Kevin Ian Schmidt

Electrical Safety

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Every quality safety and health program provides measures to control electrical hazards. The information provided in this training should be helpful in getting a better understanding of electrical safety. The responsibility for an electrical safety program should be delegated to someone with a complete knowledge of electricity, electrical work practices, and the appropriate OSHA standards for installation and performance.

Everyone has the right to work in a safe environment. Safety and health add value to your business and your workplace. Through cooperative efforts, employers and employees can learn to identify and eliminate or control electrical hazards.

Electrical Hazard Recognition

Electricity has long been recognized as a serious workplace hazard, exposing employees to electric shock, electrocution, burns, fires, and explosions. According to the Bureau of Labor Statistics, in 2016, 134 workers died from electrocutions, which represents a decrease from 174 in 2011. What makes these statistics tragic is that most of these fatalities could have been easily avoided.

The first step toward protecting yourself is recognizing the many hazards you face on the job. To do this, you must know which situations can place you in danger. Knowing where to look helps you to recognize hazards.

  • Inadequate wiring is dangerous.
  • Exposed electrical parts are dangerous.
  • Overhead powerlines are dangerous.
  • Wires with bad insulation can shock you
  • Electrical systems and tools that are not grounded or double-insulated are dangerous.
  • Overloaded circuits are dangerous.
  • Damaged power tools and equipment are electrical hazards.
  • Using the wrong PPE is dangerous.
  • Using the wrong tool is dangerous.
  • Some on-site chemicals are harmful.
  • Defective ladders and scaffolding are dangerous.
  • Ladders that conduct electricity are dangerous.
  • Electrical hazards can be made worse if the worker, location, or equipment is wet.
Check Out: How to Conduct a Job Hazard Analysis

Electrical Terms

What are Volts? A Volt is a measure of the electrical force that seems to push current along. Think of voltage as a lot of water stored in a high water tank. Because the water tank is high, the water will have more force behind it as it flows down the water pipe to your home. This is why they put water tanks up high! If the same tank was placed at ground level, your water pressure would not be as great. By the way, the symbols commonly used for voltage are “E” or “V”.

What is an “ampere?” An ampere is the unit used to measure the amount of electrical current. Amperage is often referred to as “current” by electrical workers and engineers. Let’s go back to our water tank. If the diameter of your pipe coming from the water tank is large, a lot of water (amperage) will flow through the pipe. If the pipe’s diameter is small, a smaller amount of water will flow through the pipe. If you need a lot of current (many amps) to operate your equipment, you’ll need large wires to run the current or they’ll burn up! The symbol for amperage is “I”.

What is an “ohm?” Think of an ohm as “resistance“. An ohm is the unit used to measure the opposition (a.k.a. resistance) to the flow of electrical current. This is pretty easy to understand. A small water pipe is going to oppose a lot of water from flowing. Relatively little water will be able to flow through the pipe. So, the pipe offers a high resistance to the flow of water. You can see that a large pipe would offer little resistance to the flow of water. Big pipe: a lot of water! It’s that simple. In an electrical circuit, components are usually sources of resistance. Any component that heats up due to electrical current is a source of resistance. The symbol for resistance is “R”.

    • What is a “series” circuit? The current in a series circuit takes only one path. For example, water from high in the mountains may flow down one stream (series) into a river that flows to the ocean.
    • What is a “parallel” circuit? The current in a parallel circuit takes many paths. For example, the water flowing from a water tank up on a hill will flow through many different water pipes (parallel) before it reaches the ocean.

Effects of Electrical Current on the Body

Current Reaction
1 milliamp >Just a faint tingle.
5 milliamps >Slight shock felt. Disturbing, but not painful. Most people can “let go.” However, strong involuntary movements can cause injuries.
6-25 milliamps (women)†
9-30 milliamps (men)		 >Painful shock. Muscular control is lost. This is the range where “freezing currents” start. It may not be possible to “let go.”
50-150 milliamps >Extremely painful shock, respiratory arrest (breathing stops), severe muscle contractions. Flexor muscles may cause holding on; extensor muscles may cause intense pushing away. Heart fibrillation possible. Death is possible.
1,000-4,300 milliamps (1-4.3 amps) >Rhythmic pumping action of the heart ceases. Muscular contraction and nerve damage occur; death likely.
10,000 milliamps (10 amps) >Cardiac arrest and severe burns occur. Death is probable.
15,000 milliamps (15 amps) >Lowest overcurrent at which a typical fuse or circuit breaker opens a circuit!
*Effects are for voltages less than about 600 volts. Higher voltages also cause severe burns.
†Differences in muscle and fat content affect the severity of shock.

Overloading an Electrical System Hazard

Overloads in an electrical system are hazardous because they can produce heat or arcing. Wires and other components in an electrical system or circuit have a maximum amount of current they can carry safely. If too many devices are plugged into a circuit, the electrical current will heat the wires to a very high temperature. If a tool uses too much current, the wires will heat up.

The temperature of the wires can be high enough to cause a fire. If their insulation melts, arcing may occur. Arcing can cause a fire in the area where the overload exists, even inside a wall.

To prevent too much current in a circuit, a circuit breaker or fuse is placed in the circuit. If there is too much current in the circuit, the breaker “trips” and opens like a switch. If an overloaded circuit is equipped with a fuse, an internal part of the fuse melts, opening the circuit. Both breakers and fuses do the same thing: open the circuit to shut off the electrical current.

If the breakers or fuses are too big for the wires they are supposed to protect, an overload in the circuit will not be detected and the current will not be shut off. Overloading leads to overheating of circuit components (including wires) and may cause a fire.

You must recognize that a circuit with improper overcurrent protection devices – or one with no overcurrent protection devices at all – is a hazard.

Hopefully you have learned about electricity here, it presents a hazard, which can be unseen and is often overlooked.

Consider testing your knowledge on electrical safety with this quiz

 

 

Download the Electrical Safety Training below:

View the Electrical Safety Training below:

electrical safety u of cal

OSHA Citations Explained

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OSHA has a scale for citations, which measures and accounts for the issues they find in the workplace.

