Essentials

On most roofing job sites, controlling mechanized tools is relatively simple. Most mechanized tools used by roofing workers are connected to energy sources, and ensuring a tool accidentally won't start often is achieved by unplugging the tool from its power source.

But in a sheet-metal shop, disabling equipment for inspection or maintenance and safeguarding equipment to keep workers' limbs from getting caught can be challenging. Because some pieces of equipment are used by more than one worker, work shifts change, and machine parts may be removed for repair or cleaning, ensuring equipment is safe for use requires workers to pay attention to the status of machines.

According to the U.S. Bureau of Labor Statistics, an average of 10,000 on-the-job amputations occurs each year. (Exact numbers are unavailable for roofing-related sheet-metal shops.) The statistic is disturbing because preventing on-the-job amputations can be achieved through a commitment by roofing contractors to train workers.

Standards

Minimizing potential sheet-metal shop hazards is required by Occupational Safety and Health Administration (OSHA) General Industry Standard 29 CFR 1910.147, which discusses lockouts and tagouts. A lockout renders a machine inoperable so the machine is safe for inspection and maintenance. A tagout warns workers about a machine defect or problem and that a machine should not be operated.

A lockout should be paired with a tagout to provide an unmistakable visual and written explanation about why a machine is inoperable. According to OSHA, if only a tagout is used, it should be bold and explicit enough to issue a clear warning.

OSHA also addresses machine safeguarding regulations. Safeguarding requires companies with sheet-metal shops to have written safety programs that address employee training, identify and evaluate energy sources, discuss different types of lockouts and how to install them, show the effectiveness of lockout applications, prepare for workers' shift changes and take necessary steps for removing lockouts.

According to OSHA's standard, sheet-metal shop workers also must be trained about the hazards of releasing stored energy. For example, a hydraulic press has two energy sources—the electricity that runs the hydraulic pump and stored pressure within the system.

Typically, a circuit breaker or switch can be used to disconnect the press from its electrical source, but pressure that has built up inside the equipment must be relieved via a pressure-release valve. Before the pressure is relieved, however, the area around the press should be cleared of materials and people. If the press or its components are in upright positions, they should be blocked or moved to a relaxed position to prevent them from falling. Safely releasing stored energy reduces the potential of a moving component injuring a worker.

In addition, a shop foreman regularly must observe workers to ensure they properly install and use lockouts and tagouts, as well as wear proper personal protective equipment, such as goggles, gloves, gauntlets and aprons, if necessary. Workers must be trained to properly use each piece of machinery they might use and warned to avoid machinery they haven't been trained to use. Every sheet-metal worker also should have a clear understanding of safety devices.

Injuries

According to OSHA, roofing contractors with sheet-metal shops should identify and control potential amputation hazards caused by shears, power presses, saws and other machinery. Machine parts that cut, punch, rotate, reciprocate, transverse and bend must be safeguarded with point-of-operation guards, which prevent workers' hands and fingers from entering into moving machine parts.

In addition, it is critical such machines only be operated by workers who have been trained properly.

If a machine jams or traps debris or objects, the machine should be turned off, removed from all power sources and drained of stored energy. The machine's point-of-operation guard then can be removed. When cleaning or repair work has been completed, the point-of-operation guard should be reinstalled. Before allowing employees to operate a machine, ensure point-of-operation guards are secured properly.

Stay safe

A sheet-metal shop contains many tools that potentially can injure your workers. By taking simple precautions and providing proper training, you can protect your company's sheet-metal workers from serious injury and avoid paying costly OSHA fines.

Peter Greenbaum is NRCA's manager of education programs.