GENERAL SAFETY IN WORKSHOP

INTRODUCTION
Workshops can be dangerous places. They are full of machines and tools that are
designed to cut hard, rigid materials, and unfortunately every year people are injured in them
through having accidents. Sometimes these accidents are just bad luck, but in most instances
they are the result of people behaving wrongly, or not understanding how to do something
correctly.

When you have read the health and safety rules you will realise that a lot of the
principles of safety are just common sense. Unfortunately, some people need to have this
common sense pointed out to them.
Module Objectives
After the completion of this module, student should be able to:
1. Dress safely for the workshop.
2. Behave safely in the workshop.
3. Recognize the importance of keeping the workshop clean and tidy.
4. To ensure that employees are knowledgeable in fire prevention and emergency
response in the workplace.
Module Contents
1. INTRODUCTION TO WORKSHOP SAFETY
2. PERSONAL PROTECTIVE EQUIPMENT
3. SAFE USE OF POWER TOOLS
4. WORKSHOP CLEANLINESS
5. FIRE SAFETY

General safety in workshop 1

 INTRODUCTION TO WORKSHOP SAFETY
A workshop is where you learn to use tools and machines to make things; it can be a dangerous
place, so you must learn the safety rules for the workshop.
The safety rules tell you how to dress appropriately and how to behave whilst working with tools
that may cause harm.
You must never play in the workshop, run around or throw equipment to one another.
1. General Performance Requirements
Legal requirements stipulate:
Every employer must advise workers about workplace hazards, and the preventive measures to
be employed.
Every employer must take the necessary precautions to protect workers from injury to their
health and safety by making sure that:
Adequate safety and hygienic conditions prevail in all places of work
Machinery, pieces of equipment and tackle are installed and maintained in the safest possible
way
Places of work are clean and comply with conditions of health and comfort.
A worker must:
Not carry out an action which is forbidden by workplace instructions and is bad practice or
causes damage.
Not shortcut the means provided for protection of the worker’s health and safety, or the health
and safety of fellow workers.
Use protective methods and undertake to regard them with care, and carry out instructions laid
down for the worker’s protection and the prevention of injury.
2. Workshops
2.1. Workshop Design and Construction
All workbenches and working surfaces shall be fit for purpose, constructed of suitable fire-
resistant materials and to a sound design, such that the work may be accomplished safely and
without undue strain to the worker.
Where wet processes are carried out or where machinery is liable to eject quantities of fluid,
adequate containment, in the form of channels, bunds or curbs, and drainage shall be provided.
Adequate provision shall be made for the collection, temporary storage, and disposal of solid
scrap and waste material from all workplaces.
Adequate toilets and washrooms shall be provided in all workshops
Adequate supplies of drinking water shall be provided in all workshops.

General safety in workshop 2

2.2. Layout of Workshops
Workshops shall be laid out as follows:
Clear areas shall be defined for each activity performed in the workshop. Activities shall be
segregated such that each activity does not interfere or cause hazards to others present.
Hazardous activities such as welding, cutting, grinding, grit blasting, painting etc., shall be
segregated from other activities, normally in dedicated booths.
All hazardous materials shall be securely stored in dedicated areas, separated from work areas
and, where necessary, from other hazards.
Transit walkways shall be clearly defined in all workshops, as shall all work areas, specifically
those requiring limits on access due to the nature of activity performed.
All emergency systems: escape routes; fire alarms and fire fighting equipment; first aid
equipment; etc., shall be indicated by clearly visible signs. Such signs shall conform to the
requirements of "Signs and Signboards".
Wherever possible, work areas, storage areas, walkways, hazardous areas and escape routes
shall be indicated by means of colour coding. Colour coding shall follow the ISO
recommendation R 408, as detailed in Table 1 below.
In addition to Table 1, contrast colours and/or wording or symbols may be added to improve
visibility, as detailed in Table 2 below.
Yellow and black diagonal striping shall be used to indicate hazards or sources of particular
danger (e.g., moving machinery, load lay down areas, areas requiring entry permits).
Safety colours may be applied directly to surfaces to indicate their condition. Thus emergency
walkways or escape routes should, in general, be painted green, while the flooring of a welding
shop, or other permanent restricted access or hazardous area should be painted either yellow,
or yellow with black stripes, depending on the level or type of hazard present. Safety colours
should not, however, be overused, and normal workplace floors should be a neutral colour such
as grey.
Table 1: Colour Coding
COLOUR MEANING EXAMPLE OF USE
Red Stop; harmful activity, Stop signals, Emergency shutdowns Identification of Fire fighting
Prohibition Equipment
Yellow Caution Danger Indication of Hazards (Fire, explosion, radiation, chemical, trip etc.);
Identification of thresholds, dangerous passages, obstacles
Green Safety Escape routes, refuges, first aid eye baths, deluge showers.
Blue Information Mandatory Mandatory information signs, such as: Wear personal protective
action equipment
Table 2: Contrast Colours
SAFETY COLOUR CONTRAST COLOUR SYMBOLS OR WORDING
Red White Black
Yellow Black Black
Green White White
Blue White White

