Basic Workshop Safety Guidance

Some months ago Malcolm asked me to write a” Sticky” basic guide to workshop safety. But we've had some health problems - Mrs jugs with new hip + heart attack + triple bypass, (all ok now) slowed things down so at long last, ere-tis.

As it's such a big subject I’ve tried to keep it as concise as possible while still being readable, so it is very basic.

To make it easier to navigate it’s split into 2 parts,

Pg1- Text with some links.

Pg2- lots of Links only.


Please feed back with comments / alterations / suggestions / criticism / info etc to the -
Basic guide to workshop safety - comments thread.

Basic Workshop Safety Guidance - Pg1

A lot of forum members are lone workers, therefore are much more vulnerable than a factory worker carrying out the same process. A simple trip over a cable, fracturing your skull on a steel vice as you fall and not being found for a few hours, could turn into a funeral, so safety is even more important to a DIYer.

This document is not meant to be a comprehensive guide to safe working, more a signpost to help you find the safest working methods for your individual circumstances.
There will be many omissions and lots of Do’s & Don’ts.
The guidance is issued for your Health and Safety. Following the guidance is not compulsory and you are free to take other action.

Disclaimer.

1. Any advice or links given within the forum, are purely to assist forum readers to ascertain for themselves, the safety of any process they wish to undertake.
2. No liability of any kind may be addressed to the forum or its contributors for any reason.
3. Each forum reader must judge for themselves if the process they wish to undertake complies with the Laws & Health & Safety Regulations of the Country /State in which they reside.
4. Any reference to products or links to company’s web sites are purely for illustration / example & do not constitute endorsement of any product, process or company.


1 - PROTECTING YOURSELF. (PPE = Personal Protection Equipment)

Always, and with no exceptions, wear eye protection. link
(The time saved by not looking for eye protection is soon lost sitting in A&E while they dig bits out of your eye, or fit you with a false eye).
Use an additional full face visor when cutting, grinding, wire brushing etc. link
When eye protection is scratched or damaged, REPLACE IT. (cheaper than eyes)

If you do think theres something in your eye, get it checked, dont be tempted to leave it to sort its self out. The longer its in there the worse it becomes

Always use ear muffs or ear plugs when doing any noisy work, particularly grinding, hammering. link
Deafness tends to occur 1 – 5 years after initial damage, and is irreversible.
(My ears were permanently damaged by tool screech from a lathe in a workshop, where I was working without ear protection . Jugs).
Also -
(Originally Posted by londonsean69
My hearing is going, at the age of 27 Mainly due to spending a lot of time in very loud clubs, and caning the volume on my walkman, and as a young idiot I never once used ear defenders)
If someone just starts speaking to me it takes me a few seconds to realise, they really need to get my attention first so I can 'tune in' to them. And it's only going to get worse. Sean )


Breathing safely. (A good thing to do)

Face masks link should be worn when doing any light dusty work - grinding, sanding, wire brushing etc.
Respirators link should be used for heavy or prolonged grinding, sanding, wire brushing, and for welding painted, electroplated, or zinc coated components. For this you may also consider air-fed masks.
Air-fed masks link should be used when working in inadequately ventilated areas, for heavy duty spraying, or for welding certain poisonous combinations of gas and metals.
The air MUST be drawn from a clean source outside the work area & filtered.
(Breathing bad air even for a few minutes is very stupid, if you’re lucky it kills you, if you’re unlucky, it maims you for life).

Protecting yourself from gas and fumes link

Headwear. Advisable to stop hot or sharp particles from damaging your scalp (or hair if you’ve got any).
Always use when near machinery (to prevent hair being ripped out, or worse, being scalped).
When welding use Welding hats, eg Kromers, or thick cotton baseball caps turned backwards . link

Gloves.
Do wear the appropriate gloves for angle grinding, cutting, welding, handling hot or sharp components, chemicals, paint etc. link
Discard oily or torn gloves.

Be extra careful using hand held machines.

Don’t wear gloves (exept latex) when operating machines, such as lathes, millers, drills, bench grinders, wire wheels. (When the glove catches, your hand / arm could be pulled into the machine & you would suffer injury or death.)


General Clothing. No loose or ragged clothes should ever be worn in a workshop, particularly where any revolving machinery is used. Severe injury / death may result.
Never risk wearing any jewellery – no rings (they get squezzed cutting blood supply = lose a finger) , earrings (get ripped out = lots of blood), necklaces, watches (are good aids for receving electric shocks ).

