MODULE 3

MECHANICAL SAFETY

WHAT IS PPE ?
PPE is equipment that will protect the user against health or safety risks at work. It can
include items such as safety helmets and hard hats, gloves, eye protection, high-visibility
clothing, safety footwear and safety harnesses. Hearing protection and respiratory protective
equipment provided for most work situations are not covered by these Regulations because there
are other more specific regulations that apply to them. However, these items need to be
compatible with any other PPE provided.

Cycle helmets or crash helmets worn by employees on the roads are not covered by the
Regulations. Motorcycle helmets are legally required under road traffic legislation. The
Employment Act 1989 gives an exemption for turban-wearing Sikhs working on construction
sites from the need to wear head protection.

Eyes

Hazards: Chemical or metal splash, dust, projectiles, gas and vapour, radiation.

Options: Safety spectacles, goggles, face-shields, visors.

Head

Hazards: Impact from falling or flying objects, risk of head bumping, hair entanglement.

Options: A range of helmets, hard hats and bump caps.

Breathing

Hazards: Dust, vapor, gas, oxygen-deficient atmospheres.

Options: Disposable filtering face-piece or respirator, half- or full-face respirators, airfed

Helmets, breathing apparatus.
Protecting the body
Hazards: Temperature extremes, adverse weather, chemical or metal splash, spray from
pressure leaks or spray guns, impact or penetration, contaminated dust, excessive wear or
entanglement of own clothing.

Options: Conventional or disposable overalls, boiler suits, specialist protective clothing,

eg chain-mail aprons, high-visibility clothing.

Hands and arms

 Hazards: abrasion, temperature extremes, cuts and punctures, impact, chemicals, electric
shock, skin infection, disease or contamination.

Options: Gloves, gauntlets, mitts, wrist-cuffs, armlets.

Feet and legs

Hazards: Wet, electrostatic build-up, slipping, cuts and punctures, falling objects, metal
and chemical splash, abrasion.

Options: Safety boots and shoes with protective toe caps and penetration-resistant mid-
sole, gaiters, leggings, spats.

SAFETY GUARD
Safety guarding on machines and equipment prevent or reduce access to dangerous areas
of the machine. All machine guarding must be of a solid construction and securely mounted to
the plant, to resist impact or shock from operation. If you need to remove guarding for
maintenance and cleaning, you must take steps to ensure (so far as is reasonably practicable) that
the plant cannot be restarted until the guarding is replaced. If the plant contains moving parts and
those parts may break, disintegrate or be ejected, the guard must (so far as is reasonably
practicable) effectively contain the broken or ejected parts.

If you manage or control a plant you must make sure the guarding:

1. Is a permanently fixed physical barrier or an interlocked physical barrier (if access to the
danger area is required during operation, maintenance or cleaning), or

2. Is a physical barrier that can only be altered or removed by the use of tools (when it is not
reasonably practical to use guarding referred to in 1), or

3. Is presence sensing safeguarding system (when it is not reasonably practical to use guarding
referred to in 1 or 2)

You must also make sure that:

• The guarding makes bypassing or disabling the guarding as difficult as reasonably practical

• Any pipe or other part of the plant that is subject to heat or cold is guarded or insulated if there
is a risk of injury

SAFETY PRECAUTIONS WHILE WORKING ON LATHE MACHINE

All lathe operators must be constantly aware of the safety hazards that are associated with
using the lathe and must know all safety precautions to avoid accidents and injuries. Carelessness
and ignorance are two great menaces to personal safety. Other hazards can be mechanically
related to working with the lathe, such as proper machine maintenance and setup.
Some important safety precautions to follow when using lathes are:

