GENERAL PRACTICES AND SAFETY POINTERS
No workshop activity is worth pursuing if it cannot be done safely. Safety must be practiced dutifully.
- The right way is the safe way.
–Never start any task without identifying all the Risks and Hazards involved.
–Ensure that the necessary PPE is available to perform the task safely.
–Ensure that, where applicable, checklists are used.
–Only competent personnel are allowed to use the tools mentioned.
–During risk assessments, ensure that all assisting personnel are fully informed according to the task at hand.
–All surface workshops shall be equipped with adequate lighting, but shall never be less than what is specified in SOP96.
–All illumination levels shall be as such to adequately assist with the safe operation of all tasks in a workshop or related working areas.
–All surface workshops shall have adequate through ventilation to ensure the safety of all personnel while performing their daily tasks.
–All surface workshops shall have adequate demarcation clearly indicating all working areas and normal travelling routes.
–All surface workshops shall be equipped with adequate signage (inside and outside) to clearly indicate the route of evacuation to the assembly point, in the case of an emergency.
–All assembly points shall be clearly and adequately demarcated to indicate its position.
–Adequate welding screens and a sufficient quantity thereof shall be available in all welding and boiler making workshops.
–No person shall distract any other employee’s attention while he/she is performing any of the tasks below.
–If pre-arranged, communication with regards to the job at hand will be allowed.
–All tools and equipment switched-on or in operation, shall always be under constant supervision, by the person using these items.
–No portable electrical extension shall be more than 50m in length.
–The work shop is a place of work, so do not engage in horseplay.
–Never use a machine you are not familiar with or you do not know how to operate.
–Use only tools that are in good condition. Files or hammers with cracked handles are dangerous to use. Mushroom heads of cold chisels should be ground regularly to prevent accidents.
–Keep your hands dry before touching any power tool. Make sure you are not standing on a wet spot.
–Keep your hair short or cover it with a cap when working.
–Never wear loose clothing when working with machines. Remove wristwatches, bracelets, rings, and necklaces if identified as a hazard.
–Protect your eyes from flying chips and metal abrasives by wearing goggles and eye shields when grinding, buffing, chipping, and working with hot metals and materials.
–Keep tools in good working condition.
–Keep the work area clean and orderly. Remove things and materials which can hamper your current work.
–Keep flammable materials such as paints and thinners in a cool, dry place away from the work area.
–Clean oil spills on the floor immediately.
–Tools and materials (especially cylinders) dropped on the floor can cause accidents. Pick them up immediately and store them in proper places.
–There are specific safety rules for each tool and machine. The following are safety precautions in the use of general hand tools:
–Check that machinery is well maintained and fit to be used, ie appropriate for the job, working properly and all the safety measures are in place – guards, isolators, locking mechanisms, emergency off switches etc;
–Use machinery properly and in accordance with the manufacturer’s instructions;
–Ensure that those who use machinery are competent to use it safely, provide training where necessary. For some machinery a formal qualification is needed.
–Use a machine or appliance that has a danger sign or tag attached to it is not allowed. Danger signs
–should only be removed by the person in charge and when he/she is satisfied that the machine or process is now safe;
–Removal of any safeguards, even if their presence seems to make the job more difficult is unacceptable and not allowed;
–Wearing dangling chains, loose clothing, rings or have loose long hair that could get caught up in moving parts is not allowed;
–To distract people who are using machines is not allowed.
Safety Pointers on Commonly Used Tools:
Screwdrivers
- Select screwdrivers that fit the screw head slot perfectly.
- Keep the screwdriver handle smooth and clean to prevent slippages.
- Never use a hammer on a screwdriver handle.
- Never carry screw drivers in your pockets.
- Avoid holding an article by hand when using a screwdriver on it.
- Never grind a screwdriver to a chisel edge.
Scribers
- Never place the scriber inside your pocket.
- Always keep the point of the scriber in a safe position away from you.
- Wear safety goggles when sharpening the scriber.
Dividers
- Never carry an open divider in your pocket.