 

OSHA Citations Explained

  • Willful violation: A willful violation is cited when the employer intentionally and knowingly commits the violation. It is also cited when the employer commits a violation with plain indifference to the law. OSHA may propose penalties of up to $145,027 for each willful violation.
  • Repeated violation: This violation is cited by OSHA when it is the same as a similar or previous violation. OSHA may propose penalties of up to $145,027 for each repeated violation.
  • Serious violation: OSHA cites a serious violation where there is substantial probability that death or serious physical harm could result and that the employer knew, or should have known, of the hazard.
  • Other-than-serious violation: An other-than-serious violation is cited when the violation has a direct relationship to safety and health, but probably would not cause death or serious physical harm. OSHA may propose penalties of up to $14,502 for each serious, other than serious, and repeated violation.
  • Failure to abate: When the employer fails to abate a violation, a maximum of $14,502 may be proposed for per day unabated beyond the abatement date. Generally there is a 30-day maximum limit.
  • Falsifying information: An employer that provides false information to OSHA can receive a fine up to $14,502 or up to six months in jail, or both.

State Plan States

States that operate their own Occupational Safety and Health Plans are required to adopt maximum penalty levels that are at least as effective as Federal OSHA’s.

Want to avoid citations? Learn how to conduct a mock OSHA inspection

OSHA cites employers, not employees. It’s important to know that the OSHA Act does not provide for the issuance of citations or the proposal of penalties against employees. Employers are responsible for employee compliance with the standards.

Penalty Adjustments: OSHA may adjust penalties downward depending upon the employer’s size (maximum number of employees), good faith, and the history of previous violations. Adjustments may be applied as follows:

  • A 10 percent reduction may be given for history.
  • A maximum of 25 percent reduction is permitted for good faith; and
  • A maximum of 80 percent reduction is permitted for size.
Employees Percent reduction
10 or fewer 80
11-20 60
21-30 50
31-40 40
41-50 30
51-100 20
101-250 10
251 or more 0

Fire Prevention Plans – In-depth

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An important reason to have a Fire Prevention Plan (FPP) is to identify and mitigate the causes of fire, prevent loss of life, and prevent loss of property caused by fire. The FPP should be developed to comply with the OSHA standard 29 CFR 1910.39, Fire Prevention Plans.

A quality FPP does the following:

  • Provides employees with information and guidelines that will assist them in recognizing, reporting, and controlling fire hazards.
  • Identifies materials that are potential fire hazards and their proper handling and storage procedures.
  • Distinguishes potential ignition sources and the proper control procedures of those materials.
  • The plan describes fire protection equipment and/or systems used to control fire hazards.
  • Identifies persons responsible for maintaining the equipment and systems installed to prevent or control ignition of fires.
  • The FPP identifies persons responsible for the control and accumulation of flammable or combustible material.
  • Describes good housekeeping procedures necessary to insure the control of accumulated flammable and combustible waste material and residues to avoid a fire emergency.
  • The plan provides training to employees with regard to fire hazards to which they may be exposed.

Fire safety is every employee’s responsibility. All employees should know how to prevent and respond to fires, and are responsible for adhering to company policy regarding fire emergencies.

Management: Management determines fire prevention and protection policies. They should do the following:

  • Managers should provide adequate hazard controls to provide a safe workplace.
  • Managers should also provide adequate resources and training to employees to encourage fire prevention and the safest possible response in the event of a fire emergency.

Plan Administrator: This person maintains all records pertaining to the plan. The Plan Administrator should also:

  • Develop and administer the fire prevention training program.
  • Ensure that fire control equipment and systems are appropriate and properly maintained.
  • Control fuel source hazards in the workplace.
  • Conduct fire risk surveys and make recommendations for improvement.

Supervisors: Supervisors ensure that employees receive appropriate fire safety training.

  • Supervisors should notify the plan administrator when changes in operation increase the risk of fire.
  • They are also responsible for enforcing fire prevention and protection policies.

Employees: All employees should complete all required training before working without supervision. It’s important that employees also:

  • Conduct operations safely to limit the risk of fire.
  • Report potential fire hazards to their supervisors.
  • Follow fire emergency procedures.

Like an emergency action plan a fire prevention plan must be in writing, be kept in the workplace, and be made available to employees for review. However, according to OSHA, just like an emergency action plan if you have 10 or fewer employees you may communicate the plan orally to employees.

At a minimum, your fire prevention plan must include:

  • A list of all major fire hazards, proper handling and storage procedures for hazardous materials, potential ignition sources and their control, and the type of fire protection equipment necessary to control each major hazard;
  • Procedures to control accumulations of flammable and combustible waste materials;
  • Procedures for regular maintenance of safeguards installed on heat-producing equipment to prevent the accidental ignition of combustible materials;
  • The name or job title of employees responsible for maintaining equipment to prevent or control sources of ignition or fires; and
  • The name or job title of employees responsible for the control of fuel source hazards.

An employer must inform employees upon initial assignment to a job of the fire hazards to which they are exposed. An employer must also review with each employee those parts of the fire prevention plan necessary for self-protection.

Fire Causing Hazards

Electrical Hazards: Electrical system failures and the misuse of electrical equipment are leading causes of workplace fires. Fires can result from loose ground connections, wiring with frayed insulation, or overloaded fuses, circuits, motors, or outlets.

Portable Heaters: All portable heaters should be approved by the plan administrator. Portable electric heaters should have tip-over protection that automatically shuts off the unit when it is tipped over.

Office Fires Hazards: Fire risks are not limited to industrial facilities. Fires in offices have become more likely because of the increased use of electrical equipment, such as computers.

Welding, Cutting, and Open Flame Work: Welding and cutting and working with open flames are obvious fire hazards in the workplace, and in some cases fire watches need to be positioned close by, and barriers may need to be placed between welding and materials that might catch fire.

Flammable and Combustible Materials: If your workplace contains flammable and combustible materials, the plan administrator should regularly evaluate the presence of those materials.

  • Class A Combustibles: These include common combustible materials (wood, paper, cloth, rubber, and plastics) that can act as fuel and are found in non-specialized areas such as offices.
  • Class B Combustibles: These include flammable and combustible liquids (oils, greases, tars, oil-based paints, and lacquers), flammable gases, and flammable aerosols.

Smoking in the Workplace: In an effective FPP, smoking is prohibited in all company buildings. Certain outdoor areas may also be designated as no smoking areas. The areas in which smoking is prohibited outdoors should be identified by NO SMOKING signs.

