Department of Mechanical Engineering

Environmental Technology Laboratory

6th Summer School on "Health, hygiene and safety at work

Academic Project in:

Safety Measures in Modern Work Shops

Team members (Authors):

Stylianos Dermenakis, Electrical and Computer Engineer, Dipl.El.Eng
Dimitrios Nikou, Mechanical Engineer MSc Welding engineer and NDT (IWE/EWE)

Kozani 2016

1. Summary
Machine tools pose multiple hazards. Federal regulations require that machine tools must be
provided and maintained in a safe condition and operated safely. Employee exposure to
inadequately guarded machines is prevalent in many workplaces. Consequently, workers who
operate and maintain machinery suffer amputations, lacerations, crushing injuries, abrasions, and
hundreds of deaths per year.
This subject area describes the requirements and procedures for ensuring that all machine
tools comply with all applicable safety regulations and are ready for operation. Only qualified
and authorized operators may use machines and the use of those machines must be in
conformance with this subject area.
Managers, Supervisors and Hosts shall analyze work for hazards, authorize work to proceed,
and ensure that work is performed within established controls.
Managers, Supervisors and Hosts shall ensure that the scope of work properly considers all
elements of the Work shop's operational priorities.
All authorized machine shop users shall identify, evaluate, and control hazards in order to
ensure that work is conducted safely and in a manner that is compliant, and protects the
environment and the public.
All authorized machine shop users shall promptly report accidents, injuries, deficiencies,
emergencies, and off-normal events in accordance with procedures.

2. Table of Contents
1.
2.
3.
4.
5.
6.
7.

Summary
Table of contents
Foreword
Preamble
Main part
Epilogue Conclusions
Bibliography

Page 2
Page 3
Page 4
Page 6
Page 10
Page 80
Page 81

3. Foreword
MACHINE GUARDING TERMINOLOGY
Basic Terminology:
Parts of the Machine Requiring Guarding
Point of Operation: Area where machine performs work on material
Power Transmission Apparatus: Belts, gears, flywheels, chains, pulleys, spindles, couplings,
cams, machine components that transmit energy.
Other Moving Parts: Reciprocating, rotating, traversing motions, auxiliary machine parts.
Types of Mechanical Motion that must be guarded:
Pinch Points: Points at which it is possible to be caught between moving parts, or between
moving and stationary parts of a piece of equipment
Rotating: Circular motion of shafts with a protrusion sticking out can grip clothing or pull body
part into point of operation
Reciprocating: Back-and-forth or Up-and-Down motion that may trap or strike an employee
between the moving object and a fixed object.
Traversing: Movement in straight, continuous line that may strike or catch an employee in a
pinch or shear point between a moving and fixed object.
Cutting: Action of sawing, boring, drilling, milling, slicing
Punching: Action resulting when a machine moves a slide (ram) to stamp a sheet of metal or
other material.
Shearing: Movement of a powered slide or knife during metal trimming or paper cutting
Bending: action occurring when power is applied to a slide to draw or form metal or other
materials Common Machines That Require Machine Guards: Group Discussion Topics:
Identify the machines in your shop or that you use that require machine guarding.
How could someone be injured by using these machines? How can this be prevented?

Common Machines That Require Machine Guards:

Table Saw

Lathe

Reciprocating Saw

Sander

Band Saw

Drill Press

Jointer

Grinding Wheels

Power Feed Planer

Mechanical Power Press

Shaper

Mortising Machine

4. Preamble
40 basic workshop safety rules
1. Keep your work area clean and orderly; neatly arrange equipment and material. Do not allow
parts, metal, wires, scrap or other material to accumulate on the shop floors or in work areas.
Place drink cups, cans, bottles, paper, lunch scraps, etc., in the proper containers.
2. Report every injury to your supervisor immediately, no matter how slight or insignificant the
injury may seem.
3. If you are unsure about the safe operation or process of a job, request assistance from your
supervisor.
4. Report any unsafe conditions to your supervisor immediately. Rely on your judgment and
knowledge of safety to guide you.

5. Horseplay is forbidden. Do not disturb or interfere with other technicians when they are
performing their job.
6. Be certain all safety guards are in place before operating any machine or equipment.
Guards must be replaced as soon as repairs and/or servicing on a machine has been
completed and before the machine is put into operation.
7. Verify the safety of all personnel before energizing or operating any equipment.
8. All equipment must be locked out prior to any repairs or maintenance. Never attempt to
open the switch or operate any equipment that is under repair. Lockouts may only be
removed by authorized personnel.
9. When a machine is de-energized for the purpose of changing setup or making minor
adjustments, the operator must pull the switch controlling this machine. This will allow the
equipment to come to a complete stop, enabling the operator to lock and tag out this machine.
He must then push the start button to ensure the machine is definitely de-energized.
10. Never tie down, block out or otherwise make inoperative any type of safety device,
attachment, method or guard.
11. Observe all caution and danger signs. Be alert and pay attention to horns, alarms or verbal
commands. Be sure to follow the requirements on Material Safety Data Sheets (MSDSs).
12. Never oil, remove guards or attempt to repair machinery while it is in motion (ON
condition). Do not climb on machinery while oiling or greasing. Repairs of machinery must
only be made by authorized personnel or manufacturers representatives.
13. Do not use electrical equipment while standing on damp or wet surfaces or when your
hands are wet.
14. Only Electricians or Aauthorized Personnel are permitted to perform electrical work. Do
not use electric cable, weld leads, extension cords, etc., unless they are properly grounded
and insulated.
15. Personal Protective Equipment (PPE) required in each shop must be worn as specified.
Safety-toe shoes, bump hats, safety glasses with side-shields, goggles, face-shields,
respirators and other forms of protective equipment or clothing are for employee protection.
Steel-toe safety shoes should be the high-top style.
16. Gloves should not be worn when operating drills, lathes or other types of machinery that
contain rotating spindles or cutting tools.

17. Wear clothes that are suitable for work. Long-sleeve shirts must be worn when burning,
welding, grinding or performing other types of work where sparks or hot metal are present or
where the work involves the use of acids or similar substances. Do not wear synthetic fabrics.
18. Neckties, rings, watches and loose or ragged clothing create a hazard when operating
drills, lathes or other rotating or moving equipment or machinery.
19. When lifting an object, lift with your legs and not with your back. Keep your back
straight.
20. Observe "No Smoking" areas. Never smoke near compressed oxygen and gas cylinders,
paint operations, flammable storage rooms, near gasoline or fuel stations, battery recharging
stations or at any locations that contain a combustible or explosive atmosphere or condition.
21. If using a scaffold, it must be erected safely and contain a fully planked and secured floor.
Handrail, midrail and toe boards must be used. Loose rope is not acceptable for a handrail. Use a
ladder or other proper means for gaining access to the work areas. Secure scaffolds to prevent
tipping.
22. Effectively rope off areas below scaffolds or other projects if passing below the operation
poses a potential hazard to anyone.
23. If oil, grease, paint or any other slippery substance is discovered on the floor, wipe it up
immediately to prevent a fall.
24. Flammable liquids such as gasoline, solvents, and thinners, must be stored in approved
safety cans with flame arresters.
25. Properly barricade floor openings, open manholes, machine foundations, etc. If the
lighting is poor, install red warning lights.
26. Be familiar with the locations and operation of fire extinguishers. In case of a fire,
sound an alarm and, if possible, get help to extinguish the fire. Report all fires to your
supervisor.
27. Never use an air hose for cleaning or dusting yourself off. Never point an air hose at
anyone. Special cleaning guns must be used when cleaning with air; approved safety guns
must not exceed 30 pounds per square inch (psi). Never use an air hose for dusting off
brake shoes and parts.
28. Never stack material or product so that it obstructs safety equipment, aisles, ladders,
steps, electric boxes, etc. Always pile large or heavy material on the bottom and smaller
material on top.

29. When storing material, stay clear of objects being moved or handled by any type of
conveyance. Be sure to keep your hands and body clear of moving parts, machinery, hoists,
etc.
30. Wear seat belts when driving a company vehicle, your own, or a customer's vehicle.
31. Compressed oxygen and gas cylinders must be properly secured at all times. Caps must
be installed when not in use. Only lift cylinders in approved racks or cages. Never use
cylinders as rollers. Keep a shutoff wrench on each acetylene cylinder that is not equipped
with a valve.
32. Clamp or secure equipment or material to prevent it from shifting or rotating when
drilling, grinding, operating a lathe, etc.
33. Employees with long hair must tie their hair back or tuck it under their bump cap so it
won't be caught in any rotating machinery or parts.
34. Never work on a tire with a rim ring attached to it without first placing the tire in a
protective tire cage or using a chain to secure the rim to the tire.
35. Never remove a tag labeled "caution," "danger," etc., without authorization. Safety tags
are to be in place on air-hoist controls.
36. Never use an air hose to blow dust from brake drums. Use an approved HEPA vacuum
device or wet-wash method.
37. Work trousers should be cuffless and extend over the shoe to prevent sparks from
entering the shoe. Burns of this type are painful and slow to heal.
38. Follow shop rules and OSHA/EPA guidelines for personal safety. Follow manufacturer's
recommendations for equipment.
39. Follow shop rules and EPA guidelines for disposal/recycling of used oil, antifreeze,
refrigerants and wastes.
40. Follow safe procedures when attempting to fill an inground lift. Follow manufacturer's
guidelines. First depressurize the hoist. Never place any part of your body over the fill plug.
Use hoist plugs that contain bleeder screws.

5. Main Part
5.1 General Requirements for Machine Shop Safety
This section provides the general requirements for machine shop safety.
Students, Guests, and Visitors, who do not meet the definition of a User according to the Guests
and Visitors Subject Area, may not use machine tools in machine shops.
Users and job shoppers (temporary employees and leased workers, see Definitions) may be
authorized to use machine tools in machine shops provided they meet and comply with the
requirements in the section Machine Shop Operation.
5.2 Department/Division Requirements
This section provides the requirements for Departments/Divisions that use machine tools.
The Department Chair/Division Manager or designee:

a. Appoints a Machine Shop Supervisor for machine shops and notifies the Machine Shop Safety
Subject Matter Expert (SME) of the appointment and personnel changes.
b. Verifies the training and qualifications of Machine Shop Supervisor as a machine shop
evaluator.
c. Ensures only authorized personnel are trained and signed off to operate machine tools in
machine shops.
d. Ensures all non-employees comply with the requirements of the section Satellite Machine
Shop Operation prior to granting authorization to use machine tools in machine shops.
e. Ensures machine tools in machine shops comply with the requirements of this subject area.
f. Ensures operators of machine tools in machine shops comply with the requirements of this
subject area.
g. Ensures all persons entering machine shops comply with the area-based personal protective
equipment requirements as required by the Personal Protective Equipment and Respirators
Subject Area. These consist of:
i. Light Machine Shop - Long pants, fully enclosed
shoe, safety glasses with side shields
ii. Heavy Machine Shop - Long pants, safety-toe
shoe, safety glasses with side shields
h. Maintains all available owner's or operator's manuals for machine tools and makes these
manuals available to operators.
i. Ensures that a machine operator aid for pre-use inspections is available for each machine.
Operator aids must identify existing controls that address predominant hazards of machine use.
Note: Machine operator aid templates for many machine types are available on the ESH
Guide: Machine Shop Safety and may be adapted to be machine specific.
j. Ensures that the exhibit Machine Shop Rules is displayed in each area with five or more
machine tools. The shop rules address appropriate clothing, hair and dress, safe conduct in the
shop, machining of hazardous materials, clean up, and prohibited activities.
Note: It is recommended that the exhibit be posted in any area where machine tools are
used regardless of the number of machines.
k. Prepares a maintenance schedule for each machine tool based upon the recommendations of
the manufacturer, and ensures this maintenance is performed on a periodic basis.

l. Retains records of inspection and maintenance for all machine tools in machine shops for a
period of at least two (2) years.

The Machine Shop Supervisor:

a. Reviews machine safe operating guidelines and completes a Machine Shop Safe Work
Practices Evaluation Form for each piece of equipment the candidate intends to operate.
b. Maintains a list of authorized personnel and the equipment they are authorized to operate.
c. Inspects machine shop areas monthly in accordance with section 2.2 Monthly Machine Shop
Inspections.
d. Monitors and documents authorized personnel operation of machine tools in machine shops to
ensure continued safe work practices.
Note: For shops with infrequent use and where a full-time machine shop supervisor is not
available, this requirement can be waived.
e. Revokes authorization for personnel that violate Machine Shop Rules or engage in unsafe
behavior in Machine Shops.
f. Conducts reevaluation of operator competency using a Machine Shop Safe Work Practices
Evaluation Form when requested by operator as refresher, operators supervisor, ESH
Coordinator, or Machine Shop Safety SME.

