address:

• Fire
• Metal fumes
• Sparks
• Combustible materials
• Compressed gases
• Ventilation
• PPE
• Fire watch

The metal or coating being heated should be considered when evaluating fumes.

Oxygen and Fuel-Gas Systems

Steelmaking and maintenance may use oxygen, natural gas, propane, acetylene, or other gases.

Procedures should address:

• Storage
• Piping
• Regulators
• Hoses
• Valves
• Leak detection
• Ignition control

Oxygen should be kept away from oil, grease, and other incompatible materials.

Compressed Gas Cylinders

Compressed-gas cylinders should be:

• Identified
• Secured
• Protected
• Stored appropriately
• Transported safely

Employees should inspect regulators, hoses, valves, and connections before use.

Mobile Equipment

Steel mills may operate:

• Forklifts
• Loaders
• Scrap handlers
• Yard trucks
• Coil carriers
• Slag carriers
• Specialized transporters

Traffic rules should address interaction between mobile equipment, pedestrians, cranes, and rail operations.

Forklift Safety

Only trained and authorized employees should operate powered industrial trucks.

Operators should:

• Inspect equipment.
• Wear seat belts where provided.
• Observe capacity.
• Maintain visibility.
• Control speed.
• Remain alert to pedestrians.

Loads should be stable before travel.

Pedestrian Safety

Employees on foot can be difficult for operators of large industrial equipment to see.

Controls may include:

• Designated walkways
• Barriers
• Restricted zones
• High-visibility apparel
• Warning devices
• Mirrors
• Traffic rules

Employees should avoid equipment blind spots.

Railroad and Railcar Safety

Steel mills may use locomotives and railcars to transport raw materials, scrap, molten-metal containers, or finished products.

Procedures should address:

• Rail movement
• Crossings
• Coupling areas
• Loading and unloading
• Employee clearance
• Communication
• Derailment hazards

Employees should not position themselves between moving rail equipment and fixed objects.

Railcar Loading and Unloading

Loading and unloading railcars can expose employees to moving equipment, shifting loads, falls, and pinch points.

Railcars should be appropriately secured before employees begin work when required.

Employees should remain clear during movement.

Material Handling

Steel products and mill components can weigh many tons.

Material-handling procedures should address:

• Load weight
• Stability
• Rigging
• Crane capacity
• Employee positioning
• Storage

Employees should avoid placing hands or feet beneath unsupported steel.

Manual Material Handling

Even smaller steel components, tools, refractory materials, and maintenance parts can create ergonomic hazards.

Mechanical assistance should be used when practical.

Employees should avoid unnecessary twisting, overreaching, and uncontrolled lifting.

Sharp Edges

Sheet, strip, plate, scrap, and cut steel can have extremely sharp edges.

Employees should use appropriate hand protection when handling sharp materials, provided gloves do not create an entanglement hazard.

Scrap and sharp material should be stored safely.

Fall Protection

Employees may work on:

• Furnaces
• Cranes
• Platforms
• Buildings
• Process equipment
• Elevated walkways
• Roofs
• Structures

Fall hazards should be evaluated and appropriate protection provided.

Openings and edges should be protected as required.

Walking-Working Surfaces

Steel mill floors and platforms can be affected by:

• Scale
• Oil
• Coolant
• Water
• Scrap
• Dust
• Hoses
• Cords

Walking-working surfaces should be maintained to reduce slip, trip, and fall hazards.

Spills and leaks should be addressed promptly.

Ladders and Access

Ladders, stairs, platforms, and fixed access systems should be maintained in safe condition.

Employees should report:

• Damaged ladders
• Missing rails
• Loose grating
• Poor lighting
• Obstructed access
• Slippery surfaces

Employees should use designated access routes.

Hazard Communication

Steel mills may use:

• Acids
• Caustics
• Lubricants
• Hydraulic fluids
• Cleaning chemicals
• Coatings
• Welding materials
• Refractory products
• Process chemicals

Employees should have access to Safety Data Sheets and receive appropriate hazard information and training.

Pickling and Chemical Processing

Where pickling or other chemical surface-treatment processes are used, procedures should address:

• Corrosive chemicals
• Tanks
• Transfer systems
• Ventilation
• PPE
• Emergency washing
• Spill response

Only trained employees should handle process chemicals.

Emergency Eyewashes and Showers

Emergency washing facilities should be provided where required by chemical exposures.

Access should remain unobstructed.

Employees should know the locations of emergency eyewashes and showers in their work areas.

Fire Prevention

Steel mill fire hazards may involve:

• Furnaces
• Molten metal
• Hydraulic fluids
• Fuels
• Electrical equipment
• Hot work
• Combustible materials
• Process gases

Fire-prevention procedures should reflect actual facility hazards.

Employees should know how to report fires and respond to alarms.