General safety in workshop 3

2.3. Workshop Work Practices
2.3.1.Workshop Discipline
Smoking shall not be permitted in any workshop or industrial area, except in designated
smoking zones.
Eating food shall be restricted to designated areas and work breaks.
Horseplay of any kind shall be prohibited in the workplace.
2.3.2. Lifting Operations in Workshop Areas
Personnel working under or in the vicinity of an active overhead crane inside the workshop or
workshop area shall wear safety helmets.
3.2.3. Fixed Workshop Equipment
General
Fixed workshop equipment, such as compressors, lathes, grinders, drills and hydraulic presses
present specific hazards. All such equipment shall be installed in such a way that these
hazards are minimised. As a minimum, temporary or permanent screens should be in place,
particularly next to lathes, grinders and drilling machines to protect personnel working nearby.
ACCIDENT
An accident is an unexpected, unplanned and undesirable event, which causes – or nearly
causes – human injury or damage to property.
Examples: falling from a ladder, objects falling from overhead, etc.
 Accidents mean suffering and loss for everyone!
 Accidents seldom just happen – they are usually caused!
Causes of Accidents
 Carelessness - Fooling around, running about. Paying no regard for others working near
you. Not paying attention to safety rules.
 Ignorance – of the dangers of a machine or tool, and of safety precautions.
 Unsuitable clothing – Large, loose clothing, unbuttoned shirt, wearing neckties.
 Untidiness – Overcrowded passageways, objects on the floor, grease or oil on the floor.
 Hand Tools – Using dull blunt or broken tools. Using incorrect tools.
 Exposed Eyes – Not wearing proper eye protection during practical work.
 Machine Tools – No knowledge of how to operate machines. No permission to use
machines. Machine tools and parts not secured properly.
 Lifting Objects – Lifting anything that is too heavy for you to manage.
Accidents happen when people are
 Trying to do the wrong activity with a tool or machine.
 They are not paying regard to personal safety requirements.
 They are not concentrating.

General safety in workshop 4

Injury
An instance of physical harm or damage suffered
 Examples: fractures, Burns, bruises, strains, Sprains, etc
Hazards
Anything that can expose a person to danger or injury.
 Hazardous situations, if detected early and corrected speedily, can significantly
reduce the chances of accidents occurring.
Identify Workplace Hazards
Every workplace should have a system in place to identify, assess and control the hazards.
What is a safety hazard?
Safety hazards include any force that is strong enough to cause injury in an accident. Safety
hazards occur most often when adequate workplace safety standards are not met.
What is an occupational health hazard?
An occupational health hazard is any material or condition that can cause occupational injuries
and/or illness. Health hazards can cause immediate and serious effects, or slow and gradual
injury. Some occupational health hazards include:
 chemicals (acid, solvents, paint)
 biological hazards (bacteria, viruses, dust, moulds)
 physical agents (electric currents, heat, light, noise, radiation)
 ergonomic hazards (poor work station designs)
 other stress agents (violence, abuse, harassment)
What is the best way to control hazards in the workplace?
There are three main steps that can be taken in order to control hazards.
 Eliminate the hazards posed by equipment and work processes (i.e. redesign work
stations, switch chemicals used in work, etc.).
 If eliminating the hazard is not possible, control the hazard to reduce the risk to workers
(i.e. install machine guards or better ventilation systems, etc.)
 If controlling the hazards is not effective, protect the workers from risk with use of tools
and protective equipment, and proper safety training.
How do I identify workplace hazards?
Employers should always ensure that work environments are as safe as possible. Part of
assessing risk is setting up a proper job site analysis. Safety analysis should include the
following steps:
 Select the job to be analyzed by reviewing injury data. Select the most common injuries
and severe injuries to be analyzed first.
 Separate the job into its separate tasks or stages
 Identify the potential health and safety hazards at each stage

General safety in workshop 5

  Choose and implement safety standards
 Review the workplace safety analysis document regularly
 Update changes and improvements as necessary
 Effectively communicate safety standards and training throughout company
What questions should I ask when performing a workplace hazard assessment?
To help uncover potential workplace hazards, ask questions such as:
 Can any body part be caught between objects?
 Do any tools or machines present any hazards?
 Can the worker make harmful contact with any machine parts?
 Can the worker slip, trip, or fall?
 Can the worker suffer from strains from lifting, pushing or pulling?
 Is the worker exposed to extreme temperatures?
 Is the worker exposed to extreme noise or vibration?
 Is there a danger from falling objects?
 Is proper lighting a concern?
 Can weather conditions affect safety?
 Is the worker exposed to harmful levels of radiation?
 Is the worker exposed to chemical or biological hazards?
 Is the worker exposed to dust, paint fumes, mists or vapours?
 What unexpected hazards could arise?
 What external forces could impact safety?
safe and healthy working environment
A safe and secure working environment is one which eliminates or minimizes:
 The chances of fire occurring
 Accidents such as falls, cuts, burns, electrical shocks
 Theft
 Fraud
Falls: to reduce the chance of someone falling, the following may be used:
 Non skid mats on surfaces which may be slippery
 Appropriate safety signs such as “wet floor”, “watch your step”
Theft: use burglar alarm, door chains, security camera,
Fire: use fire extinguisher, fire alarm, smoke detector, wet blanket, sprinkler, sand