Best to wear close fitting overalls, cotton not polyester (it melts).
If welding, buy flame retardant overalls. link
Don‘t tuck overall legs into boots, (hot swarf and weld spatter will get in your boots & hurt).
For welding, cutting, grinding use a leather apron to protect your overalls. link

Footwear. Sparks burn through trainers very easily so wear - Strong shoes / boots, preferably steel toe capped (stubbed / broken toes ain’t fun)
No long laces to trip you up. link


2 - WORKSPACE. Try to keep area tidy.

Always know your escape routes (at least 2)

No trailing cables or pipes. (If you must, run them along the edge of work areas ) (Trip Hazard.)
Put old rags/paper out of the way. (Fire hazard)
Clean up liquid spills. (Slip hazard)

In welding areas, paint walls dark, (to avoid reflections which might cause arc eye).

It’s advisable that all Food & Drink be kept out of workshops (but we all like a cuppa on the bench so use a covered ‘thermal cup’ to keep the crud out). NEVER have food or drink where it can be contaminated, eg near welding or any process that you should be wearing a mask or respirator for.

Have the appropriate fire extinguishers close to posible sorces of ignition + near door, & know how to use them. link
Keep flammable stuff link in a steel cabinet vented to the outside. This should be outside the main work area, but never near an exit (you may be the one trapped).

Make sure you have adequate lighting - at least 2 separately fused sources, (to avoid being plunged into total darkness, with, say, a saw or pneumatic angle grinder still running).

Never aim compressed air on to the skin. (It can enter the blood stream giving you an embolism leading to death).
Use safety blowdown guns.
Flexible AIR-lines must be fitted with self-sealing couplings. (A disconnected airline thrashing about can break your ribs).


3 - PORTABLE POWER TOOLS – pneumatic & electrical
eg. Drills, grinders, sanders, saws…

All these machines can give you hand & arm injury such as, Vibration White Finger, so don’t use for prolonged periods without anti-vibration gloves. link

Inspect power cables regularly - (a chafed cable can make an unearthed piece of metal live. YOU could be the path to earth !!!)
Don’t operate broken or defective tools.
Don’t operate without wearing correct PPE. see section 1
Don’t operate anything with the safety devices or guards defeated / disabled / removed.

Don’t change blades, discs, drills etc with the power connected.
(If you snag the on switch, HORROR !!! ..many tools are over 2 HP. A kitchen blender is only 1/3 HP – would you put your hand in one?)

Angle grinders can be lethal. Make sure wheels / discs are properly mounted using only the correct nut & washers. See maker’s handbook.
Destroy & discard damaged / broken discs immediately. (At high speed they can explode)

Because of the danger & the popular use of angle grinders, the following is more detailed information -

1. People who do not protect themselves as best they can from a mishap using a grinder, including their torso, neck, face and head, and hands are putting their life at risk – no one is perfect and all machines fail. “The gun is always loaded, and the horse always kicks”.

2. Bonded abrasives, such as many cutting wheels, are generally made from an organic resin, and as such, have a “life”. Over time they lose their effectiveness. A newly manufactured disc will always cut faster and last longer than one that is 12 months or 2 years old. One of the first things people who work in kitchens are taught is that a sharp knife is safer than a blunt one: there is less temptation to exert excessive pressure and therefore less chance of a slip that causes injury. The same applies to cutting wheels. A very sharp, good quality cutting wheel will slice quickly, with just the weight of the grinder, allowing the user to concentrate on keeping a straight blade along the desired line of cut while maintaining a sensible balanced hold on the machine.

3. Thin Cutting wheels (especially) should only be used letting the “weight” of the grinder do the work. Thin Cutting Wheels should only be used for cutting straight cuts, never curves, and they should never be twisted or bent.

4. All abrasives, including those used on hand – held grinders, bench grinders, linishing machines etc. should only be used in one direction, whatever the situation. For example, with a cutting wheel, the edge of the wheel used to make the cut needs to be that edge that if the wheel binds, will “kick” the grinder AWAY from the user – not towards the user. They should never be used the other way.

5. Cutting wheels with a metal ring around the arbour should always be fitted with the metal ring facing in towards the grinder. Some grinders have a small void in the clamping ring. In these cases, although unusual, it is possible for the metal ring to fall away from the Wheel and into this void. These metal rings also curve into the hole in the Wheel, and so when they are dislodged, there is a fine gap between the hole in the wheel and the grinder’s spindle. This may allow the wheel to move off centre, which, at 15,000 RPM, can be very dangerous.