Operator Requirements:
Operators of machine tools are exposed to noise, laceration, bite, strike, pinch point, and other
hazards and must utilize engineering controls including physical guards, observe postings and
administrative controls and wear required personal protective equipment to abate and mitigate
these hazards. This section provides the requirements for operators of machine tools.
Employees and non-employees authorized to use machine tools must comply with this subject
area and their host department procedure for using machine tools in machine shops. All persons
entering machine shops will comply with the area-based personal protective equipment
requirements as required by the Personal Protective Equipment and Respirators Subject Area.
These consist of
a. Light Machine Shop Machining and assembly of small parts using small machine tools such
as sanders, scroll saws and drill presses. Parts and tools are light and drop/crush hazard is
minimal. Requires: Long pants; fully enclosed shoe; safety glasses with side shields;

b. Heavy Machine Shop Machining and assembly of large parts with major machine tools such
as lathes, milling machines, and band saws. Parts and tools drop or crush hazard has the potential
to cause significant injury to feet or legs. Requires:
Long pants; safety-toe shoe; safety glasses with side shields. Operators of machine tools in
machine shops must comply with the rules as described in the exhibit Machine Shop Rules. No
alterations to its format or content can be made without the approval and authorization of the
SME. Observations of unsafe acts or unsafe conditions must be immediately reported to the
Machine Shop Supervisor.

5.3 Equipment Requirements

This section provides the requirements for machine tools. These requirements are further divided
into general requirements for all machine tools, and specific requirements for specific types of
machine tools.
General Equipment Requirements
Operating Controls
1. A mechanical or electrical power control must be provided on each machine to make it
possible for the operator to cut off the power from each machine without leaving his
position at the operator control station.
2.

Power controls and operating controls should be located within easy reach of the
operator while he is at his regular work location, making it unnecessary for him to reach
over the cutter to make adjustments. This does not apply to constant pressure controls
used only for setup purposes.

Machine Guarding

i.

ii.

iii.
iv.
v.

vi.
vii.

One or more methods of machine guarding must be provided to protect the

operator and other workers in the area of the machine from hazards such as those
created by points-of-operation, ingoing nip points, rotating parts, flying chips and
sparks. Examples of guarding methods are barrier guards, two-hand tripping
devices, electronic safety devices, etc. Point-of-operation guarding must be so
designed and constructed as to prevent the operator from having any part of their
body in the danger zone during the operating cycle.
ii. Special hand tools for placing and removing material must be such as to permit
easy handling of material without the operator placing a hand in the danger zone.
Such tools must not be in lieu of guarding requirement and only provide
supplemental protection.
iii. The following are some of the machines which usually require point-ofoperation guarding:
Guillotine cutters, shears, alligator shears, power presses, lathes, milling
machines, bandsaws, power saws, jointers, table saws, pedestal grinders, chop
saws, and belt/disc sanders.
iv. All mechanical power transmission apparatus, including belts, pulleys, gears,
shafts and moving parts, must be guarded. All horizontal belts pulleys, flywheels,
and fan blades and those portions of vertical and inclined belts seven (7) feet or
less from the floor (or working level) are required to be enclosed by a guard when
worker exposure is possible. Flywheel guards must be placed no less than 15
inches or more than 20 inches from the rim. If wheels are in a pit or within 12
inches of the floor, a toeboard is required. Note: If workers are naturally guarded
from exposure to hazardous areas by location of the belt/components (such as
walls and mechanical structures), no additional guard enclosure is required.
v. Guards must be affixed to the machine where possible and secured elsewhere if
for any reason attachment to the machine is not possible. The guard must be such
that it does not offer an accident hazard in itself.
vi. OSHA does not grant a grandfather clause for old equipment. All equipment
must be safeguarded. Equipment must also be installed in conformance to other
applicable facility standards.

Anchoring fixed machinery

i.
Machines designed for a fixed location must be securely anchored to prevent walking
or moving.
Emergency Stops
i.
Machine tools, other than those operated with constant pressure switches, require an
NFPA 79-2012 Category 0 or 1 emergency stop that is easily accessible from the
normal operator position(s). The installed emergency stop should be selected so as to
not add or increase the hazard of the machine.
Anti-restart Devices
i.
Provision must be made to prevent machine tools from automatically restarting upon
restoration of power after a loss of power.

5.4 Equipment Analysis

Abrasive wheel grinder
Abrasive wheels and grinding machines come in many styles, sizes, and designs. Both benchstyle and pedestal (stand) grinders are commonly found in many industries. These grinders often
have either two abrasive wheels, or one abrasive wheel and one special-purpose wheel such as a
wire brush, buffing wheel, or sandstone wheel.
These types of grinders normally come with the manufacturers safety guard covering most of
the wheel, including the spindle end, nut, and flange projection. These guards must be strong
enough to withstand the effects of a bursting wheel. In addition, a tool/work rest and transparent
shields are often provided

Hazard
Bench-style and pedestal grinders create special safety problems due to the potential of the
abrasive wheel shattering; exposed rotating wheel, flange, and spindle end; and a naturally
occurring nip point that is created by the tool/work rest. This is in addition to such concerns as
flying fragments, sparks, air contaminants, etc. Cutting, polishing, and wire buffing wheels can
create many of the same hazards.
Grinding machines are powerful and are designed to operate at very high speeds. If a grinding
wheel shatters while in use, the fragments may travel at more than 300 miles per hour. In
addition, the wheels found on these machines (abrasive, polishing, wire, etc.) often rotate at
several thousand rpms. The potential for serious injury from shooting fragments and the rotating
wheel assemblies (including the flange, spindle end, and nut) is great. To ensure that grinding
wheels are safely used in your workplace, know the hazards and know how to control them.

Solution
Abrasive wheels used on bench and pedestal grinding machines must be equipped with safety
guards. The safety guard encloses most of the wheel covering the flange, spindle end, and nut
projection while allowing maximum exposure of the wheel periphery. The exposure of the
wheel should not exceed 90 or one-fourth of the periphery (see diagram below).

This exposure begins at a point not more than 65 degrees above the horizontal plane of the wheel spindle. Wherever
the nature of the work requires contact with the wheel below the horizontal plane of the spindle, the exposure must
not exceed 125 degrees.

Because the safety guard is designed to restrain the pieces of a shattered grinding wheel, the
distance between the safety guard and the top periphery of the wheel must not be more than 14inch. If this distance is greater because of the decreased size of the abrasive wheel, then a
tongue guard must be installed to protect workers from flying fragments in case of wheel
breakage. This tongue guard should be adjustable to maintain the maximum 14-inch distance
between it and the wheel.
An adjustable tool/work rest must also be installed and maintained at a maximum clearance of
18-inch between it and the face of the wheel. In addition to offering a stable working position,
this small clearance must be maintained to prevent the operators hands or the work from being
jammed between the wheel and the rest, which may cause serious injury or wheel breakage.

Proper exposure angle (90)

Adjustable tongue guards (14)
Adjustable tool/work rest (18)
Plastic glass (Plexiglas) shields are optional. They are not a substitute for eye/face protection and are not included as
a part of the guard (unless they are adjusted accordingly and have strength equal to that of the safety guard).

All abrasive wheels must be closely inspected and ring-tested before mounting to ensure that
they are free from cracks or other defects. Wheels should be tapped gently with a light,
nonmetallic instrument. A stable and undamaged wheel will give a clear metallic tone or ring.
If a wheel sounds cracked (dead), do not use it. This is known as the ring test.
The spindle speed of the machine must also be checked before mounting the wheel to be certain
that it does not exceed the maximum operating speed marked on the wheel.
Always follow the manufacturers recommendations.
Band saw
Horizontal band saw

A horizontal band saw uses a thin, flexible, continuous steel strip with cutting teeth on one edge.
Horizontal band saws are used primarily for cutting metal stock, such as angle iron and other
round and flat stock. The blade runs horizontally on two pulleys through two separate guides.
The operator secures the stock on the table and manually assists the saw as it cuts.
Hazard
Serious cuts or amputations can occur if the operator contacts the blade. Extreme caution is
necessary because the operators hands may come close to the saw blade, and the entire run of
the blade cannot be fully guarded.
Solution
Guard the entire blade except at the point of operation (the working portion of the blade between
the two guides). Band saw wheels must be fully encased (enclosed).
Make sure the saw includes a tension-control device to indicate proper blade tension.

Vertical band saw

A vertical band saw uses a thin, flexible, continuous steel strips with cutting teeth on one edge. It
is a versatile saw used to cut both wood and metal stock and also to cut and trim meat. The blade
runs on two pulleys, driver and idler, and through a work table where material is fed manually.
In order to cut, the operator is required to hand-feed and manipulates the stock against the blade.
The operator must also keep the stock flat on the work table and exert the proper amount of
force.
Hazard
Serious cuts or amputations can occur if the operator contacts the blade. Extreme caution is
necessary because the operators hands may come close to the saw blade and a band saw
cannot be fully guarded.
Solution
Guard the entire blade except at the point of operation (the working portion of the blade between
the bottom of the sliding guide rolls and the table).
Use an adjustable guard for the portion of the blade above the sliding guide rolls so that it raises
and lowers with the guide. Properly adjust the blade guide to fit the thickness of the stock and
ensure the guard is as close as possible to the stock.
Bandsaw wheels must be fully encased (enclosed).

 CNC turning machine

Computer Numerically Controlled (CNC) machining centers cut and shape an assortment of
precision products from automobile parts to general machine parts. Operating in either horizontal
or vertical positions, CNC machinery includes machining tools such as lathes, multi-axis
spindles, and milling and boring machines; the functions formerly performed by human
operators are performed by a computer-control module. CNC machinery is either hand-loaded or
automatically fed.
Most CNC machinery is partially or totally enclosed by metal enclosures equipped with
thermoplastic vision panels, most commonly polycarbonate.

Hazard
Two primary hazards arise from CNC turning operations: Entanglement and/or the ejection of
parts. Serious lacerations, fractures, amputations, or even death can occur if an operator contacts
or becomes entangled in or between the tooling or rotating work piece. Similar injuries or death
can also occur from being struck by ejected parts (e.g., cutters or other tools, chucks, or the work
piece).
Although the risk of injury from ejected parts is lessened due to the interlocked enclosure of
CNC machinery, recent research has shown that polycarbonate materials used in the units vision
panels can degrade after exposure to the metalworking fluids and lubricants used in the
machining process. Over time, vision panels may not be able to contain ejected parts. Most
ejections at CNC turning machines are caused by a setup error or failing to properly maintain
work-holding devices.
Unexpected movement or startup caused by faults in the control system can also cause potential
serious injury.

Solution
To prevent access into the point of operation area, ensure the CNC machine is fully enclosed and
equipped with an interlocked guard (door). The cutting tools should not start unless the door is in
position (closed) and should stop when the door is opened. Many machines lock the guard in
position during operation and can only be opened when the tooling stops. If access into the point
of operation is infrequent, install a fixed enclosure that can be removed only for maintenance
activities.
Automatic loading and unloading methods and automatic tool changing further reduce the
exposure to the point of operation.
To prevent injury from ejected parts, make sure the polycarbonate vision panels are strong
enough to contain ejected parts. Also, verify the appropriate rotational speed for the particular
work piece and inspect the chuck jaw assemblies, work piece clamps, and all component parts of
the turning fixtures.

Determine if the polycarbonate vision panels are strong enough to contain ejected parts.

 Compacting and baling equipment

Compacting and baling equipment reduces large amounts of solid waste to smaller, more
manageable units by means of powered rams. In general, compactors compress refuse into
containers for transport. Baling equipment is designed to compress material (e.g., cardboard
boxes) and produce a bale (bound or unbound) that is handled as a unit.
A wide range of hazards exist simply due to the size, configuration, and operation of compactors
and balers. Some machines allow direct access to the compression chamber, while others have a
hopper or chute through which material feeds into the machine. Machines may operate in a
manual, semiautomatic, or automatic mode. The rams may move vertically or horizontally.

Hazard
Workers can be crushed by the ram motion if guarding is missing or bypassed, or if lockout
procedures are not followed during maintenance activities. Older compacting equipment may not
have appropriate interlock guarding or may not have enough guarding to enclose the chamber or
point-of-operation area completely.
Severe injury and death can also occur during service or maintenance tasks on or inside an
energized or jammed machine if the machine cycles automatically, or if the machine is activated
by another worker who is unaware that someone is inside the chamber. Furthermore, because
ram motion ceases during a jam, workers may not recognize that the machine remains energized
and that the ram could activate unexpectedly. Similarly, if conveyors are used to feed material
into a compactor or baler, workers may mistakenly believe that shutting down the conveyor also
prevents the compactor or baler from operating.
In addition to the hazardous-energy potential, working inside these machines may also present
confined-space hazards such as hazardous atmospheres and engulfment.

Solution
Access covers and point-of-operation guarding must be interlocked in such a manner that the
compactor cannot be operated if the guard or loading door is removed or opened. Most
compactors and balers today prevent workers from reaching into the point of operation by
configuration, cycling controls, and interlock guarding that interrupt or reverse the rams motion
if the compression chamber doors are opened. However, older equipment may not have these
features and it would be wise to consult with the manufacturer for possible retrofits or upgrades.
Whenever unjamming, adjusting, cleaning, repairing, or performing other maintenance tasks, the
machine must be isolated from all its energy sources and locked out. If conveyors are used,
they should be interconnected so that a single, lockable device can de-energize and isolate the
power to both machines. Lockout procedures are further explained on Page 64.
Follow permit-required confined space entry procedures whenever working inside these
machines.
Also, refer to Oregon OSHAs rules for Stationary Compactors, Self Contained Compactors and
Balers for specific control, marking, and signage requirements.

