CH 3.

Hazards and Emergencies

 Introduction (1 of 3)

• Occupational safety and health is very important

to ensure everyone can work without being
injured.
• Governments have legislation with significant
penalties for those who do not follow safe
practices in the workplace.
 Introduction (2 of 3)

• Some hazards are obvious.

• Some hazards are less obvious.
• Ability to recognize unsafe practices or
equipment
– Put in place measures to prevent injuries.
 Introduction (3 of 3)

• You are responsible for working safely.

• Your employer has a responsibility to provide a
safe work environment.
• Listen carefully to safety information.
• Think about how you perform shop tasks.
 Safety Overview (1 of 5)

• Don’t underestimate the dangers.

• Think about what you are doing and how you
are doing it.
– Anticipate things that may go wrong.

• Be wary of taking shortcuts.

 Safety Overview (2 of 5)

• Learn and follow correct safety procedures.

– Always wear the right PPE.
– Stay alert and aware of what is happening.
 Safety Overview (3 of 5)

• Accidents and injuries happen at any time.

• Examples of accidents:
– Fire and explosions
– Shocks and burns
– Broken bones or crushed fingers and toes
– Burns or blindness
– Trips and falls
– Chronic strain injuries
 Safety Overview (4 of 5)

Poor lifting and handling techniques can cause chronic strain

injuries, particularly to your back.
 Safety Overview (5 of 5)

• Accidents and injuries are avoidable.

• Think about what you are doing, how you are
doing it, and its effects on others.
• Know what to do in case of emergency.
• Document and report accidents and injuries.
• Take proper steps to make sure they never
happen again.
 Evacuation Routes (1 of 2)

• Have more than one

evacuation route.
– Shop may have an
evacuation procedure.

• Evacuation routes will

be marked on the
floors.
 Evacuation Routes (2 of 2)

• Exit should be highlighted.

• Identify which route you will take if an
emergency occurs.
 Work Environment

• A safe work environment contains:

– Well-organized shop layout
– Shop policies and procedures
– Safe equipment
– Safety equipment
– Safety training
– Employees who work safely
– A workplace orientation
– Good supervision
– Workplace that supports safe work practices
 OSHA and EPA (1 of 2)

• Occupational Safety and Health Administration

(OSHA)
– Government agency created to provide national
leadership in occupational safety and health

• Finds effective ways to help prevent:

– Worker fatalities
– Workplace injuries and illnesses

• Has authority to conduct inspections

 OSHA and EPA (2 of 2)

• Environmental Protection Agency (EPA)

– Federal agency that deals with issues related to
environmental safety
– Shop activities need to comply with EPA laws and
regulations.
• Dispose of waste products in environmentally
responsible way.
• Correctly store chemicals and fluids.
• Ensure work practices do not contribute to
damaging the environment.
 Shop Policies and Procedures (1 of 2)

• Outline how tasks and activities are to be

conducted and managed
• Ensure shop operates according to OSHA and
EPA laws and regulations
• Policy vs. procedure
• Each shop has own set of policies and
procedures.
 Shop Policies and Procedures (2 of 2)

• Regularly reviewed and updated

• Guide shop practices
• You are responsible to know and follow rules.
Identifying Hazardous Environments
(1 of 2)

• Almost impossible to remove all hazards

• A risk analysis of a bench grinder
– High-velocity particles
– The grinding wheel breaking apart
– Electrocution
– Risk to hands
– Risk to your hearing
– Risk of entrapment of clothing or body parts through
rotating machinery
Identifying Hazardous Environments
(2 of 2)

• To reduce risks of bench grinder:

– Position the bench grinder in a safe area.
– Make sure electrical items are regularly checked.
– Wear PPE.
– Don’t wear loose clothing.
 Standard Safety Measures (1 of 3)

• Signs
– Make people aware of specific hazards
– Give adequate warning of unsafe situations
 Standard Safety Measures (2 of 3)

• Signs
– Each sign has four
components:
• Signal word
• Background color
• Text
• Pictorial message
– Colors denote level of
severity.
 Standard Safety Measures (3 of 3)

• Safety Equipment
– Handrails
– Machinery guards and yellow lines
– Painted lines
– Soundproof rooms
– Adequate ventilation
– Gas extraction hoses
– Doors and gates
– Temporary barriers
 Air Quality (1 of 5)

• Running engines
– Can produce dangerous exhaust gases
• Carbon monoxide
• Carbon dioxide
• Hydrocarbons and oxides of nitrogen
 Air Quality (2 of 5)

• Carbon monoxide
– Extremely dangerous
– Odorless and colorless
– Can build up to toxic levels very quickly
 Air Quality (3 of 5)

