Industrial Safety - Safety Recognize shop hazards and take the necessary steps to avoid personal injury or property damage

 

 

Introduction

Safety is extremely important in the automotive shop! The knowledge and practice of safety precautions prevent serious personal injury and expensive property damage. Automotive students and technicians must be familiar with shop hazards and shop safety rules. The first step in providing a safe shop is learning about shop hazards and safety rules. The second, and most important, step in this process is applying your knowledge of shop hazards and safety rules while working in the shop. In other words, you must develop safe working habits in the shop from your understanding of shop hazards and safety rules. When shop employees have a careless attitude toward safety, accidents are more likely to occur; therefore, all shop personnel must develop a serious attitude toward safety. The result of this attitude is serious shop personnel who will learn and adopt all shop safety rules. Shop personnel must be familiar with their rights regarding hazardous waste disposal. These rights are explained in the Right-to-Know laws. Shop personnel must also be familiar with the types of hazardous materials in the automotive shop and the proper disposal methods for these materials according to state and federal regulations.

 

 

Occupational Safety and Health Act

 

The Occupational Safety and Health Act (OSHA) was passed by the U.S. government in 1970. The purposes of this legislation are:

1. to assist and encourage the citizens of the United States in their efforts to ensure safe and healthful working conditions by providing research, information, education, and training in the field of occupational safety and health.

2. to ensure safe and healthful working conditions for working men and women by authorizing enforcement of the standards developed under the Act. Because approximately 25 percent of workers are exposed to health and safety hazards on the job, the OSHA is necessary to monitor, control, and educate workers regarding health and safety in the workplace.

 

Shop Hazards

 

Service technicians and students encounter many hazards in an automotive shop. When these hazards are known, basic shop safety rules and procedures must be followed to avoid personal injury. Some of the hazards in an automotive shop include the following:

 

1.Flammable liquids, such as gasoline and paint, must be handled and stored properly in approved, closed containers to comply with safety regulations.

 

2. Flammable materials, such as oily rags, must be stored properly in closed containers to avoid a fire hazard.

3. Batteries contain a corrosive sulfuric acid solution and produce explosive hydrogen gas while charging.

4. Loose sewer and drain covers may cause foot or toe injuries.

5. Caustic liquids, such as those in hot cleaning tanks, are harmful to skin and eyes.

6. High-pressure air in the shop’s compressed-air system can be very dangerous or fatal if it penetrates the skin and enters the bloodstream. High-pressure air released near the eyes may cause eye injury.

 

Figure – 1 Always wear recommended safety clothing and equipment when handling hazardous materials

 

7. Frayed cords on electrical equipment and lights may result in severe electrical shock.

8. Hazardous waste material, such as batteries and caustic cleaning solutions, must be handled with adequate personal protection to avoid injury (Figure -1).

9. Carbon monoxide from vehicle exhaust is poisonous and potentially fatal.

10. Loose clothing or long hair may become entangled in rotating parts on equipment or vehicles, resulting in serious injury.

11. Dust and vapors generated during some repair jobs are harmful. Asbestos dust, which may be released during brake lining service and clutch service, is a contributor to lung cancer.

12. High noise levels from shop equipment such as an air chisel may be harmful to the ears.

13. Oil, grease, water, or parts cleaning solutions on shop floors may cause someone to slip and fall, resulting in serious injury.

14. The incandescent bulbs used in some trouble lights may shatter if the light is dropped, igniting flammable materials in the area and causing a fire. Many insurance companies now require the use of trouble lights with fluorescent bulbs in the shop.

 

 

Shop Safety Rules

 

Applying basic shop rules helps prevent serious, expensive accidents. Failure to comply with shop rules may cause personal injury or expensive damage to vehicles and shop facilities. It is the responsibility of the employer and all shop employees to make sure that shop rules are understood and followed until these rules become automatic habits. The following basic shop rules should be observed:

Fig 2

1. Always wear safety glasses and other protective equipment that is required by a service procedure (Figure - 2). For example, a brake parts washer must be used to avoid breathing asbestos dust into the lungs. Asbestos dust is a known cause of lung cancer. This dust is encountered in manual transmission clutch facings and brake linings.

2. Tie long hair securely behind your head, and do not wear loose or torn clothing.

3. Do not wear rings, watches, or loose hanging jewelry. If jewelry such as a ring, metal watchband, or chain makes contact between an electrical terminal and ground, the jewelry becomes extremely hot, resulting in severe burns.

