Woodworking Safety Manual

What Should a Woodworking Safety Manual Include?

The contents of a Woodworking Safety Manual should reflect the work actually performed.

Depending on operations, the manual may address:

• Woodworking safety responsibilities.
• Hazard assessments.
• Job Safety Analysis (JSA/JHA).
• Machine guarding.
• Table saw safety.
• Radial-arm saw safety.
• Band saw safety.
• Rip saw safety.
• Jointers.
• Planers.
• Shapers.
• Routers.
• Sanders.
• Wood lathes.
• Boring and drilling machines.
• Tenoning machines.
• CNC woodworking equipment.
• Kickback prevention.
• Push sticks and jigs.
• Lockout/Tagout.
• Machine maintenance.
• Wood dust.
• Dust collection.
• Combustible dust.
• Fire prevention.
• Spray finishing.
• Adhesives and coatings.
• Hazard Communication.
• Respiratory protection.
• Personal Protective Equipment.
• Hearing Conservation.
• Ergonomics.
• Material handling.
• Forklift safety.
• Emergency procedures.

Programs should be selected according to the company’s equipment, production methods, chemicals, finishing processes, dust-generation potential, and employee exposures.

Woodworking Safety Program

An effective Woodworking Safety Program establishes responsibilities and procedures for protecting employees from machinery, hazardous energy, wood dust, chemicals, fire, noise, material handling, and other woodworking hazards.

Management should provide employees with properly guarded machinery, appropriate dust-control systems, PPE, training, supervision, maintenance resources, and safe work procedures.

Managers, supervisors, and designated safety personnel should:

• Identify and evaluate workplace hazards.
• Maintain applicable written safety programs.
• Verify machine guards and safety devices are maintained.
• Establish safe operating procedures.
• Control wood-dust accumulation.
• Maintain dust-collection systems.
• Control ignition sources.
• Establish hazardous-energy procedures.
• Evaluate chemical exposures.
• Provide appropriate PPE.
• Correct unsafe conditions.
• Investigate incidents.
• Provide employee training.
• Maintain applicable records.

Employees should follow safe operating procedures, inspect equipment before use, use guards and safety devices, wear required PPE, maintain housekeeping, follow Lockout/Tagout requirements, and promptly report unsafe equipment, missing guards, dust accumulations, chemical releases, fires, injuries, and other hazards.

Woodworking Hazard Assessments

Hazard assessments should consider:

• Machine points of operation.
• Rotating equipment.
• Reciprocating equipment.
• Nip points.
• Saw blades.
• Cutter heads.
• Kickback.
• Flying chips.
• Tool projection.
• Wood dust.
• Noise.
• Vibration.
• Electrical hazards.
• Chemicals.
• Material handling.
• Fire and explosion.
• Maintenance.

Potential injuries and illnesses may include:

• Amputations.
• Lacerations.
• Eye injuries.
• Crushing.
• Entanglement.
• Hearing loss.
• Respiratory irritation.
• Occupational asthma.
• Dermatitis.
• Chemical exposure.
• Musculoskeletal disorders.

Hazard assessments should be reviewed when machinery, production methods, chemicals, or work processes change.

Job Safety Analysis (JSA/JHA)

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

Potential JSAs/JHAs may address:

• Table saw operation.
• Radial-arm saw operation.
• Band saw operation.
• Jointer operation.
• Planer operation.
• Shaper operation.
• Router operation.
• Sanding.
• CNC machine operation.
• Spray finishing.
• Dust-collector maintenance.
• Machine jam clearing.
• Blade or cutter replacement.
• Forklift operation.
• Loading and unloading lumber.

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

Machine Guarding

Machine guarding is one of the most important elements of woodworking safety.

Woodworking machinery may expose employees to:

• Saw blades.
• Cutter heads.
• Rotating shafts.
• Belts.
• Pulleys.
• Chains.
• Gears.
• Nip points.
• Reciprocating parts.
• Flying material.

Machines should be equipped with appropriate guards and safety devices.

Employees should not operate equipment when required guards or safety devices are missing, damaged, or improperly adjusted.

Point-of-Operation Hazards

The point of operation is where the machine cuts, shapes, bores, forms, sands, or otherwise works on the wood.

Employee hands should be kept away from hazardous cutting and shaping areas.

Where appropriate, protection may include:

• Fixed guards.
• Adjustable guards.
• Self-adjusting guards.
• Push sticks.
• Push blocks.
• Featherboards.
• Combs.
• Jigs.
• Fixtures.

The selected method should allow the operation to be performed without unnecessarily exposing the operator’s hands to the cutting tool.