1. Correct dress is important, remove rings and watches, and roll sleeves above elbows.
2. Always stop the lathe before making adjustments.
3. Do not change spindle speeds until the lathe comes to a complete stop
4. Handle sharp cutters, centers, and drills with care.
5. Remove chuck keys and wrenches before operating
6. Always wear protective eye protection.
7. Handle heavy chucks with care and protect the lathe ways with a block of wood when
installing a chuck.
8. Know where the emergency stop is before operating the lathe.
9. Use pliers or a brush to remove chips and swarf, never your hands.
10. Never lean on the lathe.
11. Never lay tools directly on the lathe ways. If a separate table is not available, use a wide
board with a cleat on each side to lay on the ways.
12. Keep tools overhang as short as possible.
13. Never attempt to measure work while it is turning.
14. Never file lathe work unless the file has a handle.
15. File left-handed if possible.
16. Protect the lathe ways when grinding or filing.
17. Use two hands when sanding the work piece. Do not wrap sand paper or emery cloth around
the work piece

SAFETY PRECAUTIONS WHILE WORKING ON DRILL PRESS

This type of equipment can be a great tool for shop work but you must take precautionary
measures when operating a drill press. And because it is important we’ve decided to list 14 top
precautionary measures that are essential when operating a drill press.

1. Understand It before You Start

We understand how tempting it can be to just get started. A drill press is a fun machine to
use. That doesn’t mean “learn as you go.” This is a professional shop machine and you need to
know how to use it before use it. Know your drill press. Inspect machine before use, read the
owner’s manual and find someone who has already use that machine. If it’s a new drill press, be
sure to find as much information about safe use as possible. Understand the specific potential
hazards that this particular machine could have.

2. Safety Goggles are there for a Reason

 Some people assume that using safety goggles for simple job seems to be something a
little too precautionary. However, doctors will testify that it even the simplest job or bore without
the use of safety wear like goggles that can cause facial damage or irreversible eye problems.
Even for the smallest of jobs, it is important that you wear goggles.

3. Initial Inspection

Sometimes it’s the little things that can cause an accident. Quick inspections before using
the drill press and save you a lot of time and headaches. Make sure that you remove the chuck
key from the chart before you power on the drill. Of course, you can save time and problems by
using the self-ejecting chuck key. You also want to avoid accidental starts by making sure that
use which the drill press to the off position before plugging or unplugging the electrical cord.
And when making repairs.Make sure you disconnect the drill from the power source.

4. Use Appropriate Accessories

When you use a drill press be sure that you use accessories made for that particular
model. Never use a hand auger bit for a drill press. Make sure you only use bits and drills that are
designed for the model and make of the drill press you are using. Be sure to consult the owner’s
manual for the recommended parts and accessories. Using other parts and accessories can present
a hazard for that particular drill press.

5. Use Best Practices

Use your best practices when working with a drill press. Make sure you hold the
workpiece firmly so that it doesn’t spin or fly off the table and hit you. If possible fasten the
workpiece with clamps or a vise. This is especially good idea when the pieces you’re working
with are smaller.

6. Proper Clothing

Make sure things are right fully in their place; for example you want to keep the guard on
the spindle pulley to prevent error clothing getting caught. When working with the drill press,
avoid using those clothing, gloves or jewelry. If your hair is longer make sure that you use a hair
net.

7. Use the Proper Accessories for the Proper Job

Use the proper drill chuck for the job you’re working on. Most operations can work with
the 0 or half inch drill chuck. But check to make sure. If you do need to adjust the drill press,
make sure that it’s powered off.

8. Operational Precautions

You want to adjust the table so that the hole in the table center is directly beneath the
drill. You also want to let the depth correctly on the drill press and thereby avoid drilling into the
table. As a precautionary measure, you might want to place a piece of wood underneath the work
piece to prevent this from happening.
 Avoid using too high a spindle speed and stay close to the recommended speeds for that
particular drill. When in doubt, just stick to a lower speed. A wrong application of a high-speed
can burn the cutting tool or even the work piece. In may even make the work piece fly off the
table and hit you or someone standing nearby. By the same token, to slower speed with a heavy
feed may cause the tool to dig into the work piece and start the motor or break the edges. When
changing your speed, just make sure you power off the drill press.