Fire Extinguishing Systems

A fire extinguishing system is an engineered set of components that work together to quickly detect a fire, alert occupants, and extinguish the fire before extensive damage can occur. All system components must be:

  • Designed and approved for use on the specific fire hazards they are expected to control or extinguish.
  • Protected against corrosion or either made or coated with a non-corrosive material if it may be exposed to a corrosive environment.
  • Designed for the climate and temperature extremes to which they will be exposed.

Fixed Extinguishing Systems: Fixed fire extinguishing/suppression systems are commonly used to protect areas containing valuable or critical equipment such as data processing rooms, telecommunication switches, and process control rooms. Their main function is to quickly extinguish a developing fire and alert occupants before extensive damage occurs by filling the protected area with a gas or chemical extinguishing agent.

Portable Extinguishing Systems: Workplace fires and explosions kill hundreds and injure thousands of workers each year. One way to limit the amount of damage due to such fires is to make portable fire extinguishers an important part of your FPP. When used properly, fire extinguishers can save lives and property by putting out a small fire or controlling a fire until additional help arrives.

 

How to Use a Fire Extinguisher

Even though extinguishers come in a number of shapes and sizes, they all operate in a similar manner.  Here’s an easy acronym for fire extinguisher use:

Pull the pin at the top of the extinguisher that keeps the handle from being accidentally pressed.

Aim the nozzle toward the base of the fire.

Squeeze the handle to discharge the extinguisher. Position yourself approximately 8 feet away from the fire. If you release the handle, the discharge will stop.

Sweep the nozzle back and forth at the base of the fire. After the fire appears to be out, watch it carefully since it may re-ignite!

Make sure all employees who are expected to use fire extinguishers if a controllable fire occurs are properly trained with hands-on practice. There’s no OSHA requirement to actually extinguish a fire or discharge a fire extinguisher during training. However, each employee should handle the fire extinguisher and demonstrate they can perform the PASS steps.

Check out Fire Extinguisher Basics

This video explains how to use a fire extinguisher

P.A.S.S. – Using a Fire Extinguisher from Washington Township on Vimeo.

Training Requirements

Employers should train workers about fire hazards in the workplace and about what to do in a fire emergency.

Management Training Responsibilities. Unless a specific manager is designated, all managers should be responsible for coordinating with the Plan Administrator for training all employees covered under the FPP.

  • All managers should be educated to understand their FPP responsibilities including inspection and drill procedures.
  • Managers should also make sure all employees who might be expected to use portable fire extinguishers are properly trained.
  • Supervisors should train employees about the fire hazards associated with the specific materials and processes to which they are exposed, and maintain written documentation of the training.

Many of the topics taught in the FPP training may be presented in the classroom. If employees are expected to use portable fire extinguishers, they must participate in “hands-on” exercises that help them understand the procedures. Hands-on training also gives employees an opportunity to demonstrate to trainers that they have the skills required to use fire extinguishers.

At a minimum, FPP Training should include all of the following topics:

  • review OSHA requirements contained in 29 CFR 1910.38, Emergency Action Plans,
  • review OSHA requirements contained in 29 CFR 1910.39, Fire Prevention Plans,
  • person(s) responsible for Control of Fuel Source Hazards,
  • the location of the company FPP and how it can be accessed,
  • good fire-prevention housekeeping practices and equipment maintenance,
  • alarm systems and evacuation routes,
  • proper response and notification in the event of a fire,
  • the use of portable fire extinguishers, and
  • recognition of potential fire hazards.

 

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Emergency Action Plan Special Considerations

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An emergency is a chaotic time, as part of a quality emergency response plan, there are specific considerations a workplace may require beyond a basic plan.

Below I review some of the special considerations you may need to include in your plan.

 

Persons with Disabilities

During an evacuation, a workplace may have employees requiring assistance, and should be considered as part of the evacuation section of your emergency action plan. Failure to account for employees or visitors within your facility during an evacuation, can result in unnecessary injuries, or worse death. Below are some of the standard provisions for persons with disabilities that may be included in your facilities emergency evacuation planning.

Disabled Persons

Persons using crutches, canes or walkers:

In emergency evacuations, these individuals should be treated as if they were injured. Have the individual sit on a sturdy chair, preferably a chair with arms, and follow the procedure for non-ambulatory persons discussed below.

Non-ambulatory persons:

Evacuation may not be necessary or advisable. Many stairwells are designed to provide temporary protection from fire or other danger. An able bodied volunteer shall stay with a wheelchair user on the stairwell platform while a second person notifies emergency personnel or paramedics of the exact location of the wheelchair user. If immediate evacuation is necessary, be aware of the following considerations:

  1. Wheelchairs have movable parts; some are not designed to withstand stress or lifting.
  2. You may need to remove the chair batteries; life-support equipment may be attached.
  3. In a life-threatening emergency, it may be necessary to remove an individual from their wheelchair. Use caution, as lifting persons with restricted mobility, may cause them bodily harm or injury.
  4. Wheelchairs should not be used to descend stairwells. Use an emergency evacuation chair.
  5. Non-ambulatory persons may have respiratory complications. Take them to a location away from smoke or fumes. Ask them if they have any needs or preferences.
  6. Check the evacuation routes for obstructions before assisting the person to the exit.
  7. Delegate other volunteers to collect the wheelchair.
  8. Return the person to their wheelchair as soon as it is safe to do so.

Providing Assistance

Always consult with people in the wheelchairs, asking them how you might assist them; i.e.,

  1. The number of people they require for assistance.
  2. Methods to remove them from the wheelchair.
  3. Taking precautions for pain, catheters, catheter-bags, limb-plasticity, braces, etc.
  4. Whether to carry them face-forward or -backward down a flight of stairs.
  5. Whether a seat cushion or pad shall be brought along, should the wheelchair be left behind?
  6. In lieu of a wheelchair, ask if they prefer a stretcher, cushioned- or padded-chair, or car seat.
  7. Whether paramedic assistance is required.

Visually Impaired

Most visually impaired persons shall be familiar with their immediate work area. In an emergency situation, describe the nature of the emergency and offer to act as a “sighted guide.” Offer your elbow and escort them to a safe place. As you walk, describe where you are and advise them of any obstacles. When you have reached safety, orient the person as to where you are and ask if any further assistance is needed.

Hearing Impaired

Because persons with impaired hearing may not hear emergency alarms, alternative warning techniques are required. Two methods are:

  1. Write a note describing the emergency and nearest evacuation route, “Fire. Go out rear door, to the right, and down. Now!”
  2. Turn the light switch off and on to get their attention, then indicate with gestures what is happening and what to do.

