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Institute for Critical Technology and Applied Science ICTAS II Fabrication Laboratory Policy Manual Developed by the ICTAS Facilities Group June 2013
Institute for Critical Technology and Applied Science
ICTAS II Fabrication Laboratory
Policy Manual
Developed by the ICTAS Facilities Group
June 2013
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Table of Contents Purpose ........................................................................................................................................... 5
Access. ............................................................................................................................................. 5
Hours of Operation ......................................................................................................................... 6
Training ........................................................................................................................................... 6
Proper Use of the ICTAS Fabrication Laboratory ............................................................................ 7
Personal Protective Equipment and the Buddy System ................................................................... 7
Safety Glasses ......................................................................................................................................... 7
Gloves ....................................................................................................................................................... 8
Respirators .............................................................................................................................................. 8
Hearing Protection ................................................................................................................................. 9
First Aid Kits, Fire Extinguishers, and Eyewash Stations ................................................................... 9
Material Safety Data Sheets ................................................................................................................. 9
Hazard Control ...................................................................................................................................... 10
Housekeeping and Materials Storage................................................................................................ 10
Worker Actions ..................................................................................................................................... 11
Mechanical Motion .............................................................................................................................. 11
Point-of-Operation Hazards ................................................................................................................ 12
Proper Code of Conduct................................................................................................................ 12
Fabrication Lab Potential Hazards ................................................................................................ 13
Potential Injuries .................................................................................................................................. 13
Scalping (due to hair getting caught in moving machinery) ........................................................... 13
Loss of fingers (coming into contact with any cutting or shearing machinery) .............................. 13
Bruising ........................................................................................................................................... 13
Cuts ................................................................................................................................................. 13
Burns ............................................................................................................................................... 13
Severe Injuries ...................................................................................................................................... 13
Amputations ........................................................................................................................ 13
Lacerations .......................................................................................................................... 13
Eye injuries .......................................................................................................................... 13
Punctures............................................................................................................................. 13
Impact Hazards ..................................................................................................................................... 13
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Bruising ................................................................................................................................ 13
Broken skin .......................................................................................................................... 13
Loss of eyesight .................................................................................................................... 13
Broken bones ....................................................................................................................... 13
Entanglement Hazards......................................................................................................................... 14
Amputations ........................................................................................................................ 14
Scalping ............................................................................................................................... 14
Choking/asphyxiation ........................................................................................................... 14
Cuts and scrapes................................................................................................................... 14
Sharp Object Hazards .............................................................................................................................. 14
Cuts ..................................................................................................................................... 14
Punctures............................................................................................................................. 14
Loss of fingers ...................................................................................................................... 14
Hazardous Areas for Injuries Due to Physical Contact .................................................................... 14
Nip Points. ........................................................................................................................... 14
Shear Points. ........................................................................................................................ 14
Pinch Points. ........................................................................................................................ 14
Point of Operation. ............................................................................................................... 14
Power Transmission Equipment. ........................................................................................... 14
Injuries Due to Potential (Stored) Energy ......................................................................................... 14
Unexpected start-up of machinery. ....................................................................................... 14
Hydraulic/Pneumatic and electrical energy release. ................................................................ 14
Wires or cables under high tension. ....................................................................................... 15
Frayed or damaged electrical cords. ...................................................................................... 15
Guarding Devices .......................................................................................................................... 15
Machine Guards ................................................................................................................................... 15
Other Safeguarding Devices ................................................................................................................ 15
Cleaning Fabrication Lab Equipment and Facility ......................................................................... 15
In Case of Emergency .................................................................................................................... 16
Appendix A: A Death in the Lab - Real Life Hazards ..................................................................... 17
Appendix B: First Aid for Cuts and Puncture Wounds .................................................................. 21
Appendix C: First Aid for Blood Loss & Open-Injury Bleeding ...................................................... 22
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Appendix D: Severe Bleeding or Shock ......................................................................................... 23
Appendix E: Standard Operating Procedure for Drill Press .......................................................... 24
Drill Press Safety Guidelines ............................................................................................................... 24
Appendix F: Standard Operating Procedure for Grinder .............................................................. 25
Grinder Safety Guidelines ................................................................................................................... 25
Appendix G: Standard Operating Procedure for Power Saw ........................................................ 26
Power Saw Safety Guidelines ............................................................................................................. 26
Appendix H: Safety Guidelines for Working with Solvents, Resins, and Other Chemicals ........... 27
Appendix I: Standard Operating Procedure for CNC Mill ............................................................. 28
Appendix J: Standard Operating Procedure for Metal Brake ....................................................... 29
Record of Training & User Agreement .......................................................................................... 30
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Purpose This policy manual is intended to provide a comprehensive document containing rules and regulations for the proper use of the ICTAS II Fabrication Laboratory including all materials, equipment, and resources contained herein. All undergraduate students, graduate students, faculty, and staff are required to have a copy of this manual in paper or electronic format and to be familiar with its contents. Please read the items contained in this document and sign the attached contract and Chemical Hygiene Plan training form. This ICTAS-specific manual was created in conjunction with Virginia Tech Environmental Health and Safety (EHS), the Virginia Bioinformatics Institute, and the Virginia Tech College of Engineering Joseph F. Ware, Jr. Advanced Engineering Lab and may be updated as needed. Adherence to the Fabrication Lab policies and procedures is expected at all times. Please remember that having access to the fabrication lab is a privilege, not a right.