General safety in workshop 6

 PERSONAL PROTECTIVE EQUIPMENT
Personal protective equipment (PPE) is designed to protect employees from serious workplace
injury or illnesses resulting from hazards in the work environment.
Manufacturing environments addresses potential hazards by removing the hazard or reducing
the risks associated with the hazard in accordance with hierarchy of control measures in the
following order:
1. Elimination
2. Substitution
3. Engineering Controls
4. Administrative (Procedural) Control
5. Personal Protective Equipment (PPE)
Hazard Control clearly defines PPE to be the last control on the risk management hierarchy.
 PPE is required when a Risk Assessment (RA) or Job Safety Analysis (JSA) indicates
the need for added protection.
 The selection of PPE is determined by the type that is most appropriate and provides the
most protection.
 PPE does not eliminate the hazard nor protect you if not properly fitted and maintained
in a clean and serviceable condition.
PPE TYPES
There are many types of PPE available for all levels of protection.
This site has reviewed all RAs and JSAs and will provide the correct level and type of PPE for
each employee.
HEAD PROTECTION
Eye Protection
The structure of your face protects your eyes, still, some injuries can damage your eye severely
enough that you can lose your vision. Most eye injuries are preventable with proper PPE.
Eye and face protection is used to Protect eyes from hazards from:
 Airborne particles
 Liquid chemicals
 Molten metals
 Light radiation
 Dust
Eye & Face Protection includes:
 Safety glasses with side shields
 Goggles
 Face shields
 Welding Helmets

General safety in workshop 7

Safety Goggles
Needed to be used when protection is required against chemicals or particles
 Only provide protection to the eyes
 Goggles are not considered a sources of protection for the whole face, and cannot be
used for this purpose.

Hearing Protection
Noise can become a hazard when it enters the ear at 85 decibels (dBA) or above. Noise can
damage the hair cells inside the cochlea (inner ear). Damage to the hair cells is irreparable and
can result in hearing loss.
 Within the manufacturing plants or other noise polluted work environments, employees
are required to wear hearing protection.
 At different workplaces, employees may only use ‘metal detectable earplugs’ provided by
the company.

Head Protection
Head injuries can cause neck sprains, concussions and skull fractures.
If at any time the need for head protection is identified by RA or JSA at any site, PPE will be
provided.

General safety in workshop 8

UPPER EXTREMITY PROTECTION
Arms, Hands & Skin (Cut resistant)
Hand injuries are common. Without the use of the hand or fingers, the ability to work is greatly
reduced if not almost impossible.
To protect the hands, the proper types of gloves and proper fit must be obtained.

LOWER EXTREMITY PROTECTION

Foot Protection
Slips, trips and falls result in sprains, strains or tears - injuries that can be painful, long lasting,
and may result in time lost from work. Falls may also cause head injuries, knee injuries,
fractures and broken bones. Treasury Wine Estates provides yearly footwear consisting of:
 Above the ankle
 Lace Up
 Waterproof or water resistant
 Fitted by a professional

TORSO/BODY PROTECTION
Many hazards can threaten the torso/body such as heat or cold temperatures, splashes from
chemicals and being struck by a moving object.
A variety of protective clothing is provided, including vests, shirts, aprons and coveralls

CONCLUSION
To ensure a culture of responsibility and accountability, employees are trained and made aware
of company policy so that each understands HSE considerations and incorporates them into
their decisions and daily activities.

General safety in workshop 9

 QUIZ
1. PPE stands for People’s Process Equipment.
True
False

2. When is PPE required?

a. Only when a supervisor or manager is around to see.
b. When the employees feels like wearing it or thinks that it looks good.
c. When a Risk Assessment or JSA indicates the need for added protection.

3. Ear muffs, ear plugs and headphones are all considered proper hearing protection.
True
False

4. When can PPE be introduced as an additional control?

a. Once as the hazard has been recognized.
b. After elimination, substitution, engineering and administration controls have been used and
the need for additional protection is required.
c. Others in the industry use it and it’s new and cool.

5. High visibility vests are required in, at and around production areas on at this site.
True
False

6. PPE does not eliminate the hazard; if not properly fitted and well maintained
it will not provide adequate protection.
True
False

7. Using hearing protection incorrectly can result in permanent hearing loss.

True
False
7. PPE shall be worn as directed by posted signs by all persons entering or within
that area, regardless of the purpose of entry or the length of stay.
True
False

9. Slips, trips and falls result in sprains, strains or tears – injuries that can be painful,
long lasting and may result in time lost from work.
True
False

10. When should hearing protection be worn?

a. When an employee’s supervisor or manager is around.
b. When an employee is exposed to excessive noises as indicated in the RA or JSA and is
written in the SOP.
c. When an employee’s feels or thinks it may be necessary.

General safety in workshop 10

 SAFE USE OF POWER TOOLS
Hand and power tools have become vital components in nearly all tasks we do. Their
widespread use both on and off the job dictates the need for safe practices to prevent injury to
ourselves and others in the work area. We need to be aware of the hazards associated with
these tools. Training therefore is essential in the correct use of hand and power tools.
Safety Hazards
Workers using hand and power tools may be exposed to these safety hazards:
 objects that fall, fly, are abrasive, or splash
 harmful dusts, fumes, mists, vapors, and gases
 frayed or damaged electrical cords, hazardous connections and improper grounding
Basic Tool Safety Rules
Basic Equipment Safeguards
All moving parts of machinery, such as drive belts, gear wheels, etc., shall have adequate
guards in place at all times to prevent injury.
Adequate protection shall also be in place at the point of operation, i.e. circular or band saw
blades, grinding wheels, power presses, etc., to prevent operator injury from both the equipment
and debris such as metal chips, sawdust etc. created in the work process.
Adequate support and guides shall be provided for work pieces, such that they are secured and
controlled when being cut, ground or otherwise worked and cannot "kick back" to injure the
operator.
Powered workshop equipment shall be used only by trained operators. Operators shall
demonstrate their competence to their supervisor before being allowed to work unsupervised.

