Module - 3

Mechanical safety
PPE,safety guards, safety while working with machine tools like lathe, drill press
,power and band saws , grinding machines ,safety during welding ,forging and
pressing ,safety while handling materials ,compressed gas cylinders ,corrosive
substance, waste drum and containers ,
Case studies: visit to machine shop, workshop, and foundary lab and local
industries to record the practical observation and report the same with the relevant
figures and comment.

Prepared by NEHAL AHMAD, ME

3.1 Introduction
Why Mechanical safety is needed?
Everybody using the Laboratory and Workshop facilities has a responsibility to keep them in
proper working order and to maintain a safe working environment in the working area.
People working in Laboratory and Workshop should be considerate, have good working
attitude and be self-disciplined. It is important to prevent accident or mishap from happening
when operating mechanical equipment.
How mechanical safety can be imposed?
There are general guidelines to follow in the Laboratory and Workshop areas. There are also
operational manuals and specifics for every mechanical equipment to be followed by users.
Always if we are in doubt, do not attempt to operate by ourselves,
What makes mechanical equipment dangerous?
It is because of the Mechanical Movement and Forces. We should never underestimate the
hazardous objects, when we are operating a machine or a mechanical apparatus, we should
always adopt a defensive attitude and be aware of the source of danger or the likely outcome
of each sequence of operation.
Movement of a machine can be hazardous and may sometime cause life
threatening to death if it is not handled carefully. The following fig shows an
example of handling of mechanical system in workplace.

FIG

Fig : 3.1 Avoid work without safety helmet

 Fig : 3.2 Machine Layout

3.2 What is called personal protective equipment’s (PPE) and what is their use?

PPE stands for personal protective equipment. PPE means any device or appliance designed
to be worn or held by an individual for protection against one or more health and safety
hazards.
Personal protective equipment (PPE) can also be defined as the use of respirators, special
clothing, safety glasses, hard hats, or similar devices whose proper use reduces the risk of
personal injury or illness resulting from occupational hazards.
The basic types of PPE based on its application are as follows

 Head
 Eyes
 Face
 Hands
 Feet
 Body
 Hearing
 Respiratory

3.2.1 Head PPE Fig : 3.3 basic safety tools

Needed when employees are exposed to hazards that have potential to cause a head injury.
Examples of hazards:

 Flying objects.
 Falling objects or materials.
 Working near exposed energized electrical equipment.
 Working around or on scaffolds.
 Working at construction sites.
 Working around overhead tools or machinery.
Types of Head Protection
 Impact Protection
Type I – Is designed to protect only against objects falling from straight overhead, hitting
the hardhat on the top.
Type II – Is designed to protect against blows on the top of the head as well as side impacts.
Electrical
 Class A (old American National Standards Institute standard) or Class G (new ANSI
Standard) good up to 2,200 volts.
 Class B (old ANSI standard) or Class E (new ANSI Standard) good up to 20,000
volts.
 Class C not rated for electrical protection.
Donning Head Protection
 Hard hat protection is effective only if the hat is adjusted to fit properly and is worn
squared and not cocked at an angle or perched on the back of the head.
 Severe lacerations from relatively light blows have been incurred by workers wearing
hard hats in unusual positions.
 Must not be worn backwards.

3.2.2 Eye PPE

Required when employees are in areas where there is exposure to eye and face
hazards from flying particles, molten metal, liquid chemicals, acids, caustic liquids,
chemical gases or vapors or potentially injurious light radiation
 Examples of hazards:
 Machines
 Lasers
 Impacts
 Heat
 Tools
 Flying Particles / Dust
 Electrical work
 Chemical handling
Types of eye protection Fig : 3.4 safety glasses
 Non-Prescription safety glasses.
 Prescription safety glasses.
 Employees that wear prescription (Rx) lenses can use non-prescription eye
protection worn over prescription lenses as long as it does not compromise the
fit of either piece of eyewear.
 All eye protection must be ANSI Z87 approved.
 Goggles
 Chemical
 Laser
 Welding
 Chemical goggles protect your eyes, eye sockets, and the facial area
immediately surrounding the eyes from impact, dust, and splashes.
 Chemical goggles are generally stronger than safety glasses and are used
for higher impact, particle and chemical splash protection.
 Laser and Welding goggles protect the eyes from harmful light.
 All eye protection must be ANSI Z87 approved.
Care and Maintenance
 Check prior to each use for cracks or damage.
 Replace as necessary.
 Store in a clean area.
 3.2.3 Face PPE:
Needed when work presents the potential of causing facial injury from physical,
chemical, or radiation agents.
Examples of hazards:
 Contents under pressure
 Splash hazard
 Flying objects / particles
 Electrical work

3.2.4 Types of Face Protection

Face Shield

Welding Shield

Donning Face PPE

Fig : 3.5 Face protection

 Safety goggles or goggles must always be worn under a face shield.
 Once goggles are in place, position face shield over face and secure on brow
with headband
 Adjust to fit comfortably.

3.2.5 Hand PPE

 Needed when work presents the potential of causing hand injury from physical,
chemical, or radiation agents.
 Examples of hazards:

 Absorbing harmful substances

 Sharp objects capable of causing cuts, abrasions, or punctures
 Chemical or thermal burns
 Electrical work
 High/Low temperatures

Fig : 3.6 Hand Glove

 Chemical Resistant - (check MSDS) or compatibility charts

 Puncture / cut / abrasion Resistant
 Those with a latex allergy can use vinyl, nitrile, etc. based on the compatibility
charts or MSDSs.
Types of Hand Protection :
Voltage Rated
Temperature Resistant
Infectious Agent / Biohazard Resistant – Latex, Vinyl, Nitrile, etc)

Fig : 3.7 Hand PPE

Care and Maintenance:

 Check prior to each use for cuts, cracks or discoloration.

 Replace as necessary.
 Discard single use gloves after use. (Latex, Nitrile, Vinyl, etc)
 Store in a clean area.

3.2.6 Feet PPE:

 Needed when work presents hazards that have potential to cause a foot injury:
 Examples of hazards:

 Falling objects
 Rolling objects
 Piercing/cutting injuries
 Electrical work
 Chemical exposure

 Steel toed
 Electrical resistant – (will have the letters ―EH‖ on the tongue)
 Chemical resistant

 Must be ANSI Z41 or ASTM F2413-05 approved.

Fig : 3.8 FEET PPE

Care and Maintenance:

 Check safety shoes prior to each use for cuts, cracks or other damage. Replace as
necessary.
 Keep electrical hazard shoes dry and free from conductive materials. Replace if sole
is punctured, cut, or embedded with conductive materials.
 Chemical resistant shoes should be replaced if they are discolored, disfigured, or
exhibit any breaks, cracks, or other surface degradations.
 Store all shoes in a clean, dry location.

3.2.7 Body PPE

 Needed when work presents a potential for contamination or injury to other parts of
the body such as legs, arms, back, chest.
  Examples of hazards:

 Heat
 Splashes
 Hot/cold metals and liquids
 Impacts
 Sharp objects
 Chemicals
 Electrical work
 Radiation

Types of body protection Fig : 3.9 Body PPE

 Lab coats
 Aprons
 Chemical resistant sleeves
 Tyvek suits
 Coveralls
 Arc Flash Rated

Fig : 3.10 Body PPE

3.2.8 Hearing PPE
 Needed when the average (over an 8 hour period) noise level of an area
reaches 90 decibels.
 Hearing protection must be made available to employees when the
average (over an 8 hour period) noise level reaches 85 decibels.
 Examples of high noise areas can be:
 Mechanical rooms
 Shops
 Construction Sites
 When working with machinery/power tools

 Types of Hearing Protection

 Ear Plugs
 Ear Muffs
 Canal Caps
 Donning Hearing Plugs Fig : 3.11 Hearing protection
 Follow manufacturers recommendations. The steps below is a commonly used
method.
 1. Roll the earplug up into a small, thin "snake" with your fingers. You can use one or
both hands.
 2. Pull the top of your ear up and back with your opposite hand to straighten out your
ear canal. The rolled-up earplug should slide right in.
 3. Hold the earplug in with your finger. Count to 20 or 30 out loud while waiting for
the plug to expand and fill the ear canal. Your voice will sound muffled when the plug
has made a good seal.

Fig : 3.12 types of hearing aids

3.2.9 Respiratory PPE:

 Needed when work presents an inhalation hazard.

 Examples of hazards:

 Working with uncontained chemicals.

 Working with highly toxic chemicals.
 Working in dusty environment.
 Painting.
 Welding.

Types of Respiratory Protection

 Dust Mask
 ½ mask
 Full Mask
 Powered Air Purifying respirator (PAPR)
 Supplied Airline Respirator
 Self Contained Breathing Apparatus (SCBA)

Fig : 3.13 types of respiratory protection

 3.3 PPE Maintenance and Repair

 Do not use PPE if it is damaged and in need of repair.

 It is the responsibility of the employee to make their supervisor aware as soon as PPE
becomes damaged so that new PPE can be obtained.
 Do not attempt to repair PPE.

Summary of Work Unit PPE

 Supervisor, PI, safety officer, faculty member, etc. should now hand out and/or
review a summary of the PPE required for your particular work unit.
 This should cover the findings that were listed in Appendix C based on the hazard
assessments.