9. Pay Attention to Drilling Best Practices

When drilling deep, raise the bit frequently and clean chips out of the hole. This will keep
the drill from wearing down, breaking or flying out. If the drill does becomes stuck in the hole,
turn off the machine before you raise the bit. Make sure you use a brush to keep the table,
accessories and workpiece constantly clean. Before cleaning be sure to power off and disconnect
from the electrical outlet. Use a brush to clean off chips and sawdust.

Avoid using a drill press when there are issues. Problems won’t fix themselves so make
sure that you inform someone or have accessories replaced when needed. Never run a drill press
that has repair issues.

10. Problems

When operating the machine you should always expect something to go wrong. This
means you need to buy extra material, so that any mistake you make can be redone.

11. Avoid Health Hazards

When drilling large amounts of work be sure to use respiratory protection masks. By the
same token when you use sanding drums or abrasive accessories make sure you use these work
masks but also be sure that the area is well ventilated.

12. Listen to the Machine

A machine will tell you when something is wrong; you just have to listen to the way it
works. When there is a mechanical problem the operation will sound differently. This is when
you should call a specialist to inspect the machine.

13. Stay Calm

Most health professionals and OSHA representatives will tell you that many accidents
happen because operators got nervous. Never! Never try to stop the machine by grabbing the
chuck, even when the machine is powered off. Not run the tool when you’re not attending it.
When you finish a project, turn off the power and remain in place until the chuck comes to a
complete stop.

14. Child Proof your Drill Press

If your drill press is located in your home or other area where children frequent. You
must kid proof the machine. The best way to do this is to position the key to the off position and
remove the switch toggle. This way, children cannot turn on the drill press.
 WHAT ARE THINGS YOU SHOULD AVOID?

• Do not wear any loose clothing or ties. Roll sleeves above the elbow to prevent them from being
caught in revolving parts. Confine long hair.
• Do not wear gloves, rings, watches, or bracelets while working with a drill press.
• Do not set speeds, adjust, or measure work until machine is completely stopped.
• Do not force the drill with extra pressure.
• Do not leave chuck key in drill chuck. Make adjustments and remove key immediately.
• Do not hold work by hand when drilling holes; secure the work with clamps or vices.
• Do not place hands under the stock being drilled.
• Do not stop rotation of chuck and spindle with your hand.
• Do not remove a broken drill with a center punch and hammer.
• Do not leave the drill press running unattended

POWER &BAND SAW SAFETY AND OPERATIONAL SAFETY RULES

The operators must follow the following instructions while working on Power & band
saw machine for safety.

1. Always disconnect the power before changing the blade or performing any other maintenance
operation.

2. Make all adjustments to the band saws while the machine is off and stopped.

3. Operating instructions vary by make and model of band saw. Always check with the Shop
Attendant before using a band saw that you have not used before. Currently, the Guild Shop has two
band saws: a. Felder 21” – Set up for resawing b. Jet 18” – Set up for general use

4. Follow the 3” rule from the blade; always keep fingers 3” from the path of the blade. To
control the stock, use push sticks, feather boards, or any other safety device when cutting small
or short stock.

5. The teeth of the band saw blade should point down toward the table.

6. See the Shop Attendant if you need to change blades.

7. Check the blade tension and tracking before starting. The blade should be 1/32” from the rear
roller bearing behind the blade. See the Shop Attendant if the blade guides need adjustment.

8. The blade alignment tracking should be: a. Felder 21” – Forward on the tire, so that the teeth
do not touch the tire b. Jet 18” - At the center of the wheels.

9. Make sure that the upper and lower wheel guard doors are closed when running.
10. Keep the blade guard & guide 1/2” above your stock.

11. Turn on dust collection and open blast gate before starting saw.

12. Don’t cut stock that is not flat on the bottom without a jig.

13. Keep a balanced stance at the band saw.

14. Cut at a moderate feed rate into the blade, do not force a cut.

15. Cut relief cuts prior to cutting a long or tight curve. The relief cuts will free the blade of the
tension of the tight curve and the wood will fall away. The blade size will dictate the radius of
the cut.