Fire alarms notify building occupants of an emergency, a quality system will have audible and visual signals to alert building occupants.

Not all buildings have a fire alarm system, instead using air horns and/or intercoms.

If your facility has a fire alarm system, ensure you include a section in your emergency action plan, and in the training on evacuations, so it is understood what the system means.

Fire Alarm

When the Fire Alarm sounds, act immediately to ensure your safety. The Fire Alarm System is designed and engineered to provide you with an early warning to allow you to safely exit the building during an emergency situation.

  • Never ignore or assume the alarm is false or the result of a test.
  • Everyone must evacuate the building by way of the safest and closest exit and/or stairway.
  • Never use an elevator to exit during a fire alarm activation.
  • Once outside the building, move away from the building. Assemble across the street or along the sidewalk of the adjacent building.
  • The front of the building is where the fire fighters and fire trucks will be operating. Do not obstruct their access to the building.
  • If there is an incident occurring on the upper floors and glass is being blown out of the windows, the area below is the hazard zone where serious personal injuries will happen. Do not remain in or near the hazard zone.
  • Once outside, never re-enter the building until you are told to do so by the fire department or police.

Emergency Exits

Emergency exits are something easily overlooked, until an emergency occurs.

What exactly constitutes an “emergency exit”? Is it different from a regular exit? What does OSHA have to say?

Exit Route – Definition

OSHA defines an exit route as “a continuous and unobstructed path of exit travel from any point within a workplace to a place of safety.” An exit route consists of exit access (the space that leads to an exit), the exit itself (which is separated from other areas so it protects people using the exit) and the exit discharge (which leads to the street, open space or a refuge area).

Exit routes are sometimes referred to as “means of egress” and are covered under OSHA standards 1910.36 (“Design and construction requirements for exit routes”) and 1910.37 (“Maintenance, safeguards, and operational features for exit routes).

Check Out: Emergency Exits – OSHA Standards

While employers and safety managers will want to consult the regulations to make sure their facilities are completely compliant, the following lists of general rules of exit routes will help explain the basics. Many workplaces may already follow these requirements, especially those related to construction, but let’s take a brief look at construction requirements for exit routes. Then we’ll take a look at maintenance and safety features of exit routes that are necessary to achieve compliance.

Construction and Design Requirements for Exit Routes (1910.36)

First of all, exits must be designed for easy access. Keep the following rules for the construction and design of exit routes in mind:

  • Exit routes must be permanent.
  • There must be enough exit routes. – Usually this means two exits that are far enough from each other that both won’t be blocked by a fire or other hazard. Sometimes one exit is adequate or three or more exits are needed depending on the occupancy of the building.
  • Exits must lead to a street, refuge area, open space or other area with access to the outdoors.
  • Openings to exits must be protected by self-closing fire doors (to ensure those using the exit stay safe).
  • Exit doors must be unlocked so they can be opened from the inside.
  • Any room connected to an exit route must have a side-hinged door that swings outward (if more than 50 people occupy the room).
  • An exit access must be at least 28 inches wide.
  • An exit must be 7.5 feet high.
  • Fire-resistant materials should protect exits – If the exit connects one, two or three stories, these materials should have a one-hour fire-resistance rating. If the exit connects more than three stories, a two-hour resistance rating is required.

Ensure you understand what OSHA has to say about Emergency exits, both while operating and while building.

Maintenance and Safety Features of Exit Routes (1910.37)

Once proper exits are in place, it’s easy to think nothing else needs to be done to stay OSHA compliant. Like most parts of a workplace, however, exit routes require proper maintenance. They also need to have certain safety features. The following rules apply to exit routes:

  • Flammable furnishings and décor should be kept away from exit routes.
  • Exit routes should be unobstructed.
  • Exit routes should be well lit.
  • Door areas should be kept unobstructed.
  • Exit doors shouldn’t be obscured by decorations.
  • Doors that are not exits but are located near exit access points should be labeled “Not an Exit” or labeled with their use (for example, “To Basement” or “Closet”).
  • Signs should be posted directing people to exits.
  • “EXIT” signs must be placed at exits.
  • Routes must be maintained during any construction or repair work that occurs at the workplace.

OSHA has also published a fact sheet concerning emergency exits, which is available for members to view and download:

emergency-exit-routes-factsheet

OSHA has also published a quick card for reference concerning emergency exits, view and download it below:

osha3183 - exit route quick card

 

Ensure your emergency response plan includes all specific workplace considerations, to minimize confusion during an emergency.

OSHA 3138 Permit Required Confined Space Guidelines

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Confined Space Entry is a complex topic to say the least. These entries are different every time even though the same equipment is used each time. The same crew may be utilized as well, however conditions more than likely will differ on each occasion. These could include toxic fumes, gas leaks and reduced oxygen levels. These conditions are so detrimental that you could pass out at any moment. For this reason, permits are required as enforced by Confined Space Regulation.

These spaces may be large enough to enter, but that is about it. Movement is quite limited there. People can work in them but certainly not for extended periods.

There are varieties of different places that qualify as confined spaces. These would be pits, vaults, hoppers, storage bins, vessels and tanks. Hazards are different depending on the kind of space involved. You need to be aware of spaces that contain toxic or flammable vapors and gases. There may be and excess of oxygen or a decrease of oxygen, either situation is not healthy. Cramped areas could cause suffocation to happen.

One-way to avoid getting involved with these hazards is to try doing the work outside of the confined space. For practical reasons this is not always possible. The workers will have to establish facilities in which to work in and permit space entry programs are needed to regulate entrance into the confined spaces. At all danger points, an entry permit in writing is to be used. Danger signs should be visible at all entry points where the hazardous work is going to begin. These signs will indicate either that the space is off limits or entry is only permissible with a written permit.

Training is provided as part of the course. There is a variety of posts for which training is required and these include, entrant attendant or entry supervisor. Determining acceptable entry conditions, terminating entry projects as well as overseeing these are the responsibility of the entry supervisor.

Another important responsibility of the supervisor is to manage atmospheric testing. Three different types of tests exist for this kind of testing. The order in which they are done which is very specific is, determining the oxygen content, next to see if flammable gases are present and lastly to identify contaminants especially if they are toxic.

Check Out: How to Put Together a Workplace Safety Training Workshop

The oxygen content test is first and the level cannot be lower than nineteen and a half percent, this will prohibit the person from doing physical work, as he will not be able to breath. Conversely, an oxygen level of twenty-three and a half percent or higher could be the catalyst to cause an explosion or fire.