3.4 Safety while working with lathe tools:

Safety glasses must be Long and loose hair Gloves must not be
worn at all times in must be contained. worn when using this
work areas. machine.

Sturdy footwear must Close Rings and jewellery

be worn at all times in fitting/protective must not be worn.
work areas. clothing must be worn.

 PRE-OPERATIONAL SAFETY CHECKS

 Locate and ensure we are familiar with all machine operations and controls.
 Ensure all guards are fitted, secure and functional. Do not operate if guards are
missing or faulty.
 Check workspaces and walkways to ensure no slip/trip hazards are present.
 Check the job is clamped tight in the chuck.
 Remove all tools from the bed and slides of the machine.
 Ensure the correct speed for machining process is selected.
 Remove the chuck key before starting the lathe.

 OPERATIONAL SAFETY CHECKS

 Before making adjustments or measurements, switch off and bring the machine to a
complete standstill.
 Always remove the chuck key from the chuck.
 ENDING OPERATIONS AND CLEANING UP
 Switch off the machine when work completed.
 Reset all guards to a fully closed position.
 Avoid letting swarf build up on the tool or job. Stop the machine and remove it.
 Leave the machine in a safe, clean and tidy state.

 POTENTIAL HAZARDS AND INJURIES

 Flying objects such as the chuck key left in chuck.
 Cutting tool injury when cleaning, filing or polishing.
 Hair/clothing getting caught in moving machine parts.
 Metal splinters and swarf.
 Eye injuries.
 DON’T
 Do not use faulty equipment. Immediately report suspect machinery.
 Do not try to lift chucks or face plates that are too heavy for us.
 Never leave the machine running unattended.
 Do not attempt to slow or stop the chuck or revolving work by hand.
 Do not leave equipment on top of the machine.

Fig : 3.14 safety while working with lathe Tools

 3.5 Safety while working with Drilling Machine tools:
Drilling machine tools are one of the most essential tools now days in mechanical system. It
can be operated under the following safety guidance.
1. Measure safety test: We need to take proper drill safety test regularly. We need to check if we
have left the machine without switching it off. Look out if the wire of the drill press is
plugged in when not in use. If we leave the drill press plugged on and forget to take the drill
press safety test, then this may increase the chance of any incidents. In testing the safety of
the drill press, we should also check out drill press parts and function. If the parts of the DP
are working smoothly or having any trouble. Also, we should see the functions in the safety
test of the drill press.

2. Precaution:
Maintain the speed while drilling. Avoid high spindle speed and stay closer to the
recommended speed. This is because, when we’re in using the high speed wrongly, it might
burn the cutting tool or the work piece. Besides, the work piece might flight off as an
accident. On the other hand, we’re at lower speed with heavy feed; the tool might dig into the
work piece and break the edge of the tool. Finally, don’t forget to power off the drill press
while changing the required speed.

Again, while we’re drilling, adjust the table just beneath the drill so that the hole remains in
the table center. Moreover, check the depth of the drilling as a precaution we cans the place a
piece of wood beneath the work piece.

3. safety goggles
We might think that drill press safety glasses are just for show and for the style and nothing
important like other safety things, but we’re very wrong. It’s not just a too precautionary
thing rather it might cause facial damage. There are some chances of drill press hazards, as
they are power tools. So, we need to cover ourr eyes to save these from these kinds of drill
press [Link] do not take proper action then, ourr eyes can be hit by any parts from any
problems or drill press hazards. Moreover, it might cause irreversible eye problem according
to the experiment from different doctors. Hence, even for the smallest job, never forget to
wear safety goggles.

4. Proper dressing:
While working with the drill press, wear tight clothes. Avoid loose cloth which might result
in a sudden accident. Again, if we’ve long hair, use hair net and make a tight bun. Many of
us can ignore this drill press safety tips. But it is really [Link] loose clothing,
jewelry or gloves so that these might not get caught in the machine. This precaution will save
ourr hair from any drill press hazards.

5. Use sander safety concept:

 While using the drill press, we must use protection masks. Again, while we’re using abrasive
drums or sanding accessories, ensure that the room is airy and has a good ventilation system.
We should follow sander safety s along with having a proper ventilation system.
Otherwise, the sawdust getting mixed with the air might cause suffocation. There are some
different ways we can take follow sander safety s like using a proper belt, wear a dust
respirator, inspect sanding belts before switching the machine, clean dust and vents regularly,
etc.
Avoid touching of drilling tools:
There are some drill press dangers if we do not know the drill press safety properly. Some of
us do not hesitate to touch here and there of a running [Link], with the drill press this
can cause different types of drill press dangers and harms. Never touch the rotating tool
which is spinning and doesn’t get stopped even after the drilling is [Link] shave and
the work piece after drilling as the surface are extremely hot, and it might burn our hand. So,
avoid putting the hand on running drill press without knowing roperly.

Fig : 3.15 Safety while working with drilling machine

7. Cutting tool should be properly locked with the clamp.

Well some of the top class drill press such as Rockwell Drill Press comes with excellent
safety system with itself to avoid most of the drill press dangers. But, we must to follow the
drill press safety guide to be extra protective.
 we need to ensure that the cutting tool is clamped and locked properly. Otherwise, the tool
and the instrument may shake and waiver. Thus, we won’t get the proper output of the
drilling. Besides, we might catch in injury.
8. Ensure the all safety accessories
While working with the drill press, sue the bits and the drill which are designed for the particular
model. Go through the manual properly and use the recommended parts and the accessories. We
need proper precaution of belt disc sander safety s before using these functions of a drill press.
Don’t try to use a hand auger bit for the press. The wrong drill bit and accessories must be
hazardous for wear drill press. We can read the belt disc sander s of safety for better information.
9. Enriched from the children
A lot of American homeowners take drilling as their home improvement hobby. So they
place their drill press in the home. So the other members can enter the workroom, where the
press is kept. But, it is necessary to keep the younger member away from the room or
machine to avoid drill press hazards. Make the machine kid proof. For that, remove the
switch toggle and place the key to the off position. Thus, in this way we can childproof the
press.
10. Keep away our hands from drilling tool:
While drilling, keep the fingers at least 3 inches away from the cutting tools. Before starting
to follow the instruction properly. Otherwise, it can leave we wounded. So while drilling,
safety is a must.
11. Last but not least
If we follow these top ten safety precautions properly, we can avoid most of the dangers and
drill press hazards. The drill press is a power tool, and most of them need to put some
attention during working.
3.6 Safety while working with Band saws tools:
Precaution before using band saws
 A band saw can be dangerous if not used properly.
 Read the machine manual carefully.
 Make sure we understand the instructions before attempting to use any tool or
machine. Learn the applications and limitations before use.
 Securely anchor the band saw to the floor (or a workbench of appropriate height) to
reduce vibration.
 Following are the safety measure while operating the Band sawsmachine.
 Wear safety glasses or goggles, or a face shield (with safety glasses or goggles).
 Wear hearing protection that is suitable for the level and frequency of the noise you
are exposed to in the woodworking area.
 Wear protective footwear when required.
 Make sure all guards are in place and properly adjusted. Ensure all band wheels are
enclosed.
 Adjust blade guard height to about 3 mm or 1/8 inch above the top of the material
being cut.
 Ensure the blade is tracking correctly and runs freely in and against the upper and
lower guide rollers.
 Ensure the blade is under proper tension. A band saw equipped with automatic tension
control is desirable.
 Use band saw blades that are sharp, properly set and otherwise suitable for the job
(e.g., the right tooth pitch; tooth form; blade width).
 Hold stock firmly and flat on the table to prevent the stock from turning and drawing
our fingers against the blade. Keep hands braced against the table.
 Use a push stick when we remove cut pieces from between the fence and saw blade or
when our hands are close to the blade. Keep our hands on either side of the blade - not
in line with the cutting line and the blade. Make release (relief) cuts before tight
curves when doing intricate scroll-type work.
 Keep the floor around a band saw clean and free of obstructions or clutter.
 Keep the machine properly oiled and [Link] adequate lighting at the
machine table. A light fixture with a flexible connection can provide essential
lighting.

Fig : 3.16 Safety while working with band saws machine

 Don’t do list at the time of band saws operation

 Do not use excessive force when pushing the wood past the blade.
 Do not back the stock away from the blade while the saw is in motion if the work
piece binds or pinches on the blade.
 Do not stop a band saw by thrusting stock against the cutting edge or the side of a
blade immediately after the power has been shut off.
 Do not remove sawdust or cuttings from the table by hand or with compressed air.
Use a stick or brush.
 Do not leave a saw running unattended. Turn off the power and make sure the
machine has stopped running before leaving the area.