16. If you need to back out of a cut, shut the machine off. After the blade stops, back out.

17. If the work is too large for one person, get help holding the stock.

18. When cutting with the table at an angle, clamp a block to the table to prevent your stock from
slipping off the table.

19. Never clear small pieces while the blade is moving.

20. Always keep your fingers and hands away from the path of the blade, use a push stick.

21. Use a “V” block when cutting cylindrical stock.

22. Turn the power off immediately and stand clear if you hear a clicking sound or the blade
breaks.

SAFETY PRECAUTIONS WHILE CARRYING GRINDING WORK

The grinding work is carried out by rotating grinding wheel at higher speed. So operate
should follow below mentioned some safety precautions.

1. We should ensure that the work is held firmly and properly. The grinding wheel should be
inspected and mounted on the spindle.

2. Proper work speed, wheel speed and table feed should be selected according to the nature of
the work.

3. Safety goggles should be worn by the operator.

4. It should be checked whether the safety guards are fitted.

5. The operator should not touch the rotating work or the grinding wheel.

6. The operator should not wear loose shirts and neck tie.

7. The work rest of a bench grinder should be placed close to the grinding wheel.
8. The speed of the vitrified grinding wheels should not exceed 2800 meters per minute.

9. When new wheels are used, the wheel speed should be kept minimum.

10.If the job is held in a magnetic chuck, extra grips should be placed around the work pieces

Mentioned below are important points that must be taken into consideration while
carrying out grinding work

1. Check the Speed

The speed of the grinder must always be monitored. Grinder should not rotate faster than
the maximum RPM stated on the wheel.

2. Check Grinding wheel and Grinding Guard

Never use a grinder without the grinding wheel guard which is provided for protection.
Check the grinding wheel for any kind of crack or damage before using the grinder.

3. Ensure proper assembly of flanges and other parts

Grinding wheel consists of several smaller parts which should be properly assembled and
tightened together. Make sure that the right flanges are used and attached properly for a smooth
movement. Ensure that there are no traces of burr or flash.

4. Use Right Wheel Dimension

Using the right dimension of grinding wheel plays an important role in ensuring safety
and achieving higher efficiency. Using the right dimension wheel also helps in achieving the
maximum allowed rotation speed of the grinding wheel.

5. Always Test Before Running

Grinders must always be tested before beginning any kind of work. Test run the grinder
in a safe enclosed area such as beneath the workbench to detect any kind of damage or fault in
the wheel or the grinder.

6. Always Wear Personal Protective Equipment

Never use the grinder without wearing all the personal protective equipment and clothing
such as goggles, helmets, masks, ear protection, gloves, leather aprons etc. Also ensure that the
personal protective equipment and tools are in proper condition before using them.

7. Carry out Maintenance at Regular Intervals of Time

Carry out maintenance of grinders at regular intervals of time and as stated by the
manufacturer. Never use a faulty device and carry out all possible preventive maintenance for
safe operation of the grinder.

12 TIPS FOR IMPROVING WELDING SAFETY

 Best welding safety practices and equipment are universally applicable. Welding exposes
everyone to similar hazards, whether you're responsible for safety at a large, welding-intensive
manufacturing company, a billion dollar engineering-construction firm or a small independent
fabricator. Here are 12 tips for improving welding safety in your company, including advice that
also improves productivity.

1. Read the Book. A welder’s operating manual contains important safety information, as well as
information procedures that maximize the machine’s potential. Make sure everyone who
operates the machine is familiar with its contents. If the manual becomes lost or damaged,
contact the manufacturer for a replacement. Many manufacturers provide manuals on-line.
Neither this article, nor any other, should be used as a substitute for the manufacturer’s
recommendations.