Cut-off saws
Although there are many specific types of cut-off saws, they are all circular saws designed to
cross cut stock at exact lengths and angles. The following are some of the common cut-off saws
used today.
Miter saw
A miter saw is a versatile circular power saw mounted on a hinged frame and designed to make
accurate angle cuts. When the blade is lowered in a chopping motion, the blade cuts through the
work piece, passing through a slot in the base.

Chop saw
A chop saw is a lightweight circular saw mounted on a spring-loaded pivoting arm and supported
by a metal base. The operator clamps the stock to the fence, pulls the blade through the work
piece, and guides the saw back to its upright position. Chop saws typically do not have the
cutting capacity of miter saws.

Swing saw
Swing saws, both overhead and inverted, are swung from a pivot, either above or below the saw
arbor. The operator positions the stock, pulls the saw across to make the cut, and then returns the
saw to its original position.
Jump saw

Similar to an inverted swing saw, a jump saw is a circular saw located underneath the stock and
hold down (clamp) and is attached on an arm that pivots from behind the saw arbor at
approximately the same height. After the stock is positioned, the blade comes up, cuts the stock,
and drops below the table surface. These undertable saws are normally operated by a knee or
foot pedal.
Hazard
Severe cuts to or amputations of the fingers or hands can occur if they come in contact with the
saw blade. If the rotating blade is not properly guarded, exposure can occur during operation or
when the saw is idling.

Overhead swing saws can pose additional hazards if the return device fails, if the saw bounces
forward from a retracted position, or if the saw blade is able to go past the edge of the table,
possibly contacting the operators body.
Although not as common as with ripsaws, hazardous kickbacks might also occur.
Overhead swing saw missing a lower
blade guard and extending beyond table
edge.

Solution
Overtable cut-off saws (miter,
chop, and overhead swing saws)
must be provided with fixed hood
guards that enclose the arbor and
top half of the saw. These saws
also must be equipped with a
self-adjusting lower blade guard
that automatically adjusts itself to
the thickness of the material
being
cut
and
provides
continuous protection from the
blade. Most guards supplied by manufacturers are designed to move out of the way as the blade
nears the cut. If a guard seems slow to return to its normal position, adjust or repair it
immediately.
Overhead swing saws must be provided with a device (i.e. counterweight) to return the saw
automatically to the back of the table when released at any point of its travel. Limit chains must
also be provided to keep the saw from swinging beyond the front or back edges of the table.
Inverted (undertable) swing saws and jump saws when idling are guarded by their enclosure.
During operation, a hood-type guard or clamping means must be provided for the blade portion
that protrudes above the table or above the stock being cut in addition to holding down the stock.
Furthermore, these saws must have a nose guard affixed to the saw table in front of the hood
guard (or another method providing equivalent protection) to prevent accidental entry of fingers
or hands into the path of the saw blade from the front (Oregon OSHA Employer Alert, Sept. 15,
2000).

 Drill press
The drill press is a versatile machine that uses a multiple-cutting-edged drill bit secured in a
rotating chuck to bore and drill holes, normally into wood stock. Either in floor or bench-top
designs, drill presses are usually arranged vertically, requiring the operator to raise and lower an
operating handle in order to control the drill bit. These machines also have variable speeds and
some have multiple spindles for gang drilling. The most commonly used drill press is a singlespindle, floor-mounted, belt-driven machine for non-production drilling.

Hazard
Serious lacerations and entanglement can occur if operators contact the rotating bit or chuck, or
when operators try to hold the stock by hand when drilling. If not adequately secured, the stock
can spin violently and contact the operator and others nearby. Also, injuries can occur from a
projected chuck key if it is left in the chuck.
Solution
Use jigs or fixtures to fasten the stock to the bed and stabilize the work piece. This allows the
stock to be secured for drilling and also allows the operators free hand to be positioned away
from the rotating chuck and drill bit. The drill bit is more likely to grab and twist an unstable
work piece.
In many repetitive drilling applications, specially designed guards or shields are installed to
protect the operator from the potential exposure to rotating drill chucks and drill bits. A fixed
universal-type shield can be used on larger gang drills.
Ironworker
Ironworkers are versatile, multistation metal fabricating machines that offer component tooling
options to perform punching, shearing, notching-coping, and sometimes bending operations. The

workstations can work singly or simultaneously and all tooling moves vertically. Ironworkers are
normally powered hydraulically.

Hazard
Severe crushing injuries or amputations can occur if an operator makes contact with any of the
pinch or shear points this machine provides.
Flying or ejected parts from either the stock or the tooling can strike operators and other workers
in the area. Furthermore, punches are hardened and will not bend as they collide with dies. If a
punch is out of alignment, it is more likely to flake or even explode, causing serious harm to the
operator.
Unprotected foot pedals can also introduce the possibility of accidental cycling.
Solution
Guard all pinch and shear points with fixed or adjustable guarding. Guards should be adjusted
down to within 14-inch from the top of the material to the bottom of the guard (or stripper when
punching). Most new machines are equipped with adjustable restrictors that surround the
material in-going areas and should allow just enough clearance for the material to enter.
Beware of machines with automatic urethane hold-downs. These hold-downs, if not adjusted
properly, also come down with many tons of force and can be hazardous pinch points.
Ensure proper alignment of the punch and dies.
Cover foot pedals to prevent accidental cycling.
Jointer

Jointers face and straighten wood and are used primarily to square edges. The operator passes
stock over a cylindrical, multiple-knife cutting head while keeping the stock flush against a
guide.

Hazard
Severe lacerations or amputations can occur if the operators hands and fingers come in contact
with the knives. This can happen when operating an unguarded machine, jointing narrow lengths
of stock when not using a jig or other holding device, or when the operators fingers ride along
the surface of the jointer and through the self-adjusting guard while feeding the wood. Also,
stock may kick back and expose the operators hands to the cutter head.
Solution
A spring-loaded, self-adjusting guard must be provided to enclose the horizontal cutting head
when stock is not being fed. The guard automatically adjusts to cover the unused portion of the
head and remains in contact with the stock at all times. A guard must also cover the section of
cutting head behind the fence (gage). For vertical-head jointers, completely enclose the cutter
head except for the slot to apply the stock. This guard can be part of the local exhaust system.
The knife projection on the cutting head must not be more than 18-inch beyond the cylindrical
body of the head. The clearance between the edge of the rear table (in feed) and the cutting head
must not exceed 18-inch. The opening in the table must be kept as small as possible.
Hold-down push shoes and sticks are recommended when using the jointer.
Metal lathe

A metal lathe is a precision turning machine that rotates a metal rod or irregular-shaped material
while a tool cuts into the material at a preset position. Similar to the wood lathe, the metal lathe
normally consists of a headstock and base that houses one or more spindles on which a workholding device (chuck) can drive the stock and the cutting tools can remove metal, producing
mainly cylindrical and conical shapes.
There are basically two main types of metal lathes: Lathes for shaft work (material supported at
two or more locations) and lathes for bar (bar stock introduced through the spindle) or chucking
work (individual pieces secured at the chuck). Shaft lathes include engine lathes, vertical-shaft
lathes, and turning centers. Bar and chucking lathes include turret lathes (vertical and horizontal)
and vertical boring mills.

Hazard
Severe injuries and death can occur primarily from being caught in or struck by rotating parts.
An operator can be pulled into the lathe from working perilously close (e.g., polishing a slotted
shaft with emery cloth) and/or wearing gloves, loose clothing, hair, jewelery, etc. Trapping
spaces are also created between the cutting tool, its mounting, and the work piece or chuck.
Projected parts or material such as chuck keys or unsecured work pieces can also strike nearby
operators.
Flying chips and coolant also present hazards to the operator.

Solution
Avoid wearing gloves, loose clothing, long hair, jewelry, or other dangling objects near lathe
operations. Pay close attention to work pieces that have keyway slots or other surface profiles

that may increase the risk of entanglement. Assess the need to manually polish (e.g., emery
cloth) rotating material. If necessary, consider milling keyways or other profiles after polishing
or use emery cloth with the aid of a tool or backing boards. Always use a brush or tool to remove
chips.
Cover work-holding devices (chucks) and tool trapping space hazards (especially in automatic or
semiautomatic modes) with secured fixed or movable guards or shields. Vertical lathes and
controlled turning centers are normally provided with fixed or interlocked guarding that prevents
access during the automatic cycle.

Make sure all work pieces and work-holding devices are secure and free from defects. Remove
the chuck key from the chuck after securing the material. A good rule is to never take your hand
off the chuck key until you set it back onto a table. Consider using a spring-loaded wrench.
Provide a chip/coolant shield unless another guard or shield already provides protection. This
does not replace the need for eye and face protection, however.
NOTE: Guards or shields used to protect lathe operators from projected parts must either be from
the manufacturer or, if fabricated in-house, meet or exceed the same impact-resistance
specifications as the original manufactured part. Various materials (such as polycarbonates) may
possess different and less effective impact-resistance characteristics than the original materials
used by the manufacturer.
In one case, an operator was killed when the bell casting on a lathe came loose while the lathe
was turning and was propelled through two, -inch-thick Plexiglas windows. The Plexiglas was
installed as a replacement for the manufacturers original composite window on the machines
door frame. The operator was fatally struck in the head and neck as he was looking through the
window.
The manufacturers original observation window was made of a -inch-thick laminated glass
plate with a -inch-thick polycarbonate window, separated by an approximately -inch air
space. The original window was replaced with Plexiglas material that had a lower impact
resistance than the polycarbonate shield originally supplied by the machine manufacturer.
Polycarbonates are a family of various polymers that includes Macrolux, Lexan, Relex, Replex,
Dynaglass, Exolite, Verolite, Cyrolon, and Makrolon. These materials have different impactresistance characteristics for different thicknesses and surface areas. It is important to note that
increasing the thickness beyond a certain level does not always improve or increase the impact
resistance. Furthermore, some studies have shown polycarbonate degrades due to age and
prolonged contact with metalworking fluids and lubricants.
Milling machine

A milling machine removes material from a work piece by rotating a cutting tool (cutter) and
moving it into the work piece. Milling machines, either vertical or horizontal, are usually used to
machine flat and irregularly shaped surfaces and can be used to drill, bore, and cut gears, threads,
and slots.
The vertical mill, or column and knee mill, is the most common milling machine found in
machine shops today. The general construction of this mill includes the quill, which moves
vertically in the head and contains the spindle and cutting tools. The knee moves up and down by
sliding parallel to the column. The column holds the turret, which allows the milling head to be
positioned anywhere above the table. Hand wheels move the work table to the left and right (X
axis), in and out (Y axis), in addition to moving the knee, saddle, and worktable up and down (Z
axis).

Hazard
Serious injuries and entanglement can occur if the operator contacts the rotating cutter. Metal
shavings and lubricating/cooling fluids might also present a risk from the point of operation area.
Material might spin and strike an operator if the material is not secured to the table.
Injuries can also occur from a projected wrench if it is left in the spindle.
Solution
Secure the work piece either by clamping it onto the work table or by clamping it securely in a
vise that is clamped tightly to the table. Note: Computer numerical controlled (CNC) mills are
rapidly replacing manually fed machines, mainly for versatility and production reasons. The
increased automation does not normally require the operator to move the hand wheels (like the
traditional machines) so operators must always keep their hands away from the point of
operation. A guard or shield that encloses the cutter head or milling bed may be considered to
protect the operator from the cutting area, flying metal shavings, and lubricating or cooling
fluids.
Make sure the tightening wrench is removed from the mill.
Portable tools
Portable abrasive grinder

One of the most common portable tools found in virtually any shop, the portable grinder is
incredibly useful for grinding and finishing material of all shapes and sizes.

Hazard
The hazards associated with portable grinders are similar to those of pedestal or bench grinders.
First of all, serious abrasion or cuts can occur from contacting the rotating abrasive stone. There
is also the potential for the abrasive stone to shatter, plus the dangers of exposure to the rotating
wheel, flange, and spindle end from kickback. Finally, other concerns such as flying fragments
and sparks are present during portable grinding operations.
Solution
These types of grinders normally come with the manufacturers safety guard covering most of
the wheel. Abrasive grinder exposure must not exceed a maximum angle of 180 degrees and the
top half of the wheel must be enclosed at all times. The guard must be mounted so it maintains
proper alignment with the wheel.
Vertical right angle grinders must have a 180-degree guard between the operator and wheel.
The guard must be adjusted so that pieces of a broken wheel will be deflected away from the
operator. The above picture depicts a properly guarded right angle grinder.
Cup wheel grinders must be guarded as described above or be provided with special revolving
cup guards, which mount behind the wheel and turn with it.
There are exceptions for guarding based on work practices and for other grinders (Oregon OSHA
Division 2/Subdivision P 29 CFR 1910.243(c)(1)). Natural sandstone wheels and metal, wooden,
cloth, or paper discs that have a layer of abrasive on the surface are not covered by Oregon
OSHAs portable abrasive grinder rule.
All abrasive wheels must be closely inspected and ring-tested before mounting to ensure that
they are free from cracks or other defects. The spindle speed of the machine also must be
checked before mounting the wheel to be certain that it does not exceed the maximum operating
speed marked on the wheel. Always follow the manufacturers recommendations.
Portable belt sander

The portable belt sander is a general-purpose finishing tool. The belt is looped around two or
more pulleys. The belt sanders linear motion makes it an excellent tool for sanding with the
grain of the wood.