Safety while working with Grinding machine:

Grinding wheels are safe tools when they are used in accordance with some basic s.
However if they are used incorrectly or not installed carefully onto the machine, there is
the possibility that the grinding wheel may fracture.
Be sure to observe the ―Dos‖ and ―Don’ts‖ for safe work.
The following basic s are based on the Ordinance on Industrial Safety and Health and on
Structural Standard for grinders and Related Equipment.
Do’s list while operating grinding machine operation
 Handle and store wheels in a careful manner.
Observe the 3 basic s of ―no rolling, no dropping, and no contact with other
objects‖.
Store wheels on a shelf or storage rack in a dry place.
 If the grinding wheel is marked with a service limit, be sure to use it only within
the service limit period.
 Before mounting a wheel onto a machine, perform a visual inspection and ring
test (hammering test) to check for cracks, chips, and other problems.
 Check that the outer diameters and contact widths of the mounting flanges are
equal and correct on the left and right sides..
 Balance the wheel with balancing weights.
 Be sure that the work rest is properly adjusted. The wheel should be no more
than 3 mm away from the work rest and 3 – 10 mm away from the adjustment
piece.
 The standard length of the wheel spindle after mounting should be 13 mm.
 Wear safety goggles, dust-proof mask, and other necessary protective gear
during operation.
 In order to avoid disrupting the balance, completely shut off the coolant before
stopping the wheel rotation.
  Use shield plates or other means to protect operators from sparks.

Fig : 3.17 Safety while working with grinding machine

Don’ts list while operating grinding machine operation
 Do not use a grinding wheel that was dropped or subjected to other impact, or a
grinding wheel where any abnormality was found during inspection.
 Do not exceed the maximum operating speed that is marked on the wheel.
 When mounting onto the flanges, do not over-tighten the nuts.
 Do not use excessive force to press the work piece against the grinding wheel, or
the grinding wheel against the work piece.
 Do not directly touch a rotating grinding wheel with any part of our body.
 During test operation, do not stand in front of the grinding wheel direction of
rotation.
 When working with a portable grinder, do not place the grinder onto a table,
floor, work piece, or other surface before the grinding wheel has fully stopped.
 Do not perform grinding in a location where there is the risk of ignition or
explosion.
 Do not change grinding wheels or perform test operation unless we have
completed all necessary education and training.
 Do not perform grinding in a location where there is the risk of ignition or
explosion

3.7 Safety in the Operation of Robots

 Always follow the exact sequence of operation for power-up and power- down.
 2. Always start arm motions at slow speed. Only when arm paths are fully defined and
verified, then the speed may be increased.
 Always be aware of obstacles on the arm paths, and the limits of its working range.
 Never enter the working range of the arm during its operations, or when someone is
programming it with the controller.
 Never press "Arm Power Off" button while the robot is moving, except for emergency
stop purposes.
 Do not replace components or make adjustments to the interior of the robot while the
electrical supply is still switched on.
 Cables to any connection port must never be inserted or removed unless the power has
been switched off from the robot.
  When on manual free mode, make sure that when the appropriate joint switch is
pressed, the arm is properly supported and prevented from free- swinging.

Safety in welding

Fig 3.17 Safety Fig : 3.18 Safety in the operation of robots

 nTo prevent injury to personnel, extreme caution should be exercised when using
any types of welding equipment. Injury can result from fire, explosions, electric
shock, or harmful agents. Both the general and specific safety precautions listed
below must be strictly observed by workers who weld or cut metals.
 Do not permit unauthorized persons to use welding or cutting equipment.
 Do not weld in a building with wooden floors, unless the floors are protected
from hot metal by means of fire resistant fabric, sand, or other fireproof
material. Be sure that hot sparks or hot metal will not fall on the operator or on
any welding equipment components.
 Remove all flammable material, such as cotton, oil, gasoline, etc., from the
vicinity of welding.
 Fig:3.19 safety while welding

 Before welding or cutting, warm those in close proximity who are not
protected to wear proper clothing or goggles.
 Remove any assembled parts from the component being welded that may
become warped or otherwise damaged by the welding process.
 Do not leave hot rejected electrode stubs, steel scrap, or tools on the floor or
around the welding equipment. Accidents and/or fires may occur.
 Keep a suitable fire extinguisher nearby at all times. Ensure the fire
extinguisher is in operable condition.
 Mark all hot metal after welding operations are completed. Soapstone is
commonly used for this purpose.

3.8 FIRE HAZARDS IN WELDING

 Fire prevention and protection is the responsibility of welders, cutters, and
supervisors. Approximately six percent of the fires in industrial plants are
caused by cutting and welding which has been done primarily with portable
equipment or in areas not specifically designated for such work. The
elaboration of basic precautions to be taken for fire prevention during welding
or cutting is found in the Standard for Fire Prevention in Use of Cutting and
Welding Processes, National Fire Protection Association Standard 51B, 1962.
Some of the basic precautions for fire prevention in welding or cutting work
are given below.

 During the welding and cutting operations, sparks and molten spatter are
formal which sometimes fly considerable distances. Sparks have also fallen
through cracks, pipe holes, or other small openings in floors and partitions,
starting fires in other areas which temporarily may go unnoticed. For these
reasons, welding or cutting should not be done near flammable materials
unless every precaution is taken to prevent ignition.
 Hot pieces of base metal may come in contact with combustible materials and
start fires. Fires and explosions have also been caused when heat is transmitted
through walls of containers to flammable atmospheres or to combustibles
 within containers. Anything that is combustible or flammable is susceptible to
ignition by cutting and welding.
 When welding or cutting parts of vehicles, the oil pan, gasoline tank, and other
parts of the vehicle are considered fire hazards and must be removed or
effectively shielded from sparks, slag, and molten metal.
 Whenever possible, flammable materials attached to or near equipment
requiring welding, brazing, or cutting will be removed. If removal is not
practical, a suitable shield of heat resistant material should be used to protect
the flammable material. Fire extinguishing equipment, for any type of fire that
may be encountered, must be present.

3.9 HEALTH PROTECTION AND VENTILATION

CAUTION Welding may produce fumes and gases hazardous to health. Avoid breathing
these fumes and gases. Use adequate ventilation. Safety in Welding and Cutting published by
the American Welding Society. Brazing (welding) filler metals containing cadmium in
significant amounts shall carry the following notice on tags, boxes, or other containers:
WARNING
CONTAINS CADMIUM - POISONOUS FUMES MAY BE FORMED ON HEATING
Do not breathe fumes. Use only with adequate ventilation, such as fume collectors, exhausts
ventilators, or air-supplied respirators . If chest pain, cough, or fever develops after use, call
physician [Link] and gas welding fluxes containing fluorine compounds shall
have a cautionary wording. One such wording recommended by the American Welding
Society for brazing and gas welding fluxes reads as follows:
Precaution while handling with Flourides

 This flux, when heated, gives off fumes that may irritate eyes, nose, and throat.
 Avoid fumes--use only in well-ventilated spaces.
 Avoid contact of flux with eyes or skin.
 Do not take internally.

Q .what are the various safety measure required in confined space welding?

[Link]

(1) All welding and thermal cutting operations carried on in confined spaces must be
adequately ventilated to prevent the accumulation of toxic materials, combustible
gases, or possible oxygen deficiency. Monitoring instruments should be used to detect
harmful atmospheres. Where it is impossible to provide adequate ventilation, air-
supplied respirators or hose masks approved for this purpose must be used. In these
situations, lockouts must be used on the outside of the confined space to ensure the
safety of those working within. Requirements in this section have been established for
arc and gas welding and cutting. These requirements will govern the amount of
contamination to which welders may be exposed:
 Dimensions of the area in which the welding process takes
place (with special regard to height of ceiling).
 Number of welders in the room.
 Possible development of hazardous fumes, gases, or dust
according to the metals involved.
 Location of welder's breathing zone with respect to rising
plume of fumes.
 (2) In specific cases, there are other factors involved in which respirator
protective devices (ventilation) should be provided to meet the equivalent
requirements of this section. They include:

 Atmospheric conditions.
 Generated heat.
 Presence of volatile solvents.

(3) In all cases, the required health protection, ventilation standards, and standard
operating procedures for new as well as old welding operations should be coordinated
and cleaned through the safety inspector and the industrial hygienist having
responsibility for the safety and health aspects of the work area.
b. Screened Areas. When welding must be performed in a space entirely screened on
all sides, the screens shall be arranged so that no serious restriction of ventilation
exists. It is desirable to have the screens mounted so that they are about 2.0 ft (0.6 m)
above the floor, unless the work is performed at such a low level that the screen must
be extended closer to the floor to protect workers from the glare of welding.
c. Concentration of Toxic Substances. Local exhaust or general ventilating systems
shall be provided and arranged to keep the amount of toxic frees, gas, or dusts below
the acceptable concentrations as set by the American National Standard Institute
Standard 7.37; the latest Threshold Limit Values (TLV) of the American Conference
of Governmental Industrial Hygienists; or the exposure limits as established by Public
Law 91-596, Occupational Safety and Health Act of 1970. Compliance shall be
determined by sampling of the atmosphere. Samples collected shall reflect the
exposure of the persons involved. When a helmet is worn, the samples shall be
collected under the helmet. Where welding operations are incidental to general
operations, it is considered good practice to apply local exhaust ventilation to prevent
contamination of the general work area.
d. Respiratory Protective Equipment. Individual respiratory protective equipment
will be well retained. Only respiratory protective equipment approved by the US
Bureau of Mines, National Institute of Occupational Safety and Health, or other
government-approved testing agency shall be utilized. Guidance for selection, care,
and maintenance of respiratory protective equipment is given in Practices for
Respiratory Protection, American National Standard Institute Standard 788.2 and TB
MED 223. Respiratory protective equipment will not be transferred from one
individual to another without being disinfected.
e. A number of potentially hazardous materials are used in flux coatings, coverings,
and filler metals. These materials, when used in welding and cutting operations, will
become hazardous to the welder as they are released into the atmosphere. These
include, but are not limited to, the following materials: fluorine compounds, zinc,
lead, beryllium, cadmium, and mercury.
f. Ventilation for General Welding and Cutting.
(1) General. Mechanical ventilation shall be provided when welding or cutting is
done on metals under the following conditions:
 In a space of less than 10,000 cu ft (284 cu m) per welder.
 In a roan having a ceiling height of less than 16 ft (5 m).
 In confined spaces or where the welding space contains partitions, balconies, or other
structural barriers to the extent that they significantly obstruct cross ventilation.