2. Button Up. Any exposed skin is susceptible to the painful and damaging effects of ultraviolet
and infrared rays. Further, sparks catch in open pockets, pant cuffs or down a shirt that isn’t
completely buttoned. They can smolder unnoticed while the welder is “under the hood.” Button
shirt collars, cuffs and front pockets to prevent them from catching sparks and to cover exposed
skin. Do not keep matches or butane lighters in your pockets. Avoid wearing cuffed pants, as the
cuffs may catch sparks.

3. Wear the Proper Gear. Neither shorts nor short-sleeved shirts belong in a welding cell. Even a
quick tack weld requires the proper safety gear, including helmet, gloves and clothing.

Wear only flame-resistant clothing, such as denim pants and a shirt made from tightly
woven material or a welding jacket. The excuse that welding jackets are too heavy, hot,
restricting or cumbersome is quickly becoming a thing of the past. Makers of safety gear now
produce lightweight clothing from flame resistant cloth, pigskin leather and combinations of the
two that offer better protection and increased ease of movement than ever before.

Gloves, too, have progressed beyond the one-size-fits-all type. They are now available
with ergonomically curved fingers and with different designs for specific welding processes.
Heavy-duty MIG/Stick gloves, medium-duty MIG gloves and TIG gloves that provide added
dexterity and touch and are just some of the options available. Note that gloves are not sufficient
to pick up just-welded material. Use pliers to avoid burns.

4. The Right Shoes. High-top leather shoes or boots provide the best foot protection. Pants legs
should go over the shoes. Do not wear tennis or cloth shoes. The first warning you ignored this
rule may be a burning sensation as your shoes smolder.

5. Breathe Freely. Fumes and smoke emitted during welding pose a health hazard. When welding
in confined spaces, toxic fumes may accumulate, or shielding gasses may replace breathable air.
Use an exhaust hood to remove fumes from the area and ensure enough clean breathing air is
available. Some materials specifically require respirators when welding, so consult the
manufacturers welding electrode’s data sheet, your welding engineer or industrial safety
specialist for proper procedures.
6. Don’t See the Light. It takes only a moment of exposure to a welding arc’s rays for
unprotected eyes to experience “arc flash,” a painful condition that may not appear until hours
after the exposure.

Welding helmets should be fitted with a proper filter shade to protect the operator’s face
and eyes when welding or watching. Note that approved safety glasses with side shields and ear
protection should also be worn under the helmet. Install screens or barriers where appropriate to
protect others from the arc.Pick a lens shade appropriate for your welding application. OSHA
offers a guide for choosing the correct lens based on welding criteria. If your weld parameters
and materials don’t vary, a fixed-shade lens may be right for you.

7. Auto-Darkening Helmets. The sensors on an auto-darkening helmet darken the lens in a

fraction of a second. All auto-darkening helmets must meet ANSI standards,

Newer helmets have different modes, allowing the same helmet to be used for welding,
cutting and grinding. The most recent development is a mode that senses the arc
electromagnetically, offering full protection when the sensors are obstructed, as when pipe
welding or welding out-of-position.

Avoid auto-darkening helmets that darken with a reaction time of 1/2,000 to 1/3,600 of a
second. This is not adequate for industrial applications. Further, cold weather delays the reaction
time on all auto-darkening helmets. Higher-end helmets are rated for use down to 14 degree F.
However, low-end helmets with slower reaction times may not darken quickly enough in cold
weather.

8. Avoid Repetitive Stress Injuries. Compared to a traditional fixed shade helmet, an auto-
darkening helmet reduces neck fatigue because it is usually lighter and operators no longer need
to snap their head to drop the hood down. Further, an auto-darkening helmet saves several
seconds between welds, which quickly adds up to several minutes on larger components. Saving
these minutes enables a company to more easily adhere to its build time.

9. Lose the Clutter. In its welding areas, Vermeer clearly labels and marks the place for each
piece of equipment. There is a place for everything, and everything in its place. The weld area
contains only the tools and equipment that operator uses; nothing more, nothing less. Rather than
strictly using a fixed-height table, weld tables have a scissors mechanism that presents the work
to the operator at the appropriate height.