Hand Tools
General Regulations
All hand tools shall be assigned to a responsible person. This may be on an individual basis, or
a single person may be assigned to control the hand tools of a particular work area or shop.
The responsible person shall ensure that hand tools are maintained in good condition. Regular
six monthly inspections shall be made of all hand tools and records of these inspections

General safety in workshop 11

maintained. If any defects are identified the tool shall be removed from service and either be
repaired or replaced.
Tools shall only be issued to personnel who have the necessary knowledge and skill to operate
them safely. Supervisors shall ensure that workers are competent to work safely with any tool
prior to leaving them to work unsupervised.
Tools shall be used only for the specific purpose for which they were designed
Tools shall at all times be transported from one work location to another in adequate containers
and in such a way as not to endanger the safety of others.
When using hand tools on small work pieces, the work pieces shall be suitably secured to the
workbench using a vice or clamps.
The use of non-sparking tools is not recommended. In the event that their use is justified in an
exceptional case, then the condition of such tools shall be thoroughly checked by competent
personnel and users shall be made aware that they are not a complete safeguard against spark
production.

Hand tools Used at Machines

The use of hand tools with powered machines such as lathes or grinders shall be strictly
controlled. Only competent personnel shall be allowed access to such powered machines.
Portable Electrically Powered Tools
General Regulations
Only competent personnel shall be allowed to use them.
All portable electrically-powered tools shall have the following construction features:
Fitted with adequate fuse protection, either in the tool body or its electric plug.
Provided with an automatic shut-off device which renders it inoperative if the operator releases
grip, e.g. a non-sustaining trigger switch. The use of trigger switch locking devices or sustaining
buttons should be avoided.
Portable electrically-powered tools shall not be used in potentially hazardous or explosive
environments. In addition, extreme care shall be taken in working areas containing oil, water,
caustic, corrosive or conductive fluids, particularly with regard to routing of power leads.
Where applicable, protective guards shall be securely fitted, and correctly adjusted.

General safety in workshop 12

Electrically Powered Portable Hand Saws
All electrically-powered portable saws (circular saws) shall be fitted with both a fixed guard over
the upper half, and a movable guard over the lower part. Both guards shall at all times be
operative. Blocking open of the lower guards is prohibited.
When cutting materials which generate dust, proper respiratory protection shall be worn.
In addition, when cutting in areas occupied by other workers, protection in the form of dust
extractors shall be provided.

Pneumatic Tools
General
All pneumatic hand tools shall be fitted with spring valves such that when the operator releases
grip, the tool is deactivated.
Where applicable, protective guards shall be securely fitted, and correctly adjusted.
Use of Pneumatic Tools
Using high pressure air to clean or remove dust and chips from personnel, clothing or
workbench is prohibited.
Workers using percussive or rotary pneumatic tools are exposed to the harmful effects of
vibration. Since the harmful effect is related to the length of exposure, frequency and vibration
intensity, proper supervision is required to identify vibration stress.
Workers using percussive or rotary pneumatic tools are also exposed to the harmful effects of
noise.
The Compressor
The compressor supplying air shall be installed such that it:
 Receives an adequate supply of fresh,
uncontaminated air.
 Does not represent a fire hazard.
 Does not represent a noise hazard.

General safety in workshop 13

The compressor shall be fitted with the following:
 A manual isolation valve between its storage tank and the air lines to permit their
isolation.
 A bleed-down valve to de-pressurise the air lines prior to disconnecting them.
 An automatic check valve operating to isolate the air lines from the storage tank in the
event of line failure causing an uncontrolled loss of air.
 An adequate purging system on the accumulator tank to remove any water or oil
contamination.
Grinders
Grinding wheels shall be covered with a solid guard over that part of the circumference not used
for grinding, in order to protect operators in case of wheel breakage. Also an adjustable guard
shall be set over the usable area of the wheel.
Grinders shall be fitted with a transparent eye shield. In addition, operators shall wear eye
protection which meets the requirements.
The spindle end shall be covered to prevent catching of clothing
An adjustable work rest shall be fitted to the machine and shall normally be adjusted no more
than 3 mm from the wheel face.
Operators shall use the circumference face of the wheel, never the side.
Only fit for purpose grinding wheels shall be used, i.e:
 correct diameter for the grinding machine
 Correctly sized hole to fit snugly on the spindle, without either forcing or slack.
Where grinding generates any harmful dust, a dust extraction system shall be provided. Wheels
containing free silica (sandstone for example) are prohibited.

General safety in workshop 14

 QUIZ
1. Always examine the tool for damages before use.

True

False
2. It is OK to wear loose clothing, dangling objects and jewellery using hand tool.

True

False
3. Keep cords and hoses away from heat, oil and sharp edges.

True

False
4. Use only tools and equipment in good condition.

True

False
5. It is OK to make adjustments or clear a jam while the power tool is running.

True

False
6. If any tool breaks or malfunctions, report it to your supervisor immediately.