(2) Minimum rate. Ventilation shall be at the minimum rate of 200 cu ft per minute
(57 cu m) per welder, except where local exhaust heeds, as in paragraph 2-4 g below,
or airline respirators approved by the US Bureau of Mines, National Institute of
Occupational Safety and Health, or other government-approved testing agency, are
 used. When welding with rods larger than 3/16 in. (0.48 cm) in diameter, the
ventilation shall be higher as shown in the following:

Natural ventilation is considered sufficient for welding or cutting operations where

the conditions listed above are not present. Figure 2-5 is an illustration of a welding
booth equipped with mechanical ventilation sufficient for one welder

Fig : 3.20 Safety while welding in confined space

g. Local Exhaust Ventilation. Mechanical local exhaust ventilation may be obtained by

either of the following means:

 Hoods. Freely movable hoods or ducts are intended to be placed by the welder
as near as practicable to the work being welded. These will provide a rate of
airflow sufficient to maintain a velocity the direction of the hood of 100 in
linear feet per minute in the zone of welding. The ventilation rates required to
accomplish this control velocity using a 3-in.
 Fixed enclosure. A fixed enclosure with a top and two or more sides which
surrounds the welding or cutting operations will have a rate of airflow
sufficient to maintain a velocity away from the welder of not less than 100
linear ft per minute. Downdraft ventilation tables require 150 cu ft per minute
per square foot of surface area. This rate of exhausted air shall be uniform
across the face of the grille. A low volume, high-density fume exhaust device
attached to the welding gun collects the fumes as close as possible to the point
of origin or at the arc. This method of fume exhaust has become quite popular
for the semiautomatic processes, particularly the flux-cored arc welding
process. Smoke exhaust systems incorporated in semiautomatic guns provide
the most economical exhaust system since they exhaust much less air they
eliminate the need for massive air makeup units to provide heated or cooled
air to replace the air exhausted.
 Local ventilation should have a rate of air flow sufficient to maintain a
velocity away from the welder of not less than 100 ft (30 m) per minute. Air
velocity is measurable using a velometer or air flow inter. These two systems
can be extremely difficult to use when welding other than small weldments.
The down draft welding work tables are popular in Europe but are used to a
limited degree North America. In all cases when local ventilation is used, the
exhaust air should be filtered.

h. Ventilation in Confined Spaces.

(1) Air replacement. Ventilation is a perquisite to work in confined spaces.
All welding and cutting operations in confined spaces shall be adequately
ventilated to prevent the accumulation of toxic materials -or possible oxygen
deficiency. This applies not only to the welder but also to helpers and other
personnel in the immediate vicinity.
(2) Airline respirators. In circumstances where it is impossible to provide
adequate ventilation in a confined area, airline respirators or hose masks,
approved by the US Bureau of Mines, National Institute of Occupational
Safety and Health, or other government-approved testing agency, will be used
for this purpose. The air should meet the standards established by Public Law
91-596, Occupational Safety and Health Act of 1970.
(3) Self-contained units. In areas immediately hazardous to life, hose masks
with blowers or self-contained breathing equipment shall be used. The
breathing equipment shall be approved by the US Bureau of Mines or National
Institute of Occupational Safety and Health, or other government-approved
testing agency.
(4) Outside helper. Where welding operations are carried on in confined
spaces and where welders and helpers are provided with hose masks, hose
masks with blowers, or self-contained breathing equipment, a worker shall be
stationed on the outside of such confined spaces to ensure the safety of those
working within.
(5) Oxygen for ventilation. Oxygen must never be used for ventilation.

Fig : 3.21 Safety while working in confined space

 3.10 WELDING IN CONFINED SPACES
 A confined space is intended to mean a relatively small or restricted space such as a
tank, boiler, pressure vessel, or small compartment of a ship or tank.
 When welding or cutting is being performed in any confined space, the gas cylinders
and welding machines shall be left on the outside. Before operations are started,
heavy portable equipment mounted on wheels shall be securely blocked to prevent
accidental movement.
 Where a welder must enter a confined space through a manhole or other all opening,
means will be provided for quickly removing him in case of emergency. When safety
belts and life lines are used for this purpose, they will be attached to the welder's body
so that he cannot be jammed in a small exit opening. An attendant with a pre-planned
rescue procedure will be stationed outside to observe the welder at all times and be
capable of putting rescue operations into effect.
 When arc welding is suspended for any substantial period of time, such as during
lunch or overnight, all electrodes will be removed from the holders with the holders
carefully located so that accidental contact cannot occur. The welding machines will
be disconnected from the power source.
 In order to eliminate the possibility of gas escaping through leaks or improperly
closed valves when gas welding or cutting, the gas and oxygen supply valves will be
closed, the regulators released, the gas and oxygen lines bled, and the valves on the
torch shut off when the equipment will not be used for a substantial period of time.
Where practical, the torch and hose will also be removed from the confined space.
 After welding operations are completed, the welder will mark the hot metal or provide
some other means of warning other workers. The Case of the Inadequate Machine
Guard.
3.11 Safety while working with forging machine:
 Wear eye protection when hammering.

 Hearing protection is essential.

 Change our posture and working height now and then.

 Take breaks every forty-five minutes or so and do something different now and then.

 Do not use our wrist much when hammering; use our elbow sparingly, our shoulder
most. Listen to our body! Snap the hammer forwards a bit at the bottom of the swing-
let go and stop pushing then and the hammer will snap itself back up, lifting itself so
we have to do less work.

 Keep our forging area separate from the work areas of others, to reduce the damage to
their hearing. As well as damaging our ears, noise can distract we or our coworkers,
which can lead to injury if they’re doing something requiring concentration. It’s also
just irritating; to quote the American Association of Otolaryngology, ―some people
react to loud noise with anxiety and irritability, an increase in pulse rate and blood
pressure, or an increase in stomach acid.

 Wear safety glasses during hot forging and when hammering in general. Protective
clothing (long sleeves, leather shoes, a face shield if sparks are flying around) is also
recommended for hot forging.

 Tie our hair back if it’s long.

  ―Other protective measures with hot forging should include ice for treatment of minor
burns, salted water for heat stress, and a cool room for work breaks‖

 Follow all established procedures and perform job duties as we’ve been trained.

 Be cautious and plan ahead. Think about what could go wrong and pay close
attention to what we’re doing while we work.

Fig : 3.22 Safety precaution while dealing with forging machine.

3.12 What is called compressed gas cylinder
Compressed gases are stored in heavy-walled metal cylinders designed, produced and tested
for use with compressed gases. Cylinders are made in a wide variety of sizes and shapes.
They range from small lecture bottles, often used for demonstration purposes, to large
cylinders over 3 metres long. Cylinders for transportation must meet CSA standard
CAN/CSA-B339 "Cylinders, cylinders must be retested or inspected every five or ten years.
The date of each test must be stamped on the cylinder.

Fig : 3.23 Safety precaution while dealing with compressed gas cylinder.
What is the Safety device for compressed gas cylinder?
Most cylinders have one or more safety-relief devices. These devices can prevent rupture of
the cylinder if internal pressure builds up to levels exceeding design limits. Pressure can
become dangerously high if a cylinder is exposed to fire or heat, including high storage
temperatures.
There are three types of safety-relief devices. Each relieves excessive gas pressures in a
different way:

Fig : 3.24 Safety precaution while dealing with gas cylinder.

Safety- or Pressure-Relief Valves: These valves are usually a part of the cylinder. They are

Fig : 3.25 Safety precaution while dealing with compressed gas cylinder.
normally held closed by a spring. The force holding the valve closed is set according to the
type of gas in the cylinder. The valve opens if the cylinder pressure exceeds the set safety
limit. Gas is released until the cylinder pressure drops back to the safety limit. The valve then
closes and retains the remaining gas in the cylinder.
Rupture Discs (also known as frangible or bursting discs): These discs are usually made
from metal. They burst or rupture at a certain pressure, releasing the gas in the cylinder. The
bursting pressure is designed so that the disc ruptures before the cylinder test pressure is
reached. These devices cannot be reclosed, so the entire contents of the cylinder are released.