6. Thin cutting wheels should always be protected from being dropped or bumped sideways. Always discard a thin cutting wheel (and any other cutting wheel for that matter) where any damage may have been done to its structural integrity.

7. All different sized hand held grinders run at different speeds and all tools used on these machines are generally manufactured with these speeds in mind.

For example, a 3” cutting wheel – used on an air tool generally has a maximum speed of approx. 20,000RPM, while a 4” cutting wheel generally has a maximum speed of approx 15,000RPM, and a 5” (125mm) Cutting Disc generally has a maximum speed of approx: 12,000RPM.

It is dangerous to use the wrong sized Wheel on a grinder, either faster or slower.
Individuals that remove guards to fit larger wheels on faster grinders should always make sure that their personal affairs, including wills & life insurance, are in order.



4 - NON-POWERD TOOLS.
Hammers, chisels, punches, saws, files, spanners etc.

Never work with blunt, broken or cheap tools, they will slip, or suddenly disintegrate – (usually hurting you).
Spend a few minutes finding the correct tool, (because it takes several weeks for skinned knuckles to repair).
Always fit handles on files.
Grind any sharp mushrooming off cold chisels -(the burrs can shatter of and fly asound the workshop at speed).
Always use the correct size spanner (not an oversize with a screwdriver jammed in).

Learn the correct way to use tools (not always apparent)
Eg hacksaws actually cut better on the back stroke, so fit the blade with the teeth pointing towards you, and pull to cut. You have more control so blades last longer & don’t shatter, cuts are straighter & you’re less lightly to hurt you’re self.
After a few times it becomes normal.



5 - WORKING

Do not use workshop or tools when tired, ill, under the influence of drugs (prescribed or otherwise!) or alcohol.

Do plan ahead of each job before starting it.
(HSE call it risk assessment… We call it common sense).
Do the job twice in your head & once for real.

Eg When you cut that steel sheet, think – will the scrap fall, cutting the pipe to the propane gun, allowing gas to be ignited by the parafin heater, and can I run at over 800mph – or should I just re-route the pipe, and support the off-cut.

If you have to work in a confined space, arrange for someone to be standing by. Give them full instruction of what to do in case of emergency – before you start work.

Clamp your work, particularly when drilling thin sheet.
(Sheet steel spinning in a drill will take your fingers off before you can say “Bug…r”)

Never poke your fingers in holes – (the finger monster may well bite the end off !)

Lifting - is one of the biggest causes of long term injury. Link

Learn to lift correctly. DON’T struggle, arrange for someone to help.
Use jacks, chain blocks & other lifting apparatus.

Don’t support heavy objects on jacks, empty oil drums, bricks, etc. (they can collapse without warning),
- use timber blocks or properly designed steel frames.



6 - MORE INFORMATION is available from –

The videos & links on the Safety LINKS page, BOOKS on Workshop Practice, the WEB, a basic engineering course @ a local College…

…. And this FORUM ..... It may feel silly asking “a dumb question”, but it is stupid not to.


_________________
Basic Workshop Safety Guidance - Pg1 by Jugs

Basic Workshop Safety Guidance -Pg2 - Links Page.

Health & Safety Links.
Any reference to products or links to company’s web sites are purely for illustration / example / information & do not constitute endorsement of any product, process or company.

Protective Clothing (PPE)-

Visor / Face Shield - http://www.machinemart.co.uk/shop/pr...al-face-shield

Safety Specs - http://www.arco.co.uk/static/safety_glasses.html + http://www.axminster.co.uk/product-A...pecs-21419.htm

Ear defenders - http://www.machinemart.co.uk/shop/pr...ear-protection

Leather Apron - http://www.welding-supplies-online.c...-4-36-38.ihtml

Leather Sleeves - http://www.welding-supplies-online.c...-4-36-33.ihtml

Gloves Welding - http://www.diywelding.co.uk/products.asp?d=5&c=23

Gloves Anti-vibration - http://www.seton.co.uk/setoneurope/c...0300779-3.html

Gloves Latex - http://www.justgloves.co.uk/?gclid=C...FQ9RQgodLj9CCw

See also > Latex Allergy -http://www.medicinenet.com/latex_allergy/article.htm

Flame Retardant Coverall - http://www.cjsafety.co.uk/products_v...D=22&category=
+ http://www.machinemart.co.uk/shop/ra...lls-workwear-2