Hazard
Serious abrasion can occur from contacting the moving belt.
In-running nip points created where the belt meets the pulley can be present on the side of
the tool. Nip points allow fingers, clothing, or hair to become caught in the tool.
Solution
Both hands should be used to operate the portable belt sander, one on the trigger switch and the
other on the front handle.
Guard the unused runs of the sanding belt and all in-running nip points. This is normally
accomplished by the tools casing, enclosing the top portion of the belt and much of the side. The
enclosure, or guard, on the sides must prevent the operator from contacting the nip points.

Power roll forming and bending machine

Conventional metal forming and bending machines, also known as plate bending rolls, produce
smooth, circular bends in sheet, strip, or coiled stock. Metal is fed between successive pairs of
rolls that progressively bend and form it until the desired shape and cross section is obtained. The
radius of the bend can be adjusted by changing the location of the rolls. These machines are
normally equipped with instant start, stop, and reverse controls.

Hazard
Severe crushing injuries, amputations, and even death can occur if a worker is caught and drawn
into the counter-rotating infeed rolls. The risk of injury is high during the initial feeding of the
stock. Wearing gloves with fingertips and loose clothing also increase the risk of entanglement.
Workers can also be struck by the moving work piece or pinned between it and a fixed structure.
Solution
Installing fixed or adjustable barrier guarding at the point of operation is usually not practical,
primarily due to the flexibility needed to bend various sizes of stock. Some protection for the
operator and anyone near the machine can be provided by using devices such as safety trip cables
(emergency stop) and hold-down controls; however, these safety devices do not directly prevent
entanglement or entrapment. They are intended to help prevent or minimize injury by stopping
the machine quickly.
Hold-down button or foot controls are designed to actuate roll movement only when held in the
run position. The control should automatically return to the stop position when released.
A trip device (bar, tensioned wire/cable, or kick panel) is interlocked with the machines control
circuit and positioned so that it may be easily actuated by any person caught or drawn toward the
rolls and will stop the machine before serious injury can occur. It should run the entire length of
the machine at the front and in the back. Also, ensure the braking system is adequate, as the
safety devices are only effective if the dangerous parts of the machine stop quickly.
In addition to the measures detailed above, an emergency stop button should be provided at the
machine control console and at any remote work station. If more than one person is needed to
operate the machine, controls should be furnished for each person.
Shear

Power squaring shears and plate shears cut sheets of metal using either mechanical or hydraulicdriven rams for the shearing action. The ram moves a non-rotary blade at a constant rate past the
edge of a fixed blade.
The operator feeds or places the stock between the blades, ensures it is properly positioned, and
activates the cutting cycle with either foot or hand controls. The material hold-down devices,
exerting a tremendous amount of force, clamp the stock immediately prior to the shearing action.
Two other types of shears are also used in industry: alligator and guillotine shears. Both of these
types are used to cut metal stock and scrap metal. Guillotine shears also are used for paper and
plastic.

Hazard
Like all machines that have operating cycles, shears present the possibility of placing a hand in
the danger zone. And in the case of a shear, the consequences are severe.
The primary hazard of the point of operation is the shear hazard. Since shears use blades to sever
many forms and various sizes of stock, there is no doubt what can happen to hands or fingers.
The hold-down devices on power squaring shears also create a very serious pinch point, which
can lead to amputation or fractures to the hands or fingers.
Serious lacerations can also occur from handling the blades.

Solution

The shear blades are normally safeguarded by the equipment manufacturers barrier guard. If not,
a barrier guard, capable of adjusting to the thickness of the stock, must be installed in front of the
shear blades. The jagged-edge barrier guard behind the hold-down devices in the picture (right)
is the shear blade guard.

An adjustable barrier guard must also be provided in front of the hold-down devices to protect
the operator from the pinch point hazard.
These guards must meet the safe opening requirements found on page 41. They must be
adjustable so that operators can feed the stock but cannot get their hands or fingers into the
hazard area.
On mechanical shears equipped with a part-revolution clutch or for those that are hydraulically
powered, light curtain presence-sensing devices or two-hand control devices can also be
considered to be safeguarding options.
Wear gloves when handling the stock. In addition to gloves, appropriate mechanical devices or
assistance should be used when removing, handling, and installing the blades.
Hand/foot controls should be enclosed or shrouded to eliminate accidental cycling.
The back of the shear, where sheared debris drops, should be barricaded.

Welding

5.4.1 GENERAL
a. To prevent injury to personnel, extreme caution should be exercised when using any types of
welding equipment. Injury can result from fire, explosions, electric shock, or harmful agents.
Both the general and specific safety precautions listed below must be strictly observed by
workers who weld or cut metals.
b. Do not permit unauthorized persons to use welding or cutting equipment.
c. Do not weld in a building with wooden floors, unless the floors are protected from hot metal
by means of fire resistant fabric, sand, or other fireproof material. Be sure that hot sparks or hot
metal will not fall on the operator or on any welding equipment components.
d. Remove all flammable material, such as cotton, oil, gasoline, etc., from the vicinity of
welding.
e. Before welding or cutting, warm those in close proximity who are not protected to wear proper
clothing or goggles.
f. Remove any assembled parts from the component being welded that may become warped or
otherwise damaged by the welding process.
g. Do not leave hot rejected electrode stubs, steel scrap, or tools on the floor or around the
welding equipment. Accidents and/or fires may occur.
h. Keep a suitable fire extinguisher nearby at all times. Ensure the fire extinguisher is in operable
condition.
i. Mark all hot metal after welding operations are completed. Soapstone is commonly used for
this purpose.
5.4.2 PERSONAL PROTECTIVE EQUIPMENT
a. General. The electric arc is a very powerful source of light, including visible, ultraviolet, and
infrared. Protective clothing and equipment must be worn during all welding operations. During
all oxyacetylene welding and cutting processes, operators must use safety goggles to protect the
eyes from heat, glare, and flying fragments of hot metals. During all electric welding processes,
operators must use safety goggles and a hand shield or helmet equipped with a suitable filter
glass to protect against the intense ultraviolet and infrared rays. When others are in the vicinity of
the electric welding processes, the area must be screened so the arc cannot be seen either directly
or by reflection from glass or metal.

b. Helmets and Shields.

(1) Welding arcs are intensely brilliant lights. They contain a proportion of ultraviolet light which
may cause eye damage. For this reason, the arc should never be viewed with the naked eye
within a distance of 50.0 ft (15.2 m). The brilliance and exact spectrum, and therefore the danger
of the light, depends on the welding process, the metals in the arc, the arc atmosphere, the length
of the arc, and the welding current. Operators, fitters, and those working nearby need protection
against arc radiation. The intensity of the light from the arc increases with increasing current and
arc voltage. Arc radiation, like all light radiation, decreases with the square of the distance. Those
processes that produce smoke surrounding the arc have a less bright arc since the smoke acts as a
filter. The spectrum of the welding arc is similar to that of the sun. Exposure of the skin and eyes
to the arc is the same as exposure to the sun.
(2) Being closest, the welder needs a helmet to protect his eyes and face from harmful light and
particles of hot metal. The welding helmet (fig. 2-1) is generally constructed of a pressed fiber
insulating material. It has an adjustable headband that makes it usable by persons with different
head sizes. To minimize reflection and glare produced by the intense light, the helmet is dull
black in color. It fits over the head and can be swung upward when not welding. The chief
advantage of the helmet is that it leaves both hands free, making it possible to hold the work and
weld at the same time.

(3) The hand-held shield (fig. 2-1) provides the same protection as the helmet, but is held in
position by the handle. This type of shield is frequently used by an observer or a person who
welds for a short period of time.
(4) The protective welding helmet has lens holders used to insert the cover glass and the filter
glass or plate. Standard size for the filter plate is 2 x 4-1/4 in. (50 x 108 mm). In some helmets
lens holders open or flip upwards. Lenses are designed to prevent flash burns and eye damage by
absorption of the infrared and ultraviolet rays produced by the arc. The filter glasses or plates
come in various optical densities to filter out various light intensities, depending on the welding
process, type of base metal, and the welding current. The color of the lens, usually green, blue, or
brown, is an added protection against the intensity of white light or glare. Colored lenses make it
possible to clearly see the metal and weld. Table 2-1 lists the proper filter shades to be used. A
magnifier lens placed behind the filter glass is sometimes used to provide clear vision.

A cover plate should be placed outside the filter glass to protect it from weld spatter. The filter
glass must be tempered so that is will not break if hit by flying weld spatter. Filter glasses must
be marked showing the manufacturer, the shade number, and the letter "H" indicating it has been
treated for impact resistance.
NOTE
Colored glass must be manufactured in accordance with specifications detailed in the "National
Safety Code for the Protection of Hands and Eyes of Industrial Workers", issued by the National
Bureau of Standards, Washington DC, and OSHA Standards, Subpart Q, "Welding, Cutting, and
Brazing", paragraph 1910.252, and American National Standards Institute Standard (ANSI)
Z87.1-1968, "American National Standard Practice for Occupational and Educational Eye and
Face Protection".

(5) Gas metal-arc (MIG) welding requires darker filter lenses than shielded metalarc (stick) welding. The intensity of the ultraviolet radiation emitted during gas
metal-arc welding ranges from 5 to 30 times brighter than welding with covered
electrodes.
(6) Do not weld with cracked or defective shields because penetrating rays from
the arc may cause serious burns. Be sure that the colored glass plates are the
proper shade for arc welding. Protect the colored glass plate from molten metal
spatter by using a cover glass. Replace the cover glass when damaged or spotted
by molten metal spatter.
(7) Face shields (fig. 2-2) must also be worn where required to protect eyes.
Welders must wear safety glasses and chippers and grinders often use face shields
in addition to safety glasses.

(8) In some welding operations, the use of mask-type respirators is required.

Helmets with the "bubble" front design can be adapted for use with respirators.
c. Safety Goggles. During all electric welding processes, operators must wear safety goggles (fig.
2-3) to protect their eyes from weld spatter which occasionally gets inside the helmet. These
clear goggles also protect the eyes from slag particles when chipping and hot sparks when
grinding. Contact lenses should not be worn when welding or working around welders. Tinted
safety glasses with side shields are recommended, especially when welders are chipping or
grinding. Those working around welders should also wear tinted safety glasses with side shields.

d. Protective Clothing.
(1) Personnel exposed to the hazards created by welding, cutting, or brazing
operations shall be protected by personal protective equipment in accordance with
OSHA standards, Subpart I, Personal Protective Equipment, paragraph 1910.132.
The appropriate protective clothing (fig. 2-4) required for any welding operation
will vary with the size, nature, and location of the work to be performed. Welders
should wear work or shop clothes without openings or gaps to prevent arc rays
from contacting the skin. Those working close to arc welding should also wear
protective clothing. Clothing should always be kept dry, including gloves.

(2) Woolen clothing should be worn instead of cotton since wool is not easily
burned or damaged by weld spatter and helps to protect the welder from changes
in temperature. Cotton clothing, if used, should be chemically treated to reduce its
combustibility. All other clothing, such as jumpers or overalls, should be
reasonably free from oil or grease.

(3) Flameproof aprons or jackets made of leather, fire resistant material, or other
suitable material should be worn for protection against spatter of molten metal,
radiated heat, and sparks. Capes or shoulder covers made of leather or other
suitable materials should be worn during overhead welding or cutting operations.
Leather skull caps may be worn under helmets to prevent head burns.
(4) Sparks may lodge in rolled-up sleeves, pockets of clothing, or cuffs of overalls
and trousers. Therefore, sleeves and collars should be kept buttoned and pockets
should be eliminated from the front of overalls and aprons. Trousers and overalls
should not be turned up on the outside. For heavy work, fire-resisant leggings,
high boots, or other equivalent means should be used. In production work, a sheet
metal screen in front of the worker's legs can provide further protection against
sparks and molten metal in cutting operations.
(5) Flameproof gauntlet gloves, preferably of leather, should be worn to protect
the hands and arms from rays of the arc, molten metal spatter, sparks, and hot
metal. Leather gloves should be of sufficient thickness so that they will not shrivel
from the heat, burn through, or wear out quickly. Leather gloves should not be
used to pick up hot items, since this causes the leather to become stiff and crack.
Do not allow oil or grease to cane in contact with the gloves as this will reduce
their flame resistance and cause them to be readily ignited or charred.
e. Protective Equipment.
(1) Where there is exposure to sharp or heavy falling objects or a hazard of
bumping in confined spaces, hard hats or head protectors must be used.
(2) For welding and cutting overhead or in confined spaces, steel-toed boots and
ear protection must also be used.
(3) When welding in any area, the operation should be adequately screened to
protect nearby workers or passers-by froman the glare of welding. The screens
should be arranged so that no serious restriction of ventilation exists. The screens
should be mounted so that they are about 2.0 ft above the floor unless the work is
performed at such a low level that the screen must be extended closer to the floor
to protect adjacent workers. The height of the screen is normally 6.0 ft (1.8 m) but
may be higher depending upon the situation. Screen and surrounding areas must
be painted with special paints which absorb ultraviolet radiation yet do not create
high contrast between the bright and dark areas. Light pastel colors of a zinc or
titanium dioxide base paint are recommended. Black paint should not be used.