• Carbon monoxide
– Maximum OSHA permissible exposure limit (PEL)
• 50 parts per million (ppm) of air for 8-hour period
– National Institute for Occupational Safety and Health
recommended exposure limit
• 35 ppm for an 8-hour period
– Attaches itself to blood cells more easily than oxygen
does
Air Quality (4 of 5)

• Directly couple the

vehicle’s exhaust pipe
to an exhaust
extraction system
hose.
– Vented to where the
fumes will not be drawn
back indoors, and
away from people
 Air Quality (5 of 5)

• An engine fitted with a catalytic converter cannot

run safely indoors.
• A catalytic converter can never substitute for
adequate ventilation or exhaust extraction
equipment.
 Electrical Safety (1 of 9)

• Poor electrical safety

practices can cause:
– Shocks and burns
– Fires and explosions

• Know where electrical

panels are located.
 Electrical Safety (2 of 9)

• Circuit breakers and fuses clearly labeled

• Keep the circuit breaker and/or electrical panel
covers closed.
• Don’t block or obstruct access to electrical
panel.
– 3″ (0.91 m) of unobstructed space around panel
 Electrical Safety (3 of 9)

• Sufficient number of electrical receptacles in

work area to a single receptacle with a simple
double adapter
– Use a multi-outlet safety strip with built-in overload
cutout feature.

• Electrical receptacles should be at least 3″

(0.91 m) above the floor level.
 Electrical Safety (4 of 9)

• Extension cords
– Made of flexible wiring
and fitted with ground
wire
– Neoprene-covered
– Check for damage.
– No tripping hazard
– Avoid rolling equipment
or vehicles over it.
 Electrical Safety (5 of 9)

• Portable electric tools

– Tools that operate at 240 volts are sources of serious
shock and burn accidents.
– Always inspect cord for damage.
– Check security of attached plug before connecting the
item to power supply.
– Use 110-volt or lower voltage tools if available.
 Electrical Safety (6 of 9)

• Electric tools
– Must have ground prong or be double insulated
– Never use in a wet environment.
– Air-operated tools cannot give electric shock.
 Electrical Safety (7 of 9)

• Portable shop lights

– Useful to add light to particular area or spot
– Always follow safety directions.
– Should have protective covers fitted to them
– Some lights are now cordless.
Electrical Safety (8 of 9)

• Electric droplights
– Electrical parts can
never come in contact
with outer casing of the
device.
– Very vulnerable to
impact
– Must not be used
without insulating cage
protection
 Electrical Safety (9 of 9)

• Incandescent bulbs
– Present an extreme fire hazard if broken in presence
of flammable vapors or liquids
– Should not be used in repair shops
– LED and fluorescent bulbs are much safer.
 Shop Layout (1 of 2)

• Should have an efficient and safe layout

– Clearly defined areas and walkways

• Customers should not be allowed to wander

through work areas unescorted.
 Shop Layout (2 of 2)

• Good shop layout

– How the work is to be done
– How equipment is used
– What traffic movements occur within the shop

• The shop should have clearly defined areas for

various activities.
• Flammable items should be kept in an approved
fireproof storage container or cabinet, with
firefighting equipment close.
 Preventing Fires (1 of 5)

• Automobiles carry a fuel tank with large

quantities of fuel on board.
– Sufficient to cause a destructive and potentially
explosive fire

• Clean up spills immediately.

 Preventing Fires (2 of 5)

• Fuel vapor
– Liquid fuel vaporizes rapidly and extremely easy to
ignite
– Invisible and heavier than air
– Can spread unseen across a wide area
– Source of ignition can be some distance from original
spill
– Can vaporize from cloths or rags used to wipe up
spills
 Preventing Fires (3 of 5)

• Spillage risks
– When removing and replacing fuel filters
– During removal of a fuel tank sender unit
– Fuel lines are damaged and are being replaced
– When fuels systems are being checked
– When fuel is being drained into unsuitable containers

• Avoid spills.
– Keep a spill response kit nearby.
 Preventing Fires (4 of 5)

• Draining fuel
– Remove fuel safely first.
– Remove in a well-ventilated, level space outside in
the open air.
– Remove potential sources of ignition from area.
– Disconnect the battery on vehicle.
– Do not drain fuel over an inspection pit.
– Container should be an approved fuel storage
container (fuel retriever).
 Preventing Fires (5 of 5)

• Using a fuel retriever

– Remove fuel through a
filler neck.
– Minimizes chance of
spills occurring
– Narrow-diameter hoses
or adapters
– Check service manual.
 Extinguishing Fires (1 of 2)

