Kevin Ian Schmidt

Preventing Tech and Mechanic Injuries

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Based on the Bureau of Labor Statistics injury and illness report, automotive techs and mechanics experience 13,150 nonfatal occupational injuries and illnesses resulting in valuable time away from work. Auto mechanics and technicians work with dangerous machinery, tools and chemicals, often in cramped spots, which puts them at greater risk for a workplace injury.

Just one workplace injury can have many negative repercussions beyond the employees’ injury.

For business owners, these could include higher wage replacement or medical costs, repairs to damaged equipment and increased workers’ compensation insurance premiums.  Business owners can help keep employees safe by understanding the common causes of auto shop accidents, providing regular training and requiring all staff to follow important safety procedures. There are many private organizations that can provide local on-site training and materials. The Occupational Safety and Health Administration (OSHA) provides comprehensive standards information online to help business owners keep employees safe and stay in compliance.

These tips can improve the safety of auto mechanics and help them avoid accidents.

For injured employees, these could be the loss of wages or worse a life altering injury. Employees should also strive to work safely, and ask for guidance of tasks in which they are unsure on how to work safely. To get this buy-in from employees, it requires a strong safety culture built around reporting all issues, and hazard identification.

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Below are the most common injuries and illnesses  mechanics and technicians experience at work, as well as practical steps to mitigate auto shop injuries:

  • Sprains, strains and tears. These are the leading injuries sustained by auto mechanics and auto technicians. Repetitive motions while working under the chassis or hood can increase the likelihood of a sprain or strain. Lifting and lowering machinery and heavy tools can also contribute to these types of injuries. A few minutes of morning warm-up exercises can make a big difference in the health and safety of workers.
    • Proper Lifting – Mechanics work with vehicle lifts on a regular basis and have to lift heavy auto parts and other heavy items. Using proper lifting techniques is extremely important, as lifting properly can prevent back injuries and other types of accidents. Workers should bend their knees while lifting and use the power of their legs to pick up objects. A mechanic should never bend over and lift with the back, as this can cause muscle strains and other injuries. Workers should use caution when working with vehicle lifts, as using them improperly can cause crush injuries and even deaths.
      • Back Safety & Lifting Technique: Virginia Commonwealth University explains how to lift properly to prevent back injuries.
      • Material Handling Program (PDF): The University of Texas at Austin provides tips for safe manual and mechanical lifting.
      • Forklift Safety (PDF): Mechanics sometimes need to use forklifts to move heavy parts. This resource from the Oregon Occupational Safety and Health Administration explains how to use this equipment safely.

Consider implementing a low-cost workplace stretch-and-flex program. These low-impact exercises can help reduce sprains, strains and tears.

Check Out: Safe Lifting and Carrying Training
  • Eye injuries. Each day, approximately 2,000 U.S. workers sustain a work-related eye injury that requires medical attention. Working under cars and hoods puts auto shop workers at particular risk for these kinds of injuries. .
    • Eye Protection – Mechanics have an increased risk of eye injury because of the work they do with chemicals and small auto parts. Auto shop workers should always wear eye safety equipment when working with chemicals, welding, grinding, or performing any work that poses a risk of injury. Safety goggles should surround the eyes completely to prevent debris or liquids from entering the eye.
      • Eye Protection in the Workplace: This article from the U.S. Department of Labor explains the most common causes of eye injuries in the workplace and discusses the prevention of these injuries.
      • Eye Safety Checklist: The Centers for Disease Control and Prevention offers a checklist for preventing eye injuries in the workplace.

The best way to prevent them is to make sure workers wear safety glasses at all times

  • Chemical burns. Flammable and hazardous liquids and chemicals should be properly labeled following Occupational Safety and Health Administration (OSHA) standards. Labels are required to have a pictogram; a signal word, like “danger”; hazard and precautionary statements; the product name and the supplier identification. They also need to include safety handling information and what to do in case of exposure. It’s also important to routinely check containers around the shop to make sure lids fit tightly and there is no spillage or leakage.
    • Chemical Burns – Solvents, paints, vehicle fluids, and other chemicals can cause poisoning if ingested or if they come into contact with the skin for a long period of time. Mechanics should avoid eating and drinking in their work areas, as chemicals can contaminate foods and beverages. All chemicals should be labeled so that there is no question as to what each fluid container holds. Mechanic shops should have material safety data sheets where they can be quickly and easily found, as the information on these sheets can help poison control workers determine the best way to treat a chemical poisoning victim.