 Fusible Plugs (also called fuse or melt plugs): Temperature, not pressure, activates
fusible plugs. These safety devices are used where heat could initiate an explosive chemical
reaction. A pressure-relief valve or rupture disc acts too slowly and too late to prevent rupture
of the cylinder if an explosive reaction has already begun. The fusible plug releases the gas
before the hazardous reaction can begin. Fusible plugs are made of metals that melt at low
temperatures. For example, acetylene cylinders have a fusible plug which melts at about
100°C (212°F). This temperature is safely below the temperature at which hazardous
polymerization may [Link] all compressed gas cylinders have safety devices. Some gases
are so toxic that their release through a safety device would be hazardous. Cylinders for these
gases are built to withstand higher pressures than normal cylinders. When these "toxic gas"
cylinders are involved in a fire, the area must be evacuated.

3.13 Safety precaution for storing compressed gas cylinder

 Check fire code for guidelines regarding the storage of flammable gas cylinders.
 Store cylinders in a clearly identified, dry, well-ventilated storage area that is not
exposed to heat or the direct rays of the sun, and away from doorways, aisles,
elevators, and stairs.
 Post "no smoking" signs in the area.
 Store cylinders, both empty and full, in the upright position and secure with an
insulated chain or non-conductive belt.
 During storage, close the cylinder valves with the protective caps in place.
 With outside storage, place on a fireproof surface and enclose in a tamper-proof
enclosure.
 Protect cylinders from contact with ground, ice, snow, water, salt, corrosion, and high
temperatures.
 Protect cylinders from falling. Use a chain or adequate support system. Consider
securing each cylinder separately to prevent other cylinders from falling when items
are removed from storage.
 Store oxygen cylinders and fuel gas cylinders separately. Indoors, separate oxygen
from fuel gas cylinders by at least 6.1 m (20 ft), or by a wall at least 1.5 m (5 ft) high
with a minimum half-hour fire resistance. (From: CSA W117.2-12 (R-2017) "Safety
in welding, cutting and allied processes". Local jurisdiction requirements may vary.)
 Cylinders must also be separated away from flammable and combustible liquids and
from materials that easily ignite (such as wood, paper, oil, grease, etc.) by similar
requirements as oxygen cylinders (6.1 m, or a fire wall at least 1.5 m high with ½ hr
fire resistance).
 Don’t do list

o Do not use a cylinder as an electrical ground connection.

o Do not fasten cylinders to a work table or to structures where they could
become part of an electrical circuit.
 Do not strike an arc on a cylinder.
 Do not use a flame or boiling water to thaw a frozen valve. Valves or cylinders may
contain fusible plugs which can melt at temperatures below the boiling point of water.
Warm water is acceptable.
 Do not use pry bars under valves or valve protection devices to pry cylinders loose
when frozen to the ground. Use warm water.
 Do not place or store cylinders in unventilated enclosures such as lockers or
cupboards.
 Do not use full or empty cylinders as rollers or supports.
 Do not tamper with or alter safety devices.
 Do not use a cylinder for any purpose other than to contain the gas for which the
cylinder was designed.
 Do not place acetylene cylinders in a horizontal position.
 Do not accept compressed gas cylinders from the supplier unless they are properly
labelled and have protective valve caps in place.
 Do not lift a cylinder by the valve cap. Never sling with ropes or chains or lift with
electromagnets.
 Do not drag, slide, or drop cylinders. They can be rolled for short distances on their
base.
 Do not allow the cylinders to strike each other violently.
 Never place cylinders on their sides as rollers to move equipment.
 Do not lay acetylene cylinders on their sides. If an acetylene tank has accidentally
been left on its side, set it upright for at least one hour before it is used.
 Do not try to refill a cylinder or mix gases in a cylinder

What should be done with empty or out of service cylinder?

 Mark or label them as "Empty cylinder" and store empty cylinders away from full
cylinders.
 Return empties to the supplier.
 Remove regulators when not in use and store these away from grease and oil. Put
protective caps on the fittings when in storage.
 Keep cylinders and fittings from becoming contaminated with oil, grease or dust.
 Do not use a cylinder that is not identified or if the label is not legible. The colours of
industrial gas cylinders are not standardized.

3.14 Safety precaution while dealing with corrosive substance.

 Always handle containers of corrosives carefully. Damaged containers may leak.
 Many workplaces receive corrosive liquids in large metal drums or barrels and fill
smaller containers from them.
  Moving full drums weighing hundreds of pounds by hand can be difficult and
hazardous. Drums can be moved in specially designed drum cradles which can also be

used as individual drum storage racks.

 We can also purchase special carboy caddies for bulky bottles of corrosives and safety
bottle carriers for smaller-sized bottles of corrosives. Safety equipment and laboratory
supply retailers sell this equipment.
 Self-closing, portable containers for carrying, storing, and dispensing small amounts
of corrosive liquids are also available. They are made from high density polyethylene
and come in different shapes with capacities up to 19 litres. These containers have
spring-mounted spout caps that close automatically when we finish filling or pouring
from the container, or if they are dropped. They also automatically open when the
vapour pressure builds up inside, to allow vapours to escape and prevent rupture.
 Take care when dispensing or transferring corrosives from one container to another.
Dispense from only one container at a time. Finish all the dispensing of one material
before starting to dispense another. Be sure containers are closed after dispensing.
 Handle corrosives so that dusts, mists, vapours, or fumes do not get into the air. Be
very careful when transferring from larger containers into smaller ones. Many injuries
have been caused by spillage from open, unstable, or breakable containers during
material transfer.
 If liquid corrosives are stored in drums, use a corrosion-resistant drum pump for
transferring liquids into other containers. Pumps are also available for dispensing
corrosive liquids from most sizes and types of the supplied containers.
 Do not transfer liquids by pressurizing their usual shipping containers with air or inert
gas. Ordinary drums and barrels may be damaged by the pressure.
 Never pipette corrosive liquids by mouth. Use a pipette bulb or aspirator instead.
 Transfer corrosive solids using tools like scoops or shovels that are corrosion
resistant.
3.15 Safety precaution while dealing with Waste drum and container.
 Corrosive wastes are hazardous and must always be handled safely.
 All containers for corrosive wastes must be made from corrosion-resistant materials.
  Identify the contents of these containers with suitable labels.
 "Empty" drums, bottles and other containers often have hazardous corrosive residues
inside them. Never use these "empty" containers for anything else, no matter how
clean they seem to be. Treat them as corrosive wastes. It may be possible to safely
decontaminate "empty" containers. The chemical manufacturer or supplier can give
advice about this.

Fig : 3.26 Safety precaution while dealing with waste drum and container
 Never dispose of corrosives down sinks or drains that connect to sanitary or storm
sewers. Dispose of them according to the manufacturer's or supplier's directions, or through
hazardous waste collection and disposal companies.
 In all cases, dispose of corrosive wastes according to the environmental laws that
apply to your jurisdiction. Contact the appropriate environmental officials for details about
the disposal laws that apply for specific corrosives.
 Good housekeeping, personal cleanliness and equipment maintenance are important
wherever any chemicals, including corrosives, are used.
 Maintain cleanliness and order at all times in the workplace:
 Clean up any spills and build-ups of corrosives promptly and safely.
 Properly dispose of unlabelled or contaminated chemicals.
 Remove empty containers at once from work areas.
 Ensure that all containers for waste are properly marked and easily located.
 Personal cleanliness is a very important way of protecting personnel working with
hazardous chemicals.
 Wash hands before eating, drinking, smoking or going to the toilet.
 Remove and clean contaminated clothing before wearing it again, or discard it.
 Do not smoke, drink, chew gum or eat in any areas where hazardous chemicals are
present.
 Store food and tobacco products in uncontaminated areas.
 Avoid touching yourself with contaminated hands.

 Clean yourself thoroughly at the end of the workday.

 Regular maintenance of equipment is important in preventing leaks or emissions of
corrosives into the workplace.
 Ensure maintenance personnel know the possible hazards of the materials they might
be exposed to.
  Be sure they know any special procedures and precautions that might be needed
before they begin to work on equipment.
 Regular workplace inspections can help in spotting areas where health and safety
problems may be developing.
Avoid Skin contact
 wear protective gloves, aprons, boots, hoods, or other clothing depending on
how much chance there is of skin contact. This clothing must be made of
materials that resist penetration or damage by the chemical. The MSDS should
recommend appropriate materials. If it does not, contact the chemical's
manufacturer or supplier for specific information.
Protect Your Eyes and Face
Always wear eye protection when working with corrosives. Although ordinary safety glasses
provide some protection, chemical safety goggles are best. In some cases, we should also
wear a face shield (with safety glasses or goggles) to protect our face from splashes.
Avoid Breathing Corrosive Vapours, Fumes, Dusts or Mists
If respirators must be used for breathing protection, there should be a written respiratory
protection program to follow. Guidance for developing a program can be found in the current
CSA Standard Z94.4, "Selection, Care, and Use of Respirators." Follow all legal
requirements for respirator use and approvals. These may vary between jurisdictions in
Canada.
Know and be familiar with the right PPE for emergencies, as well as normal operations.
You must wear the PPE needed for doing a particular job. PPE cannot protect you if it is not
worn.
3.16 Safety while working with heavy machinery
Handling and storing materials involve diverse operations such as hoisting tons of steel with a
crane; driving a truck loaded with concrete blocks; carrying bags or materials manually; and
stacking palletized bricks or other materials such as drums, barrels, kegs, and lumber.
The efficient handling and storing of materials are vital to industry. In addition to raw
materials, these operations provide a continuous flow of parts and assemblies through the
workplace and ensure that materials are available when needed. Unfortunately, the improper
handling and storing of materials often result in costly injuries.
Always use required PPE—and inspects it carefully before each use to make sure it’s safe to
use. Replace worn out or damage PPE; it won’t provide adequate protection.