True

False
7. Before connecting to a power source, make sure the power is on.

True

False
8. Safety glasses shall always be worn whenever you are using power hand tool.

True

False
9. There are several types of power tools, including electric, pneumatic, hydraulic.
True

False

10. Never use electric tools in wet conditions.
.True
.False
11. When not in use, power tools should be disconnected.
.True
.False

General safety in workshop 15

12. Keep safe distance between your hands and all moving parts of the power tool.
.True
.False
13. Don’t leave a power tool unattended while it is running.
.True
.False
14. It is OK to startle someone who is using a power tool.
.True
.False
15. Use safety guards exactly as they are supposed to be used.
.True
.False
16. When tightening a nut with an adjustable wrench, always pull the wrench toward you; never
push the wrench away from you.
.True
.False
17. Plastic covered handles on wire-cutting pliers may be used to cut low-voltage live electrical
wire.
.True
.False
18. Screwdrivers may be used for purposes other than driving or removing screws, for example as
a chisel.
.True
.False
19. When selecting a standard screwdriver be certain that the tip is almost as thick and as wide as
the slot of the head of a screw.
.True
.False
20. When using a hacksaw, safety glasses must be worn.
.True
.False
21. When you are finished using a hacksaw, tension should be eased.
.True
.False

General safety in workshop 16

 WORKSHOP CLEANLINESS
It is very important to keep the workshop clean and tidy. This will help save time and prevent
accidents. When you have finished using tools, they must be put away and kept in the proper
place as shown in Fig.1. Do not leave tools lying around the benches or workshop; accidents
may occur.

Fig.1: Shows how tools are kept in their proper place

Good housekeeping is a vital factor in preventing accidents. The great majority of all work
accidents are caused during the handling of goods or materials, and by people falling, being hit
by falling objects, or striking against objects in the workplace. All these causes can be reduced
by good housekeeping practices—in fact, good housekeeping is the only cure for hundreds of
accidents that occur.
Here are some kinds of accidents commonly caused by bad housekeeping:
• Tripping over loose objects on floors, stairs and platforms.
• Articles dropping from above.
• Slipping on greasy, wet or dirty surfaces.
• Striking against projecting, poorly stacked, or misplaced material.
• Tearing the hands or other parts of the body on projecting nails, wire, steel strapping on bales
or crates, etc.
Typical examples of poor housekeeping that lead to these accidents are:
• Excessive material, waste or chips in the working area.
• Congested aisles.
• Tools left on machines.
• Waste containers overflowing.
• Lockers and workrooms in disorder.
• Acids in open containers.
• Broken glass.
• Electric leads or air lines across aisles.
• Dirty light fittings, windows and skylights

General safety in workshop 17

Where housekeeping is bad, fire is a constant hazard. It can be caused by many housekeeping
problems—such as oil-soaked rags and clothing igniting from spontaneous combustion; dust
collectors not being properly or frequently cleaned; or piles of paper and other packing materials
being allowed to accumulate.
Poor housekeeping can also lead to infestation by pests such as rodents and cockroaches and
create serious health risks.
Elements of a good housekeeping campaign
The following are the basic elements of a good housekeeping campaign that need attention:
Aisles—Wide enough for traffic movements, marked off by floor lines from work positions and
storage areas.
Space: Sufficient room for the individual to work.
Storage: Adequate and convenient space for materials and tools.
Materials Handling: Layout planned for materials flow, with efficient methods and equipment.
Ventilation: Good general ventilation plus local exhaust ventilation to remove air contaminants
at the source.
Floors and Walls: Of construction and materials that are easy to keep clean and in good repair.
Lighting: Well-distributed artificial light and effective use of available daylight.
Amenities: Clean, up-to-date washrooms and lockers for clothing. A clean, inviting lunch room
for employees to eat their meals.
Waste Removal: Adequate facilities to prevent congestion and disorder. Let us look at some of
these elements in detail.

KEEP AISLES CLEAR: Aisle space should be reserved for the movement of personnel,
products and materials. It should be kept clean and clear and should never be used for
“bottleneck” or “overflow’’ storage. This also applies to passageways and emergency exits. Blind
corners should be eliminated or be adequately protected by warning signs.
Aisle boundary markings should be drawn to show clearly the space which has been reserved
for traffic.