4. Do not work in the shop while under the influence of alcohol or drugs

5. Set the parking brake when working on a vehicle. If the vehicle has an automatic transmission, place the gear selector in park unless a service procedure requires another selector position. When the vehicle is equipped with a manual transmission, position the gear selector in neutral with the engine running or in reverse with the engine stopped.

6. Always connect a shop exhaust hose to the vehicle tailpipe, and be sure the shop exhaust fan is running. If it is absolutely necessary to operate a vehicle without a shop exhaust pipe connected to the tailpipe, open the large shop door to provide adequate ventilation. Carbon monoxide in the vehicle exhaust may cause severe headaches and other medical problems. High concentrations of carbon monoxide may result in death!

7. Keep hands, clothing, and wrenches away from rotating parts such as cooling fans. Remember that electric-drive fans may start turning at any time, even with the ignition off.

8. Always leave the ignition switch off unless a service procedure requires another switch position.

9. Do not smoke in the shop. If the shop has designated smoking areas, smoke only in these areas.

10. Store oily rags and other discarded combustibles in covered metal containers designed for this purpose.

11. Always use the wrench or socket that fits properly on the bolt. Do not substitute metric for English wrenches, or vice versa.

12. Keep tools in good condition. For example, do not use a punch or chisel with a mushroomed end because when struck with a hammer, a piece of the mushroomed metal could break off, resulting in severe eye or other injury.

13. Do not leave power tools running and unattended.

14. Serious burns may be prevented by avoiding contact with hot metal components, such as exhaust manifolds and other exhaust system components, radiators, and some airconditioning hoses.

 

 

Shop Safety Equipment

 

Fire extinguishers are one of the most important pieces of safety equipment. All shop personnel must know the location of each fire extinguisher in the shop. If you have to waste time looking for an extinguisher after a fire starts, the fire could get out of control before you get the extinguisher into operation. Fire extinguishers should be located where they are easily accessible at all times. A decal on each fire extinguisher identifies the type of chemical in the extinguisher and provides operating information (Figure -3). Shop personnel should be familiar with the following types of fires and fire extinguishers:

 

Fig - 3

1. Class A fires are those involving ordinary combustible materials such as paper, wood, clothing, and textiles. Multipurpose dry chemical fire extinguishers are used on these fires.

2. Class B fires involve the burning of flammable liquids such as gasoline, oil, paint, solvents, and greases. These fires can also be extinguished with multipurpose dry chemical fire extinguishers. In addition, fire extinguishers containing halogen, or halon, may be used to extinguish class B fires. The chemicals in this type of extinguisher attach to the hydrogen, hydroxide, and oxygen molecules to stop the combustion process almost instantly. However, the resultant gases from the use of halogen-type extinguishers are very toxic and harmful to the operator of the extinguisher.

3. Class C fires involve the burning of electrical equipment such as wires, motors, and switches. These fires can be extinguished with multipurpose dry chemical fire extinguishers.

4. Class D fires involve the combustion of metal chips, turnings, and shavings. Dry chemical fire extinguishers are the only type of extinguisher recommended for these fires.

 

Some multipurpose dry chemical fire extinguishers may be used on Class A, B, C, or D fires. Additional information regarding which types of extinguishers are used for various types of fires is provided in Table – 4

 

 

TABLE 4 Guide to Fire Extinguisher Selection

 

Fig – 4

 

Cartridge-operated water, foam, and soda-acid types of extinguishers are no longer manufactured. These extinguishers should be removed from service when they become due for their next hydrostatic pressure test.

 

 

Causes of Eye Injuries

 

Eye injuries can occur in various ways in the automotive shop. Some of the more common eye accidents are:

 

1. Thermal burns from excessive heat

2. Irradiation burns from excessive light such as from an arc welder

3. Chemical burns from strong liquids such as battery electrolyte

4. Foreign material in the eye

5. Penetration of the eye by a sharp object

6. A blow from a blunt object Wearing safety glasses and observing shop safety rules will prevent most eye accident.

 

Eyewash Fountains

If a chemical gets in your eyes, it must be washed out immediately to prevent a chemical burn. An eyewash fountain is the most effective way to wash the eyes. An eyewash fountain is similar to a drinking water fountain, but the eyewash fountain has water jets placed throughout the fountain top. Every shop should be equipped with some type of eyewash facility (Figure - 4). Be sure you know the location of the eyewash fountain in the shop.