Machine Guards

Guards should:

• Prevent employee contact with hazardous moving parts.
• Remain secure during operation.
• Be maintained in serviceable condition.
• Avoid creating additional hazards.
• Allow safe operation of the equipment.

Employees should not remove or defeat guards simply because the guard slows production or makes a task inconvenient.

Safety Devices

Woodworking machinery may use safety devices such as:

• Anti-kickback fingers.
• Spreaders.
• Riving knives.
• Hold-down devices.
• Return mechanisms.
• Emergency stops.
• Interlocks.

Safety devices should be inspected and maintained.

Defective devices should be repaired before the machine is returned to service when they are necessary for safe operation.

Machine Inspection

Employees should inspect woodworking equipment before use.

The inspection may include:

• Guards.
• Blades.
• Cutter heads.
• Belts.
• Controls.
• Emergency stops.
• Fences.
• Gauges.
• Anti-kickback devices.
• Electrical cords.
• Dust-collection connections.

Defects affecting safe operation should be reported and corrected.

Machine Setup

Machine setup should be completed before cutting begins.

Employees should verify:

• Guards are properly adjusted.
• Cutting tools are secure.
• Fences and guides are positioned correctly.
• Stock is appropriate for the machine.
• Work areas are clear.
• Dust collection is connected where required.

Adjustments that expose employees to hazardous moving parts should not be made while the machine is operating unless specifically designed and permitted for that adjustment.

Machine Controls

Machine controls should be readily identifiable and positioned to reduce accidental activation.

Employees should know how to:

• Start equipment.
• Stop equipment.
• Activate emergency stops.
• Isolate equipment when necessary.

Controls should not be bypassed.

Coasting Machinery

Saw blades, cutter heads, sanding equipment, and other rotating components may continue moving after power is switched off.

Employees should not reach into machinery until all movement has stopped.

A machine that has been shut off should not be assumed safe merely because the motor is quiet.

Table Saw Safety

Table saws can expose employees to:

• Blade contact.
• Kickback.
• Flying material.
• Amputation.
• Laceration.

Employees should use appropriate guards, fences, spreaders or riving devices, anti-kickback devices, and push devices as applicable to the operation.

Rip Sawing

During rip sawing, stock should be guided using the appropriate fence.

Employees should never perform uncontrolled freehand ripping.

Push sticks or push blocks should be used when necessary to keep hands away from the blade.

Crosscutting

Crosscutting should be performed using an appropriate gauge, sled, fixture, or other means intended for the operation.

Employees should maintain control of the workpiece and keep hands outside the blade hazard area.

Push Sticks and Push Blocks

Push sticks and push blocks should be used when stock size or machine configuration would otherwise require hands to approach the cutting area.

Push devices should:

• Provide control of the stock.
• Keep hands away from the blade.
• Be appropriate for the material and operation.

Employees should not substitute their fingers for a push device simply to finish a cut.

Freehand Sawing

Freehand sawing should not be performed on machines requiring a fence, gauge, or fixture to safely control the stock.

Loss of stock control can result in blade contact or kickback.

Kickback

Kickback occurs when stock is unexpectedly thrown toward the operator.

Potential causes include:

• Stock binding.
• Misaligned fences.
• Dull blades.
• Improper feeding.
• Warped material.
• Improper machine setup.
• Missing anti-kickback devices.

Employees should avoid standing directly in the anticipated kickback path where practical.

Radial-Arm Saws

Radial-arm saws should be properly guarded, maintained, and adjusted.

The saw should have an appropriate return mechanism so the cutting head returns to its starting position where required.

Employees should maintain control of the stock and avoid placing hands in the blade path.

Radial Saw Direction

Operators should understand the direction in which the blade tends to pull the saw head and stock.

Incorrect feeding or positioning can cause rapid movement and loss of control.

Band Saws

Band saws should be guarded so only the portion of the blade necessary for the cut is exposed.

Blade guides should be adjusted appropriately for the workpiece.

Employees should keep hands away from the blade and use push devices or fixtures where necessary.

Band Saw Blade Condition

Band saw blades should be inspected for:

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

Damaged blades should be replaced.

Jointers

Jointers expose employees to rotating cutter heads.

Guards should cover exposed portions of the cutter head as required.

Employees should use push blocks or push sticks when necessary to keep hands away from cutting areas.

Planers

Planers may expose employees to:

• Cutter heads.
• Feed rolls.
• Nip points.
• Kickback.
• Flying material.

Machine guards and anti-kickback devices should remain in serviceable condition.

Employees should not reach into operating planer feed areas.

Shapers

Shapers use rapidly rotating cutter heads that can cause severe injury.

Appropriate guards, jigs, fixtures, fences, and hold-down devices should be used.

Employees should understand the correct feed direction for the equipment.