General safety in workshop 18

Markings should be sufficiently wide (say a minimum of 30 mm) and of a colour to make them
clearly visible. Paint or durable plastic strips can be used.
IMPROVE STORAGE FACILITIES: Tidiness and order are essential in overcoming storage
problems, both in storerooms and in the yard. Good storage utilises air space instead of floor
space, and also saves time-wasting delays. It’s important to prevent stores and scraps
accumulating on the floor and around machines. Never keep more stores and materials than
necessary near machines and provide proper facilities (such as bins, shelves, boxes, racks,
etc.) in which to store them.
KEEP FLOORS CLEAN: Every year thousands of work injuries are caused by people falling.
Floor conditions are responsible for many of these accidents. When floors are given the right
treatment they are much easier to keep clean and hygienic.
Spilt oil and other liquids should be cleaned up at once. Chips, shavings, dust, and similar
wastes should never be allowed to accumulate. They should be removed frequently, or better
still, be suitably trapped before they reach the floor.
PAINT THE WALLS: Paint is one of the cheapest means of renovating walls, and a fresh coat
of paint can give a boost to morale. Light-colored walls reflect light. Dirty or dark-colored walls
absorb light.
Dirty walls have a depressing effect and encourage dirty habits and sloppy attitudes. Choose
suitable colors to paint walls, ceilings and working surfaces.
See that the paintwork is cleaned down periodically.
Color can be harnessed to assist with safety. For example it can be used to warn of physical
hazards and to mark obstructions such as pillars. Painting handrails, machine guards and other
safety equipment renders them distinctive and also prevents rust. Color can be used to highlight
the hazardous parts of machinery but it can never substitute for a needed guard.
MAINTAIN THE LIGHT FITTINGS: Attention to light fittings should be an integral part of any
good housekeeping programme. Dirty lamps and shades, and lamps whose output has
deteriorated with use, deprive employees of essential light. It’s been found that lighting
efficiency may be improved by 20 to 30 percent simply by cleaning the lamps and reflectors.
CLEAN THE WINDOWS: Clean windows let in light; dirty ones keep it out. Insufficient light
causes eye strain and leads to accidents because employees are unable to see properly.
Ensure that windows are not blocked by stacked materials, equipment or articles on the ledges.
DISPOSE OF SCRAP AND PREVENT SPILLAGE: It’s a common practice to let the floor catch
all the waste and then spend time and energy cleaning it up. It is obviously better to provide
convenient containers for scrap and waste and educate employees to use them. Safety will
benefit, expense will be saved, and the factory will be a better place in which to work.

General safety in workshop 19

Oily floors are a common accident and fire hazard. Splash guards and drip pans should be
installed wherever oil spills or drips may occur. Prevent accidents by keeping oil and grease off
the floor.
GET RID OF DUST AND DIRT: In some jobs, dust, dirt, chips, etc., are unavoidable. If they
can’t be collected as part of the process (e.g. by enclosure and exhaust methods) you need a
way to clean them up. Vacuum cleaners are suitable for removing light dust and dirt. Industrial
models have special fittings for cleaning walls, ceilings, ledges, machinery, and other hard-to-
reach places where dust and dirt collect. If light dust is removed by sweeping, floors should be
dampened first rather than swept dry. Oiling floors occasionally with a light oil helps to lay the
dust but take care that slipping hazards do not occur.
Remember, it is not only floors that need sweeping. Dust and grime also collect on ledges,
shelves, piping, conduits, lamps, reflectors, windows, cupboards, lockers, and so on—and all
these places need attention.
MAINTAIN A HIGH STANDARD IN MEAL ROOMS, REST ROOMS, ETC: No housekeeping
programme should ignore the facilities provided for meals, rest and sanitation, where
cleanliness is essential for walls, floors, and fixtures. A light-coloured paint can work wonders in
these places and set a standard to which employees will try to conform. Soap and towels should
be renewed regularly and wash basins properly cleaned.
KEEP TOOLS TIDY: Tool housekeeping is very important, whether in the tool room, on the
rack, out in the yard, or on the bench. Suitable fixtures for tools are required to provide orderly
arrangement, both in the tool room and near the work bench, and a regular system of
inspecting, cleaning, and repairing is an essential part of any programme.
LOOK AFTER YOUR FIRST AID GEAR: First aid facilities and equipment should be kept under
spotlessly clean conditions and fully stocked so that they are always ready in the event of
accidents or illness.
INSPECT FIRE-CONTROL EQUIPMENT: It is essential to ensure that all fire-fighting
equipment such as extinguishers and fire hoses is regularly inspected and kept in good working
order. Fire protection facilities — fire doors and exits, automatic alarms, etc. should be in good
working order. Doors and exits should always be kept clear of obstructions.
ATTEND REGULARLY TO MAINTENANCE: Perhaps the most important element of good
housekeeping is the attention paid to maintenance of buildings and equipment. If something
gets broken or damaged it should be replaced or fixed as quickly as possible (e.g., defective
ladders, broken handrails, steps, etc.). Apart from the possibility of causing accidents, a
workplace can take on a very neglected appearance if broken windows, damaged doors,
defective plumbing, leaking gutters, broken floor surfaces and the like are allowed to remain in
that condition. Employees may take the hint in a neglectful attitude to their jobs.

General safety in workshop 20

A good maintenance programme will make provision for the inspection, lubrication, upkeep and
repair of tools, equipment, machines and processes.
ASSIGN RESPONSIBILITY FOR CLEANING: Where practicable, the cleaning of the workplace
should be the responsibility of a special cleaning staff and not an additional job for employees
engaged in production. Where this is not possible, adequate time during working hours should
be allowed for cleaning up to be done. Responsibility should be clearly assigned as to who is to
do the cleaning and what area is to be cleaned. If this is not done, out-of-the way places such
as shelves, yards, small buildings, sheds, cellars, basements, and boiler rooms are overlooked
until they get into a deplorable state.