Workers should wear protective gloves and glasses any time they handle chemicals.

Check Out: Hazard Communication Plan
  • Loss of limb or digit, or just cuts and lacerations. Working with power tools like angle grinders and electric metal shears can increase the risk of losing a limb or digit. Train employees to always follow proper equipment operating instructions, keep guards in place and wear proper protective gear when working with power tools.
    • Wearing Gloves – In addition to their work with caustic chemicals, mechanics also have to worry about exposure to hot engines and injuries from sharp equipment. Auto shop workers should always wear gloves to prevent chemical burns, chemical irritation, heat burns, cuts, and other types of injuries. These gloves should be left in the workplace at the end of each shift so that dangerous chemicals are not transferred from the garage to the home.
      • Codes of Safe Practices – Mechanics (PDF): This resource explains how to use personal protective equipment to prevent eye injuries, burns and other types of injuries.
      • Glove Selection Guidance: Imperial College London explains the benefits of wearing gloves in the workplace and offers advice for selecting the right gloves for various hazards.

Safely stow all tools when any job is complete, and conduct routine inspections to make sure tools are in safe operating condition.

Check Out: Hand and Power Tool Safety Plan
  • Slips, trips and falls.  Oil changes, transmission flushes and other routine vehicle maintenance procedures that involve slippery or greasy fluids can make the shop floor slick, increasing the risk of accidents. Make sure technicians wear close-toed, anti-skid footwear.
    • Floor Care – Oil changes, transmission fluid changes, and other vehicle maintenance procedures involve working with slippery fluids that can coat the garage floor and increase the risk of accidents. Mechanics should clean up spills immediately, as slick spots increase the risk for slip-and-fall injuries. Leaving chemicals on the floor also increases the risk of chemical inhalation, which can cause respiratory irritation and other problems. Auto shop workers should also take care in putting away auto parts and repair tools, as leaving them on the floor increases the risk that someone will trip and fall. Anyone who works in a garage should wear boots with non-slip soles. These boots will prevent slip-and-fall accidents and provide protection in the event that something falls on the feet.
      • Prevention of Slips, Trips and Falls: The Canadian Center for Occupational Health and Safety explains how to avoid slip-and-fall accidents in the workplace.
      • Foot Safety: This resource explains how to select a safety boot for the workplace. The article discusses the use of steel-toed boots and other types of safety footwear.

Keep the floor clear and uncluttered and clean up spills as soon as they occur. Place cones or signage to warn workers of slick areas.

Check Out: Slip, Trip, and Fall Audit

By taking proactive steps to address potential workplace risks, auto shop owners can reduce the likelihood of an employee injury or illness and keep their businesses safer.

Training and Certification

Proper training is one of the best ways to prevent accidents and injuries in auto shops. Every shop should have a formal safety training program that every employee must complete. The safety program should include information on wearing personal protective equipment, identifying workplace safety hazards, reducing the risk of electrocution, working with hazardous chemicals, and procedures for reporting safety hazards to management. Employers should also encourage employee participation in workplace safety committees. Safety committee members should regularly inspect work areas and identify any potential hazards. Once identified, hazards should be removed or repaired immediately.

Certification is also another important part of keeping the workplace safe for everyone. Employers should consider offering employees increased pay if they successfully complete a relevant certification program. In addition to mechanic certification, auto shop workers can take certification courses in working with hazardous materials, using forklifts, and using heavy equipment. The Occupational Safety and Health Administration also offers a voluntary training course that teaches participants how to identify and fix workplace hazards.

 

Fact sheets on best practices

  • Profit Through Prevention
    This fact sheet is the first in a series highlighting the best environmental practices for automotive repair shops and fleet maintenance facilities. The step-by-step instructions can help you reduce waste, avoid regulatory problems, and save money.
  • Aqueous Parts Cleaning
    Using solvents creates unnecessary environmental, worker health, and fire liabilities for your shop. With this fact sheet, learn how to minimize costs and liabilities by switching from solvents to aqueous (water-based) solutions.
  • Case Studies In Aqueous Parts Cleaning
    Each of the shops featured in these case studies successfully switched from solvent to aqueous parts cleaning. These case studies prove that aqueous cleaners are capable of meeting or exceeding the many parts cleaning challenges encountered in a wide variety of automotive repair operations.
  • Aqueous Brake Washers
    Aqueous brake washers perform as effectively as traditional solvent washers, they are better for the environment, and they reduce hazardous waste management costs and liability.
  • Antifreeze Recycling
    Learn why it is important to recycle waste antifreeze and get started recycling your waste antifreeze.
  • Refillable Spray Bottles
    This fact sheet is designed to help automotive repair shop owners and fleet managers make informed decisions about implementing refillable spray bottles.
  • Floor Cleanup
    The methods and equipment presented in this fact sheet will help you reduce floor wash water volume and contamination.
  • Oil Water Separators (OWSs)
    This fact sheet discusses the basic operation of OWSs in handling vehicle and floor wash water, and techniques to improve OWS performance and reduce costs and liabilities.