Router Safety

Routers may be handheld or machine-mounted.

Employees should evaluate:

• Cutter condition.
• Guarding.
• Feed direction.
• Stock control.
• Tool stability.

Handheld routers should be disconnected or otherwise rendered safe before changing bits or performing servicing.

CNC Woodworking Equipment

Computer-controlled woodworking equipment can still expose employees to:

• Cutting tools.
• Automated movement.
• Tool changers.
• Pinch points.
• Unexpected startup.
• Flying material.

Guards, enclosures, interlocks, and access controls should be maintained.

Employees should not enter hazardous machine areas unless applicable energy-control procedures have been followed.

Sanders

Sanding machines may create:

• Abrasion hazards.
• Nip points.
• Entanglement.
• Wood dust.
• Noise.
• Fire hazards.

Employees should keep hands away from hazardous sanding surfaces and use guards and work supports as appropriate.

Belt Sanders

Belt sanders should be guarded around pulleys, nip points, and unused portions of the sanding belt as required.

Employees should maintain control of the workpiece.

Disc Sanders

Employees should use the appropriate portion of a disc sander according to the machine’s design to prevent the workpiece from being lifted or thrown.

Work rests should be adjusted and maintained.

Drum and Wide-Belt Sanders

Industrial sanding equipment can generate substantial quantities of fine wood dust.

Dust collection should be maintained and connected as designed.

Employees should remain clear of feed rolls and internal sanding components.

Wood Lathes

Wood lathes can expose employees to:

• Rotating stock.
• Tool kickback.
• Flying pieces.
• Entanglement.

Stock should be properly secured before operation.

Employees should avoid loose clothing, jewelry, unsecured hair, or other items that can become caught in rotating equipment.

Boring and Drilling Machines

Woodworking boring and drilling machines should be guarded and operated using appropriate fixtures where necessary.

Workpieces should be secured to prevent unexpected rotation or movement.

Tenoning Machines

Tenoning machines may expose employees to:

• Cutter heads.
• Saw blades.
• In-running rolls.
• Feed chains.
• Flying chips.
• Kickback.

Cutting heads, saws, chains, sprockets, and other moving components should be appropriately guarded.

Miter and Chop Saws

Miter and chop saws should have functioning blade guards.

Employees should keep hands out of the blade path and allow the blade to stop before reaching near the cutting area.

The workpiece should be supported and secured as necessary.

Portable Circular Saws

Portable circular saws should have functioning upper and lower guards.

The lower guard should move freely and return to its protective position.

Employees should disconnect or otherwise render the tool safe before changing blades or performing servicing.

Nail Guns and Staplers

Pneumatic nailers and staplers can cause puncture injuries and may discharge fasteners unexpectedly.

Employees should:

• Keep hands away from the fastening path.
• Avoid pointing tools at themselves or others.
• Disconnect the tool before clearing jams where appropriate.
• Use trigger systems suitable for the task.
• Wear required eye protection.

Hand and Power Tools

Hand and portable powered tools should be inspected and maintained.

Employees should use tools only for their intended purposes.

Damaged tools should be removed from service.

Kickback and Flying Material

Employees should remain aware that woodworking machines can throw:

• Stock.
• Broken cutters.
• Saw teeth.
• Wood fragments.
• Knots.
• Chips.

Appropriate guarding, machine setup, stock inspection, and eye or face protection should be used.

Stock Inspection

Wood should be inspected before machining where practical.

Potential hazards include:

• Nails.
• Screws.
• Staples.
• Embedded metal.
• Loose knots.
• Splits.
• Warping.
• Other defects.

Foreign material can damage tools or become a projectile.

Reclaimed Wood

Reclaimed wood may contain hidden nails, screws, wire, or other foreign objects.

Employees should use appropriate inspection methods before cutting or machining reclaimed material.

Lockout/Tagout

Woodworking machinery may contain hazardous electrical, mechanical, pneumatic, hydraulic, or stored energy.

Applicable Lockout/Tagout procedures should be followed during covered servicing and maintenance.

Activities may include:

• Blade replacement.
• Cutter replacement.
• Jam clearing.
• Internal cleaning.
• Guard removal.
• Belt replacement.
• Repair.
• Adjustment.

Employees should not rely solely on stop buttons or control switches to prevent unexpected startup.

Machine Jam Clearing

Before employees place any part of the body into a hazardous machine area to clear a jam, hazardous energy should be controlled as required.

Employees should never reach into operating machinery to remove stuck stock or debris.

Blade and Cutter Changes

Machines should be shut down and rendered safe before employees change saw blades, cutter heads, router bits, knives, sanding belts, or similar components.

