I.

Shop Safety

I.1 Introduction to shop safety

Safety is an important issue in metal fabrication because of the complexity of the production process. By
ensuring that well-trained employees know all aspects of each task along with the tools and machines in the
metal fabrication process, the risk of injuries will be lowered in the steel industry and other related facilities.

I.2 Common safety measures for metal fabrication shop

1. Implement Safety Measures

General Shop Safety Guidelines

Follow these guidelines for general shop safety:

 Know the hazards associated with your work. Be sure you are fully educated on the proper use and
operation of any tool before beginning a job.
 Always wear appropriate safety gear and protective clothing.
 Wear nitrile gloves when cleaning with degreasers or ferric chloride.
 Ensure that there is adequate ventilation to prevent exposure from vapors of glues, lacquers, paints
and from dust and fumes.
 Maintain good housekeeping standards.
o Keep the work area free from slipping/tripping hazards (oil, cords, debris, etc.).
o Clean all spills immediately.
o Remove sawdust, wood chips, and metal chips regularly.
o It is recommended that electrical cords pull down from an overhead pulley rather than lying on
the floor.
 Leave tool and equipment guards in place.
 Know where fire extinguishers are located and how to use them.
 Make sure all tools and equipment are properly grounded and that cords are in good condition.
o Double-insulated tools or those with three-wire cords are essential for safety.
o Use extension cords that are large enough for the load and distance.
 Secure all compressed gas cylinders. Never use compressed gas to clean clothing or skin.
 Always use flashback arrestors on cutting/welding torches.
 Take precautions against heat stroke and heat exhaustion.
 Wear infrared safety goggles when appropriate.

Student Shop Safety Rules

 Safety glasses with side shields or goggles are to be worn at all times while in the shop. Bring your own
glasses.
 No loose fitting clothing allowed when working in the shop.
 No open toe shoes or sandals allowed in shop.
 Two persons must be in shop to operate mill or lathe unless authorized.
 Door to shop must remain open while using shop.
 All users must sign in before using shop.
 Students must have prints or drawings of parts with dimensions, hole locations, thread sizes, and other
machining information prior to machining.
  Users must clean up area used every time work is finished. If you have not completed your project and
must leave the shop you must clean area prior to leaving. Others may need to use the area in your
absence.
 Students must clean and return all tools to proper location when finished.
 No tools are to be removed from shop without authorization.
 No horseplay allowed in shop. Do not distract anyone using equipment.
 Report all injuries to Russ Reynolds or Bryan Merritt immediately.
 Floor area where work was done must be swept after every use.
 Never enter the student shop through the main shop. If the door is locked, use your key. If you don’t
have a key you are not authorized to use the shop. Always shut shop door when you leave if no one
else is in the shop.
 Safety is your top priority when using the shop. If you are not sure what you are doing, “ASK”.
 Never attempt to use equipment you have not received training on.
 Report any broken tools or machines immediately to main shop.

2. Proper Training

Before an employee begins working in a metal fabrication shop, they should receive the proper training and
certifications needed to correctly perform their job duties. When an employee holds a welding certification,
they are knowledgeable and know how to properly weld without becoming injured.

If an employee is properly trained, they will be more satisfied with their job, and they will be proud of their
accomplishments. Training can also result in a better quality of work and higher productivity. The employee
will be more efficient when assessing the overall job performance. For example, a welder who possesses an
AWS D1.1 Certification is trained and has passed a test in the welding and the cutting process.

3. Prevent Back and Neck Injuries

Preventing major injuries such as back and neck injuries saves the company money and downtime. Employees
should receive training in the proper procedure to use when lifting heavy materials and objects. If employees
are taught to use their legs muscles, not their back or neck when lifting, fewer injuries will occur.

4. Wear Protective Clothes

Metal fabrication workers should always wear protective clothing. They should make sure they are wearing, all
necessary, protective clothing to cut down on the possibility of sustaining injuries. Workers should wear long
sleeve shirts, long pants, gloves, goggles, and hard hat when working with metal. Proper safety shoes are also
important. They can keep a person from slipping on material and falling. Loose fitting clothes and jewelry
should not be in this type of environment.