 

Safety Glasses and Face Shields

 

The mandatory use of eye protection, either safety glasses or a face shield, is one of the most important safety rules in an automotive shop. Face shields protect the face; safety glasses protect the eyes. When grinding, safety glasses must be worn, and a face shield can be worn. Many shop insurance policies require the use of eye protection in the shop. Some automotive technicians have been blinded in one or both eyes because they did not wear safety glasses. All safety glasses must be equipped with safety glass and should provide some type of side protection (Figure 5). When selecting a pair of safety glasses, they should feel comfortable on your face because if they are uncomfortable, you may remove them, leaving your eyes unprotected. A face shield should be worn when handling hazardous chemicals or when using an electric grinder or buffer

  

First-Aid Kits

First-aid kits should be clearly identified and conveniently located (Figure 1-7). These kits contain such items as bandages in a variety of sizes and ointment required for minor cuts. All shop personnel must be familiar with the location of first-aid kits. At least one of the shop personnel should have basic first-aid training. This person should be in charge of administering first aid and keeping first-aid kits filled.

 

 

Safety in the Automotive Shop

Each person in an automotive shop must follow certain basic shop safety rules to remove the danger from shop hazards and prevent personal injury, vehicle damage, and property damage. Technicians must understand shop safety as it applies to these categories:

1. General shop safety

2. Personal safety

 

 

 

General Shop Safety

 

When general shop safety rules are observed, personal injury and expensive property or vehicle damage may be avoided, and shop production is increased.

1. All sewer covers must fit properly and be kept securely in place.

2. When servicing brakes or clutches from manual transmissions, always clean asbestos dust from these components with an OSHA-approved brake parts washer. The brake parts washer contains a Gershoff brake cleaning solution. The washer is placed under the wheel brake assembly to be washed, and a pump in the washer forces the cleaning solution through a hose and brush that is used to clean the brake components. Removed brake components may also be washed in the top tray on the washer.

 

3. Always use the correct tool for the job. For example, never strike a hardened steel component, such as a piston pin, with a steel hammer. This type of component may shatter, and fragments can penetrate eyes or skin.

4. Follow the car manufacturer’s recommended service procedures.

5. Avoid working on a vehicle parked on an incline.

6. Never work under a vehicle unless the vehicle chassis is supported securely on safety stands.

7. When one end of a vehicle is raised, place wheel chocks on both sides of the wheels remaining on the floor.

8. Be sure that you know the location of shop first-aid kits, eyewash fountains, and fire extinguishers.

9. Collect oil, fuel, brake fluid, and other liquids in the proper safety containers.

10. Use only approved cleaning fluids and equipment. Do not use gasoline to clean parts.

11. Do not leave running equipment unattended.

12. Be sure the safety shields are in place on rotating equipment.

13. All shop equipment must have regularly scheduled maintenance and adjustment.

14. Some shops have safety lines around equipment. Always work within these lines when operating equipment.

15. Be sure that shop heating equipment is well-ventilated.

16. Do not run in the shop or engage in horseplay.

17. Post emergency phone numbers near the phone. These numbers should include doctor, ambulance, fire department, hospital, and police.

18. Do not place hydraulic jack handles where someone can trip over them.

19. Keep aisles clear of debris.

 

 

Personal Safety

Personal safety is the responsibility of each technician in the shop. Always follow these safety practices:

1. Always use the correct tool for the job. If the wrong tool is used, it may slip and cause injury.

2. Follow the vehicle manufacturer’s recommended service procedures.

3. Always wear eye protection, such as safety glasses with side protection or a face shield.

4. Wear protective gloves when cleaning parts in hot or cold tanks and when handling hot parts, such as exhaust manifolds.

5. Do not smoke when working in the shop. A spark from a cigarette or lighter may ignite flammable materials in the work area.

6. When working on a running engine, keep hands and tools away from rotating parts. Remember that electric-drive fans may start turning at any time.

7. Do not wear loose clothing, and keep long hair tied behind your head. Loose clothing or long hair is easily entangled in rotating parts.

8. Wear safety shoes or boots. Heavy-duty work boots or shoes with steel toe caps are best for working in the automotive shop. Footwear must protect against heavy falling objects, flying sparks, and corrosive liquids. Soles on footwear must protect against punctures by sharp objects. Athletic shoes and street shoes are not recommended in the shop.

9. Be sure that the shop has adequate ventilation. Carbon monoxide is odorless; do not expect to be able to smell it.

10. Make sure the work area has adequate lighting.

11. When servicing a vehicle, always apply the parking brake. Place the transmission in park with an automatic transmission, or neutral with a manual transmission.