Employees should use appropriate tools and hand protection where sharp components must be handled.

Machine Maintenance

Maintenance employees may be exposed to serious machinery hazards.

Maintenance procedures should address:

• Lockout/Tagout.
• Stored energy.
• Sharp tools.
• Heavy components.
• Electrical hazards.
• Hydraulic systems.
• Pneumatic systems.
• Dust accumulation.

Only appropriately trained and authorized employees should perform specialized maintenance.

Wood Dust

Woodworking machinery can generate substantial quantities of airborne and settled wood dust.

Potential employee health effects may include:

• Eye irritation.
• Skin irritation.
• Nasal irritation.
• Respiratory irritation.
• Allergic reactions.
• Occupational asthma.
• Dermatitis.

Some wood species and wood-dust exposures present greater health concerns than others.

Employee exposure should be evaluated according to the materials and processes used.

Wood Species

Health risks can vary depending on the species of wood being processed.

Some woods may be associated with:

• Sensitization.
• Asthma.
• Dermatitis.
• Nasal irritation.
• Other adverse health effects.

Employers should consider the specific wood species used in the facility when evaluating exposure.

Wood Dust Control

The preferred method of controlling airborne wood dust is effective dust capture at or near the point where it is generated.

Controls may include:

• Local exhaust ventilation.
• Machine-mounted extraction.
• Hoods.
• Ductwork.
• Dust collectors.
• Enclosures.

Dust-control equipment should be maintained so it continues to operate effectively.

Local Exhaust Ventilation

Local exhaust ventilation should be positioned and designed to capture wood dust as close as practical to the source.

Dust hoods should not be removed or disconnected simply because they interfere with production.

Damaged ducts, disconnected hoses, or inadequate airflow should be reported.

Dust Collection Systems

Dust-collection systems should be inspected and maintained.

Inspection may address:

• Ductwork.
• Hoods.
• Filters.
• Collection bins.
• Fans.
• Motors.
• Static-control provisions where applicable.
• Dust leakage.

Collected dust should be removed and disposed of safely.

Combustible Wood Dust

Fine wood dust can present a serious fire and explosion hazard when sufficient dust becomes suspended in air and an ignition source is present.

Woodworking facilities should evaluate combustible-dust hazards associated with:

• Sanders.
• Routers.
• Shapers.
• Saws.
• Dust collectors.
• Conveying systems.
• Fine-particle processes.

Dust prevention and ignition-source control should be addressed together.

Dust Accumulation

Wood dust should not be allowed to accumulate excessively on:

• Floors.
• Machines.
• Rafters.
• Beams.
• Pipes.
• Ledges.
• Electrical equipment.
• Structural members.

Housekeeping should address elevated and concealed surfaces as well as visible floor areas.

Housekeeping for Wood Dust

Wood-dust housekeeping should be performed regularly.

Appropriate methods may include:

• Vacuum cleaning.
• Dust collection.
• Other methods that minimize airborne dispersion.

Cleaning methods should not create a more hazardous dust cloud.

Compressed Air Cleaning

Compressed-air blowdown can disperse accumulated fine dust and increase fire or explosion hazards.

Woodworking facilities should use safer cleaning methods and control compressed-air use in accordance with applicable requirements and the facility’s dust-hazard procedures.

Dust Collector Location

Dust collectors and associated equipment should be installed and operated according to applicable requirements, equipment design, and recognized fire and explosion controls.

The facility should evaluate the consequences of a fire or explosion within the dust collection system.

Ignition Source Control

Potential ignition sources may include:

• Electrical faults.
• Hot bearings.
• Sparks.
• Welding.
• Cutting.
• Smoking.
• Open flames.
• Static discharge.
• Hot surfaces.

Ignition sources should be controlled wherever combustible wood dust or flammable materials may be present.

Fire and Explosion Prevention

Woodworking facilities may contain large quantities of combustible fuel in the form of:

• Lumber.
• Wood products.
• Sawdust.
• Fine wood dust.
• Finishes.
• Solvents.
• Adhesives.
• Coatings.

Fire prevention should address both combustible materials and ignition sources.

Fire Prevention Program

The facility’s fire-prevention procedures may address:

• Dust accumulation.
• Flammable liquids.
• Chemical storage.
• Hot Work.
• Electrical equipment.
• Smoking.
• Dust collectors.
• Emergency response.
• Fire extinguishers.

Employees should promptly report smoke, burning odors, sparks, overheated equipment, and other indications of fire.

Hot Work

Welding, cutting, brazing, and grinding may introduce ignition sources into areas containing wood dust and combustible materials.

Hot Work should be controlled through appropriate procedures.