5.4.3 FIRE HAZARDS

a. Fire prevention and protection is the responsibility of welders, cutters, and supervisors.
Approximately six percent of the fires in industrial plants are caused by cutting and welding
which has been done primarily with portable equipment or in areas not specifically designated
for such work. The elaboration of basic precautions to be taken for fire prevention during
welding or cutting is found in the Standard for Fire Prevention in Use of Cutting and Welding
Processes, National Fire Protection Association Standard 51B, 1962. Some of the basic
precautions for fire prevention in welding or cutting work are given below.
b. During the welding and cutting operations, sparks and molten spatter are formal which
sometimes fly considerable distances. Sparks have also fallen through cracks, pipe holes, or other
small openings in floors and partitions, starting fires in other areas which temporarily may go
unnoticed. For these reasons, welding or cutting should not be done near flammable materials
unless every precaution is taken to prevent ignition.
c. Hot pieces of base metal may come in contact with combustible materials and start fires. Fires
and explosions have also been caused when heat is transmitted through walls of containers to
flammable atmospheres or to combustibles within containers. Anything that is combustible or
flammable is susceptible to ignition by cutting and welding.
d. When welding or cutting parts of vehicles, the oil pan, gasoline tank, and other parts of the
vehicle are considered fire hazards and must be removed or effectively shielded from sparks,
slag, and molten metal.
e. Whenever possible, flammable materials attached to or near equipment requiring welding,
brazing, or cutting will be removed. If removal is not practical, a suitable shield of heat resistant
material should be used to protect the flammable material. Fire extinguishing equipment, for any
type of fire that may be encountered, must be present.

5.4.4 HEALTH PROTECTION AND VENTILATION

a. General.
(1) All welding and thermal cutting operations carried on in confined spaces must
be adequately ventilated to prevent the accumulation of toxic materials,
combustible gases, or possible oxygen deficiency. Monitoring instruments should
be used to detect harmful atmospheres. Where it is impossible to provide adequate
ventilation, air-supplied respirators or hose masks approved for this purpose must
be used. In these situations, lookouts must be used on the outside of the confined
space to ensure the safety of those working within. Requirements in this section
have been established for arc and gas welding and cutting. These requirements
will govern the amount of contamination to which welders may be exposed:

(a) Dimensions of the area in which the welding process takes place (with
special regard to height of ceiling).
(b) Number of welders in the room.
(c) Possible development of hazardous fumes, gases, or dust according to
the metals involved.
(d) Location of welder's breathing zone with respect to rising plume of
fumes.
(2) In specific cases, there are other factors involved in which respirator
protective devices (ventilation) should be provided to meet the equivalent
requirements of this section. They include:
(a) Atmospheric conditions.
(b) Generated heat.
(c) Presence of volatile solvents.
(3) In all cases, the required health protection, ventilation standards, and standard
operating procedures for new as well as old welding operations should be
coordinated and cleaned through the safety inspector and the industrial hygienist
having responsibility for the safety and health aspects of the work area.
b. Screened Areas. When welding must be performed in a space entirely screened on all sides,
the screens shall be arranged so that no serious restriction of ventilation exists. It is desirable to
have the screens mounted so that they are about 2.0 ft (0.6 m) above the floor, unless the work is
performed at such a low level that the screen must be extended closer to the floor to protect
workers from the glare of welding. See paragraph 2-2 e (3).
c. Concentration of Toxic Substances. Local exhaust or general ventilating systems shall be
provided and arranged to keep the amount of toxic frees, gas, or dusts below the acceptable
concentrations as set by the American National Standard Institute Standard 7.37; the latest
Threshold Limit Values (TLV) of the American Conference of Governmental Industrial
Hygienists; or the exposure limits as established by Public Law 91-596, Occupational Safety and
Health Act of 1970. Compliance shall be determined by sampling of the atmsphere. Samples
collected shall reflect the exposure of the persons involved. When a helmet is worn, the samples
shall be collected under the helmet.
NOTE
Where welding operations are incidental to general operations, it is considered good practice to
apply local exhaust ventilation to prevent contamination of the general work area.

d. Respiratory Protective Equipment. Individual respiratory protective equipment will be well

retained. Only respiratory protective equipment approved by the US Bureau of Mines, National
Institute of Occupational Safety and Health, or other government-approved testing agency shall
be utilized. Guidance for selection, care, and maintenance of respiratory protective equipment is
given in Practices for Respiratory Protection, American National Standard Institute Standard
788.2 and TB MED 223. Respiratory protective equipment will not be transferred from one
individual to another without being disinfected.
e. Precautionary Labels. A number of potentially hazardous materials are used in flux coatings,
coverings, and filler metals. These materials, when used in welding and cutting operations, will
become hazardous to the welder as they are released into the atmosphere. These include, but are
not limited to, the following materials: fluorine compounds, zinc, lead, beryllium, cadmium, and
mercury. The suppliers of welding materials shall determine the hazard, if any, associated with
the use of their materials in welding, cutting, etc.
(1) All filler metals and fusible granular materials shall carry the following notice,
as a minimum, on tags, boxes, or other containers:
CAUTION
Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and
gases. Use adequate ventilation. See American National Standards Institute Standard Z49.11973, Safety in Welding and Cutting published by the American Welding Society.
(2) Brazing (welding) filler metals containing cadmium in significant amounts
shall carry the following notice on tags, boxes, or other containers:
WARNING
CONTAINS CADMIUM - POISONOUS FUMES MAY BE FORMED ON HEATING
Do not breathe fumes. Use only with adequate ventilation, such as fume collectors, exhaust
ventilators, or air-supplied respirators. See American National Standards Institute Standard
Z49.1-1973. If chest pain, cough, or fever develops after use, call physician immediately.
(3) Brazing and gas welding fluxes containing fluorine compounds shall have a
cautionary wording. One such wording recommended by the American Welding
Society for brazing and gas welding fluxes reads as follows:
CAUTION
CONTAINS FLUORIDES
This flux, when heated, gives off fumes that may irritate eyes, nose, and throat.
Avoid
fumes--use
only
in
well-ventilated
spaces.
Avoid
contact
of
flux
with
eyes
or
skin.
Do not take internally.
f. Ventilation for General Welding and Cutting.

(1) General. Mechanical ventilation shall be provided when welding or cutting is

done on metals not covered in subparagraphs i through p of this section, and
under the following conditions:
(a) In a space of less than 10,000 cu ft (284 cu m) per welder.
(b) In a roan having a ceiling height of less than 16 ft (5 m).
(c) In confined spaces or where the welding space contains partitions,
balconies, or other structural barriers to the extent that they significantly
obstruct cross ventilation.
(2) Minimum rate. Ventilation shall be at the minimum rate of 200 cu ft per
minute (57 cu m) per welder, except where local exhaust heeds, as in paragraph 24 g below, or airline respirators approved by the US Bureau of Mines, National
Institute of Occupational Safety and Health, or other government-approved testing
agency, are used. When welding with rods larger than 3/16 in. (0.48 cm) in
diameter, the ventilation shall be higher as shown in the following:

Rod
(inches)

diameter Required
(cfm)

1/4 (0.64 cm)

3500

3/8 (0.95 cm)

4500

ventilation

Natural ventilation is considered sufficient for welding or cutting operations

where the conditions listed above are not present. Figure 2-5 is an illustration of a
welding booth equipped with mechanical ventilation sufficient for one welder.

g. Local Exhaust Ventilation. Mechanical local exhaust ventilation may be obtained by either of
the following means:
(1) Hoods. Freely movable hoods or ducts are intended to be placed by the welder
as near as practicable to the work being welded. These will provide a rate of
airflow sufficient to maintain a velocity the direction of the hood of 100 in linear
feet per minute in the zone of welding. The ventilation rates required to
accomplish this control velocity using a 3-in. wide flanged suction opening are
listed in table 2-2.

(2) Fixed enclosure. A fixed enclosure with a top and two or more sides which
surrounds the welding or cutting operations will have a rate of airflow sufficient
to maintain a velocity away from the welder of not less than 100 linear ft per

minute. Downdraft ventilation tables require 150 cu ft per minute per square foot
of surface area. This rate of exhausted air shall be uniform across the face of the
grille. A low volume, high-density fume exhaust device attached to the welding
gun collects the fumes as close as possible to the point of origin or at the arc. This
method of fume exhaust has become quite popular for the semiautomatic
processes, particularly the flux-cored arc welding process. Smoke exhaust
systems incorporated in semiautomatic guns provide the most economical exhaust
system since they exhaust much less air they eliminate the need for massive air
makeup units to provide heated or cooled air to replace the air exhausted. Local
ventilation should have a rate of air flow sufficient to maintain a velocity away
from the welder of not less than 100 ft (30 m) per minute. Air velocity is
measurable using a velometer or air flow inter. These two systems can be
extremely difficult to use when welding other than small weldments. The down
draft welding work tables are popular in Europe but are used to a limited degree
North America. In all cases when local ventilation is used, the exhaust air should
be filtered.
h. Ventilation in Confined Spaces.
(1) Air replacement. Ventilation is a perquisite to work in confined spaces. All
welding and cutting operations in confined spaces shall be adequately ventilated
to prevent the accumulation of toxic materials -or possible oxygen deficiency.
This applies not only to the welder but also to helpers and other personnel in the
immediate vicinity.
(2) Airline respirators. In circumstances where it is impossible to provide
adequate ventilation in a confined area, airline respirators or hose masks,
approved by the US Bureau of Mines, National Institute of Occupational Safety
and Health, or other government-approved testing agency, will be used for this
purpose. The air should meet the standards established by Public Law 91-596,
Occupational Safety and Health Act of 1970.
(3) Self-contained units. In areas immediately hazardous to life, hose masks with
blowers or self-contained breathing equipment shall be used. The breathing
equipment shall be approved by the US Bureau of Mines or National Institute of
Occupational Safety and Health, or other government-approved testing agency.
(4) Outside helper. Where welding operations are carried on in confined spaces
and where welders and helpers are provided with hose masks, hose masks with
blowers, or self-contained breathing equipment, a worker shall be stationed on the
outside of such confined spaces to ensure the safety of those working within.
(5) Oxygen for ventilation. Oxygen must never be used for ventilation.

