A new “Warehouse Safety Hazards and Solutions Guide” is now available free from Graphic Products, Inc. It lists common warehouse safety hazards, presents safety solutions and provides “Think Safety” checklists for avoiding certain hazards.

Battery powered electric industrial forklift trucks are becoming more and more prevalent. With benefits of longer run times, shorter recharging times and reduced emissions, electric trucks are going to become even more common. From small, motorized pallet trucks to larger capacity forklift trucks. No matter what kind of truck you have, there are similar hazards associated with batteries and their maintenance.

-Weight issue - even the smallest of industrial forklift batteries weigh as much as 2000 lbs. or more
-Gases emitted during charging can be highly volatile
-Corrosive chemicals exist within the unit

For these reasons, battery charging areas must be properly equipped with personal protective equipment (PPE) for workers in addition to having safety procedures in place. Batteries should only be moved and replaced from the forklifts using a special equipped forklift or battery lift specifically created for transporting batteries, securely placed and restrained in that equipment.

Batteries release oxygen and hydrogen gases as they are charging. In the right concentrations, these gases can be highly explosive. Called “gassing”, it is more noticeable if the battery is being overcharged. Due to “gassing”, charging areas should be in well ventilated areas, and ideally even equipped with specially provided systems eg fume hoods or exhaust fans, a well ventilated area will prevent hydrogen and oxygen from reaching volatile levels.

Sulphuric acid is a common and hazardous component in a forklift (or other) battery. In the event of a battery acid spill, neutralizing agents and cleanup materials which should be to hand at all times should be placed on the liquid. After the spill is neutralized, it can be safely cleaned up and disposed of in accordance with your local regulations. Only properly trained and authorized employees should perform an acid cleanup.

PPE: proper footwear, such as steel toe capped boots should be worn. Chemical-resistant gloves, acid apron, eye wear and face protection are a must. They will reduce the risk of injury should an acid spill occur. As stated by OSHA 29 CFR 1910.133(a)(1), “The employer shall ensure that each affected employee uses appropriate eye or face protection when exposed to eye or face hazards from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapours, or potentially injurious light radiation.”

Face protection should meet the ANSI Z87.1-1989 specifications or be proven equally effective. Face shields are considered as secondary eye protection only. Indirect or non-vented safety spectacles should also be worn to protect the eyes. An eye/face wash and shower are other required pieces of equipment that must be provided in or near a battery changing area. According to OSHA 29 CFR 1910.151, “…where the eyes or body of any person may be exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body shall be provided within the work area for immediate emergency use.”

A Confined Space Safety Policy can be divided into 9 sections.
This article briefly describes the nine parts of a comprehensive yet efficient confined space safety program.

1 - Purpose - The confined space safety policy states the requirements for the identification and safe entry into both permit required and non-permit required confined spaces.  The policy applies to areas of the workplace not designed for continuous occupancy and containing recognized serious safety or health hazards.
2 - Reference - OSHA 29 CFR 1910.146
3 - Scope - Applicable to all of the business’s employees, visitors and contractors.
4 - Administration - Variable, but generally administration of the confined space policy is by safety coordinators, supervisors, engineers and other trained managerial staff.
5 - Definitions - Can be standard, see: OSHA, Occupational Safety and Health Act
6 - Descriptions -

Confined Space is an area/space where an employee: - has limited openings for entry and egress; - can bodily enter and which is large enough to perform assigned work; - could be engulfed by bulk materials; - is not intended to continuously occupy.
Non-Permit Required Confined Space is a confined space neither containing nor having the potential to contain any hazard.
Permit Required Confined Space is a confined space with: - a hazardous atmosphere or potential for it; - material that could engulf an entrant; - converging/tapering walls/floors that could entrap or asphyxiate; - a recognized hazard.
Procedures Followed For All Permit Required Confined Space Entry
- - Permit
- - Issuance - By the supervisor, mandatory for the employee, one shift in duration.
- - Cancellation - At shift end or on job completion.
- - Retention - Must be reviewed and kept. -
- - Alternate Entry/Space Reclassification - Specific ref: OSHA 29 CFR 1910.146 (c)(5)/(c)(7)
- - Pre-Entry Briefing - By permit issuing entry supervisor.
- - Contractor Notification - Outside contractor adheres to procedures - compliance must be assured.
- - Lighting Requirements - Natural, auxiliary, emergency.
- - Special Tools and Equipment - Intrinsically safe in flammable or combustible atmosphere.
- - Preparation and Hazard Control - Preventing engulfment, burns. Lockout/tagout procedures.
- - Assuring adequate ventilation.
- - Pre-Entry Atmospheric Testing - Includes employee training with testing equipment.
- - Monitor Calibration and Testing
- - Field and Manufacturer Testing.
- - Attendant Duties - Mandatory for permit required confined space entry, no other duties.
- - Entry Supervisor Duties - Trained and authorized entry supervisor.
- - Safety Equipment - PPE, non-entry rescue, rescue, general.
- - Equipment Inspection - Per manufacturer’s recommendation.
- - Handling Problems
- - Rescue and Emergency Services - Documented, available, trained, equipped.
- - Summoning Rescue Services Procedure