Before work begins, employees should evaluate:

• Sawdust.
• Wood stock.
• Dust collectors.
• Flammable finishes.
• Solvents.
• Adhesives.
• Nearby equipment.

Combustible material should be removed or protected as appropriate.

Spray Finishing

Spray-finishing operations can expose employees to chemical vapors, overspray, and significant fire or explosion hazards.

Spray booths and spray areas should be designed, ventilated, maintained, and operated in accordance with applicable requirements.

Employees should understand the hazards of the specific coatings being applied.

Spray Booth Ventilation

Spray booths should maintain effective airflow.

Filters and exhaust systems should be inspected and maintained.

Employees should report:

• Reduced airflow.
• Damaged filters.
• Excessive overspray.
• Ventilation failures.

Spraying should not continue when required ventilation is not functioning.

Finishing Chemicals

Wood finishing may involve:

• Lacquers.
• Varnishes.
• Stains.
• Solvents.
• Catalysts.
• Hardeners.
• Sealers.
• Adhesives.
• Epoxy products.

The specific hazards depend on the products used.

Safety Data Sheets and product labels should be reviewed when establishing controls.

Solvent Exposure

Solvents may enter the body through inhalation or skin contact.

Potential effects may include:

• Irritation.
• Headache.
• Dizziness.
• Nausea.
• Central nervous system effects.
• Organ toxicity.

Exposure should be minimized through substitution, ventilation, safe handling, and PPE where appropriate.

Formaldehyde — When Applicable

Some adhesives, resins, composite wood products, or finishing systems may involve formaldehyde exposure.

Where employee exposure may occur, the employer should determine whether applicable Formaldehyde requirements apply.

Formaldehyde should not be treated as a universal woodworking exposure.

Isocyanates — When Applicable

Certain coatings, finishes, adhesives, or polyurethane products may contain isocyanates.

Where these products are used, the company should evaluate inhalation and skin exposure and establish appropriate controls.

Isocyanate exposure is process- and product-specific.

Adhesives

Adhesives may contain solvents, epoxy resins, formaldehyde-containing resins, sensitizers, or other hazardous chemicals.

Employees should follow manufacturer instructions, product labels, Safety Data Sheets, and company procedures.

Hazard Communication

A Hazard Communication Program should address hazardous chemicals used in woodworking operations.

Applicable elements may include:

• Chemical inventory.
• Product labels.
• Safety Data Sheets.
• Employee training.
• Non-routine tasks.
• Chemical storage.

Employees should know how to obtain chemical hazard information before using a product.

Flammable and Combustible Liquids

Woodworking facilities may store or use flammable or combustible:

• Solvents.
• Finishes.
• Stains.
• Adhesives.
• Cleaning agents.
• Fuels.

These materials should be stored, transferred, and used according to applicable requirements.

Ignition sources should be controlled.

Chemical Storage

Chemicals should be stored:

• In appropriate containers.
• With labels intact.
• Away from incompatible materials.
• Away from uncontrolled ignition sources.
• In appropriate cabinets or areas where required.

Damaged or leaking containers should be addressed promptly.

Respiratory Protection

Respiratory protection may be required for certain wood-dust or chemical exposures.

Where respirators are required, the employer should maintain an appropriate Respiratory Protection Program.

Applicable elements may include:

• Exposure evaluation.
• Respirator selection.
• Medical evaluation.
• Fit testing.
• Training.
• Inspection.
• Maintenance.
• Program evaluation.

Respirators should not be used as a substitute for feasible engineering controls where those controls are required.

Personal Protective Equipment

PPE should be selected based on the hazard assessment.

Depending on assigned work, PPE may include:

• Safety glasses.
• Goggles.
• Face shields.
• Hearing protection.
• Gloves.
• Protective footwear.
• Respiratory protection.
• Chemical-resistant gloves.
• Protective clothing.

Employees should understand PPE limitations.

Eye and Face Protection

Eye protection is commonly necessary during woodworking operations because of flying:

• Chips.
• Sawdust.
• Splinters.
• Tool fragments.
• Chemical splashes.

Face protection may be appropriate for certain higher-hazard operations.

Hand Protection

Gloves may be appropriate for:

• Lumber handling.
• Splinters.
• Chemical handling.
• Sharp material.

Gloves should not be worn where they could increase entanglement risk around exposed rotating machinery.

Task-specific evaluation is necessary.

Foot Protection

Protective footwear may be necessary where employees are exposed to:

• Falling lumber.
• Heavy materials.
• Forklift traffic.
• Sharp objects.
• Slippery surfaces.

Footwear should also provide suitable traction for the work environment.

Noise Exposure

Woodworking equipment can produce hazardous noise.