Emergency Action Plan

Steel mill emergency planning should address foreseeable events such as:

• Molten-metal releases
• Furnace explosions
• Fires
• Gas releases
• Carbon monoxide
• Electrical incidents
• Equipment failures
• Chemical releases
• Medical emergencies
• Severe weather

Employees should understand alarms, evacuation routes, assembly locations, and emergency communications.

Molten-Metal Emergency Response

Employees should know how to respond to molten-metal spills, breakouts, and other abnormal releases.

Procedures should establish:

• Restricted areas
• Evacuation
• Emergency shutdown
• Communication
• Response responsibilities

Employees should not approach uncontrolled molten-metal incidents unless trained and assigned to do so.

Gas Release Emergency

Facilities using or generating hazardous gases should establish procedures for leaks or releases.

Employees should understand:

• Alarm signals
• Evacuation
• Restricted areas
• Emergency communication
• Respiratory hazards

Only appropriately trained and equipped personnel should enter potentially hazardous atmospheres.

First Aid and Burn Response

Steel mills should prepare for thermal burns, chemical burns, eye injuries, cuts, crushing injuries, and other foreseeable emergencies.

Employees should know:

• How to summon assistance
• First-aid locations
• Emergency washing locations
• Emergency communication methods

Serious burns and other significant injuries require prompt professional medical attention.

Contractor Safety

Steel mills frequently use contractors for maintenance, construction, refractory work, electrical work, rigging, cleaning, and shutdown activities.

Contractor coordination should address:

• Facility hazards
• Hazardous energy
• Molten metal
• Process gases
• Confined spaces
• Electrical systems
• Hot work
• Emergency procedures
• PPE

Contractors should receive information appropriate to their work and exposure.

Simultaneous Operations

Steel mills may have production employees, maintenance employees, and contractors working simultaneously.

Activities should be coordinated when one operation can affect another.

Examples include:

• Crane movement over maintenance areas
• Hot work near process operations
• Equipment startup
• Energy isolation
• Rail movement
• Material transfer

Communication should be maintained as conditions change.

Management of Change

Changes to steelmaking processes, equipment, materials, controls, or operating procedures should be evaluated for potential safety consequences.

Changes may affect:

• Energy sources
• Guarding
• Employee access
• Chemical exposure
• Molten-metal hazards
• Ventilation
• Emergency procedures
• Training

Affected employees should receive appropriate information before changes are implemented.

Housekeeping

Steel mill housekeeping should address:

• Scale
• Scrap
• Dust
• Oil
• Coolant
• Tools
• Hoses
• Cords
• Combustible materials

Aisles, exits, platforms, electrical equipment, and emergency equipment should remain accessible.

Cleaning methods should not create unnecessary airborne exposure.

Incident Reporting and Investigation

Employees should promptly report:

• Injuries
• Occupational illnesses
• Near misses
• Molten-metal incidents
• Equipment damage
• Fires
• Gas releases
• Hazardous conditions

Incidents should be investigated to identify contributing and root causes.

Corrective actions should address underlying equipment, engineering, procedures, training, supervision, maintenance, and management-system deficiencies.

Steel Mill Safety Training

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

Training may include:

• Molten-metal safety
• Furnace safety
• Rolling-mill safety
• Machine guarding
• Lockout/tagout
• Crane and hoist safety
• Rigging
• Heat stress
• PPE
• Respiratory protection
• Hearing conservation
• Electrical safety
• Confined spaces
• Hazard communication
• Mobile equipment
• Emergency procedures

Training should be documented as applicable and updated when equipment, processes, materials, work assignments, or hazards change.

Building a Steel Mill Safety Manual

A Steel Mill Safety Manual should be customized to the facility’s actual steelmaking and processing operations rather than relying solely on a generic Manufacturing Safety Manual, Metal Fabrication Safety Manual, Foundry Safety Manual, or Steel Erection Safety Manual.

An electric arc furnace mini-mill may require extensive programs for scrap inspection, EAF safety, molten metal, water intrusion, carbon monoxide, ladle handling, continuous casting, rolling mills, overhead cranes, LOTO, electrical safety, industrial hygiene, heat stress, and emergency response.

An integrated steel mill may additionally require programs addressing raw-material handling, coke operations, blast furnaces, basic oxygen furnaces, furnace gases, hot-metal transfer, slag, and other integrated steelmaking processes.

A rolling mill or steel-processing facility that does not melt steel may place greater emphasis on machine guarding, rolling equipment, coils, strip and plate handling, overhead cranes, LOTO, hydraulics, material handling, sharp edges, noise, and industrial maintenance.

The manual should reflect the facility’s furnaces, casters, rolling mills, finishing lines, cranes, steel products, mobile equipment, electrical systems, chemicals, employees, maintenance activities, contractors, and industrial-hygiene exposures.

The completed manual should provide practical procedures employees and supervisors can use while supporting OSHA compliance, employee training, JSAs, equipment inspections, hazardous-energy control, industrial-hygiene programs, incident investigations, contractor coordination, emergency planning, and the facility’s overall safety-management system.