Secondly, the gases and vapors need to be limited to fewer than ten percent of their inflammable limit. In this environment, there are many flammable gases to be found.

Confined Space Entry work is clearly very complex and potentially harmful. The right type of person needs to be selected to do this work. He will also require comprehensive training for the job.

Download the OSHA 3138 Guidelines for Permit Required Confined Spaces below

View the OSHA 3138 Guidelines for Permit Required Confined Spaces below

osha3138

12 Months of Toolbox Talks

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A Toolbox Talk is an informal safety meeting, conducted at the job site prior to the commencement of a job or work shift. Toolbox talks focus on safety aspects related to the specific job at hand. These meetings are normally 10-15 minutes, and cover topics such as workplace hazards and safe work practices.

Toolbox talks are a very effective way to refresh workers’ knowledge, cover last minute safety checks and exchange information with experienced workers.

The Occupational Health and Safety Act (OHSA) requires organizations in some industries to conduct safety talks and training. According to the OHSA, you have a duty to protect your employees and to ensure you train them on the risks around them and how perform job tasks safely. Toolbox Talks are an effective way to comply with these obligations. They are not intended to take the place of formal OSHA safety training for workers. Talks are meant to supplement training and serve as reminders of your organization’s safety goals.

Here are 4 tips for a quality Toolbox Talk

1. Talk directly to your audience. Ensure the topic is relevant to your industry and worksite. You can also focus on their personal agenda—staying safe so they can attend their kid’s soccer game after work, participate in off-the-job hobbies and continue providing for their families. Make sure the talk matters to employees both on and off the job. If workers don’t feel the topic applies directly to them you will have a hard time keeping their interest.

2. Keep it brief. People have limited attention spans and they’ll eventually start tuning you out no matter how important the topic of your toolbox talk is. Make only the necessary points, and put additional information in a handout or a follow-up toolbox talk on a later day.

3. Stay positive! Incident investigations are a reactive approach to something negative happening—and toolbox talks can be the exact opposite. They’re an opportunity to proactively encourage safe behavior before an incident takes place. Keep the focus on what can be done to create a safe workplace instead of focusing on what has gone wrong in the past.

4. Demonstrate your point. Nobody wants to feel like they’re at a lecture so try to make your talk interactive – when the audience is involved they are more likely to pay attention. Demonstrations, discussions and hands-on examples are all effective ways to get people to participate—and it will help them retain more of the information too.

12 Monthly Toolbox Talk Topics – FREE

 

 

In need of more toolbox talks? Check out my book of One year of Toolbox Talks

Fall Protection Program

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Fall protection is often seen as only a construction standard for safety, but it is equally important for general industry employee safety as well.

A quality fall protection program is the basis for ensuring employee safety when working at heights, this can include using powered equipment such a scissor lifts or order pickers, or working on unguarded surfaces above 4 feet.

This policy spells out all important aspects of fall protection for employee safety:

  • When to use fall protection
  • What fall protection is used
  • Employee training for fall protection
  • Fall Protection Inspection standards
  • Rescue Plan

 

Check Out: Forklift Safety Training

To prevent employees from being injured from falls, employers must:

  • Guard every floor hole into which a worker can accidentally walk by use of a railing and toeboard or a floor hole cover.

  • Provide a guardrail and toeboard around every open-sided platform, floor or runway that is 4 feet or higher off the ground or next level.

  • Regardless of height, if a worker can fall into or onto dangerous machines or equipment (such as a vat of acid or a conveyor belt), employers must provide guardrails and toeboards to prevent workers from falling and getting injured.

  • Other means of fall protection that may be required on certain jobs include safety harness and line, safety nets, stair railings and handrails.

–Source

These tips will help you remember the safe way to do things.

  • Never work off the ground when you are extremely tired or under extreme stress. Your reflexes need to be at 100% to work in this dangerous environment.
  • Never work off the ground if you are under the influence of drugs or alcohol. This applies to prescription drugs that might alter your balance or mind.
  • Never forget to remove tripping hazards. Tools, equipment and debris must be removed from all walking areas. They are responsible for a large percentage of workplace injuries above and on the ground.
  • Never forget to watch your step. It sounds simple but you need to always be alert and aware of your environment above the ground. Things are active in a work environment and every time you enter an area things could have changed. Loose boards or debris could suddenly appear in an area they weren’t at five minutes ago.
  • Never forget about personal protective equipment. Personal protective equipment can range from hard hats and gloves, to complex safety harnesses and netting and railing. Know your workplace and know what is required and never waiver from safety procedures.
  • Never work in an off the ground environment without completing mandated OSHA training. The training is there for a reason – to protect you. Having the knowledge needed to work safety is critical to avoiding injuries and even death.

Welding Safety Training

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Welding is a general term for various processes used to join metal parts by producing a coalescence, called a weld, at a joint. This is usually done by applying heat and energy when bringing the pieces of metal together.

Welding has many applications. Some welded products include ships, aircraft, automobiles, electric and electronic parts, and in building and construction work. Although over 50 welding processes are used today, the most common ones are gas welding and arc welding.

Welding is a hazardous process that joins materials together by melting a metal work piece along with a filler metal to form a strong joint.

What is Welding?

Coalescence occurs when two metals seem to pull together, or grow into one body, of the base metal parts when there is the slightest contact. There are two basic requirements for coalescence: heat and intimacy of contact.

Heat: Welding processes differ depending on the source of heat, the manner in which heat is applied or generated, and the intensity of the heat. The fuel used as a heat force may be:

  • acetylene or hydrogen in air or in oxygen;
  • an electric arc;
  • an electric, gas, or oil furnace;
  • the resistance of metal to the flow of electric current; or
  • a chemical reaction between a metal oxide and finely divided aluminum.

The intensity of heat applied or generated at the joint varies according to the metals being joined and to the welding process being used. All welding processes, except brazing, use temperatures high enough to melt the base metals. However, all welding, cutting, and brazing processes generate enough heat to seriously injure workers.

Intimacy of Contact: The second basic requirement for coalescence, intimacy of contact, is accomplished in two ways: pressure processes and non-pressure processes. In pressure processes, there is no space between the surfaces being joined. Welders apply pressure while the contact surfaces are at a high enough temperature to allow plastic flow of the metal. In non-pressure processes, the space between the joined surfaces is filled with molten metal.