Potential sources include:

• Saws.
• Routers.
• Planers.
• Sanders.
• Dust collectors.
• Pneumatic equipment.
• Compressors.

Employee noise exposure should be evaluated.

Hearing Conservation

Where employee exposure reaches applicable thresholds, required Hearing Conservation measures should be implemented.

These may include:

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

Vibration

Handheld and stationary woodworking equipment may expose employees to vibration.

Tasks involving repeated use of vibrating equipment should be evaluated for:

• Duration.
• Grip force.
• Tool condition.
• Employee symptoms.

Equipment maintenance and work organization may reduce exposure.

Electrical Safety

Woodworking facilities may contain substantial electrical loads and numerous powered machines.

Electrical systems and equipment should be maintained in safe condition.

Employees should report:

• Damaged cords.
• Missing covers.
• Exposed wiring.
• Defective switches.
• Improper grounding.
• Overheated electrical equipment.

Specialized electrical work should be performed by appropriately qualified employees.

Electrical Equipment in Dust Areas

Wood dust can affect electrical fire and explosion risks.

Electrical installations should be appropriate for the environment in which they are used.

The company should evaluate locations where combustible dust may influence equipment classification or installation requirements.

Material Handling

Woodworking operations may involve manual or mechanical handling of:

• Lumber.
• Sheet goods.
• Plywood.
• Composite panels.
• Finished products.
• Pallets.

Procedures should address weight, sharp edges, splinters, awkward dimensions, falling material, and equipment movement.

Lumber Handling

Employees handling lumber should be alert to:

• Splinters.
• Nails.
• Sharp edges.
• Shifting stacks.
• Falling boards.
• Heavy pieces.

Team lifting or mechanical assistance should be used where appropriate.

Sheet Material

Plywood, particleboard, MDF, and other sheet products can be large, awkward, and heavy.

Mechanical handling devices, carts, panel lifts, team handling, or other assistance should be used where appropriate.

Lumber Storage

Lumber should be stored so stacks remain stable.

Storage areas should avoid:

• Leaning stacks.
• Excessive stack height.
• Blocked aisles.
• Protruding material.
• Unstable dunnage.

Employees should not climb unstable lumber stacks.

Rack Safety

Storage racks should be suitable for the material and loads placed on them.

Damaged racks should be reported.

Material should not extend into aisles or work areas in a manner that creates struck-by or collision hazards.

Forklift Safety

Woodworking facilities may use forklifts for lumber, pallets, finished products, chemicals, and other materials.

Only trained and authorized employees should operate powered industrial trucks.

Operators should consider:

• Load stability.
• Visibility.
• Pedestrians.
• Rack clearances.
• Floor conditions.
• Speed.
• Trailer loading.

Pedestrian Safety

Facilities should reduce employee exposure to forklift and vehicle traffic.

Potential controls may include:

• Designated walkways.
• Barriers.
• Mirrors.
• Warning signs.
• Traffic rules.
• Restricted areas.

Employees should not assume equipment operators can see them.

Loading and Unloading

Loading and unloading activities may involve:

• Lumber trucks.
• Flatbed trailers.
• Box trailers.
• Forklifts.
• Finished products.

Procedures should address vehicle movement, unstable loads, falling material, trailer condition, and employee positioning.

Trailer Safety

Before forklifts enter trailers, employees should evaluate:

• Trailer restraint.
• Trailer floor condition.
• Dock plate condition.
• Capacity.
• Vehicle movement.

Applicable procedures should prevent unintended trailer movement.

Ergonomics

Woodworking employees may perform repetitive or forceful tasks during:

• Assembly.
• Sanding.
• Finishing.
• Material handling.
• Packaging.
• Machine feeding.

Workstations and methods should be evaluated to reduce unnecessary musculoskeletal stress.

Repetitive Assembly

Assembly tasks may involve repeated:

• Reaching.
• Gripping.
• Fastening.
• Bending.
• Lifting.

Controls may include workstation adjustment, fixture design, mechanical assistance, job rotation where appropriate, and improved work methods.

Manual Lifting

Employees should evaluate the weight, size, shape, and stability of materials before lifting.

Mechanical assistance or team handling should be used where loads cannot be safely controlled by one employee.

Housekeeping

Good housekeeping is particularly important in woodworking operations.

Floors and aisles should be kept free of:

• Sawdust.
• Scrap wood.
• Extension cords.
• Packaging.
• Protruding nails.
• Spilled liquids.
• Other trip hazards.

Employees should not allow waste to accumulate around operating machinery.

Scrap Wood

Scrap should be removed regularly.

Scrap containing protruding nails, screws, or sharp edges should be controlled to prevent cuts and punctures.

Scrap containers should not obstruct aisles or emergency exits.