Safety Boots - http://www.safetybootsuk.co.uk/safet...or-c-5118.html

Masks & Respirators -
Dust mask - http://www.hivis.net/c73/Respiration...Fc0e3godGk8hCw + http://www.machinemart.co.uk/shop/pr...ks-respirators

Air feed mask - http://www.machinemart.co.uk/shop/pr...ks-respirators + http://www.machinemart.co.uk/shop/ca...ks-respirators


Safety Equipment Supplies -http://www.safetysupplies.co.uk/trolleyed/index.htm

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Fire & Fire-extinguishers. -

http://www.fireprotectiononline.co.u...FRqH1QodPSb_hA

+ http://www.actfire.co.uk/general/fir...her_advice.php

+ http://www.firesafe.org.uk/html/fsequip/exting.htm

+ http://www.fire.gov.uk/Workplace+saf...alPrecautions/


Flamable liquid storage -http://www.hse.gov.uk/fireandexplosi...ammliquids.htm

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PERSONAL SAFETY

Hand / arm Vibration - http://www.hse.gov.uk/vibration/hav/yourhands.htm

Vibration White Finger - http://www.medterms.com/script/main/...ticlekey=19739

Noise & Hearing. - http://www.hse.gov.uk/noise/worried.htm


Eye Problems-

Arc eye - http://en.wikipedia.org/wiki/Arc_eye

Anti flash spectacles -http://multimedia.3m.com/mws/mediawe...6EVs6E666666--

+ http://www.eyesafety.4ursafety.com/terms.html

+ http://www.yamout.us/eyeinformation/...isks_of_uv.htm

Eye damage thread - http://www.mig-welding.co.uk/forum/s...ead.php?t=8725


Spinal Injury / Lifting - http://www.orthonurse.org/portals/0/...ack%20pain.ppt


Nasty Accidents Thread. - http://www.mig-welding.co.uk/forum/s...ighlight=nasty

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SAFETY TRAINING VIDEOS - (Look for the video No on each site, Click on > On Line Preview)

Hand Injuries (1020b) - http://www.safetytrainer.com/videos/gory/impact.htm

My Precious Eyes (1023b) - http://www.safetytrainer.com/videos/gory/impact.htm

Eye Protection- A New Approach (9022a) - http://www.safetytrainer.com/videos/auto/automotive.htm

Hand & Power Tool Safety (9007a) - http://www.safetytrainer.com/videos/auto/automotive.htm

MORE SAFETY FILMS -

Cutting, Filing, Grinding and Fitting Metal for Welding (Safely). - http://uk.youtube.com/watch?v=PXmQX4...eature=related

Example of dangerous grinding (not properly protected –or controlled. - http://uk.youtube.com/watch?v=f74U6J...eature=related

Correct grinding techniques, but NO ear protection - http://uk.youtube.com/watch?v=Ro3dT9...eature=related

Metal Forming - Part 1 - http://uk.youtube.com/watch?v=AiBnWJD0HIc&NR=1

Metal Forming - Part 2 - http://uk.youtube.com/watch?v=wtj_Gh...eature=related

Basic MIG Welding Safety. –Part 1 - http://www.youtube.com/watch?v=lzBGZaS1apw&NR=1

Basic MIG Welding techniques + Safety Part 2. - http://www.youtube.com/watch?v=sMdQT-eswYY&NR=1


Oxy-Acetylene Cylinder explosions -

O2 CYLINDER EXPLOSION. Don’t play with High Pressures. - http://uk.youtube.com/watch?v=9lw_fh...eature=related

Oxy-Acetylene Cylinder explosion in a van. - http://uk.youtube.com/watch?v=uUmLe9...eature=related


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GENERAL INFO -

H&SE. main site - http://www.hse.gov.uk/mvr/index.htm

COSHH. Main site - http://www.hse.gov.uk/coshh/index.htm

MISCELLANEOUS -

COSHH essentials for welding, cutting and allied tasks. -http://www.hse.gov.uk/welding/guidance/index.htm


Electrical –
Installation - http://www.planningportal.gov.uk/upl...LESenglish.pdf

Document P Electrical Safety -http://www.communities.gov.uk/public...building/partp

+ http://www.surreycc.gov.uk/sccwebsi...+safety+before+doing+it+yourself?opendocument