10. Use Boom-Mounted Wire Feeders. Boom-mounted wire feeders add flexibility, efficiency
and operator comfort to high-production welding stations. Booms place the wire feeder controls
at the base of a 12- or 16-ft. boom and the drive assembly at the end of the boom. The boom
rotates 360 degrees and moves 60 degrees up and down to create a 24- or 32-ft. diameter work
area. A counterbalance holds the boom in place once the operator sets its position.

11. Optimize Fixturing. Use fixturing whenever possible. The simple gearbox (see “Vermeer
Fixture” image) rotates a 2,200-lb. component. It increases safety by eliminating the use of a
chain and hoist to flip thecomponent, which in turns eliminates the source of potential hazards.
12. Stick and Carrot Approaches. For successful implementation, don’t make welding safety a
“program.” Employees tend to suspect programs, as programs tend to fade away after a brief
flurry of initial activity. Instead, incorporate safety into daily work habits and incentivize
compliance. Brookville uses the carrot approach to safety.

SAFETY PRECAUTIONS IN FORGING & PRESSIG WORK

1. Always avoid the use of damaged hammers.
2. Never try to strike a hardened surface with a hardened tool.
3. No person should stand in line with the flying objects.
4. Always use the proper tongs tool to grip and lift objects according to the type of work.
5. The anvil should always be clean and free from moisture and grease while in use.
6. Always wear proper clothes such as apron, foot-wears and goggles.
7. The handle of the hammer should always be tightly fitted in the head of the hammer.
8. Always put out the fire in the forge before leaving the forging shop.
9. Always keep the working space clean and tidy.
10. Proper safety guards should be provided on all revolving parts.
11. Head of the chisel should be free from burrs and should never be allowed to spread.
12. During machine forging, always observe the safety rules prescribed for each machine.
13. One must have the thorough knowledge and working of the forging machine before going
to operate it.
14. Wear eye protection when hammering.

15. Hearing protection is essential.

16. Change your posture and working height now and then.
17. Take breaks every forty-five minutes or so and do something different now and then.
18. Tie your hair back if it’s long.

SAFETY WHILE HANDLING THE MATERIALS

The National Safety Council suggests employers relay the following information and some
rules to employees to help reduce workplace incidents when handling and moving materials:

• Avoid lifting materials from the floor or while seated.