Oxyacetylene Welding/Cutting

Oxyacetylene welding or cutting is also called torch or gas welding or cutting. Two metals are joined by melting or fusing their adjoining surfaces in the process. This is done by directing a flame from burning gas (usually acetylene) to melt metal at a joint to be welded, and is a common method for welding iron, steel, cast iron, and copper.

Oxyacetylene Cylinders: Oxyacetylene equipment consists of a cylinder of acetylene, a cylinder of oxygen, two regulators, two lengths of hose with fittings, a welding torch with tips, and either a cutting attachment or a separate cutting torch.

Accessories include a friction igniter to light the torch, an apparatus wrench to fit the various connections on the regulators, the cylinders, and the torches; goggles with filter lenses for eye protection; and gloves for protection of the hands. Flame-resistant clothing is worn when necessary.

Regulators: Reduce the gas pressure in a cylinder to a suitable working pressure before it can be used. This is done by a regulator or reducing valve. Regulators are either the single-stage or the double-stage type:

  • Single-stage regulators reduce the pressure of the gas in one step;
  • two-stage regulators do the same job in two steps or stages. Less adjustment is generally necessary when two-stage regulators are used.

Acetylene regulators and oxygen regulators are of the same general type, although those designed for acetylene are not made to withstand such high pressures as are those designed for use with oxygen cylinders.

Welding Torches: The oxyacetylene welding torch is used to mix oxygen and acetylene gas in the proper proportions and to control the volume of these gases burned at the welding tip.

  • Torches have two needle valves, one for adjusting the flow of oxygen and the other for adjusting the flow of acetylene.
  • They have a handle (body), two tubes (one for oxygen and one for acetylene), a mixing head, and a tip.
  • Welding tips are made from a special copper alloy, which dissipates heat (less than 60 percent copper), and are available in different sizes to handle a wide range of plate thicknesses.

Hoses: Hoses used to make the connection between a torch and a regulator are strong, nonporous, and flexible and light enough to make torch movements easy. It is made to withstand high internal pressures, and the rubber used in its manufacture is specially treated to remove sulfur to avoid the danger of spontaneous combustion.

The hoses used for acetylene and oxygen are the same in grade, but they differ in color and have different types of threads on the hose fittings. The color codes are as follows:

  • The oxygen hose is GREEN.
  • The acetylene hose is RED.

For added protection against mixing of the hoses during connection:

  • The oxygen hose has right-hand threads and the acetylene hose has left-hand threads.
  • The acetylene fittings have a notch that goes around the circumference of the fittings for an additional identification factor.
Check Out: Budgeting for Training

Electric Arc Welding and Cutting

Arc welding is the process in which fusion is produced by heating with an electric arc that is generated between an electrode and the surface of the base metal.

Arc cutting is the process in which the cutting or removal of metals is done by melting with the heat of an arc between an electrode and base metal.

In electric welding, electrodes form a part of the electrical circuit. In gas tungsten arc welding, electrodes melt off and are a source of the filler metal supply.

  • Solid Electrodes- These electrodes are consumable (composed of steel, copper, aluminum, various alloys, and other metals) or non-consumable (primarily tungsten). They produce less fumes, compared with flux-cored wire or coated electrodes.
  • Covered and Coated Electrodes- These are the largest group of electrodes used in welding. The covering provides the flux from the weld. Major metals from the coatings include fluoride, nickel, iron, chromium, manganese, copper, and molybdenum.

Overexposure to these substances can cause injury and illness over the long-term.

For more information on arc welding, read Safe Arc Welding by Lincoln Electric.

Brazing

Brazing is a welding process using nonferrous filler alloys that do not contain iron or steel and have a melting point above 840°F but below that of the base metal. Brazing is also called ‘hard soldering’ or ‘silver soldering.

Brazing is the only welding process in which the melting of the base metal is not necessary for coalescence. Coalescence occurs when two metals seem to pull together, or grow into one body, of the base metal parts when there is the slightest contact. Click here for more information on brazing alloys.

Soldering

Soldering is a joining process using non-ferrous filler alloys. Soft soldering uses alloys that melt between 190°F to 840°F and is used in electronics, plumbing, and joining sheet metal parts. Soldering is not considered a welding process. Lead and tin are common alloys used in soldering, but there is also less common lead-free solder to decrease environmental impacts.

Check Out: 10 Reasons Why Safety Training is Often Ineffective

Welding Defects

Defects in welds can cause unforeseen injuries and accidents. Common weld defects to be familiar with to ensure your safety include:

    • Incomplete fusion: Incomplete fusion occurs when the weld fails to fuse one side of the joint in the root. The most common type of incomplete fusion is overlap.
    • Inadequate joint and root penetration: Inadequate joint and root penetration is cause for rejection of a weld even if it is sound in all other respects. The strength required in a weldment is achieved only when the specified joint and root penetration is achieved.
    • Spatter: Spatter is the term used to describe metal particles or globules expelled during welding and that do not form part of the weld. When spatter occurs, small balls of metal are stuck to the surface of the base metal along the line of weld.
    • Overlap: Overlap is a protrusion of the weld metal beyond the bond at the toe of the weld. This is the most common type of incomplete fusion.
    • Undercut: An undercut is a groove melted into the base metal adjacent to the toe and not filled with weld metal.
    • Root cracks: Root cracks are similar to toe cracks except that they occur at the root of the weld. Root cracks may be in the weld metal or in the base metal.
    • Toe cracks: Toe cracks occur in the base metal, at the toe of the weld.
    • Crater cracks: One common kind of crack is the crater crack. This occurs in the crater or depression at the termination of a weld bead in gas or arc welding.
    • Underbead cracks: Underbead cracks occur in the heat-affected zone underneath a bead and do not extend to the surface of the metal.
    • Voids: Voids, also called gas pockets or blow holes, occur as the result of gas being absorbed during the welding and then trapped as the metal solidifies.
    • Inclusions: Slag inclusion is the term used to describe the weld defect in which non-metallic solid material is trapped in the weld metal or at the bond between the weld metal and the base metal.

Welding Hazards

Protecting yourself when performing welding operations depends on your understanding of the hazards involved and the proper way to control them. Controlling welding hazards includes avoiding eye injury, respiratory protection, ventilation of the work area, protective clothing, and having safe equipment to use.