• Three elements must be present for a fire to

occur:
– Fuel
– Oxygen
– Heat

• Remove one of the elements

– Usually oxygen or heat
– Fire blanket removes oxygen.
– Water extinguisher removes heat.
 Extinguishing Fires (2 of 2)

• Fire extinguishers are used to extinguish

majority of small fires.
– Never hesitate to call the fire department.
 Fire Classifications (1 of 2)

• Class A fires
– Involve ordinary combustibles

• Class B fires
– Flammable liquids or gaseous fuels

• Class C fires
– Involve electrical equipment
 Fire Classifications (2 of 2)

• Class D fires
– Involve combustible metals

• Class K fires
– Involve cooking oil or fat
 Fire Extinguisher Types (1 of 2)

• Marked with pictograms depicting types of fires

that extinguisher is approved to fight
 Fire Extinguisher Types (2 of 2)

– Class A
• Green triangle
– Class B
• Red square
– Class C
• Blue circle
– Class D
• Yellow pentagram
– Class K
• Black hexagon
 Fire Extinguisher Operation (1 of 4)

• Sound alarm before attempting to fight fire.

• Leave area if you cannot fight fire safely.
• Size up fire before you decide to fight it.
 Fire Extinguisher Operation (2 of 4)

• To operate a fire extinguisher, follow the

acronym PASS:
– Pull out pin that locks handle at top of fire
extinguisher to prevent accidental use.
– Aim nozzle at base of fire.
• Stand 8–12′ away from the fire.
– Squeeze handle to discharge.
– Sweep handle side to side at base of the fire.

• Continue to watch the fire.

 Fire Extinguisher Operation (3 of 4)

• If the fire is indoors:

– Stand between fire and nearest safe exit.

• If the fire is outdoors:

– Stand facing fire with wind on your back.

• Make sure you have a means of escape.

 Fire Extinguisher Operation (4 of 4)

• When you are sure fire is out, report to your

supervisor.
– What actions you took to put it out

• Once circumstances of fire have been

investigated and supervisor or fire department
has given you all clear:
– Clean up debris.
– Submit used fire extinguisher for inspection.
 Safety Overview

• Fire blankets
– Designed to smother a small fire
– Useful to put out a fire on a person
– Used where a fire extinguisher could cause damage
– Study the how-to-use instructions.
– Replace or return blanket for future use.
 Eyewash Stations and Emergency
Showers (1 of 2)
• Flush eye if foreign
substance in eye
• Types of eye washers

– Disposable eye wash

packs
– Eye wash stations © Guy Croft SciTech/Alamy Images

– Some emergency or
deluge showers
 Eyewash Stations and Emergency
Showers (2 of 2)
• Typically individuals need assistance
– Take their arm and lead them.
– Encourage them to use fingers to pull eyelids open.
– Encourage them to wash for 15 minutes.
– Call for medical assistance while they are rinsing their
eyes.
 Hazardous Materials Safety

• Hazardous material
– Any material that poses an unreasonable risk of
damage or injury to persons, property, or the
environment if it is not properly controlled

• Materials can be solids, liquids, or gases.

• Most shops use hazardous materials daily.
• Hazardous materials must be properly handled,
labeled, and stored.
Material Safety Data Sheets (MSDS)
(1 of 3)

• Contain detailed information about hazardous

materials
• Obtained from manufacturer of material
– Should have an MSDS for each hazardous substance
or dangerous product

• Consult MSDS to learn how to use a product

safely.
 Material Safety Data Sheets (MSDS)
(2 of 3)

• Be aware that certain combinations can be more

dangerous than any separately.
• In the US it is required that workplaces have an
MSDS for every chemical on site.
• MSDS are kept in a clearly marked binder.
– Updated regularly
Material Safety Data Sheets (MSDS)
(3 of 3)

• MSDS must contain at least the following

information:
– Revision date
– Material and manufacturer ID
– Hazardous ingredients
– Health hazard data
– Fire and explosion data
– Details about material mixing or reacting
 Cleaning Toxic Dust Safely (1 of 4)

• Toxic dust
– Any dust that may contain fine particles that could be
harmful to humans or the environment
– If you are unsure of toxicity of dust, always treat as
toxic.

• Brake and clutch dusts are potential toxic dusts.

 Cleaning Toxic Dust Safely (2 of 4)

• Common source of toxic dust

– Inside drum brakes and manual transmission bell
housings

• Avoid all dust if possible.