• Make use of available handling aids.
• Refrain from using sudden or jerky movements.
• Never lift a load over an obstacle.
• Perform lifts in areas with adequate footing, space and lighting.
• Modify objects and redesign jobs to make moving easier.
• Seek assistance from co-workers.
• Stay in good physical shape.
• Begin lifts close to the body.
• Use containers made of lighter materials.
• Reduce load sizes when possible.
• Do not twist or bend while lifting objects.
• Ensure repetitive, heavy and bulky lifts are not performed.
• Keep lifts between shoulder and knuckle height.
• Use conveyors, slides or chutes to eliminate pushing or pulling.
RULES WHILE HANDELING MATERIALS
Rule-1. Follow all established procedures and implement job duties as you’ve been instructed.
Rule-2. Think about what could go wrong because of offhand incidents and pay close
attention to what you’re doing while you work. Be alert and plan ahead.
Rule-3. Always use PPE which is required for your particular work and check it carefully
before using to make sure it’s safe to use. Replace damaged PPE immediately as it won’t
provide satisfactory protection.
Rule-4. Check whether all containers are properly labeled or not and the material is stored in
the proper container. Don’t use any open or unlabeled material. Report if there are any
damaged containers or illegible labels to your controller right away.
Rule-5. Check out the tags and material safety data sheet before using any material to prevent
any hazards and follow precautions listed.
Rule-6. Do not eat or drink while handling Hazardous Materials. In the case of contact with
such materials, do not touch contact lenses, eyes, mouth or any other vulnerable areas.
Rule-7. Read the labels carefully and refer to the safety rules in order to identify properties of
chemical products and their hazards in advance.
Rule-8. Store all the materials carefully with separate labels in some ventilated, dry or cool
storage place.
Rule-9. Keep yourself and your work premises clean. Always wash your hand thoroughly
with soap and water before and after handling any material.
Rule-10. Get complete knowledge about all equipment, and emergency procedures like
evacuation, emergency reporting, and fire safety procedures. It also includes knowing the
correct procedure to deal with medical emergencies caused by chemicals.
SAFETY PRECAUTIONS IN CYLINDERS HANDELING
Before cylinders are first used the following precautions should be taken:
• Make sure the cylinder is equipped with the correct regulator.
• Inspect the regulator and cylinder valves for grease, oil, dirt, and solvent. Never use grease or
oil to lubricate regulators or cylinder valves because they can cause an explosion.
• The cylinder should be placed so that the valve handle at the top is easily accessible.
• When using toxic or irritating gas, the valve should only be opened while the cylinder is in a
working fume hood.
• Only use wrenches or tools that are provided by the cylinder supplier to open or close a valve.
Pliers should never be used to open a cylinder valve. Some regulators require washers; this
should be checked before the regulator is fitted.
• Refer to Safety Data Sheet [SDS] for the gas being used for information regarding use and
toxicity.
• Fire extinguishing equipment should be readily available when combustible materials can be
exposed to welding or cutting operations using compressed cylinder gases.
CYLINDER STORAGE
• Gas cylinders must be secured at all times to prevent tipping.
• Use appropriate material, such as chain, plastic coated wire cable, commercial straps, etc., to
secure cylinders.
• Gas cylinders cannot be stored in public hallways or other unprotected areas
• Cylinders must be segregated in hazard classes while in storage. Oxidizers (oxygen) must be
separated from flammable gases, and empty cylinders must be isolated from filled cylinders.
• The proper storage for oxygen cylinders requires that a minimum of 20 feet is maintained
between flammable gas cylinders and oxygen cylinders or the storage area be separated, at a
minimum, by a firewall five (5) feet high with a fire rating of 30 minutes.
WHILE MOVING CYLINDERS
• Never drag, slide or roll a cylinder; use a cylinder cart or basket.
• Always have the protective cap covering the valve when transporting the cylinder.
• Never transport the cylinder with the regulator in place.
• Make sure the cylinder is secured to the cart before moving it.
• Do not drop cylinders or strike them against each other or against other surfaces violently.
• Do not use the valve cover to lift cylinders; they could be damaged and become unattached. If
the cylinder is dropped on a hard surface it can cause an explosion.
SAFE HANDLING OF CORROSIVE MATERIALS
Corrosive materials cause destruction of tissue through chemical action at the point of
contact. As corrosive chemicals can be liquids, solids, or gases, corrosive effects can affect the
skin, eyes, and respiratory tract. Examples of corrosive chemicals include: liquids such as acids
and bases, bromine, and hydrogen peroxide; gases such as chlorine and ammonia; and solids
such as phosphorus and phenol.

Before handling corrosive materials:

• Users must be specifically trained in the use of each chemical.

• Users must be trained in the use and location on emergency equipment.
• Workers must consult the valid Material Safety Data Sheet (MSDS) for the material(s) being
used; a valid MSDS is provided by the supplier of the material and has been issued within the
past three years. While handling corrosive or any incompatible materials:
• A properly functioning fume hood must be used.
• Personal protective equipment (PPE) including chemical splash goggles, splash shield, gloves
and protective clothing must be worn as specified in the PPE section of the MSDS.
• Additional protective clothing (i.e., apron, oversleeves) is appropriate where chemical contact
with body and/or skin is possible.
• Do not pour water into acid. Slowly add the acid to the water and stir.
• Do not allow residue to build up, wipe drips from containers and bench surfaces especially.
Skin contact with dry residue will result in burns

TIPS FOR THE SAFE HANDLING OF DRUMS AND CONTAINERS

The drums are usually used for storing the liquids like Chemicals, water, petrol,
keroseneetc. and containers are used in ship transportation. The following points are very
important while handling the drums and containers.