Basic Types of PPE

However, even the strictest controls will not necessarily eliminate all the risks associated with most job tasks
and this is where the need for PPE must be evaluated. A hazard assessment can help identify which specialized
PPE will be required. However, the following basic types of PPE should be made available in every worksite.
1. Head Protection
PPE includes hard hats and headgears and should be required for tasks than can cause any force or object
falling to the head. When performing head protection safety checks, ensure that there are no dents or
deformities on the shell and connections are tightened inside. Do not store in direct sunlight and always
replace a hard hat if it was used for any kind of impact, even if damage is unnoticeable.
2. Face and Eye Protection
PPE includes safety goggles and face shields and should be used for tasks that can cause loss of vision and an
eye, burns, splashes, sprays of toxic liquids etc. When conducting equipment safety checks, ensure that there
are no cracks or deformities on the lenses, ensure the strap is in good working order and is firmly sealed to the
cheek and forehead.

3. Foot Protection
PPE includes knee pads and safety boots and should be used for tasks that can cause serious foot and leg
injuries from falling or rolling objects, hot substances, electrical hazards and slippery surfaces. Use boots with
slip-resistant soles that protect against compression and impact.

4. Hands Protection
PPE includes safety gloves and should be used for tasks that can cause hand and skin burns, absorption of
harmful substances, cuts, fractures or amputations. When inspecting hand protection equipment, ensure that
they fit perfectly with no spaces and are free from cuts, burns and chemical residue. Always replace them if
any sign of contamination was observed.

5. Body Protection
PPE includes safety vests and suits and should be used for tasks that can cause body injuries from extreme
temperatures, flames and sparks, toxic chemicals, insect bites and radiation. Ensure that they are clean and
free from cuts and burns. Always get a good fit to ensure full body protection.
6. Hearing Protection
PPE includes ear muffs and plugs and should be used for tasks than can cause hearing problems and loss of
hearing. When ensuring hearing safety, the equipment must fit the ear canal perfectly. Recommended types
include formable earplugs to fit on different sizes of ear canals.

7. Fall Protection
PPE includes safety harnesses and lanyards and should be strictly used for task that can cause falling from
heights and serious injury or death. When inspecting equipment, ensure that the straps are free from tears,
deformities and burn marks and buckles are connected securely and tightly. It is very important to dispose
them if used after a falling incident.

8. Respiratory Protection
PPE includes respirators and should be used for task that can cause inhalation of harmful materials to enter
the body. When conducting respiratory protection safety, ensure that the equipment is fit-tested and the
employee has undergone proper training before wearing one.

Supervisors should ensure that adequate equipment is available to employees. Each employee should wear
the correct protective clothing necessary for the task at hand. If respiratory equipment is required it should fit
correctly, fit well, and the employee trained in its use. The correct protective clothing and safety equipment is
essential to the well-being of employees.

5. Proper Tool Usage

The first thing an employee should do before using metal fabrication tools is to read the instructions and learn
the proper way to use each tool. Misuse of a tool can cause serious injuries. First of all, an employee should be
properly trained to use the tools and safety protocols to prevent injuries. Before using a tool in should be
thoroughly inspected to ensure it is in perfect working order.

When using large machines, employees should make sure the machines are working correctly. Machines
should be thoroughly inspected before each use. Employees should not wear clothing or accessories that may
get caught in the machine and cause injuries. They should not touch the metal when it comes out of a
machine because it will be hot. The guards and safety features of the equipment should be used. Utilize these
features regularly and know the correct way to use them.

Important Safety Procedures

Safety is an important issue in metal fabrication because of the complexity of the production process. By
ensuring that well-trained employees know all aspects of each task along with the tools and machines in the
metal fabrication process, the risk of injuries will be lowered in the steel industry and other related facilities.

Welding Hand Tool Usage Tips

There are many safety risks when welding related to noise, hot metals, radiation and metal fumes. Injuries can
also be caused when incorrectly using tools, such as when they are lifted and lowered, pushed or pulled.

Areas of High Welding Safety Risk

 People in area (or welder) that are exposed to flash

 Excessive noise
 Inhaling gasses such as carbon monoxide or oxygen
 Welding in a poor position
 Poor ventilation

Welding risk can be reduced through the use of tools such as a respirator or portable fume extraction system.
Use of a high quality helmet with flip visor or auto darkening helmets also reduce risk.

To avoid harm to workers, consider using a curtain or screen. Welding booths can further insulate the weld
from others in the area.

Last, a well organized workplace can help reduce the risk of tripping over cables or knocking over cylinders.