• If you do have to work with dust:
– Never use compressed air.
– Always use PPE.
 Cleaning Toxic Dust Safely (3 of 4)

• Cleaning up after a repair

– Do not dry sweep dust.
• Use a low-pressure wet cleaning method.
– Can also use a HEPA vacuum cleaner
– Clean up dirt immediately after task is complete.
– Sweeping can cause dirt to rise.
• Push the dirt with a soft broom; do not flick.
– A water hose is another way of cleaning dirt.
 Cleaning Toxic Dust Safely (4 of 4)

• Tools have been developed to clean toxic dust

from vehicle components.
– Brake wash station
– Vacuum cleaner with a large cone attachment
• Domestic vacuums are not suitable for this.
 Used Engine Oil and Fluids (1 of 5)

• Often contain
dangerous chemicals
and impurities
 Used Engine Oil and Fluids (2 of 5)

• There are laws and regulations that control the

way they are handled and disposed of.
• Safely recycled or disposed of in
environmentally friendly way
 Used Engine Oil and Fluids (3 of 5)

• Shop will have policies and procedures that

describe how you handle and dispose of used
engine oil and fluids.
• Be careful not to mix incompatible fluids.
– Engine oil and used coolant

• Petroleum products can be mixed together.

 Used Engine Oil and Fluids (4 of 5)

• Follow local, state, and federal regulation when

disposing of waste fluids.
• Used engine oil is a hazardous material
containing impurities that can damage skin.
• Avoid direct contact as much as possible.
 Used Engine Oil and Fluids (5 of 5)

• Follow safe practices.

– Keep a high standard of personal hygiene and
cleanliness.
– Wash off harmful materials ASAP after contact.
– Regularly inspect skin for signs of damage or
deterioration.
 Shop Safety Inspections (1 of 2)

• Inspections can be formalized by using

inspection sheets to check specific items, or can
be general walk-arounds.
• Common things to look for:
– Items blocking emergency exits or walkways
– Poor safety signage
– Unsafe storage of flammable goods
– Tripping hazards
 Shop Safety Inspections (2 of 2)

• Common things to look for (cont’d):

– Faulty or unsafe equipment or tools
– Missing fire extinguishers
– Clutter
– Spills
– Unsafe shop practices
– People not wearing the correct PPE

• Formal and informal inspections should be held

regularly.
 Summary (1 of 9)

• Your employer is responsible for maintaining a

safe work environment; you are responsible for
working safely.
• Always wear the correct personal protective
equipment, such as gloves or hearing protection.
• Accidents and injuries can be avoided by safe
work practices.
 Summary (2 of 9)

• Every shop should mark evacuation routes;

always know the evacuation route for your shop.
• OSHA is a federal agency that oversees safe
workplace environments and practices.
• EPA monitors and enforces issues related to
environmental safety.
 Summary (3 of 9)

• Shop policies and procedures are designed to

ensure compliance with laws and regulations,
create a safe working environment, and guide
shop practice.
• Identify hazards and hazardous materials in your
work environment.
• Safety signs include a signal word, background
color, text, and pictorial message.
 Summary (4 of 9)

• Shop safety equipment includes handrails,

machinery guards, painted lines, soundproof
rooms, adequate ventilation, gas extraction
hoses, doors and gates, and temporary barriers.
• Air quality is an important safety concern.
• Carbon monoxide and carbon dioxide from
running engines can create a hazardous work
environment.
 Summary (5 of 9)

• Electrical safety in a shop is important to prevent

shocks, burns, fires, and explosions.
• Portable electrical equipment should be the
proper voltage and should always be inspected
for damage.
• Use caution when plugging in or using a
portable shop light.
 Summary (6 of 9)

• Shop layouts should be well planned to

maximize safety.
• Fuels and fuel vapors are potential fire hazards.
• Use fuel retrievers when draining fuel, and have
a spill response kit nearby.
• Fuel, oxygen, and heat must be present for a fire
to occur.
 Summary (7 of 9)

• Types of fires are classified as A, B, C, D, E, or

K. Fire extinguishers match them accordingly.
• Do not fight a fire unless you can do so safely.
• Operating a fire extinguisher involves the PASS
method: pull, aim, squeeze, and sweep.
 Summary (8 of 9)

• Eyewash stations and emergency showers allow

flushing of chemicals or other irritants.
• Material safety data sheets contain important
information on each hazardous material in the
shop.
• Vacuuming and using water are safer methods
of cleaning dust or dirt that may be toxic.
 Summary (9 of 9)

• Used engine oil and fluids must be handled and

disposed of properly.
• Shop safety inspections ensure that safety
policies and procedures are being followed.
 Credits

• Unless otherwise indicated, all photographs and

illustrations are under copyright of Jones &
Bartlett Learning.