Fig : 3.27 Safety precaution while dealing with heavy machinery.

3.17 What should employees know before moving, handling, and storing of materials?
Employees should be applying general safety principles—such as proper work practices,
equipment, and controls—can help reduce workplace accidents involving the moving,
handling, and storing of materials. Whether moving materials manually or mechanically,
employees should know and understand the potential hazards associated with the task at hand
and how to control their workplaces to minimize the danger. Because numerous injuries can
result from improperly handling and storing materials, workers should also be aware of
accidents that may result from the unsafe or improper handling of equipment as well as from
improper work practices. Employers and employees should examine their workplaces to
detect any unsafe or unhealthful conditions, practices, or equipment and take corrective
action.

Fig:3.28 workers hand fastend with safety belt

3.18 What are the potential hazards for workers?
Hazards include falling objects, improperly stacked materials, and various types of
equipment. We should make our employees aware of potential injuries that can occur
when manually moving materials, including the following:
 Strains and sprains from lifting loads improperly or from carrying loads that are
either too large or too heavy,
 Fractures and bruises caused by being struck by materials or by being caught in
pinch points, and
 Cuts and bruises caused by falling materials that have been improperly stored or
by incorrectly cutting ties or other securing devices.
3.19 While moving materials manually, what type of precautions workers should take?
When moving materials manually, workers should attach handles or holders to loads. In
addition, workers should always wear appropriate personal protective equipment and use
proper lifting techniques. To prevent injury from oversize loads, workers should seek help in
the following:
 When a load is so bulky that employees cannot properly grasp or lift it,
 When employees cannot see around or over a load, or
 When employees cannot safely handle a load.
  Using the following personal protective equipment prevents needless injuries when
manually moving materials
 Hand and forearm protection, such as gloves, for loads with sharp or rough edges.
 Eye protection.
 Steel-toed safety shoes or boots.
 Metal, fiber, or plastic metatarsal guards to protect the instep area from impact or
compression.
 Employees should use blocking materials to manage loads safely. Workers should
also be cautious when placing blocks under a raised load to ensure that the load is not
released before removing their hands from under the load., workers should not use
materials with rounded corners, splintered pieces, or dry rot for blocking.

3,20 What precautions should workers take when moving materials mechanically?
Workers are well knowledgeable about powered equipment, they should take precautions
when stacking and storing material. When picking up items with a powered industrial truck,
workers must do the following:

 Center the load on the forks as close as possible to minimize the potential for the truck
tipping or the load falling,
 Avoid overloading a lift truck because it impairs control and causes tipping over,
 Do not place extra weight on the rear of a counterbalanced forklift to allow an
overload,
 Adjust the load to the lowest position when traveling,
 Follow the truck manufacturer's operational requirements, and
 Pile and cross-tier all stacked loads correctly when possible.

3.21 What precautions must workers take to avoid storage hazards?

To prevent creating hazards when storing materials, employers must do the following:
Keep storage areas free from accumulated materials that cause tripping, fires, or explosions,
or that may contribute to the harboring of rats and other pests;

 Place stored materials inside buildings that are under construction and at least 6 feet
from hoist ways, or inside floor openings and at least 10 feet away from exterior
walls;
 Separate noncompatible material; and
 Equip employees who work on stored grain in silos, hoppers, or tanks, with lifelines
and safety belts.

In addition, workers should consider placing bound material on racks, and secure it by
stacking, blocking, or interlocking to prevent it from sliding, falling, or collapsing.
3.22 What safeguards must workers follow when stacking materials?
Stacking materials can be dangerous if workers do not follow safety guidelines. Falling
materials and collapsing loads can crush or pin workers, causing injuries or death. To help
prevent injuries when stacking materials, workers must do the following:

 Stack lumber no more than 16 feet high if it is handled manually, and no more than 20
feet if using a forklift;
  Remove all nails from used lumber before stacking;
 Stack and level lumber on solidly supported bracing;
 Ensure that stacks are stable and self-supporting;
 Do not store pipes and bars in racks that face main aisles to avoid creating a hazard to
passersby when removing supplies;
 Stack bags and bundles in interlocking rows to keep them secure; and
 Stack bagged material by stepping back the layers and cross-keying the bags at least
every ten layers (to remove bags from the stack, start from the top row first).

3.23 Important Safety Measures

To reduce the number of accidents associated with workplace equipment, employers must
train employees in the proper use and limitations of the equipment they operate. In addition to
powered industrial trucks, this includes knowing how to safely and effectively use equipment
such as conveyors, cranes, and slings.
What safety measures should employer stake regarding conveyors?
When using conveyors, workers may get their hands caught in nip points where the conveyor
medium runs near the frame or over support members or rollers. Workers also may be struck
by material falling off the conveyor, or they may get caught in the conveyor and drawn into
the conveyor path as a result. To prevent or reduce the severity of an injury, employers must
take the following precautions to protect workers:

 Install an emergency button or pull cord designed to stop the conveyor at the
employee's work station.
 Ensure that appropriate personnel inspect the conveyor and clear the stoppage before
restarting a conveyor that has stopped due to an overload.
 Prohibit employees from riding on a materials-handling conveyor.
 Provide guards where conveyors pass over work areas to keep employees from being
struck by falling material.
 Cover screw conveyors completely except at loading and discharging points. (At
those points, guards must protect employees against contacting the moving screw.
The guards are movable, and they must be interlocked to prevent conveyor movement
when the guards are not in place.)

What safety measures should employer stake regarding cranes?

Employers must permit only thoroughly trained and competent workers to operate cranes.
Operators should know what they are lifting and what it weighs. For example, the rated
capacity of mobile cranes varies with the length of the boom and the boom radius. When a
crane has a telescoping boom, a load may be safe to lift at a short boom length or a short
boom radius, but may overload the crane when the boom is extended and the radius increases.
To reduce the severity of an injury, employers must take the following precautions:

 Equip all cranes that have adjustable booms with boom angle indicators.
 Provide cranes with telescoping booms with some means to determine boom lengths
unless the load rating is independent of the boom length.
 Post load rating charts in the cab of cab-operated cranes. (All cranes do not have
uniform capacities for the same boom length and radius in all directions around the
chassis of the vehicle.)
  Require workers to always check the crane's load chart to ensure that the crane will
not be overloaded by operating conditions.
 Instruct workers to plan lifts before starting them to ensure that they are safe.
 Tell workers to take additional precautions and exercise extra care when operating
around power lines.
 Direct workers to always keep hoisting chains and ropes free of kinks or twists and
never wrapped around a load.
 Train workers to attach loads to the load hook by slings, fixtures, and other devices
that have the capacity to support the load on the hook.
 Teach workers to maintain proper sling angles so that slings are not loaded in excess
of their capacity.
 Ensure that the critical parts of a crane—such as crane operating mechanisms, hooks,
air, or hydraulic system components and other load-carrying components—are
inspected daily for any maladjustment, deterioration, leakage, deformation, or other
damage.

What must employers do to ensure the safe use of slings?

Fig : 3.29 Safety precaution while dealing with crane.

As an employer, we must designate a competent person to conduct inspections of slings
before and during use, especially when service conditions warrant. In addition, we must
ensure that workers observe the following precautions when working with slings:
 Remove immediately damaged or defective slings from service.
 Do not shorten slings with knots or bolts or other makeshift devices.
 Do not kink sling legs.
 Do not load slings beyond their rated capacity.
 Keep suspended loads clear of all obstructions.
 Remain clear of loads about to be lifted and suspended.
 Do not engage in shock loading.
 Avoid sudden crane acceleration and deceleration when moving suspended loads.
What must employers do to protect workers who operate powered industrial trucks?
Workers who handle and store materials often use fork trucks, platform lift trucks, motorized
hand trucks, and other specialized industrial trucks powered by electrical motors or internal
combustion engines. Employers must make these workers aware of the safety requirements
pertaining the design, maintenance, and use of these trucks.
What are the safety requirements for modification?
We and our employees must not make modifications and additions affecting capacity and
safe operation of the trucks without the manufacturer's prior written approval. In these cases,
we must change capacity, operation, and maintenance instruction plates and tags or decals to
reflect the new information. If the truck is equipped with front-end attachments that are not
factory installed, the user must request that the truck be marked to identify these attachments
and show the truck's approximate weight— including the installed attachment—when it is at
maximum elevation with its load laterally centred.
What are the safety requirements for designation?
There are 11 different designations of industrial trucks, and each designation is suitable for
use in certain locations and under specific conditions. Workers must not use powered
industrial trucks in atmospheres containing hazardous concentrations of the following
substances:

 Acetylene
 Butadiene
 Acetaldehyde
 Cyclopropane
 Ethylene
 Isoprene
 Hydrogen (or gases or vapors equivalent in hazard to hydrogen)
 Ethylene oxide
 Propylene oxide
 Diethyl ether
 Unsymmetrical dimethyl hydrazine