i. Fluorine Compounds.
(1) General. In confined spaces, welding or cutting involving fluxes, coverings, or
other materials which fluorine compounds shall be done in accordance with
paragraph 5.4.4 h, ventilation in confined spaces. A fluorine compound is one that
contains fluorine as an element in chemical combination, not as a free gas.
(2) Maximum allowable concentration. The need for local exhaust ventilation or
airline respirators for welding or cutting in other than confined spaces will depend
upon the individual circumstances. However, experience has shown that such
protection is desirable for fixed-location production welding and for all
production welding on stainless steels. When air samples taken at the welding
location indicate that the fluorides liberated are below the maximum allowable
concentration, such protection is not necessary.
j. Zinc.
(1) Confined spaces. In confined spaces, welding or cutting involving zincbearing filler metals or metals coated with zinc-bearing materials shall be done in
accordance with paragraph 5.4.4 h, ventilation in confined spaces.
(2) Indoors. Indoors, welding or cutting involving zinc-bearing metals or filler
metals coated with zinc-bearing materials shall be done in accordance with
paragraph 5.4.4 g.
k. Lead.
(1) Confined spaces. In confined spaces, welding involving lead-base metals
(erroneously called lead-burning) shall be done in accordance with paragraph
5.4.4 h.
(2) Indoors. Indoors, welding involving lead-base metals shall be done in local
exhaust ventilation.
(3) Local ventilation. In confined spaces or indoors, welding or cutting involving
metals containing lead or metals coated with lead-bearing materials, including
paint, shall be done using local exhaust ventilation or airline respirators.
Outdoors, such operations shall be done using respirator protective equipment
approved by the US Bureau of Mines, National Institute of Occupational Safety
and Health, or other government-approved testing agency. In all cases, workers in
the immediate vicinity of the cutting or welding operation shall be protected as
necessary by local exhaust ventilation or airline respirators.
l. Beryllium. Welding or cutting indoors, outdoors, or in confined spaces involving berylliumbearing material or filler metals will be done using local exhaust ventilation and airline
respirators. This must be performed without exception unless atmospheric tests under the most

adverse conditions have established that the workers' exposure is within the acceptable
concentrations of the latest Threshold Limit Values (TLV) of the American Conference of
Governmental Industrial Hygienists, or the exposure limits established by Public Law 91-596,
Occupational Safety and Health Act of 1970. In all cases, workers in the immediate vicinity of
the welding or cutting operations shall be protected as necessary by local exhaust ventilation or
airline respirators.
m. Cadmium.
(1) General. Welding or cutting indoors or in confined spaces involving cadmiumbearing or cadmium-coated base metals will be done using local exhaust
ventilation or airline respirators. Outdoors, such operations shall be done using
respiratory protective equipment such as fume respirators, approved by the US
Bureau of Mines, National Institute of Occupational Safety and Health, or other
government-approved testing agency, for such purposes.
(2) Confined space. Welding (brazing) involving cadmium-bearing filler metals
shall be done using ventilation as prescribed in paragraphs 2-4 g, local exhaust
ventilation, and 2-4 h, ventilation in confined spaces, if the work is to be done in a
confined space.
NOTE
Cadmium-free rods are available and can be used in most instances with satisfactory results.
n. Mercury. Welding or cutting indoors or in a confined space involving metals coated with
mercury-bearing materials, including paint, shall be done using local exhaust ventilation or
airline respirators. Outdoors, such operations will be done using respiratory protective equipment
approved by the National Institute of Occupational Safety and Health, US Bureau of Mines, or
other government-approved testing agency.
o. Cleaning Compounds.
(1) Manufacturer's instructions. In the use of cleaning materials, because of their
toxicity of flammability, appropriate precautions listed in the manufacturer's
instructions will be followed.
(2) Degreasing. Degreasing or other cleaning operations involving chlorinated
hydrocarbons will be located so that no vapors from these operations will reach or
be drawn into the area surrounding any welding operation. In addition,
trichloroethylene and perchloroethylene should be kept out of atmospheres
penetrated by the ultraviolet radiation of gas-shielded welding operations.
p. Cutting of Stainless Steels. Oxygen cutting, using either a chemical flux or iron powder, or
gas-shielded arc cutting of stainless steel will be done using mechanical ventilation adequate to
remove the fumes generated.

q. First-Aid Equipment. First-aid equipment will be available at all times. On every shift of
welding operations, there will be personnel present who are trained to render first-aid. All
injuries will be reported as soon as possible for medical attention. First-aid will be rendered until
medical attention can be provided.

5.4.5 WELDING IN CONFINED SPACES

a. A confined space is intended to mean a relatively small or restricted space such as a tank,
boiler, pressure vessel, or small compartment of a ship or tank.
b. When welding or cutting is being performed in any confined space, the gas cylinders and
welding machines shall be left on the outside. Before operations are started, heavy portable
equipment mounted on wheels shall be securely blocked to prevent accidental movement.
c. Where a welder must enter a confined space through a manhole or other all opening, means
will be provided for quickly removing him in case of emergency. When safety belts and life lines
are used for this purpose, they will be attached to the welder's body so that he cannot be jammed
in a small exit opening. An attendant with a preplanned rescue procedure will be stationed
outside to observe the welder at all times and be capable of putting rescue operations into effect.
d. When arc welding is suspended for any substantial period of time, such as during lunch or
overnight, all electrodes will be removed from the holders with the holders carefully located so
that accidental contact cannot occur. The welding machines will be disconnected from the power
source.
e. In order to eliminate the possibility of gas escaping through leaks or improperly closed valves
when gas welding or cutting, the gas and oxygen supply valves will be closed, the regulators
released, the gas and oxygen lines bled, and the valves on the torch shut off when the equipment
will not be used for a substantial period of time. Where practical, the torch and hose will also be
removed from the confined space.
f. After welding operations are completed, the welder will mark the hot metal or provide some
other means of warning other workers.

Safety is a critical consideration for any welding project. Arc welding is a safe occupation when
proper precautions are taken. But, if safety measures are ignored, welders face an array of
hazards which can be potentially dangerous, including electric shock, fumes and gases, fire and
explosions
and
more.

Welding operators face an array of hazards, including electric shock, fumes and gases, fire and
more.
To help keep welders safe, organizations such as the American Conference of Governmental
Industrial Hygienists (ACGIH) and the Occupational Safety and Health Administration (OSHA)
offer safety guidelines to help control, minimize or to help employers and workers avoid welding
hazards. Employers should ensure all workers have an opportunity to comply with the following
important guidelines in the workplace:
Read
and
understand
manufacturer
Carefully
review
material
Follow the companys internal safety practices

instructions
safety

for
data

equipment
sheets

Awareness of the most common welding hazards and knowing how to avoid them ensures a safe,
productive work environment for all.
Electric
shock
Electric shock is one of the most serious and immediate risks facing a welder. Electric shock can
lead to severe injury or death, either from the shock itself or from a fall caused by the reaction to
a shock.
Electric shock occurs when welders touch two metal objects that have a voltage between them,
thereby inserting themselves into the electrical circuit. For instance, if a worker holds a bare wire

in one hand and a second bare wire with another, electric current will pass through that wire and
through the welding operator, causing an electric shock. The higher the voltage, the higher the
current and, thus the higher the risk for the electric shock to result in injury or death.
The most common type of electric shock is secondary voltage shock from an arc welding circuit,
which ranges from 20 to 100 volts. Bear in mind that even a shock of 50 volts or less can be
enough to injure or kill an operator, depending on the conditions. Due to its constant change in
polarity, alternating current (AC) voltage is more likely to stop the heart than direct current (DC)
welders. It is also more likely to make the person holding the wire unable to let go.

Its important to remember to never touch the electrode or metal parts of the electrode holder
with skin or welding clothing and insulate yourself from the work and ground.
To avoid secondary voltage shock, welding operators should wear dry gloves in good condition,
never touch the electrode or metal parts of the electrode holder with skin or wet clothing and be
sure to insulate themselves from the work and ground, keeping dry insulation between their body
and the metal being welded or ground (such as a metal floor or wet surface).
Welding operators also should inspect the electrode holder for damage before beginning to weld
and keep the welding cable and electrode holder insulation in good condition, because the plastic
or fiber insulation on the electrode holder prevents contact with the electrically hot metal parts
inside. Always be sure to repair or replace damaged insulation before use. And remember, stick
electrodes are always electrically hot, even when welding is not being done and the voltage is the
highest.
An even more serious shock, primary voltage shock, may occur when a welder touches
electrically hot parts inside the welder case or the electric distribution system to which the
welder is connected. This action can lead to a shock of 230 or 460 volts.
When not in use, but still turned on, most welding equipment have a voltage that ranges from 20

to 100 volts at the welding circuit and voltages inside the welding equipment may range from
120 volts to more than 575 volts, all of which pose a risk for electric shock. Only qualified
repair technicians should attempt to service or repair welding equipment.
Fumes and gases
Its no surprise that overexposure to welding fumes and gases can be hazardous to your health.
Welding fume contains potentially harmful complex metal oxide compounds from consumables,
base metal and the base-metal coatings, so its important to keep your head out of the fumes and
use enough ventilation and/or exhaust to control your exposure to substances in the fume,
depending on the type of rod and base metal being used.
The specific potential health effects which relate to the welding consumable product being used
can be found in the Health Hazard Data section of the Safety Data Sheet available from your
employer or the consumable manufacturer.

Welding areas require adequate ventilation and local exhaust to keep fumes and gases from the
breathing zone and the general area. In most situations, employers will provide a ventilation
system- such as a fan, and an exhaust system or fixed or removable exhaust hoods- to remove
fumes
and
gases
from
the
work
area.

Welding areas require adequate ventilation and local exhaust to keep fumes and gases from the
breathing zone and the general area.
All welding operators should be aware that there are ACGIH threshold limit values (TLV) and
OSHA permissible exposure limits (PEL) for the substances in welding fume. These limits
specify the amount of a substance in your breathing air to which welding operators can be
exposed every day they work over the course of their career. Welding operators should wear an
approved respirator unless exposure assessments are below applicable exposure limits. An

industrial hygienist takes an air sample in the workers breathing zone to determine whether a
workers exposure is below the exposure limits.
If the air in your breathing zone is not clear, or if breathing is uncomfortable, check to be sure the
ventilation equipment is working and report concerns to a supervisor so your exposure to
substances in the welding fume can be checked. This is especially important when welding with
stainless steel or hardfacing products. To prevent exposure from coatings such as paint,
galvanizing, or metal platings on base metals, clean the base metal before beginning to weld. See
a doctor if symptoms from overexposure persist.
Fire
and
explosions
The welding arc creates extreme temperatures, and may pose a significant fire and explosions
hazard if safe practices are not followed. While the welding arc may reach temperatures of
10,000 degrees Fahrenheit, the real danger is not from the arc itself, but rather the intense near
the arc and the heat, sparks and spatter created by the arc. This spatter can reach up to 35 feet
away from the welding space.
To prevent fires, before beginning to weld, inspect the work area for any flammable materials
and remove them from the area. Flammable materials are comprised of three categories: liquid,
such as gasoline, oil and paint; solid, such as wood, cardboard and paper; gas, including
acetylene,
propane
and
hydrogen.

Fume Exhaust systems can be augmented with a fire safety solution system like the Lincoln
Electric Guardian system, designed to aid fire prevention, detection and suppression within the
fume control system.

Know where the fire alarms and extinguishers are located, and check the extinguishers gauge to
make sure it is full. If an extinguisher is not available, be sure to have access to fire hoses, sand
buckets or other equipment that douses fire. And, know the location of the nearest fire exit.
If welding within 35 feet of flammable materials, have a fire watcher nearby to keep track of
sparks, and remain in the work area for at least 30 minutes after finishing welding to be sure
there are no smoldering fires. Put a fire resistant material, such as a piece of sheet metal or fire
resistant blanket, over any flammable materials within the work area, if you cant remove them.
In an elevated location, make sure no flammable materials are beneath you, and watch out for
other workers below you in order to prevent dropping sparks or spatter on them. Even high
concentrations of fine dust particles may cause explosions or flash fires. If a fire starts, dont
panic and call the fire department immediately.
Injuries
from
insufficient
PPE
Personal protective equipment (PPE) helps keep welding operators free from injury, such as
burns the most common welding injury and exposure to arc rays. The right PPE allows for
freedom of movement while still providing adequate protection from welding hazards.
Thanks to their durability and fire resistance, leather and flame-resistant treated cotton clothing is
recommended in welding environments. This is because synthetic material such as polyester or
rayon will melt when exposed to extreme heat. Welding leathers are especially recommended
when welding out of position, such as applications that require vertical or overhead welding.

Personal protective equipment (PPE) helps keep welding operators free from injury, such as
burns the most common welding injury and exposure to arc rays.
Avoid rolling up sleeves or pant cuffs, as sparks or hot metal will deposit in the folds and may
burn through the material. Keep pants over the top of work boots dont tuck them in. Even
when wearing a helmet, always wear safety glasses with side shields or goggles to prevent sparks
or other debris from hitting the eyes. Leather boots with 6-to-8-inch ankle coverage are the best

foot protection; metatarsal guards over the shoe laces can protect feet from falling objects and
sparks. It will not be pleasant if a hot piece of spatter finds its way inside your clothing or shoes.
Heavy, flame-resistant gloves should always be worn to protect from burns, cuts and scratches.
As long as they are dry, they also should provide some protection from electric shock. Leather is
a good choice for gloves.
Helmets with side shields are essential for protecting eyes and skin from exposure to arc rays.
Make sure to choose the right shade lens for your process use the helmets instructions to help
select the right shade level. Begin with a darker filter lens and gradually change to a lighter shade
until you have good visibility at the puddle and weld joint but it is comfortable and does not
irritate your eyes. Helmets also protect from sparks, heat and electric shock. Welders flash from
improper eye protection may cause extreme discomfort, swelling or temporary blindness, so
dont take any risks wear a helmet at all times during welding.
To protect ears from noise, wear hearing protection if working in an area with high noise levels.
Doing so will protect your hearing from damage, as well as well prevent metal and other debris
from entering the ear canal. Choose ear plugs or ear muffs to protect the ears.
Other
safety
considerations
Welders should also be aware of other safety considerations within the work environment. For
example, those working in a confined space or in an elevated area make need to take extra
precautions. In any welding situation, welding operators should pay close attention safety
information on the products being used and the material safety data sheets provided by the
manufacturer and work with their employer and co-workers to follow appropriate safe practices
for their workplace.
Good common sense is also key. If opening cans of electrode, keep hands away from sharp
edges. Remove clutter and debris from the welding area to prevent tripping or falling. And never
use broken or damaged equipment or PPE. To keep up with the most recent safety practices,
welding operators should utilize resources from the American Welding Society (AWS), OSHA
and welding manufacturers, such as Lincoln Electrics online Interactive Safety Guide. By
following these safe practices and using common sense, operators can stay safe and keep
production moving with no lost-time accidents.