7 - Responsibilities - Employees and Entry Supervisor - Safety Coordinators - Supervisors - Contractors
8 - Training - Initial - Refresher - Annual
9 - Revision - Annually by Safety Coordinators

These are the nine parts of a Confined Space Safety Policy.
Fleshed out details of just such a policy can be read at Confined Space Safety Policy

The Compliance Resource Center has reported that both the domestic hazardous materials transportation regulations and international rules for shipping batteries have undergone significant changes over the past two years.  All batteries, alkaline, lithium, lead, nickel metal hydride, carbon zinc, etc., or battery powered products are subject to 49 CFR 173.21(c) in the U.S. hazardous materials regulations.   Many batteries that were previously unregulated or under-regulated must now be thoroughly evaluated to determine hazard potential. Detailed packaging and communication standards must be followed under. 

Adding complexity to the issue is the fact that shipping requirements vary greatly, depending on the mode of transport and the type of battery.  Battery shipping regulations affect a wide array of industries from manufacturers and part suppliers to freight forwarders and distributors.  Regardless of whether a lithium or lithium ion cell or battery qualifies for the exceptions in the regulations, shippers must still comply with requirements of 49 CFR 173.21(c). That is, the cells and batteries must be securely packaged and offered for transportation in a manner that prevents the dangerous evolution of heat and short circuits.

Both FedEx and UPS will refuse to accept packages not meeting FedEx, Government or IATA requirements.

Slips, Trips and Falls happen everywhere.  These hazards have much more potential to cause harm in a healthcare setting, where patients are not well and people are in a hurry.  Haste is the number 1 cause of Slips, Trips and Falls.  Here are some helpfuls hints to think of.

Potential Hazard
Employee exposure to wet floors or spills and clutter that can lead to slips/trips/falls and other possible injuries.  
Possible Solutions:

• Keep floors clean and dry [29 CFR 1910.22(a)(2)]. In addition to being a slip hazard, continually wet surfaces promote the growth of mold, fungi, and bacteria, that can cause infections.
• Provide warning signs for wet floor areas [29 CFR 1910.145(c)(2)].
• Where wet processes are used, maintain drainage and provide false floors, platforms, mats, or other dry standing places where practicable, or provide appropriate waterproof footgear [29 CFR 1910.141(a)(3)(ii)].
• Walking/Working Surfaces Standard requires [29 CFR 1910.22(a)(1)]: Keep all places of employment clean and orderly and in a sanitary condition.
• Keep aisles and passageways clear and in good repair, with no obstruction across or in aisles that could create a hazard [29 CFR 1910.22(b)(1)]. Provide floor plugs for equipment, so power cords need not run across pathways.
• Keep exits free from obstruction. Access to exits must remain clear of obstructions at all times [29 CFR 1910.36(b)(4)].

Other Recommended Good Work Practices:

• Ensure spills are reported and cleaned up immediately.
  Use no-skid waxes and surfaces coated with grit to create non-slip surfaces in slippery areas such as toilet and shower areas.
• Use waterproof footgear to decrease slip/fall hazards.
• Use only properly maintained ladders to reach items. Do not use stools, chairs, or boxes as substitutes for ladders.
• Re-lay or stretch carpets that bulge or have become bunched to prevent tripping hazards.
• Aisles and passageways should be sufficiently wide for easy movement and should be kept clear at all times. Temporary electrical cords that cross aisles should be taped or anchored to the floor.
• Eliminate cluttered or obstructed work areas.
• Nurses station countertops or medication carts should be free of sharp, square corners.
• Use prudent housekeeping procedures such as cleaning only one side of a passageway at a time, and provide good lighting for all halls and stairwells, to help reduce accidents.
• Provide adequate lighting especially during night hours. You can use flashlights or low-level lighting when entering patient rooms.
• Instruct workers to use the handrail on stairs, to avoid undue speed, and to maintain an unobstructed view of the stairs ahead of them even if that means requesting help to manage a bulky load.
• Eliminate uneven floor surfaces.
• Promote safe work in cramped working spaces. Avoid awkward positions, and use equipment that makes lifts less awkward. 
   