In addition, workers may not use these trucks in atmospheres containing hazardous
concentrations of metal dust, including aluminum, magnesium, and other metals of similarly
hazardous characteristics. In atmospheres containing carbon black, coal, or coke dust,
workers may use only approved powered industrial trucks designated as EX. Where dusts of
magnesium, aluminum, or bronze may be present, fuses, switches, motor controllers, and
circuit breakers of trucks must have enclosures specifically approved for such locations.
3.24 Basic Safety and Health Principles
Employers can reduce injuries resulting from handling and storing materials by using some
basic safety procedures such as adopting sound ergonomics practices, taking general fire
safety precautions, and keeping aisles and passageways clear.
What Is Ergonomics?
Ergonomics is defined as the study of work and is based on the principle that the job should
be adapted to fit the person rather than forcing the person to fit the job. Ergonomics focuses
on the work environment, such as its design and function, as well as items—such as the
design and function of work stations, controls, displays, safety devices, tools, and lighting to
fit the employees' physical requirements and to ensure their health and well being.
Ergonomics includes restructuring or changing workplace conditions, to make the job easier,
and reducing stressors that cause musculoskeletal disorders. In the area of materials handling
and storing, ergonomic principles may require controls such as reducing the size or weight of
the objects lifted, installing a mechanical lifting aid, or changing the height of a pallet or
shelf.
Although no approach completely eliminates back injuries resulting from lifting materials, we
can prevent a substantial number of lifting injuries by implementing an effective ergonomics
program and by training our employees in appropriate lifting techniques.
What About Aisles and Passage ways?
When using aisles and passageways to move materials mechanically, workers must allow

Fig : 3.30 There are no sufficient space to move workers or any objects.
sufficient clearance for aisles at loading docks, through doorways, wherever turns must be
made, and in other parts of the workplace. Providing sufficient clearance for mechanically-
moved materials will prevent workers from being pinned between the equipment and fixtures
in the workplace, such as walls, racks, posts, or other machines. Sufficient clearance also will
prevent the load from striking an obstruction and falling on an employee.
Employers must ensure that all passageways that workers use remain clear of obstructions
and tripping hazards. Workers should not store materials in excess of supplies needed for
immediate operations in aisles or passageways, and employers must mark permanent aisles
and passageways appropriately.
3.25 Training and Education
OSHA recommends that employers establish a formal training program to teach workers how
to recognize and avoid materials handling hazards. Instructors should be well-versed in safety
engineering and materials handling and storing. The training should reduce workplace
hazards by emphasizing the following factors:

 Dangers of lifting without proper training.

 Avoidance of unnecessary physical stress and strain.
 Awareness of what a worker can comfortably handle without undue strain.
 Use of equipment properly.
  Recognition of potential hazards and how to prevent or correct them.

Should the prevention of some injuries receive special emphasis?

Yes. Because of the high incidence of back injuries, both supervisors and employees should
demonstrate and practice safe manual lifting techniques. Training programs on proper lifting
techniques should cover the following topics:

 Health risks of improper lifting, citing organizational case histories, vs the benefits of
proper lifting.
 Basic anatomy of the spine, muscles, and joints of the trunk, and the contributions of
intra-abdominal pressure while lifting.
 Body strengths and weaknesses—determining one's own lifting capacity.
 Physical factors that might contribute to an accident and how to avoid the unexpected.
 Safe postures for lifting and timing for smooth, easy lifting.
 Aids such as stages, platforms, or steps, trestles, shoulder pads, handles, and wheels.
 Body responses—warning signals—to be aware of when lifting.

Glossary Boom - A long, straight beam hinged at one end and used for lifting heavy objects
by means of cables and/or hydraulics. Booms can be of lattice construction or be made of
heavy tubular material.
Boom radius - The horizontal distance from the axis of rotation of a crane or derrick boom to
the boom tip.
Bracing - A diagonal piece of structural material that serves to strengthen something.
Chassis -The frame upon which a vehicle's body is mounted.
Chock - A wedge or block for steadying a body and holding it motionless, for filling in
excess space, or for preventing the movement of a wheel.
Competent person - one who can identify health and safety hazards in the workplace and
has the authority to correct them.
Crib - To line or support with a framework of timber.
Cumulative trauma disorders - Injuries that result from continuous or repetitive motions
over prolonged periods of time.
Outrigger - A projecting member that extends from a main structure to either provide
additional stability or support.
Powered industrial trucks - Forklift trucks, tractors, platform lift trucks, motorized hand
trucks, and other specialized industrialized trucks powered by electrical or internal
combustion engines.
Rigger - A worker who prepares heavy equipment or loads of material for lifting.
3.26 What are the Causes of Accident on Construction Site?

The Occupational Safety & Health Administration (OSHA) reports that there were 3,945
worker fatalities in private industry in 2012. Of that number, 775 or 19.6% were in
construction. There are many causes of an accident on a construction site. The top causes of
construction worker deaths on the job were falls, followed by struck by object, electrocution,
and caught-in/between. These ―Fatal Four‖ were responsible for nearly three out of five of
the construction worker [Link] accidents may be attributed to some type of negligence
and may involve unsafe work site conditions, improper use of tools and-or equipment, and
lack of protective safeguards. Some examples of construction site accidents are more
common than others. Below is a list of the more common ones starting with the Fatal Four.

1. Falls. Falls accounted for 278 out of 775 (36%) total deaths in construction in 2012,
according to OSHA. An injury of this type may occur when a worker near an open-
sided floor steps backwards or sideways without looking. Falling hazards also
commonly occur on stairwells with no guardrails. Since high elevations often play a
role in these falls, the results can be catastrophic to workers who sustain serious
injuries. The main cause of death in construction occurs where inadequate or no fall
protection is provided.
2. Struck by object. Seventy-eight construction workers died as a result of being struck
by an object in 2012. A number of these deaths may have been prevented if the
workers had undergone proper training and used equipment and machinery properly.
Employees must remember to use parking brakes on nonmoving vehicles, reverse
vehicle alarms, tool guards, personal protection equipment, debris nets, catch
platforms and more.
3. Electrocutions. In 2012, 66 workers (9%) were seriously injured or killed by
electrocution. Electrocution is when a person, tool or piece of equipment comes into
contact with power lines or exposed electrical sources. Sometimes, these types of
accident occur because workers are simply unaware of all energized power sources,
from overhead and underground power lines to damaged receptacles and connectors.
As an example, a construction worker carrying a metal ladder may strike an overhead
power line.
4. Caught-in/between. Although it seems obvious to never stand between a piece of
heavy equipment and an immovable object, sometimes workers concentrating on their
jobs find themselves in unexpected danger. Caught in/between accidents are when a
worker’s body part is caught, crushed, squeezed, compressed or pinched between two
or more objects. Examples include cave-ins or collapsing materials, body parts caught
in the moving parts of an unguarded piece of machinery, equipment rollovers and
getting pinned between fixed objects, like a wall, and piece of heavy equipment.
5. Slip and falls. These are among the most common accidents on a construction site.
These accidents may be linked to unsafe conditions conditions including uncovered
holes or trenches and exposed stakes.
6. Ladder accidents. This is one of the leading causes of injury and long-term
disability. Most ladder accidents, including falls, happen because workers use the
wrong type of ladder for their job or they set up the ladder improperly, perhaps on a
slippery or unstable surface, and the ladder unexpectedly shifts or slips. Workers also
may experience a foot slip, or they may lose their balance, or overreach. Ladders may
also be defective or improperly maintained.
7. Scaffolding accidents. Despite strict regulations, scaffolding accidents occur. In a
Bureau of Labor and Statistics (BLS) study, 72% of workers injured in scaffold
accidents attributed the accident either to the planking or support giving way, or to the
employee slipping or being struck by a falling object. In a general sense, most
scaffolding accidents are caused by improper construction or negligent maintenance.
8. Power tool and machinery accidents. Power tool and machinery injuries may occur
for reasons that include mechanical defects, electrical failure, inadequate training and
failure or lack of proper safety equipment. A significant number of injuries are caused
by the use of power tools and large equipment.
9. Musculoskeletal disorders. A leading cause of injuries, disability claims and medical
costs in construction are sprains and strains of the muscles. Construction work can
also cause injuries to the joints, bones, and nerves. These injuries often stem from job
demands that constantly wear and tear on the body.
 10. Vehicle Accidents. Dangerous construction site vehicles include forklifts, graders,
backhoes and dump trucks. A common forklift accident occurs when the vehicle is
turned or maneuvered with the load raised. Large trucks all too often back up and hit a
pedestrian. Another hazard on construction sites is falling from a vehicle.
While construction sites may appear to be dangerous, many of these accidents can be
avoided through common sense and protective measures. Prevention begins with adequate
awareness and a properly maintained working environment that is safe and secure.

Fig : 3.31 people working without basic safety tools.