5.5 Risk Assessment Procedure

a. Existing equipment that cannot feasibly meet all General Equipment Requirements must be
reviewed for hazards and controls using a risk assessment procedure to identify the most
appropriate hazard mitigation strategy.
b. A team of Line Organization personnel including at least one worker representative must
evaluate the use of the machine, predictable hazards and available controls. This evaluation must
be documented on the Machine Risk Assessment (MRA) Form.
c. The completed Machine Risk Assessment Form must be signed by the Line Organization
Chair or equivalent accepting residual risk for the organization that operates the machine tool.
d. The signed Machine Risk Assessment must be forwarded to the Machine Shop Safety Subject
Matter Expert (SME) for concurrence.
e. All identified alternative controls must be in place and the Machine Risk Assessment with
SME concurrence must be posted at the machine location prior to operation of equipment that
cannot be feasibly brought into compliance with the General Equipment Requirements.
f. The posted Machine Risk Assessment must remain in place for six months following approval
to allow for comments to be submitted to the Machine Shop Safety Subject Matter Expert.
g. The Line Organization must retain the Machine Risk Assessment until the machine is
permanently removed from service or brought into compliance with the General Equipment
Requirements.
h. Modifications which impact the safety of the machine or change existing controls must
include a review of the Machine Risk Assessment.
To create a safer working environment for employees (as required by OSHA)
To reduce costs
To comply with national and international consensus standards, including:
ANSI B11.0-2010 Safety of Machinery General Requirements and Risk Assessment
ANSI B11.TR3-2000 Risk Assessment and Risk Reduction A Guide to Estimate, Evaluate
and Reduce Risks Associated with Machine Tools
ANSI/RIA R15.06-1999 (R2009) For Industrial Robots and Robot Systems Safety
Requirements
NFPA 79-2012 Electrical Standard for Industrial Machinery
ANSI/ASSE Z244.1-2003 (R2008) Control of Hazardous Energy Lockout/Tagout and
Alternative Methods
ANSI/PMMI B155.1-2011 Standard for Packaging Machinery and Packaging-Related
Converting Machinery Safety Requirements
SEMI S10-0307 Safety Guideline for Risk Assessment and Risk Evaluation Process
MIL-STD-882D-2000 Standard Practice for System Safety

CSA Z432-04 Safeguarding of Machinery Occupational Health and Safety

CSA Z434-03 Industrial Robots and Robot Systems General Safety Requirements
CSA Z460-05 Control of Hazardous Energy Lockout and Other Methods
NOM-004-STPS-1999 Protection Systems and Safety Devices for Machinery and Equipment
Used in the Workplace
ISO 12100:2010 Safety of machinery General principles for design Risk assessment and
risk reduction
EN 954-1:2000 / ISO 13849-1:1999 Safety of machinery Safety-related parts of control
systems Part 1: General principles of design
ISO 13849-1:2006 Safety of machinery Safety-related parts of control systems Part 1:
General principles of design
2006/42/EC European Machinery Directive
Assumptions
The risk assessment process includes identifying hazards regardless of the existence of risk
reduction (safeguarding) measures.
The machine should not be considered harmless as shipped and guarded.
To assure that all hazards are included, hazard identification should be conducted with all
safeguards conceptually removed.
This is to assure that hazards are not ignored due to an assumption that the safeguard supplied
is adequate for all tasks, including reasonably foreseeable misuse.
Existing safeguards that help meet the risk reduction objectives can be retained after evaluating
their performance.
This decision will be confirmed during the validation/verification portion of the risk
assessment.
Identify the Risk Level and Required Level of Risk Reduction
There are several recognized methods to identify (label) risk levels
ANSI, RIA, CSA, EN, ISO
Choose the method which is easiest and most practical to apply at your location
Risks must be aligned to a risk reduction category that incorporates the selection of
safeguarding devices and safety-related parts of the control system

ANSI B11.TR3
7.2 Severity of harm
Severity of harm addresses the degree of injury or illness that could occur. The degrees are
based on extent of injury or illness (from death to no injury), and extent of treatment involved.
The following is an example of severity levels:
Catastrophic death or permanently disabling injury or illness (unable to return to work)
Serious severe debilitating injury or illness (able to return to work at some point)
Moderate significant injury or illness requiring more than first aid (able to return to same job)
Minor no injury or slight injury requiring no more than first aid (little or no lost work time)
When determining risk, the worst credible severity of harm is to be selected.
7.3 Probability of occurrence of harm
Probability of occurrence of harm is estimated by taking into account the frequency, duration
and extent of exposure, training and awareness, and the presentation of the hazard. The following
is an example of probability levels:
Very likely near certain to occur
Likely may occur
Unlikely not likely to occur
Remote so unlikely as to be near zero
When estimating probability, the highest credible level of probability is to be selected.

 R1 Risk reduction shall be accomplished by hazard elimination or hazard substitution which

does not create an equal or greater hazard. When hazard elimination or substitution is not
possible, all provisions of a category R2 risk reduction shall apply and provisions of categories
R3 and R4 shall be provided for safeguarding residual risk.
R2 Safeguarding shall be by means that prevent access to the hazard, or cause the hazard to
cease. Provisions of categories R3 and R4 may be used for safeguarding residual risk.
R3 Safeguarding, at a minimum, shall be by means of non-interlocked barriers, clearance from
the hazard, written procedures, and personal protective equipment if applicable. Provisions of
Category R4 may also be used for safeguarding residual risk.
R4 Safeguarding, at a minimum, shall be by administrative means, awareness means including
audio/visual warnings and training.

EN 1050 / ISO 14121

S: Severity of Potential injury
S1: Slight injury(minor cuts or bruises, requires first-aid)
S2: Severe injury(broken bone, loss of limb or death)
F: Frequency of exposure to potential hazard
F1: Infrequent exposure
F2: Frequent to continuous exposure
P: Possibility of avoiding the hazard as it occurs (generally related to the speed / frequency of
movement of the hazard and distance to the hazard point)
P1: Possible
P2: Less possible
L: Likelihood of occurrence (in event of a failure)
L1: Very likely
L2: Unlikely
L3: Highly unlikely

Ref No:

MACHINERY RISK ASSESSMENT FORM

Machine Type (inc model):

Type of activity:

Location of activity:

Assessed by:

Endorsed by :

Assessment
Date:

Review date:

Description of machinery use (Give sufficient detail so that it is clear as to the range of uses
and the environment in which the machinery is used e.g. occupancy, access (slips, obstructions,
space), distractions, hot work causing fire to wood dust in close proximity)

Hazard details
Mechanical
Description and potential
Hazards
for harm
Examples
Crushing
Shearing
Drawing-in
Cutting
Entanglement
Impact
Abrasion
Stabbing
Puncture

Non-mechanical
Hazards
(Link to other Risk
Assessments)
Examples
Temperature (high or
low)
Electrical
Noise
Vibration
Dust
Pressure
Waste
Fumes
Chemicals

Description and potential

for harm

Ref No:

Ejection
Allergens
Exposure (duration/frequency of use) e.g. 10mins/daily, 3 hours/monthly

Users:
Competency, inexperience, those persons at increased risk of harm (disabled, pregnancy)

Outline the control measures for the use of the machinery i.e. Engineering controls e.g.
guarding: fixed guards, adjustable guards, protections devices e.g. photoelectric or appliances
e.g. jigs, pushsticks, holders or markings/warnings, limiting persons in the area

Outline the procedural and behavioural control measures for the use of the machinery i.e.
PPE, inspection, restrictions, safe systems of work, information, training, instruction, supervision.

Overall assessment of the risk posed by this machine type with existing control measures
Risk Level (Tick)
Low
Actions required to reduce the risk
Action
By Who

Medium

High
By When

Action Completed

Overall assessment of the risk posed by this machine type with additional control measures
Risk Level (Tick)

Low

Medium

High

ACTION LEVEL: (To identify what action needs to be taken).

Risk Level:
Low
Medium
High

Action:
No further action required. However, continue to monitor the machinery and
work activity.
Additional actions and controls must be implemented to ensure the machinery
can be used safely.
Machinery cannot be used until the risk level has been reduced to a satisfactory
level. Further controls must be implemented.

5.6 Procurement, Inspection, and Service Requirements

This section provides the requirements for procuring, inspecting, and servicing machine tools.
Procuring machine tools and components
a. Procure new machine tools and components for modifications and repairs other than like-inkind replacements.
b. Coordinate a review of requested equipment or components with the Machine Shop Safety
Subject Matter Expert (SME) to ensure that the requirements are met.
Inspecting machine tools in machine shops
a. Maintenance and servicing activities that expose personnel to hazardous energy or dangerous
machine movement must be conducted in accordance with the Lockout/Tagout (LOTO) for
Installation, Demolition, or Service and Maintenance Subject Area and applicable departmental
procedures.
b. When the devices are located out of visual sight from the control panel, such as behind an
opaque wall, energy control procedures, Lockout/Tagout (LOTO) must be used whenever
employees enter the machines danger zone with the exception of activities described below with
alternative controls in place.
c. Minor tool (including blade and abrasive wheel) changes and adjustments, and other minor
servicing activities, which take place during normal production operations, if they are routine,
repetitive, and integral to the use of the equipment for production (as often can be the case with
respect to activities like changing a tool bit on a milling machine or a drill bit on a drill press)
may be performed using local disconnects or control switches that are:
d. Placed in an "OFF" position;

e. Provide effective employee protection through proper design and application; and
f. Are under the exclusive control of the employee performing the task.
Note: In all other situations in which employees are performing servicing and maintenance
activities and may be exposed to hazardous energy, LOTO must be performed to protect
employees from hazardous energy.
Inspecting new or repaired machine tools in machine shops
a. New and relocated machine tools must be inspected by the Line Organization Machine Shop
Supervisor prior to being placed in service. The Machine Shop Safety SME must be notified of
all installations or relocations of machines prior to placing them into service.
b. Completed modifications to machine tools other than like-in-kind replacements or
maintenance activities must be inspected by the line organization Machine Shop Supervisor and
Machine Shop Safety SME prior to being returned to service.
Existing Operator's or Owner's Manuals for machine tools will be made available to the
operators and service mechanics. Operators will operate machine tools in accordance with these
manuals and best practices.
Maintenance procedures, including the schedule for performing that maintenance, must be
developed and documented for each machine tool. These procedures must be prepared using the
recommendations of the manufacturer and best practices for similar machines.
Perform maintenance consistent with these procedures.
Pre-use Inspections
This section provides the requirements for inspection of machine tools to ensure that equipment
can be operated safely.
Before operating a specific machine for the first time that day, each authorized user must conduct
a pre-use inspection and completely review the machine to ensure that safe operation of the
equipment can be performed. The operator should utilize the available machine operator aid to
identify critical inspection points and settings. Operator aids must identify existing controls that
address predominant hazards of machine use.
Note: For operator reference, it is adequate to have the laminated/protected operator aid on or near the machine.
Note: Machine operator aid templates for many machine types are available on the ESH
Guide: Machine Shop Safety and may be adapted to be machine specific.

If any deficiencies are noted during the pre-use inspection, the operator must not use the
machine. The operator must bring the deficiencies to the attention of the Machine Shop
Supervisor, their direct supervisor, or ES&H Coordinator. The machine must be removed from
service (see the see the Lockout/Tagout [LOTO] for Installation, Demolition, or Service and
Maintenance Subject Area) for deficiencies which prevent safe operation of the machine and
may not be used until the deficiency is corrected.

Monthly Machine Shop Inspections

This section provides the requirements for monthly inspection of the machine shop area to ensure
that new hazards have not been introduced, controls are satisfactory for known hazards and that
equipment is in good repair and safe condition.
The Machine Shop Supervisor completes the Monthly Machine Shop Inspection Checklist,
whether or not the shop is being used, unless there is a preventive maintenance program in place.
This checklist may be conducted in conjunction with the Tier I inspection. Copies of the
checklists will be retained by the Department Chair/Division Manager or designee for a period of
two years.
Note: Isolated machine tools may be grouped for inspection purposes if locations are indicated on the inspection
form.

All deficiencies identified during the monthly machine shop inspection must be brought to the
attention of the ES&H Coordinator and Machine Shop Subject Matter Expert for correction.
The machine must be removed from service (see the Lockout/Tagout [LOTO] for Installation,
Demolition, or Service and Maintenance Subject Area) for deficiencies which prevent safe
operation of the machine and may not be used until the deficiency is corrected.

5.7 Electrical Hazards

This section provides the possible hazards caused by electrical equipment and electricity in
general. Electric shocks and/or serious burns may be caused from using faulty electrical
equipment.
General instructions include:

All portable electrical equipment must be tested at for electrical safety at correct intervals
and labelled with the date of the test.
Electrical cables and plugs should be regularly visually inspected by the user for
damage.
Any defective equipment should be reported to the technician-in-charge and taken out of
use until the repair has been effected.
Electrical equipment must always be operated in accordance with manufacturers'
instructions.