Additional fact sheets for fleet maintenance

  • Reusable Oil Filters
    Reusable oil filters are an alternative to conventional oil filters and can last up to the life of a vehicle, eliminating the waste stream created by conventional disposable filters.
  • Oil Life Extension
    This fact sheet describes how a testing program can extend engine oil life and thus lower oil consumption, reduce used oil generation, and decrease operating costs with no risk to your vehicles.

Automotive repair and fleet maintenance pollution prevention case study

 

Auto repair shops must take safety seriously in order to stay in business. If they do not follow safety precautions when it comes to operating machinery or handling chemicals, it can lead to injuries, lost work time, and staff loss, as well as potential lawsuits or workers’ compensation claims. One important step in establishing a positive safety environment is to create a safety manual and train your employees on its policies.

WHAT DOES A SHOP SAFETY MANUAL INCLUDE?

To begin with, your shop’s safety manual should include instructions on what employees should do in case of a true emergency: a fire, an explosion, an earthquake, a flood, or a blizzard. It goes without saying that in addition to these instructions, employees should be regularly trained on what to do in case of emergency. All emergency equipment, such as fire extinguishers, first aid kits, goggles, and gloves, must be provided and maintained. Employees should also be trained to observe OSHA standards such as keeping exits clear and ensuring that their work areas are always properly ventilated.

In addition to major emergencies, your manual should contain instructions for what to do for other lesser emergencies like accidents, cuts, burns, or chemical spills. Because auto repair shops must use sharp tools, power tools, and chemicals to repair cars, your employees should be trained on how to do their work in ways that would minimize risk of accident or injury. Adding incentive programs for maintaining an accident-free workplace or rewarding employees who model your safety program are inexpensive ways to emphasize your shop’s commitment to safety.

ESSENTIAL SAFETY POLICIES

The following are policies that should be included in any auto repair shop safety manual:

Do not smoke in or around the repair bays or garages. The chemicals that are stored or are in use there are extremely flammable, and smoking is an unacceptable risk. If your company has a no smoking policy, this will, of course, be covered under that. Three or four decades ago, it might have been impossible to enforce this kind of policy, but smoking has been essentially pushed from most workplaces today.

Keep workspaces clean and organized. Put away tools when they are not in use.

Make sure all exits are clear and free of clutter.

Do not wear clothing that is loose, torn, or that could catch on equipment and endanger you. (A good dress code policy makes it easy for all employees to know what to wear.)

Wear protective gear. This includes, but may not be limited to goggles, gloves, and ear protection.

Keep safety equipment like fire extinguishers accessible and well maintained.

When working on a vehicle, remove the keys from the ignition switch. Also: disconnect the car’s battery when working on an electrical system or with wiring. A car with a key in the ignition switch can still draw current from the battery, so avoid unplugging fuses or working on wiring until you have made sure that no current can pass through the system and shock you or cause electrical damage to the vehicle.

Check the temperature of the car before working on the engine, manifold, exhaust system or the radiator as they can all cause burns when they are hot. Do not open the radiator until the car has had a chance to fully cool down.

Keep your hands, tools, and other objects away from the engine while it is running so that nothing gets caught on any moving part within.

Double check that any vehicle you are working on is fully supported before working underneath it.

Read the labels on any chemicals used in the auto shop. Workers should be aware of any hazardous chemicals used or stored in the auto shop. All chemicals should be clearly labeled and carefully stored according to the proper guidelines.

These are only the most obvious of safety tips. OSHA has extensive guidelines about all facets of safety for auto repair shops that managers must be aware of and follow to the letter or face fines or other action. An employee safety manual cannot contain all of that information, however. It’s too overwhelming. When creating your safety manual, it’s a good idea to seek input from your staff. They are on the frontlines of the work and may have good ideas about steps to take to avoid accidents. They also will have ideas about how to go about familiarizing themselves with the information. They will train the workers whose job it will be to maintain the safety culture you establish in your shop.

Does your auto repair shop have a safety manual? What further safety tips does it include?

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