Slips, Trips and Falls

Wood dust and scrap can create slippery or uneven walking surfaces.

Employees should maintain clean work areas and report:

• Damaged floors.
• Wet areas.
• Broken stairs.
• Unsafe ladders.
• Blocked walkways.

Ladders and Elevated Work

Woodworking facilities may use ladders for:

• Maintenance.
• Storage access.
• Dust-collection work.
• Lighting.
• Building service.

Ladders should be selected, inspected, and used appropriately.

Fall protection should be provided where required.

Compressed Air

Compressed air may be used for tools or process equipment.

Employees should not use compressed air in a manner that creates airborne wood-dust hazards or exposes employees to flying material.

Safer housekeeping methods should be used for accumulated dust.

Compressed Gas Cylinders

Facilities using cylinders for welding, maintenance, finishing, or other operations should secure, store, and handle them appropriately.

Cylinders should be protected from damage and incompatible conditions.

Maintenance Shops

Maintenance areas may involve:

• Welding.
• Grinding.
• Electrical work.
• Power tools.
• Chemicals.
• Machine repair.

Applicable specialized programs should be implemented according to the tasks performed.

Welding and Cutting

Welding and cutting should be controlled carefully because woodworking facilities contain abundant combustible material.

Before Hot Work begins:

• Wood dust should be controlled.
• Combustible stock should be removed or protected.
• Flammable chemicals should be addressed.
• Fire protection should be available.
• Dust-collection hazards should be evaluated.

Emergency Action Plan

The company should maintain emergency procedures appropriate to the facility.

Potential emergencies may include:

• Fire.
• Dust explosion.
• Chemical release.
• Machine injury.
• Severe weather.
• Medical emergency.
• Workplace violence.

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

Fire Emergency

Employees should know how to:

• Report a fire.
• Activate alarms.
• Evacuate.
• Proceed to assembly areas.
• Account for personnel as required.

Only employees trained and authorized under company procedures should use portable fire extinguishers.

Dust Collector Fire

A fire involving a dust collector or conveying system can spread rapidly.

Employees should follow established emergency procedures and avoid opening equipment in a manner that could introduce additional oxygen or spread fire and dust.

Emergency response should account for the potential for secondary fire or explosion.

Chemical Spill

Employees should understand procedures for spills involving:

• Solvents.
• Coatings.
• Adhesives.
• Finishes.
• Fuels.
• Maintenance chemicals.

Employees should not perform spill response beyond their training and assigned responsibilities.

First Aid

Appropriate first-aid resources should be available.

Potential woodworking injuries may include:

• Lacerations.
• Amputations.
• Eye injuries.
• Punctures.
• Chemical exposures.
• Crush injuries.
• Burns.
• Strains.

Employees should promptly report injuries and obtain appropriate medical evaluation.

Machine Injury Response

Following a serious machine injury:

• Stop equipment safely.
• Control hazardous energy as necessary.
• Obtain emergency medical assistance.
• Prevent additional employee exposure.
• Preserve the scene where appropriate for investigation.

Employees should not place themselves in danger while attempting to assist an injured coworker.

Incident Reporting

Employees should promptly report:

• Injuries.
• Near misses.
• Machine contacts.
• Kickback incidents.
• Missing guards.
• Dust fires.
• Chemical exposures.
• Forklift incidents.
• Equipment damage.
• Unsafe conditions.

Prompt reporting allows hazards to be corrected.

Incident Investigation

Significant incidents should be investigated to identify:

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

Investigations may consider:

• Machine guarding.
• Machine setup.
• Tool condition.
• Employee positioning.
• Training.
• Maintenance.
• Lockout/Tagout.
• Production methods.
• Dust control.
• Housekeeping.
• Supervision.

Root Cause Analysis

Root Cause Analysis may identify underlying factors involving:

• Equipment selection.
• Guard design.
• Preventive maintenance.
• Training.
• Procedures.
• Production pressure.
• Staffing.
• Hazard assessments.
• Dust-control systems.
• Corrective-action systems.

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

Woodworking Safety Inspections

Periodic inspections should evaluate:

• Machine guards.
• Safety devices.
• Saw blades and cutters.
• Push devices.
• Electrical equipment.
• Dust collection.
• Dust accumulation.
• Chemical storage.
• Spray-finishing areas.
• Fire protection.
• Forklifts.
• PPE.
• Walking-working surfaces.

Identified deficiencies should be corrected in a timely manner.

Woodworking Safety Training

Employee training should reflect assigned duties and equipment.