Every day an estimated 1,000 eye injuries occur in American workplaces. The financial cost of these injuries is enormous–more than $300 million per year in lost production time, medical expenses, and workers compensation. No dollar figure can adequately reflect the personal toll these accidents take on the injured workers.

The Occupational Safety and Health Administration (OSHA) and the 25 states and territories operating their own job safety and health programs are determined to help reduce eye injuries. In concert with efforts by concerned voluntary groups, OSHA has begun a nationwide information campaign to improve workplace eye protection.

Take a moment to think about possible eye hazards at your workplace. A 1980 survey by the Labor Department’s Bureau of Labor Statistics (BLS) of about 1,000 minor eye injuries reveals how and why many on-the-job accidents occur.

WHAT CONTRIBUTES TO EYE INJURIES AT WORK?

• Not wearing eye protection. BLS reports that nearly three out of every five workers injured were not wearing eye protection at the time of the accident.

• Wearing the wrong kind of eye protection for the job. About 40 of the injured workers were wearing some form of eye protection when the accident occurred. These workers were most likely to be wearing eyeglasses with no side shields, though injuries among employees wearing full-cup or flat-fold side shields occurred, as well.

WHAT CAUSES EYE INJURIES?

• Flying particles. BLS found that almost 70% of the accidents studied resulted from flying or falling objects or sparks striking the eye. Injured workers estimated that nearly three-fifths of the objects were smaller than a pin head. Most of the particles were said to be traveling faster than a hand-thrown object when the accident occurred.

• Contact with chemicals caused one-fifth of the injuries. Other accidents were caused by objects swinging from a fixed or attached position, like tree limbs, ropes, chains, or tools which were pulled into the eye while the worker was using them.

WHERE DO ACCIDENTS OCCUR MOST OFTEN?

Craft work; industrial equipment operation. Potential eye hazards can be found in nearly every industry, but BLS reported that more than 40% of injuries studied occurred among craft workers, like mechanics, repairers, carpenters, and plumbers. Over a third of the injured workers were operatives, such as assemblers, sanders, and grinding machine operators. Laborers suffered about one-fifth of the eye injuries. Almost half the injured workers were employed in manufacturing; slightly more than 20% were in construction.

HOW CAN EYE INJURIES BE PREVENTED?

Always wear effective eye protection. OSHA standards require that employers provide workers with suitable eye protection. To be effective, the eyewear must be of the appropriate type for the hazard encountered and properly fitted. For example, the BLS survey showed that 94% of the injuries to workers wearing eye protection resulted from objects or chemicals going around or under the protector. Eye protective devices should allow for air to circulate between the eye and the lens. Only 13 workers injured while wearing eye protection reported breakage.

Nearly one-fifth of the injured workers with eye protection wore face shields or welding helmets. However, only six percent of the workers injured while wearing eye protection wore goggles, which generally offer better protection for the eyes. Best protection is afforded when goggles are worn with face shields.

Better training and education. BLS reported that most workers were hurt while doing their regular jobs. Workers injured while not wearing protective eyewear most often said they believed it was not required by the situation. Even though the vast majority of employers furnished eye protection at no cost to employees, about 40% of the workers received no eye safety training on where and what kind of eyewear should be used.
Maintenance: Eye protection devices must be properly maintained. Scratched and dirty devices reduce vision, cause glare and may contribute to accidents.

WHERE CAN I GET MORE INFORMATION?

• The OSHA website or your nearest OSHA area office. Safety and health experts are available to explain mandatory requirements for effective eye protection and answer questions. They can also refer you to an on-site consultation service available in nearly every state through which you can get free, penalty-free advice for eliminating possible eye hazards, designing a training program, or other safety and health matters.

o Don’t know where the nearest federal or state office is? Call an OSHA Regional Office at the U.S. Department of Labor in Boston, New York, Philadelphia, Atlanta, Chicago, Dallas, Kansas City, Denver, San Francisco, or Seattle.

• The National Society to Prevent Blindness. This voluntary health organization is dedicated to preserving sight and has developed excellent information and training materials for preventing eye injuries at work. Its 26 affiliates nationwide may also provide consultation in developing effective eye safety programs. For more information and a publications catalog, write the National Society to Prevent Blindness, 79 Madison Ave., New York, NY 10016-7896.

EYE PROTECTION WORKS!