- Hold the divider firmly when scribing arcs or circles.
- Always cover the sharp point with a cork when it is not in use.
Hammers
- Discard hammers that are chipped and cracked.
- Never use a hammer that has a loose or split handle.
- Never strike two hammers together.
Tin snips
- Always use a tin snip that is sharp.
- Use only the end of the snip for cutting a notch.
- Sheet metal can cause serious cuts. Always wear gloves when handling them. Hold the sheet metal firmly with your left hand and hold the snip with your right hand.
Chisels & Punches
- Don’t use a cold chisel if it has a large mushroom at the head. Grind the head of the chisel first before using.
- Flying chips are dangerous. Wear safety goggles when chipping or shearing metals.
- Hold the chisel and hammer firmly. Keep the chisel head and the face of the hammer clean and free from grease.
- When shearing metal, look at the guiding line, never at the head of the chisel. Ensure the cutting edge of the chisel is sharp at all times.
Files
- Never use the file as a pry bar. Files are brittle and may crack with pressure.
- Never use a file without the handle. Keep a firm grip on the file at all times.
- Do not blow filings as they may get in your eyes.
Pliers
- Never use pliers as a substitute for a wrench.
- Always keep pliers in good condition.
- Clean and oil the pliers regularly.
Wrenches
- Never use a pipe wrench in loosening and tightening bolts and nuts.
- Pull a wrench toward yourself rather than pushing it away from you.
- Select a wrench that fits properly. A loose-fitting wrench may slip and round off corners of nuts or bolt heads.
- Do not use a wrench in moving machinery.
- Never hammer on a wrench to loosen a stubborn fastener. Wipe grease and oil from the work area to get a better grip.
Hacksaw
- Do not test the sharpness of the blade by running your fingers across the teeth.
- Be sure the saw blade is properly fitted and tensioned before using it.
- The teeth must point away from you when in use. Always ensure that objects are secure when sawed.
- Perform a mini risk assessment, on daily basis, prior to using the mentioned item for the first time. Thereafter, perform a visual inspection on the item and surrounding area before using it again.
- Check that proper PPE is available and used.
- Follow procedure for below mentioned tasks:
–How to safely use a pallet jack
–How to safely use an engine lift
–Procedure on lifting and handling of booms and buckets when line boring
–Performing line boring on parts
–Transporting and handling of steel plates
–Procedure on transporting of full and empty gas cylinders
–How to safely use a gas trolley
–Transporting of full and empty oil or diesel drums
–Transporting of new and old batteries
–How to safely use the hydraulic crimper
–Using LP Gas for heating torches
–How to safely use the high pressure washer
- Perform a mini risk assessment, on daily basis, prior to using the mentioned item for the first time. Thereafter, perform a visual inspection on the item and surrounding area before using it again.
- Check that proper PPE is available and used.
- Follow procedure for below mentioned tasks:
–Spray painting of parts
–Pre-charging of accumulators
–Hydraulic guillotine (plate-shear machine)
–Cropper
–Hydraulic bending press
–Profile cutter ioxy-acetylene
–T.I.G. Welder and high frequency welder
–Co2 welder
–Stick welder {ac machines and dc inverters)
–Air gouging torch
–Bearing press
–Radial arm drill
–Milling machine
–Lathe
- Perform a mini risk assessment, on daily basis, prior to using the mentioned item for the first time. Thereafter, perform a visual inspection on the item and surrounding area before using it again.
- Check that proper PPE is available and used.
- Follow procedure for below mentioned tasks:
–Vibratory stress relieving IVSR)
–Using the electric hoist
–Using the magnetic base drill
–How to safely use the electrical angle grinder
–How to safely use the cut-off machine
–How to safely use the portable electrical hand drill
–How to safely use the bench grinder
–How to safely use the pedestal drill
–How to safely use the portable hydraulic pack (ienerpac or porta-pack)
–How to safely use the slide sledge hammer
–How to safely use a traditional sledge hammer
–How to safely use a hammer and chisel or punch