Depending on responsibilities, training may address:

• Machine hazards.
• Guarding.
• Safe operating procedures.
• Kickback.
• Push sticks and fixtures.
• Lockout/Tagout.
• Wood dust.
• Fire prevention.
• Chemical hazards.
• PPE.
• Noise.
• Forklifts.
• Emergency procedures.

Employees should not independently operate specialized machinery until they have received appropriate instruction and demonstrated the ability to perform the work safely.

Machine-Specific Training

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

Training should address:

• Machine function.
• Controls.
• Guarding.
• Feed direction.
• Kickback hazards.
• Workpiece control.
• Emergency stopping.
• Dust collection.
• Prohibited practices.

Training on one woodworking 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:

• Machine hazards.
• Wood dust.
• Fire prevention.
• PPE.
• Hazard Communication.
• Forklift traffic.
• Housekeeping.
• Incident reporting.
• Emergency procedures.

Refresher Training

Refresher or remedial training may be appropriate following:

• Unsafe machine operation.
• Guard bypassing.
• Lockout/Tagout violations.
• Equipment changes.
• Process changes.
• Incidents or near misses.
• Identified knowledge gaps.

Safety Meetings

Periodic safety meetings may reinforce safe work practices.

Potential topics include:

• Machine guarding.
• Kickback.
• Saw safety.
• Lockout/Tagout.
• Dust housekeeping.
• Combustible dust.
• Hearing protection.
• Chemical safety.
• Forklift traffic.
• Recent incidents.

Recordkeeping

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

Records may include:

• Employee training.
• Injury and illness records.
• Machine inspections.
• Preventive maintenance.
• Lockout/Tagout inspections.
• Exposure monitoring.
• Respiratory Protection records.
• Hearing Conservation records.
• Forklift training.
• Incident investigations.
• Chemical records.

Records should be retained according to applicable requirements.

Additional Safety Programs

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

• Machine Guarding.
• Lockout/Tagout.
• Wood Dust Control.
• Combustible Dust.
• Fire Prevention.
• Hot Work.
• Welding & Cutting.
• Table Saw Safety.
• Band Saw Safety.
• Woodworking Machine Safety.
• Hand & Power Tools.
• Preventive Maintenance.
• Hazard Communication.
• Chemical Safety.
• Spray Finishing.
• Flammable & Combustible Liquids.
• Respiratory Protection.
• Personal Protective Equipment.
• Eye & Face Protection.
• Hearing Conservation.
• Electrical Safety.
• Powered Industrial Trucks.
• Material Handling.
• Loading & Unloading.
• Ergonomics.
• Manual Lifting.
• Housekeeping.
• Slips, Trips & Falls.
• Walking-Working Surfaces.
• Ladder Safety.
• Compressed Gas Cylinders.
• Emergency Action Plan.
• First Aid.
• Incident Reporting & Investigation.
• Root Cause Analysis.

Programs should be included when the company’s machinery, wood species, dust-generating processes, finishing chemicals, material-handling operations, and employee exposures make them applicable.

Building a Woodworking Safety Manual

A useful Woodworking Safety Manual should reflect the company’s actual production processes.

A cabinet shop may require extensive procedures for table saws, panel saws, routers, shapers, sanders, dust collection, adhesives, finishing chemicals, material handling, and PPE.

A millwork operation may require greater emphasis on molders, planers, rip saws, resaws, CNC equipment, dust collection, forklifts, lumber handling, Machine Guarding, and Lockout/Tagout.

A furniture manufacturer may require programs covering rough mill operations, production machinery, assembly ergonomics, adhesives, spray finishing, packaging, and material handling.

An architectural woodworking company may combine conventional woodworking machinery, CNC equipment, veneering, laminating, finishing, installation preparation, and specialty products.

A facility that performs extensive spray finishing may require substantially greater controls for ventilation, flammable materials, chemical exposure, respiratory protection, and fire prevention.

The safety manual should therefore be based on the woodworking operations actually performed rather than automatically assigning every woodworking-related program to every employer.

Customized Woodworking Safety Manuals

A Woodworking Safety Manual can be developed around the company’s saws, planers, jointers, shapers, routers, sanders, CNC equipment, dust-collection systems, finishing operations, chemicals, forklifts, material handling, maintenance activities, employees, and other occupational hazards.

The finished manual may incorporate applicable programs for Machine Guarding, Lockout/Tagout, Wood Dust, Combustible Dust, Fire Prevention, Spray Finishing, Hazard Communication, Respiratory Protection, PPE, Hearing Conservation, Forklift Safety, Ergonomics, Emergency Action Planning, Incident Investigation, and other hazards associated with woodworking operations.

This provides cabinet manufacturers, millwork shops, furniture manufacturers, wood-product manufacturers, and other woodworking employers with a practical safety manual organized around the work their employees actually perform.