General safety in workshop 21

 QUIZ
1. OSHA requires keeping all workplaces:
a. As clean and sanitary as a hospital
b. Clean, orderly, and sanitary
c. Just neat enough to find tools or materials
2. Leaving tools in aisles could create:
a. A tripping hazard
b. A chemical spill
c. Additional storage space
3. If you use flammable or combustible liquids, OSHA requires placing wastes that could
burn in:
a. Wastebaskets
b. Plastic bags
c. Covered metal containers
4. If you spill coffee, water, or other nonchemical liquids on the floor, you should:
a. Clean up the spill immediately
b. Call maintenance
c. Ignore it
5. When you stack materials, you should make sure they:
a. Can’t tip over, slide, or collapse
b. Reach the ceiling
c. Have an MSDS
6. It’s best not to keep food or beverages in your work area
a. True
b. False
7. Keep paper and other materials that could burn away from:
a. Drawers
b. Lights and electrical equipment
c. Hand tools
8. After using a sharp tool, you should:
a. Replace it in its proper location
b. Label it
c. Stand it up
9. Good housekeeping is the responsibility of:
a. Safety committee members only
b. Maintenance employees only
c. All employees

General safety in workshop 22

10. When you see a hazard in the work area that you can’t eliminate, you should:
a. Try to remember it
b. Report it
c. Ignore it
11. You can make your work day easier to manage and less stressful if you do which of
the following:
a. Eat good food, use To-Do- Lists and Work longer hours
b. Get focused, Work smarter and Refuse to do boring work
c. Get focused, Work Smarter and Eat good food
d. Use To-Do-Lists, Work smarter and Work longer hours
12. Which of the following would not be considered as part of a cleaning routine:
a. Tidying
b. Cleaning
c. Recording
d. Storing

General safety in workshop 23

 FIRE SAFETY
Fire safety and prevention is everyone's responsibility and therefore we all must know how to go
about doing these things. There are many, many things that we do that are a fire hazard and we
don't even realize it.
What’s a fire?
In order for a fire to occur, three elements need to be present: HEAT, FUEL & OXYGEN
Fire safety, at its most basic, is based upon the principle of keeping fuel sources and ignition
sources separate.

Three things must be present at the same time to produce fire:

 Enough Oxygen to sustain combustion
 Enough Heat to reach ignition temperature
 Some Fuel or combustible material
Together, they produce the chemical reaction that is fire. Take away any of these things and
the fire will be extinguished.
FUEL CLASSIFICATIONS
Fires are classified according to the type of fuel that is burning. If you use the wrong type of
extinguisher on the wrong class of fire, you might make matters worse.
Oxygen is generally always present; the other two elements however vary depending on the
environment. In your working environment fuel is present in four types or groups:

It is very important to understand the four different fire (fuel) classifications:

Class A: Wood, paper, cloth, trash, plastics—solids that are not
metals.

Class B: Flammable liquids—gasoline, oil, grease, acetone. Includes

flammable gases.

Class C: Electrical—energized electrical equipment. As long as it is

“plugged in.”

Class D: Metals—potassium, sodium, aluminum, magnesium.

Requires special extinguishing agents.

General safety in workshop 24

Most fire extinguishers will have a pictograph label telling you which types of fire the
extinguisher is designed to fight.
For example, a simple water extinguisher might have a label like this, which means it should
only be used on Class A fires.

TYPES OF FIRE EXTINGUISHERS

Different types of fire extinguishers are designed to fight different classes of fire. The three
most common types of fire extinguishers are:
1. Water (APW)

Large, silver fire extinguishers that stand about 2 feet tall and weigh
about 25 pounds when full.
APW stands for “Air Pressurized Water.”
Filled with ordinary tap water and pressurized air, they are
essentially large squirt guns.
APW’s extinguish fire by taking away the “Heat” element of the Fire
Triangle.
APW’s are designed for Class A fires only: Wood, paper, cloth.

Here are a couple of reasons you need to be careful about which extinguisher you use:
 Using water on a flammable liquid fire could cause the fire to spread.
 Using water on an electrical fire increases the risk of electrocution. If you have no choice
but to use an APW on an electrical fire, make sure the electrical equipment is unplugged
or de-energized.

APW’s will be found in older buildings, particularly in public hallways, as well as in residence
halls on campus. They will also be found in computer laboratories. It is important to remember,
however, that computer equipment must be disconnected from its electrical source before using
a water extinguisher on it.
2. Carbon Dioxide (CO2)

The pressure in a CO2 extinguisher is so

great; bits of dry ice might shoot out of
the horn!

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CO2 cylinders are red. They range in size from 5 pounds to 100 pounds or larger. On larger
sizes, the horn will be at the end of a long, flexible hose.
CO2’s are designed for Class B and C (flammable liquids and electrical sources) fires only!

CO2’s will frequently be found in laboratories, mechanical rooms, kitchens, and flammable liquid
storage areas.
In accordance with NFPA regulations (and manufacturers’ recommendations) all CO 2
extinguishers at OSU undergo hydrostatic testing and recharge every five years.Carbon dioxide
is a non-flammable gas that takes away the oxygen element of the Fire Triangle. CO 2 is very
cold as it comes out of the extinguisher, so it cools the fuel as well.
A CO2 may not be very effective in extinguishing a Class A fire because it may not be able to
displace enough oxygen to successfully put the fire out. Class A materials may also smolder
and re-ignite.
3. Dry Chemical (ABC, BC, DC)

ABC extinguishers are red. On

campus, they range in size from five
pounds to 20 pounds.