• The Occupational Safety and Health Administration has comprehensive rules and guidelines
for the handling of hazardous materials such as chemical drums. Chemical drums can contain
materials that are toxic, radioactive, corrosive, and explosive. In handling them, personnel should
use the proper equipment, techniques, and protection.

• Inspection and Classification

• The first thing to do in order to make a plan for handling chemical drums is determining the
contents. Before any handling, operators should gain as much information as possible by
inspecting drums visually. But sometimes drums are reused and therefore their markings may not
reflect their contents; therefore, operators should assume they contain hazardous materials.
• The first things to look for are symbols, marks, or words that indicate whether the contents are
hazardous. They should look indications of radioactivity, flammability, corrosiveness, toxicity,
or explosiveness. Operators should also look for marks indicating whether the drums contain
discarded laboratory chemicals or reagents. Inspect for signs of drum deterioration like
corrosion, dust, or leaks; look for signs indicating pressure in the drum, like swelling or bulging.
Operators should also monitor the immediate area of the chemical drums, which can provide
information about the contents and possible hazards, with radiation measurement instruments,
combustible gas meters, or organic vapor monitors.

• After this stage, the drums can be classified into categories according to hazard type. These
classifications could be, for example: radioactive; bulging; explosive; leaking; containing
laboratory wastes. For laboratory wastes, an extensive classification system is necessary,
including categories for inorganic acids, bases, oxidizing agents, reducing agents, toxic organics,
flammable organics, toxic metals, and others. For instruction on classification, personnel should
consult a chemist.

• Safety Preparation for Personnel

• Adopting sound ergonomics practices for personnel is essential to reducing occupational injury.
Ergonomics means simply “the study of work,” and is focused on reducing the amount of wasted
motion and strain by adapting the job to fit the person. To this end, using ergonomics can
restructure the workspace and workplace conditions; install lifting aids; or change the height of a
pallet or a shelf.

• Additionally, personnel should be instructed on proper lifting techniques. An entire education

in anatomy is not necessary, but basic info on the structure of the spine and other parts involved
in moving heavy materials is recommended.

• Additionally, comprehensive training in using the machines and protective equipment involved
can reduce injury and accident. The preferred method of moving chemical rums is the drum
grappler. It keeps personnel removed from the drum; if drums leak, the operator can rotate the
drum and immediately place it in an overpack, which is a protective outer container in which to
place dangerous drums; in the case of explosion, grappler claws protect the operator by
deflecting the explosion’s force.

• For radioactive waste, a health physicist should be immediately contacted. Operators should not
handle radioactive drums until experts are consulted.

• Explosive or shock-sensitive drums should be handled with extreme caution and only if
necessary. All non-essential personnel should be removed, and operators should use a grappler
unit constructed specifically for explosive containment. The drums must be secured safely to
pallets. An audible siren signal system should be used in order to signal the commencement and
completion of activities involving explosive drums.

• Pressurized, bulging drums are very dangerous, and should not be moved whenever possible. If
necessary, they should be handled with grappler units constructed for containment of possible
explosions. They should be moved only to the extent necessary, and should be placed in an
overpack.

• For drums contained laboratory waste—lab packs—all non-essential personnel should be

moved away. Again, a grappler unit should be used. Once moved, a chemist should inspect and
classify the waste, separating the bottles within without opening them. They should be packed
with cushioning and absorption materials in order to prevent excessive motion, and to absorb
liquids in the event of a leak.

• For deteriorating, leaking, or open drums, its contents should be transferred to a safe drum
using a pump designed specifically for this purpose if the drum cannot be moved without
rupture. A drum grappler should be used to place the drum in an overpack.

• Before excavating a buried drum, personnel should use ground penetrating systems to ascertain
the depth and location of the drums. The soil must be removed cautiously, and a dry chemical
fire extinguisher must be available to contain and control small fires.