Gas Welding Hazards

Since gas welding is slower and easier to control than electric arc welding, it is commonly used in general maintenance work, brazing, and soldering.

Equipment: Oxyacetylene equipment consists of a cylinder of acetylene, a cylinder of oxygen, two regulators, two lengths of hose with fittings, a welding torch with tips, and either a cutting attachment or a separate cutting torch. Accessories include a friction igniter to light the torch, an apparatus wrench to fit the various connections on the regulators, the cylinders, and the torches; goggles with filter lenses for eye protection; and gloves for protection of the hands. Flame-resistant clothing is worn when necessary.

Acetylene (chemical formula C2H2): a fuel gas made up of carbon and hydrogen. When burned with oxygen, acetylene produces a very hot flame, having a temperature between 5700°F and 6300°F. Acetylene gas is colorless, but has a distinct, easily recognized odor.

MAPP (methylacetylene-propadiene) gas: an all-purpose industrial fuel that has the high flame temperature of acetylene and the handling characteristics of propane.

  • MAPP is not sensitive to shock and nonflammable in the absence of oxygen. There is no chance of an explosion if a cylinder is bumped, jarred, or dropped. The cylinders may be stored or transported in any position with no danger of an explosive air pocket being formed.
  • MAPP toxicity is rated “very slight,” but high concentrations (5,000 ppm) may have an anesthetic effect. Local eye or skin contact with MAPP gas vapor causes no adverse effect. However, the liquid fuel will cause dangerous frostlike burns due to the temperature at which MAPP gas should be stored.

Oxygen: a colorless, tasteless, odorless gas that is slightly heavier than air. Oxygen will not burn by itself, but it will support combustion when combined with other gases.

  • Take extreme care to ensure compressed oxygen does not become contaminated with hydrogen or hydrocarbon gases or liquids.
  • A highly explosive mixture will be formed if uncontrolled compressed oxygen becomes contaminated. Oxygen should NEVER come in contact with oil or grease.
  • Oxygen cylinders are supplied in several sizes. The size most commonly used 9 1/8 inches in diameter, weighs about 145 pounds, and has a capacity of 200 cubic feet. At 70°F, the gas is under a pressure of 1800 psi.
Check Out: How to Put Together a Workplace Safety Training Workshop

Arc Welding Hazards and Precautions

Safe procedures and practices must always be used when working around or with arc welding equipment to avoid being injured.

Avoid the following hazards in arc welding:

  • radiation from the arc, in the form of ultraviolet and infrared rays
  • flying sparks and globules of molten metal
  • electric shock
  • metal fumes
  • burns

Radiation: Radiation from the arc is hazardous to the eyes. Eyes should be protected from radiation from the arc by use of an arc welding helmet or face shield with approved lenses.

  • Cover the face, hands, arms, and other skin surfaces to prevent exposure to the radiation.
  • Gloves should be worn and other parts of the body covered by clothing of sufficient weight to shut out the rays of the arc.
  • Without proper clothing, burns comparable to sunburn will result.

Arc Flash: When possible, shield arc-welding operations so no one may accidentally look directly at the arc or have it shine or reflect into his or her eyes.

  • An arc “flash” may cause a person to be temporarily blinded.
  • The severity of an arc flash and the time it will take to recover varies with the length of time a person was exposed to the arc.
  • Long exposure has been known to cause permanent damage to the retina of the eye.
  • If someone is severely “flashed,” medical personnel should provide special treatment at once.

Electric Shock: Avoid the possibility of dangerous electric shock by using insulated electrode holders and wearing dry leathers and gloves.

  • When possible, avoid using arc-welding equipment in wet or damp areas.
  • Perform arc-welding only in an area that is well-ventilated.

Flying sparks: usually accompany arc welding. These present a hazard if they strike unprotected skin, lodge on flammable clothing, or hit any other flammable material.

  • When arc welding, wear suitable weight clothing and cuffless trousers.
  • Cover pockets so they will not collect sparks, and remove any flammable materials, such as matches, plastic combs, or gas lighters.
  • Wear the proper foot protection. Wear high top boots with steel toes.

Hot Metal and Burns: Hot metal and flying sparks have the potential to cause serious burns. Never handle it with bare hands until it has cooled naturally or has been quenched in the quenching tank.

Be sure to use leather gloves with tight fitting cuffs that fit over the sleeves of the jacket. Many welders wear a full set of leathers that consists of the following:

  • jacket or set of sleeves
  • gauntlet gloves
  • leggings
  • spats
  • apron
  • welders hat liner

In gas welding, the high temperatures of the welding flame and the sparks will burn skin. Gas welding can also cause radiation burns due to infrared rays emitted by the red-hot material. Wear flame-resistant or flame-retardant clothing and hair protection at all times.

Gases and Fumes: Fluxes used in certain welding and brazing processes produce vapors that are irritating to the eyes, nose, throat, and lungs. Welding fumes and gases generally come from the following sources:

  • base material being welded or the filler material used
  • coatings and paints on the metal or electrode coatings;
  • shielding gases supplied from cylinders;
  • chemical reactions due to ultraviolet light of the arc and heat; and
  • contaminants in the air from cleaners and degreasers.

Perform welding in a well-ventilated area and always wear approved safety goggles. Here are a few options:

  • The darkest shade of the goggles that still show a clear outline of the work without producing eyestrain is recommended.
  • Sunglasses are not adequate.
Have you ever tested your knowledge on safe welding? Do so at the welding safety quiz I have available here

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welding safety training

Machine Guarding Basics

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Moving machine parts have the potential to cause severe workplace injuries, such as crushed fingers or hands, amputations, burns, or blindness.

Amputations, lacerations, and abrasions are costly and have the potential to increase workers’ compensation premiums.(Amputation is one of the most severe and crippling types of injuries in the occupational workplace, often resulting in permanent disability.) Due to this fact, OSHA (Occupational Safety & Health Administration) has established a set of standards around machine guarding.

The purpose of machine guarding is to protect the machine operator and other employees in the work area from hazards created during the machine’s normal operation.

Many companies adopt three basic practices when it comes to machine guarding in the workplace:

  • Safeguard the point of operation – the point of operation must be guarded to protect the operator from injury – OSHA 1910.212
  • All operators of production equipment must be properly trained on the equipment they will be working on.
  • Implant the value, and apply the best safety practices, for safety for all employees at all times.