ABC extinguishers are filled with a fine, yellow powder. This powder is mostly composed of
mono-ammonium phosphate. The extinguishers are pressurized with nitrogen.
Dry chemical extinguishers put out fire by coating the fuel with a thin layer of dust. This
separates the fuel from the oxygen in the air. The powder also works to interrupt the chemical
reaction of fire. These extinguishers are very effective at putting out fire.
Dry chemical extinguishers come in a variety of types. You may see them labeled:
 DC (for dry chemical)
 ABC (can be used on Class A, B, or C fires)
 BC (designed for use on Class B and C fires)
It is extremely important to identify which types of dry chemical fire extinguishers are located in
your area!

An “ABC” extinguisher will have a label like this,

indicating it may be used on Class A, B, and C fires.

You don’t want to mistakenly use a “BC” extinguisher on a Class A fire thinking that it was an
“ABC” extinguisher.

General safety in workshop 26

Dry chemical extinguishers with powder designed for Class B and C fires (“BC” extinguishers)
may be located in places such as commercial kitchens and areas with flammable liquids.
On campus you will find ABC’s in public hallways of new buildings, in laboratories, break rooms,
offices, chemical storage areas, mechanical rooms, University vehicles, etc.
HOW TO USE A FIRE EXTINGUISHER
It is easy to remember how to use a fire extinguisher if you remember the acronym, “PASS.”

Pull
Aim
Squeeze
Sweep

Pull the pin

This will allow you to discharge the extinguisher.

Aim at the base of the fire

Hit the fuel…if you aim at the flames, the extinguishing
agent will pass right through and do no good.

Squeeze the top handle

This depresses a button that releases the pressurized
extinguishing agent.

Sweep from side-to-side until the fire is completely out.

Start using the extinguisher from a safe distance away
and then slowly move forward. Once the fire is out, keep
an eye on the area in case it re-ignites.

General safety in workshop 27

RULES FOR FIGHTING FIRES
Fires can be very dangerous and you should always be certain that you will not endanger
yourself or others when attempting to put out a fire. For this reason, when a fire is discovered,
Assist any person in immediate danger to safety, if it can be accomplished without risk to
yourself.
Call 911 or activate the building fire alarm. The fire alarm will notify the fire department as well
as other building occupants and shut off the air handling system to prevent the spread of
smoke.
If the fire is small (and only after having done these two things), you may attempt to use an
extinguisher to put it out.
However, before deciding to fight the fire, keep these things in mind:
 Know what is burning. If you don’t know what is burning, you won’t know what kind of
extinguisher to use.
 Even if you have an ABC fire extinguisher, there might be something in the fire that is
going to explode or produce toxic fumes.
Chances are you will know what is burning, or at least have a pretty good idea, but if you don’t,
let the fire department handle it.
 Is the fire spreading rapidly beyond the point where it started? The time to use an
extinguisher is at the beginning stages of the fire.
 If the fire is already spreading quickly, it is best to simply evacuate the building.
 As you evacuate a building, close doors and windows behind you as you leave.
 This will help to slow the spread of smoke and fire.

Do not fight the fire if:

 You don’t have adequate or appropriate equipment.
If you don’t have the correct type or large enough extinguisher, it is best not to try fighting
the fire.
 You might inhale toxic smoke.
When synthetic materials such as the nylon in carpeting or foam padding in a sofa burn,
they can produce hydrogen cyanide, acrolein, and ammonia in addition to carbon
monoxide. These gases can be fatal in very small amounts.
 Your instincts tell you not to.
If you are uncomfortable with the situation for any reason, just let the fire department do
their job.

General safety in workshop 28

The final rule is to always position yourself with an exit or means of escape at your back before
you attempt to use an extinguisher to put out a fire.

In case the extinguisher malfunctions, or something unexpected happens, you need to be able
to get out quickly. You don’t want to become trapped.

General safety in workshop 29

 QUIZ

1. An example of two “Class B” fuels would be:

a. Cardboard, newspapers
b. Lamp, hot plate
c. Grease, paint thinner
2. An APW (water extinguisher) is safe to use on an electrical fire.
a. True
b. False
3. Carbon Dioxide extinguishers are designed for which types of fuels?
a. Class B and C
b. Class A, B and C
c. Class A and C
d. Class A and B
4. Which type of extinguisher has a hard horn on the end of a flexible hose or metal arm?
a. APW (air-pressurized water)
b. CO2 (carbon dioxide)
c. ABC (dry chemical)
5. As a general rule, you should not attempt to fight a fire if it is spreading rapidly.
a. True
b. False
6. ABC fire extinguishers extinguish fire by cooling it down.
a. True
b. False
7. Water will not extinguish most flammable liquid fires.
a. True
b. False
8. You should always keep an exit or means of escape at your back when trying to fight a
fire.
a. True
b. False
9. The three elements of the fire triangle are:
a. Water, a heat source, and fuel
b. Oxygen, water, and fuel
c. Oxygen, fuel, and a heat source
d. Fuel, oxygen, and earth
10. Do you know where the nearest fire extinguisher is in your work area?
a. Yes
b. No

General safety in workshop 30

Resources
• OSHA Website
http://www.osha.gov/
• OSHA Machine Guarding
http://www.osha.gov/SLTC/etools/machineguarding/index.html
• OSHA Amputation Fact Sheet
http://www.osha.gov/OshDoc/data_General_Facts/amputation-factsheet.pdf
• Safeguarding Equipment and Protecting Employees from Amputations
http://www.osha.gov/Publications/osha3170.pdf
• hand power tools
https://www.osha.gov/dte/grant_materials/

General safety in workshop 31