Case studies 3.27

Case study 1: An employee was sweeping the floor around a machine in operation.
Back ground: The employee reached under a belt and pulley guard with a hand brush in
her left hand. Her glove was caught by the in-running portion of the notched flat belt,
which was approximately 16 inches from the floor. Her left hand was pulled into motor
pulley, causing two compound fractures to her left arm and damage to the hand,
including the complete loss of the middle and index fingers.
What Went Wrong
 By reaching under the guard and under the machine, the employee put herself in
danger.
 The employee did not inspect the machine’s guard to ensure it was adequate .
 The employee attempted to clean under the machine while it was still in operation. If
the employee had waited for the machine to stop operation, then applied lockout and
tag out to the machine before cleaning under it, she would not have been injured.
Surveillance Findings on investigation
 The guard did not completely cover the hazard. According to OSHA’s inspection,
there was a 4-inch gap between the guard and the machine body,
 According to the OSHA inspection, there appeared to be a lack of written work s
regarding cleaning around machinery—especially when it is in operation.
  There also appeared to be a lack of training because the worker did seem to be aware
of machine hazards, the importance of guard inspections, or lockout and tag out
practices.
 Lesson to be learnt
 Train employees to stay away from any machinery unless they are properly trained on
the machine’s hazards, guarding requirements, and how to safely work on or near the
machine.
 Teach employees who work around machinery to identify machine hazards (e.g.,
cutting action, punching action, shearing action, and nip points) and the location of
those hazards.
 Instruct machine operators to make sure all machines are properly safeguarded and
that machine guards are in place and operating properly before operation.
 Teach employees about OSHA are guarding requirements—for example, that guards
must prevent bodily contact with the danger zone, be secured to the machine, and
prevent objects from entering the danger zone, and so on.
 Tell workers who to contact if a guard is missing, damaged, or inadequate, and
instruct them not operate the machine until the guard is fixed.
Case Study 2: Car Accidents Caused by Mechanical Failure
In General
There are numerous reasons why car accidents occur. There are over millions of accidents
happened each year over the globe due to impaired driving. Around one-third of accidents are
caused by driver negligence, such as speeding, falling asleep, distracted driving, recklessness,
or inexperience. Accidents can also occurred as the result of mechanical failure, which can
be from normal fatigue , wear and tear or inadequate service or vehicle maintenance,
comprise car accidents. Accident injuries from a vehicle where the motorist loses control as a
result of a mechanical failure can be devastating if not fatal in some instances. Injuries range
from spinal strains to vertebral fractures, head and brain injuries, broken limbs, burns,
disfigurement and emotional trauma.
 Recommendations
 To avoid mechanical failures, we can follow these simple steps:
 Check your tire pressure
 Check your tire treads and replace them if they are too worn down or have uneven
surfaces
 If your brakes are squealing or making metallic scraping noises, or it takes unusual
pressure on the pedal to slow or stop, have them checked and immediately replaced or
repaired
 Have your wiper blades replaced if they are not working as this can lead to poor
visibility during rain or snow
 If your car lists to the side or wanders, have your steering linkage and suspension
inspected
Case study 3: Elevator accident due to mechanical failure
Background: One of the freight elevators of a super market company from Bangalore, which
suffered from mechanical failure, crushing to death a delivery man in month of Feb 2018.
The incident : The delivery man was loading some cargo onto the elevator from the fourth
floor of the building where the trading company is located, when its cables snapped fell on
him, A string of violations were discovered which crushed to death a delivery man ,
What went wrong: The owner of the cargo elevator operated the elevator without a permit
from City Hall since long time and did not do any preventive maintenance.
―It was found out that the accident happened due to mechanical failure. They have no permits
and they are also not doing preventive maintenance activities,‖
Important Note: The authorised personnel plan to push for legislative measures that would
ensure well-maintained facilities like elevators and escalators in the city. They suggested that
management would put up caution signs near the elevator. An ordinance has been proposed
for mandating establishment owners to regularly maintain their facilities like elevators and
cargo lifters and put caution signs near them.
It is recommended that there is also a need to establish an emergency response system within
the establishments so that they can immediately respond to similar accidents.

Case study 4 : Lost of fore finger tip in Mechanical workshop

Background: A worker has lost his fingertips in spite of having more years of skilful
experience while working in the workshop of the metallic manufacturing company,

The incident: This incidents takes place when he was trying to drip a few drop of lubricant
on the driven gear of a hack saw, instead of refilling the empty lubricant with oil, he just used
his fore finger and, his fore finger dropped to near the driven gear.

What went wrong: The exact cause of mishap is as follows.

 The worker could not properly identify the various sources of hazard in cutting
device and failed to manage it.

 The work was carried out without using personnel protective equipment,

 Lack of installing lock out and tag out devices while dripping the lubricant.

Lesson to be learnt:

 Never operate any machine without using personnel protective equipment.

 Training and retraining of the operator should be conducted in order to avoid

recurrence.

 Do not allow to work night shift without a frequent contact with other person.
Case study 5: Slipping on dust in machinery workshop
Back ground The slip risks resulting from machining dust became a point of discussion
when a HSE inspector slipped on the workshop floor during a routine health and safety visit.
The company did agree that processing dust finding its way onto the floor in that area did
make it rather slippery. The walkways and working area floors were very slippery, even more
vulnerable were visitors to the workshops as they were often taken unawares by the slippery
nature of the floors.
What happened wrong? The painted concrete floors of the workshop could not be
completely prevented from becoming contaminated with fine dust (up to 10 microns) from
the cutting and machining of graphite components. Extract ventilation at machines was not
effective as well as the filtration systems was not seem to be able to capture as much of the
dust as was needed allowing some to be deposited on surfaces. This was compounded by the
system of emptying by hand the bags holding the filtered out dust; the manual process
resulted in some dust being re-released and contaminating [Link] over slippery sign
board was not provided as well as slippery region was not covered.
Comments:
Floor audits are carried out as part of scheduled safety checks and any areas needing attention
are identified. Indications are that the service life of the 'grit paint' finish is between 12 & 48
months depending on the type and amount of use of the area. Cleaning of the new floor finish
is no more demanding with industrial grade dry vacuum cleaners doing the job day to day
supplemented by a period clean with a mechanical scrubber-dryer. When the company looked
at the amount of carbon dust being deposited throughout the workshop they resolved to do
something about that too. They saw benefits in the contribution that it would make to
preventing slips, providing a better working environment and reducing the size of the general
cleaning task. Plans should be formulated in order to integrate all local exhaust ventilation
into a single, more effective and efficient centralised system with the filtration should be
executed.

Case study 6. Foundries

Organizing health camps to check the health of the workers and taking necessary
measures and precaution in case some problem is identified.
Training on ergonomics including proper sitting posture s during mould
preparing, machining, grinding, correct position for carrying material, charging
material in cupola (in case of manual operations), pouring molten metal in
moulds etc .Awareness about negative effect of tobacco and alcohol consumption
Occupational safety refers to the condition and status of various elements related
or connected to the profession or job that is void of any source or situation that
may cause physical ill health directly or mental fear thereto to any human life.
It includes mechanical safety, electrical safety, chemical and dust safety, fire
safety, physical safety, biological safety. The safety can be ensured through the
following measures in foundry.
Provision of personal protective equipments for physical safety. This includes
the following:
 Hand gloves during sand preparation, segregation of metal form sand,
handling heavy rod for tapping metal from cupola etc
 Goggles during pouring molten metal, grinding, machining etc
 Ear plugs during machining, grinding, shot blasting machi ne etc
 Helmet when charging raw material in cupola etc
 Masks during mould preparation, pouring molten metal, machining, grinding
etc. This will ensure dust safety as well
 Safety shoes during charging raw material in cupola and pouring etc

 Replacing manual carrying of raw material with trolleys for physical safety of
workers
 Providing instructions on all machinery for physical safety
 Using mechanized charger for charging raw material in cupola for physical
and mechanical safety
 Removing the unwanted material to avoid minor injuries and providing
dedicated spaces for different raw material in the factory premises
 Installing fire fighting equipment like fire extinguisher and sand buckets for
fire safety
 Safety guards on loose wire connections for electrical saf ety
 Name plates in different operational areas
 Yellow borders to define boundary which can minimize accidents and injuries
 Important Questions

[Link] are the various safety tools required for lathe operation.
[Link] are the various safety tools required for grinding operation.
3. with suitable case study explain the safety measure to be carried out in machine
Shop.
[Link] suitable case study explain the safety measure to be carried out in foundry lab.
5. Write a short notes on the following.
(i)PPE (ii) Machines Safety tools
(iii)Safety for compressed Gas cylinders (iv) safety for welding
6. Explain the various risks involved in working at height using
(i) Scaffolds (ii) Ladders.
7. what are the various Mechanical hazards in industry. Explain
8. What are the Causes of Accident on Construction Site?
[Link] are the safety requirements for designation?
10 What must employers do to ensure the safe use of slings?
11. What safety measures should employer stake regarding cranes?
12 What safety measures should employer stake regarding conveyors?
13 What safeguards must workers follow when stacking materials?
[Link] precautions must workers take to avoid storage hazards?
15. What precautions should workers take when moving materials mechanically?
16. What are the potential hazards for workers?
17 What should employees know before moving, handling, and storing of materials?
18 What Safety precaution while dealing with corrosive substance.
19 what are Safety precaution for storing compressed gas cylinder
20 What is the Safety device for compressed gas cylinder?
21 Safety while working with forging machine
22 what are safety precaution while welding
[Link] are different types of [Link]
24. what are the safety measure while operating band saws machine ?
[Link] are the safety measure required while working in confined space ?