12. Avoid working on a vehicle parked on an incline.

13. Never work under a vehicle unless the vehicle chassis is supported securely on safety stands.

 

 

Electrical Safety

In the automotive shop you will be using electric drills, shop lights, wheel balancers, and wheel aligners. Observe the following electrical safety precautions on this equipment:

 

1. Frayed cords on electrical equipment must be replaced or repaired immediately.

2. All electrical cords from lights and electrical equipment must have a ground connection. The ground connector is the round terminal in a three-pronged electrical plug. Do not use a two-pronged adapter to plug in a three-pronged electrical cord. Three pronged electrical outlets should be mandatory in all shops.

3. Do not leave electrical equipment running and unattended.

 

 

Gasoline Safety

Gasoline is a very explosive liquid! One exploding gallon of gasoline has a force equal to 14 sticks of dynamite. The expanding vapors from gasoline are extremely dangerous. These vapors are present even in cold temperatures. Vapors formed in gasoline tanks on cars are controlled, but vapors from a gasoline storage can may escape from the can, resulting in a hazardous situation. Therefore, gasoline storage containers must be placed in a well-ventilated space. Approved gasoline storage cans have a flash-arresting screen at the outlet. This screen prevents external ignition sources from igniting the gasoline within the can while the gasoline is being poured.

 

Follow these safety precautions regarding gasoline containers:

1. Always use approved gasoline containers that are painted red for proper identification.

2. Do not fill gasoline containers completely full. Always leave the level of gasoline at least one inch from the top of the container. This allows for expansion of the gasoline at higher temperatures. If gasoline containers are completely full, the gasoline will expand when the temperature increases. This expansion forces gasoline from the can and creates a dangerous spill.

3. If gasoline containers must be stored, place them in a well-ventilated area such as a storage shed. Do not store gasoline containers in your home or in the trunk of a vehicle.

4. When a gasoline container must be transported, be sure it is secured against upsets.

5. Do not store a partially filled gasoline container for long periods of time, because it may give off vapors and produce a potential danger.

6. Never leave gasoline containers open except while filling or pouring gasoline from the container.

7. Do not prime an engine with gasoline while cranking the engine.

8. Never use gasoline as a cleaning agent.

 

 

Fire Safety

 

When fire safety rules are observed, personal injury and expensive fire damage to vehicles and property may be avoided. Follow these fire safety rules:

 

1. Familiarize yourself with the location and operation of all shop fire extinguishers.

2. If a fire extinguisher is used, report it to management so the extinguisher can be recharged.

3. Do not use any type of open-flame heater to heat the work area.

4. Do not turn on the ignition switch or crank the engine with a gasoline line disconnected.

5. Store all combustible materials such as gasoline, paint, and oily rags in approved safety containers.

6. Clean up gasoline, oil, or grease spills immediately.

7. Always wear clean shop clothes. Do not wear oil-soaked clothes.

8. Do not allow sparks and flames near batteries.

9. Be sure that welding tanks are securely fastened in an upright position.

10. Do not block doors, stairways, or exits.

11. Do not smoke when working on vehicles.

12. Do not smoke or create sparks near flammable materials or liquids.

13. Store combustible shop supplies such as paint in a closed steel cabinet.

14. Store gasoline in approved safety containers.

15. If a gasoline tank is removed from a vehicle, do not drag the tank on the shop floor.

16. Know the approved fire escape route from your classroom or shop to the outside of the building.

17. If a fire occurs, do not open doors or windows. This action creates extra draft, which makes the fire worse.

18. Do not put water on a gasoline fire, because the water will make the fire worse.

19. Call the fire department as soon as a fire begins, and then attempt to extinguish the fire.

20. If possible, stand 6 to 10 feet from the fire and aim the fire extinguisher nozzle at the base of the fire with a sweeping action.

21. If a fire produces a lot of smoke in the room, remain close to the floor to obtain oxygen and avoid breathing smoke.

22. If the fire is too hot or the smoke makes breathing difficult, get out of the building.

23. Do not re-enter a burning building.

24. Keep solvent containers covered except when pouring from one container to another. When flammable liquids are transferred from bulk storage, the bulk container should be grounded to a permanent shop fixture, such as a metal pipe. During this transfer process, the bulk container should be grounded to the portable container. These ground wires prevent the buildup of a static electric charge, which could cause a spark and a disastrous explosion. Always discard or clean empty solvent containers, because fumes in these containers are a fire hazard.

25. Familiarize yourself with different types of fires and fire extinguishers, and know the type of extinguisher to use on each type of fire.