What are the risks from electricity?

Harm can be caused to any person when they are exposed to live parts that are either touched
directly or indirectly by means of some conducting object. Voltages over 50 volts AC or 120
volts DC are considered hazardous.

Electricity can kill. Each year about 1000 accidents at work involving electric shocks or burns
are reported to the Health and Safety Executive (HSE). Around 30 of these are fatal, most of
them arising from contact with overhead or underground power cables.
Shocks and burns from faulty equipment can cause severe and permanent injury and can also
lead to indirect injuries, due to falls from ladders, scaffolds, or other work platforms.
Faulty electrical appliances can also lead to fires. As well as causing injuries and/or loss of life,
fires cause damage to equipment and property.

Who is most at risk from electricity?

Anyone can be exposed to the dangers of electricity while at work in the workshop and everyone
should be made aware of the dangers.
Those most at risk include maintenance staff and those working with equipment and machinery.
Most electrical accidents occur because individuals:

are working on or near equipment which is thought to be dead but which is, in fact, live
are working on or near equipment which is known to be live, but where those involved
are without adequate training or appropriate equipment, or they have not taken adequate
precautions
misuse equipment or use electrical equipment which they know to be faulty.

Arc Flash Hazard Analysis

An estimated 75 to 80 percent of all serious electrical injures are related to electrical arcs created
during short circuits, ground faults, and switching procedures. In recognition of this fact,
standards organizations such as the National Fire Protection Association (NFPA) have provided
the industry with better techniques to evaluate both the magnitude of the electrical arc hazard and
appropriate protective clothing.
The principal factors used to determine the arc-flash hazard to personnel are as follows:
1. Available short circuit current at the arc location

2. Duration of the electrical arc

3. Distance from the arc to personnel
4. The arc gap
To accurately assess the arc hazard and make appropriate decisions regarding personal protective
clothing, it is necessary to fully understand the operation of the system under fault conditions.
This requires both a short circuit analysis, in all likelihood down to the panel board level, and a
protective devices coordination study.
It is a common misconception that arc hazards are an effect of only high voltage. The actual arc
hazard is based on available energy, not available voltage. In certain conditions, a low-voltage
arcs duration is longer than one of a high-voltage arc. With this information available, the
magnitude of the arc hazard at each work location can be assessed using several techniques.
These techniques include:

NFPA 70E, Standard for Electrical Safety in the Workplace

IEEE Standard 1584, IEEE Guide for Performing Arc-Flash Hazard Calculations

Each of these techniques requires an understanding of anticipated fault conditions and the
limitation of the calculation method, both of which are beyond the scope of this article.
The results of the arc-flash hazard analysis are most useful when they are expressed in terms of
the incident energy received by exposed personnel. Incident energy is commonly expressed in
terms of calories per cm2 (cal/cm2). Arc protective clothing is rated in terms of its Average
Thermal Performance Value (ATPV), also expressed in terms of cal/cm2.
In addition to protective clothing, there are some safe work practices that can be adopted to
minimize or eliminate the hazards. These practices include clothing, body positioning, and
insulated tools. Line clearance procedures and other factors must be carefully scrutinized to
ensure the risk to employees is minimized.

Legal duties and obligations around electricity

As well as a moral duty on employers to protect employees and members of the public, General
Health and Safety Legislation covers all employers and workplaces. It is imperative that they:

have the electrical systems constructed in a way that prevents danger

maintain their electrical systems as necessary to prevent danger

have work on, use of, or closure of, electrical systems carried out in a way that prevents
danger.
Additionally:

electrical equipment used in hazardous environments (e.g. extremes of weather,

temperature, corrosive conditions) must be constructed or protected to prevent it becoming
dangerous

only those with adequate knowledge or experience, or who are under adequate
supervision should work with, or on, electrical equipment that could cause danger or injury.
The reporting of certain incidents, including those involving electricity, in places of work is
obligatory.
The following incidents must be reported:

injury to staff due to an electric shock or electrical burn leading to unconsciousness or

requiring resuscitation; or admittance to hospital

electrical short circuit or overload causing fire or explosion

plant or equipment coming into contact with overhead power lines.

Assessing the risks from electricity

Consider the following hazards in your risk assessment:
Live parts Normal mains voltage, 230 volts AC, can kill. Also, contact with live parts can cause
shocks and burns.

Fire Electrical faults can cause fires. This is particularly true where the equipment contains a
heat source (e.g. heaters, including water heaters, washing machines, ovens, heat-seal packaging
equipment).
Flammable or explosive atmospheres Electricity can be a source of ignition in a potentially
flammable or explosive atmosphere, e.g. in spray paint booths or around refuelling areas.
Where and how electricity is used The risks from electricity are greatest in harsh conditions.
In wet conditions, unsuitable equipment can easily become live and can make its surroundings
live.
While outdoors, equipment may not only become wet but may be at greater risk of damage.
In cramped or confined spaces with a lot of earthed metalwork, such as inside tanks, ducts and
silos, if an electrical fault develops it can be very difficult to avoid a shock.
Types of equipment in use Some items of equipment can also involve greater risk than
others. Extension leads are particularly liable to damage to their plugs and sockets, cables, and
electrical connections. Other flexible leads, particularly those connected to equipment that is
moved a great deal, can suffer from similar problems.

Basic electrical safety

Below are some minimum steps you should take to ensure electrical safety.
Mains supplies

install new electrical systems up to date to countrys requirements for Electrical

Installations

maintain all electrical installations in good working order

provide enough socket-outlets for equipment in use

avoid overloading socket-outlets using adaptors can cause fires

provide an accessible and clearly identified switch ('Emergency Off' or 'EMO' button)
near fixed machinery to cut off power in an emergency

for portable equipment, connect to nearby socket-outlets so that it can be easily

disconnected in an emergency.
Use the right equipment

choose electrical equipment that is suitable for its working environment

ensure that equipment is safe when supplied and maintain it in a safe condition

electrical equipment used in flammable/explosive atmospheres should be designed not to

produce sparks. Seek specialist advice when choosing this type of equipment.

protect light bulbs and other easily damaged equipment there is a risk of electric shock
if they are broken.
Maintenance and repairs

ensure equipment is fitted with the correctly rated fuse for the circuit.
ensure cable ends always have their outer sheaths firmly clamped to stop wires working
loose from plugs or inside equipment

replace damaged sections of cable completely never repair cuts with insulating tape.

use proper connectors to join lengths of cable don't use connector blocks covered in
insulating tape or 'splice' wires by twisting them together

some equipment is double insulated. These are often marked with a double-square
symbol. The supply leads have only two wires live (brown) and neutral (blue)

make sure all wires are connected securely if the 13A plug is not a moulded-on type.

Good practices:
Use other forms of power where possible Electrical risks can sometimes be eliminated by using
air, hydraulic or hand-powered tools. These are especially useful in harsh conditions, but
remember they could introduce other hazards.
Reduce the voltage Using lower voltages can reduce or eliminate the risks of electric shocks and
burns:

portable tools are available which can be run from a 110 volts, centre-tapped-to-earth
supply, (usually from a transformer).

where electrically powered tools are used, battery-operated are safest.

temporary lighting can be run at lower voltages, e.g. 12, 25, 50 or 110 volts.

Use Residual Current Devices (RCDs) for extra safety An RCD can provide additional safety.
An RCD detects some (but not all) faults in the electrical system and rapidly switches off the
supply.
The best place for an RCD is built into the main supply or the socket-outlet, as this means that
the supply cables are permanently protected.
If this is not possible, use a plug incorporating an RCD or a plug-in RCD adaptor. RCDs for
protecting people have a rated tripping current (sensitivity) of not more than 30 milliamps (mA).
Remember:

an RCD is a valuable safety device never bypass it

if the RCD trips, it is a sign there is a fault. Check the system before using it again.

if the RCD trips frequently and no fault can be found in the system, consult the
manufacturer of the RCD

use the RCD test button regularly (iff possible, monthly) to check that its mechanism is
free and functioning.

Maintain your electrical equipment and installations All electrical equipment and
installations should be maintained to prevent danger. This should include an appropriate system
of formal visual inspection, and where necessary, testing.
Most faults can usually be identified by an informal visual inspection. It is important that before
an item is used a check is made on the plug, cable, cable-entry or input socket and the casing of
the equipment.
If a fault is identified, the item should be removed from use and repaired before being used
again. Staff should be trained to carry out these simple visual checks.

There should also be a system where formal visual inspections are carried out and recorded,
backed up by a system of Portable Appliance Testing (PAT) where appropriate.
There is a misconception that this testing should be carried out annually, but the legislation
requires employers to decide on the frequency of testing based on their risk assessment.
Factors to consider include:

type of equipment

where equipment is used

is equipment portable or transportable?

is it used in a harsh environment?

Fixed installations should also be inspected and tested periodically by a competent person/team.
Records of the results of inspection and testing can be useful in assessing the effectiveness of the
system.
Work safely Make sure that people working with electricity are competent to do the job. Even
simple tasks such as wiring a plug can lead to danger - ensure that people know what they are
doing before they start.
Make sure that:

suspect or faulty equipment is taken out of use immediately

suspect or faulty equipment is labelled DO NOT USE

suspect or faulty equipment is kept secure until examined by a competent person

where possible, tools and power socket-outlets are switched off before plugging in or
unplugging

equipment is switched off and/or unplugged before cleaning or making adjustments

where possible, all electrical appliances are switched off at the mains at the end of the
working day.
More complicated tasks, such as equipment repairs or alterations to an electrical installation,
should only be tackled by people with knowledge of the risks and the precautions needed.

Work on exposed live parts of equipment and systems must not be carried out unless it is
absolutely unavoidable and suitable precautions have been taken to prevent injury, both to the
workers and to anyone else who may be in the area.

Underground and overhead electrical supplies

Always assume supplies are live unless it is confirmed otherwise by a competent person or utility
company. Use plans and cable-avoiding tools to locate cables. Have overhead lines switched off
if possible or maintain safe distances from the lines for plant and equipment.
Labelling Make sure that all electrical equipment is labelled accordingly. High Voltages should
always be indicated. Non-competent personnel should always be aware of electrical dangers by
an appropriate label. Warning signs, FORBIDDEN TO OPERATE or DO NOT USE labels
should always be placed on faulty equipment. (see examples below)

6. Epilogue conclusions
KEY CONCLUSIONS AND RECOMMENDATIONS
To permit effective examination of the relationship between health and employment and workrelated factors among older workers it is necessary to create new, longitudinal data sets
containing detailed information on workers employment histories and the specific demands of
the job, as well as objective information on the health and safety risks to workers in the job. Such
data sets do not currently exist because they are costly to create.
An ideal longitudinal data set would contain baseline information on the health status and
previous work histories of a representative sample of older workers-employees, with
overrepresentation of minority and other high-risk groups. The survey that collects these data
would periodically gather from respondents and their employers data that provide researchers
with consistent, reliable, and continuous information on respondents employment and earnings,
the risk factors associated with employment, including work organization and job demands on
physical and mental capacity, and exposure to risk factors such as harmful chemicals. These data
are needed to follow work and retirement patterns in aging cohorts of workers and to assess the
effects of work on health. These data are also needed to assess the effects of health, workplace
health risks, family obligations, and other causal factors on employment in later life.
Creating an ideal data set would be very costly, but it may represent the only strategy likely to
produce sufficient data to elucidate completely the relationship between workplace risk factors
and workers health and employment patterns in later life. A more limited and less expensive
alternative is to modify existing longitudinal and no longitudinal surveys so they contain crucial
information about workplace health risks. Another alternative is to collect information on a
convenience sample for which longitudinal record gathering is less costly in contrast to a
nationally representative, random sample with periodic in-person or telephone survey updates.
One possibility is to conduct thorough baseline interviews in a cohort of workers and recent
retirees from a large national employer, such as the government. Personnel and other
administrative records and less frequent in-person interviews would be used to construct lifetime
work histories and measure subsequent employment and retirement patterns in the cohort. The
size of the government workforce would also permit targeted sampling for better assessment of
demographic subgroups. It would likely, however, exclude the possibility of assessing a full
range of occupations.

7. Bibliography References

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ANSI B11.12 Safety Requirements for Roll Forming & Roll Bending Machines
Oregon OSHA Division 2/Subdivision O 29 CFR 1910.212 General Requirements for All
Machines
ANSI B11.8 Drilling, Milling, and Boring Machines
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HSE Engineering Information Sheet #2 Accidents at metalworking lathes using emery
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ANSI B11.10 Metal Sawing Machines
Oregon OSHA Division 2/Subdivision O 29 CFR 1910.215
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Oregon OSHA Division 4/Subdivision O OAR 437-004-2100
ANSI B7.1 Safety Code for the Use, Care, and Protection of Abrasive Wheels
ANSI B11.9 Safety Requirements for Grinding Machines
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www.healthyworkinglives.com
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