BLS reported that more than 50% of workers injured while wearing eye protection thought the eyewear had minimized their injuries. But nearly half the workers also felt that another type of protection could have better prevented or reduced the injuries they suffered.

It is estimated that 90% of eye injuries can be prevented through the use of proper protective eyewear. That is our goal and, by working together, OSHA, employers, workers, and health organizations can make it happen.

This is one of a series of fact sheets highlighting U.S. Department of Labor programs. It is intended as a general description only and does not carry the force of legal opinion. This information will be made available to sensory impaired individuals upon request. Voice phone: (202) 523-8151. TDD message referral phone: 1-800-326-2577.

U.S. Department of Labor
Program Highlights
Fact Sheet No. OSHA 92-03

I recently attended the 20th Chicagoland Safety and Health Conference.  During the day I asked as many safety professionals as possible what was the #1 incident on their OSHA 300 log.  To a person the response was Slips, Trips and Falls (STF).  Because this is one of the most common incidents I thought it would be good to revisit an old article published on this site about 2 years ago.  I hope you find this interesting and useful.

Employees don’t just slip and fall because they are careless. Hidden risks exist at all work sites.  Slips and falls are complex events. If you focus on just one part of the problem, such as a cracked tile or slippery floor, the risk will still exist. Instead, attack the whole problem with a systems approach that analyzes your organization and pinpoints areas needing attention.
Taking Control
Same-level slips and falls are the second-leading cause of disabling workplace injuries. They cost private industry more than $5 billion in direct costs alone each year. The indirect costs for hiring and training replacement workers, increased absenteeism, and decreased productivity are estimated to be three to five times higher. But slips and falls are not unavoidable “acts of God” due to employee carelessness or bad luck. You can control them. Here’s how.Same-level slips and falls are the second-leading cause of disabling workplace injuries. They cost private industry more than $5 billion in direct costs alone each year. The indirect costs for hiring and training replacement workers, increased absenteeism, and decreased productivity are estimated to be three to five times higher. But slips and falls are not unavoidable “acts of God” due to employee carelessness or bad luck. You can control them. Here’s how.First, secure management buy-in. Employees don’t just slip and fall because they are careless. Hidden risks exist at all work sites. You can demonstrate to managers the cost and the cause of slip-related injuries with photos of potential hazards, qualified worker observations, and slipperiness measurements from work sites. Managers often don’t realize that a leading portion of their loss comes from preventable slips and falls; by illustrating the negative impact on the bottom line and the potential positive outcome from a system approach, you will get management buy-in.

(more…)

Do you ship or receive any materials considered hazardous by the US DOT (49 CFR 172.101)?  If so, you MUST have a security plan (49 CFR part 172.800) which includes security awareness training to all who load, unload or have some responsibility putting the hazardous materials in commerce.  This might include the person in the office who fills out the shipping papers, or the forklift driver who unloads the truck in your loading bay.  Everyone involved with the process must be trained. 

The DOT has become more active fining companies and organizations for not having a security plan and not doing the training.  Large or small, profit or not-for-profit, it doesn’t matter.  Security awareness training is now considered one of the 5 parts of HAZMAT training.  the 5 parts include: General Awareness, Function-Specific, Safety, Security Awareness, and Security In-Depth (if you need and have a security plan as classified by (49CFR 172.800(b)(1-7). If your hazardous materials fall under this last part, then you must do a full security plan including a assessment and training.  The plan needs to be in writing and available to all who are affected.

The Compliance Resource Center can help you do a security assessment, write a security plan and customize hazmat training specificly for your company.  All of our HAZMAT training is customize for the hazardous materials you ship or receive.  You employees get ALL the training required by the US DOT Pipline and Hazardous Materials Safety Adminsitration.  DOT Hazmat training for ground is required every 3 years and for air and/or ocean every 2 years. 

Here are the last set of answers.  I hope you did well.  Let me know (info@thecrcenter.com or use the comment area below) how useful this quiz was.  How did you use it and would you like more of these.  

Answers to Electrical Safety Quiz Part-2
11.    b./Are capable of being accidently approached nearer than a safe distance.

12.    a./If they are not locked/tagged out

13.    c./Is familiar with the construction and operation of the equipment and the hazards involved

14.    a./Must be done by a qualified person

15.    d./Both a. and b

16.    c./No one is allowed to stand near the grounding location

17.    a./Must be inspected before use on every shift

18.    d./The area contains exposed energized parts

19.    c./Use a non-conductive ladder

20.    b./It must be determined that it would be safe to reenergize the circuit before the circuit breaker can be re-set