 

Based upon the point of safeguarding the point of operation, OSHA mandates that there be at least one type of guarding mechanism in place.  The purpose of this guarding is to:

  • Prevent contact with areas of the device that could cause injury
  • Secure the device (and the machine guard) so that certain parts cannot be manipulated or tampered with by personnel
  • Protect against splatter or falling debris while using the machine during normal operation or during maintenance
  • Avoid causing additional hazards as a result of the machine guard installation such as sharp edges or pinching mechanisms
  • Allow easy operation of the machine without interfering with productivity or efficient use of the device

Employees require training in the need and value of machine guards, as well as how to work with them in place, how to remove them for maintenance, and what to do if they break or go missing.

Machine guarding can only provide protection if the people operating, maintaining and working near the equipment are properly trained and understand how it works. OSHA identifies several factors for a thorough documentation and training program, including:

  • Identifying the hazards and providing a description for each.
  • Identifying each of the physical guards and/or devices and defining which hazards they protect against and how.
  • How to appropriately use the safeguards.
  • Who can remove the safeguards and why (maintenance, repair, etc.).
  • Protocol when a guard is missing, damaged or malfunctioning.
  • Any PPE when required. If you need any additional information on PPE, check out this guide.

Unlike many other regulations, OSHA offers guidelines for the training expectations here. Do not assume this training is all that is required, it is a guideline for training., not a substitute for training.

When training employees emphasize that physical machine guards fall within 4 categories:

  • Fixed guards – designed as a permanent part of the device, these guards are sturdy and should not be removed or manipulated
  • Interlocked guards – when used these guards will disable or pause machine operations whenever they are raised, opened or removed
  • Adjustable guards – when a device needs protection but also needs to be adaptable to certain heights or angles, this type of guard is utilized and can be manually changed depending on the worker or the type of use
  • Self-adjusting guards – automatically adjusting guards are helpful for machines where operations require movement, such as trimming certain types of wood for furniture
Check Out: How to Put Together a Workplace Safety Training Workshop

Machine guarding should be routinely inspected to make sure all devices have the proper protection in place. If any machine guard breaks, cracks, or is damaged in any way there should be a priority action to address the issue.  Often it is best to completely replace the guard versus a repair because the structural integrity of the guard could be compromised.

Employee buy-in for machine guarding is also critical. Getting upfront input from the key people operating your equipment is vital as you look to update or enhance guarding to ensure solutions that are both safe and have a good dose of common sense attached. Going forward, guarding should be an integral part of your training.

 

Download our overview of machine guarding training below

Read our overview of machine guarding training below

Machine Guarding Basics Overview

Ground Ladder Safety

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The safe use of mobile ground ladders is often overlooked, as many employers assume employees know how to use them, since it is equipment used in most households. Any assumption when it comes to safety is a potential hazard.

A ground ladder safety policy sets expectations of use for employees, in the safe operation of the equipment in the workplace.

A policy on ground ladder safety should set expectations of what sort of ladders are used in the workplace, how to safely use the ladders, and inspection requirements.

Ground ladders require special inspections and care for use.

Even if they don’t regularly use ladder , especially if not regularly, employees should be trained on how to inspect ground ladders using the checklist attached to the policy as part of their pre-use inspection.

  • Pre-Work:
    • Before starting your project, you should check to make sure you’re using the right ladder for the job. There are a few different types of ladders (extension/straight, fixed access, tripod orchard, and stepladder), but if you’re completing household tasks, like putting up lights or clearing gutters, you’ll likely be using either a straight ladder or stepladder depending on the height.
    • Regardless of the ladder you’re using, be sure to check the load rating. The load rating needs to cover your weight AND the weight of your tools. You should also consider the material that your ladder is made of and whether it’s appropriate for your intended use. Aluminum and steel ladders conduct heat and electricity and should never be used for electrical work. Fiberglass and wood ladders are suitable for electrical work, but wood ladders are especially vulnerable to damage and decay. No matter what type of ladder you’re using, you should always inspect it, check for cracks, and ensure the frame, rungs, and feet are not compromised.
  • During Work:
    • When placing your ladder, make sure that the footing is on a firm, non-slip surface that is clear of any debris or hazards. You can also reduce the risk of a fall by wearing non-slip shoes and gloves. If you have to adjust the placement of the ladder, avoid pushing or pulling it from the sides – repeated sideways movement can make ladders wobbly since they are weaker in those directions. When you’re using any type of portable ladder, use the 4:1 ratio: for every four feet you go up, the ladder should be placed one foot out.
    • You should always face the stepladder when climbing up or down and maintain a firm grip with both hands. You have climbed too high if your knees are above top of the stepladder or if you cannot maintain a handhold on the ladder – and never stand on the top rung or step. Before you climb, always look up for powerlines and other overhead hazards and adjust the placement of your ladder if needed.
  • Post-Work:
    • Taking care of your ladder is important to ensure that it remains in good condition and useable for your next project. After each use, you should clean your ladder and ensure that any moving parts are well lubricated. Inspect for damage such as broken rungs, split side rails, worn or broken safety feet, and oil or grease which can make climbing surfaces slippery.
    • If your ladder is damaged, don’t try to repair it yourself. DIY repairs, such as tying or binding with wire, or painting over damaged areas, are not safe in the long-term and can hide cracks and weak points.
    • To take good care of your ladder, be sure to store it inside on horizontal racks with support every 2 meters. Protect yourself and others when your ladder is stored by fixing it to the wall or racks so that it doesn’t fall or present other hazards.
  • Monthly inspections:
    • Every month, ladders should be thoroughly inspected and certified for use. This is often done off a large inspection sheet, or sometimes on a tag attached to the ladder, like with fire extinguishers.

When using a ladder, always be mindful of your individual circumstances as well. Do not use a ladder if you are affected by medication or a health condition that affects your balance. Before you start your project, always make sure that you have a plan in the case of an accident, and never use a ladder if you are working alone and cannot get help easily.

When a ladder is identified as damaged, a full checklist should be filled out to document the ladder damage prior to removal from use. When removing a ladder from service, it should be destroyed to ensure it is not accidentally placed back into service.

Test you ladder safety knowledge with my Ladder Safety Quiz

Download the Ground Ladder Safety Policy below:

Download the Ground Ladder Inspection Form below:

View the Ground Ladder Safety Policy below:

Ladder Safety Policy

View the Ground Ladder Inspection Form below:

ground_ladder_checklist