Access The ICTAS Fabrication Laboratory is open to properly certified ICTAS occupants and affiliates. The ICTAS Fabrication Laboratory is a secure facility equipped with surveillance cameras with activity being continuously recorded. Access is limited to ICTAS affiliated students, staff, and faculty who meet the following requirements:
1. The person requesting access must be a current student, staff, or faculty member of Virginia Tech, with the faculty member being an ICTAS affiliate.
2. All students, staff, and faculty must pass Chemical Safety Training provided by Virginia Tech EHSS.
3. All students, staff, and faculty must complete Machine Shop Safety training provided by Virginia Tech EHS.
4. There is to be a fully trained fabrication lab representative (either a graduate student or ICTAS employee that has completed Machine Shop Coordinator training and First Aid training as well as the above mentioned trainings) present whenever the lab is in use. Note: this also applies to those acting as fabrication lab representatives.
5. Students must be approved by both an ICTAS-affiliated faculty member and a member of the ICTAS Facilities staff in order to gain admission.
6. Authorized users must receive an orientation to the facility and equipment-specific training with the Fabrication Lab Coordinator, Keith Nunn (or his designee).
7. Anyone who has not received training and approval for shop use is not authorized to be in the fabrication lab, even as an observer.
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Hours of Operation The ICTAS Fabrication Laboratory will be open from 10:00AM – 10:00PM, Monday through Friday. Once all requirements are met, a request from the faculty member in charge should be sent to [email protected]. After the ICTAS Facilities staff has reviewed the request and verified completion of training, access will be granted, making the Fabrication Laboratory accessible through Hokie Passport swipe. Card access is required at all times. After 10:00PM and until 10:00AM of the following day, the Fabrication Laboratory is closed. Students gaining access to the Fabrication Laboratory between the hours of 5:00PM – 10:00PM must sign an additional waiver form specifically for the purpose of after-hours admission. Students found to be in the machine shop between the hours of 10:00PM and 10:00AM of the following day will permanently lose their access privileges to the Fabrication Laboratory. The door to the Fabrication Laboratory is not to be propped open, nor should the latches be tampered with to prevent engaging the locking mechanism. If there is a need to move materials into or out of the fabrication lab, please contact the ICTAS Facilities staff ([email protected]); someone will assist you with unlocking the door.
Training The procedures outlined below must be followed for anyone working in the ICTAS Fabrication Laboratory:
A. Chemical Safety Training – Training is provided by EHS and may be completed online, either through the EHS online training website at https://secure.hosting.vt.edu/www.ehss.vt.edu/register.php?id=1540, or through the ICTAS Fabrication Lab Scholar website. A score of 84% or higher is required to pass the chemical safety quiz.
B. Machine Shop Safety Training – Training is provided by EHS and is completed online at https://secure.hosting.vt.edu/www.ehss.vt.edu/register.php?id=335.
C. ICTAS Building Orientation – This is a one-time-only session provided by the ICTAS Facilities group. This session is designed to introduce building occupants to the ICTAS facilities, staff, and building amenities, as well as address hazards associated with laboratory processes in the ICTAS facilities. Building orientation is held on a monthly basis, with upcoming sessions announced in weekly building-wide listserv e-mails.
In addition to the mandatory trainings above, the procedures outlined below must be followed by those graduate students, faculty, or staff acting as Fabrication Lab Representatives:
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D. Machine Shop Coordinator Training – This training is provided in-person only through Virginia Tech EHS and is accessible by registering at https://secure.hosting.vt.edu/www.ehss.vt.edu/register.php?id=1307. This training is designed to illustrate to Fabrication Lab Representatives the importance of safety in the fabrication lab, as well as demonstrate hazards of which to be aware.
E. First Aid Training – Basic first aid training is offered by EHS and will be coordinated on an annual basis by the ICTAS Laboratory Facilities Manager. Red Cross First Aid/CPR training, EMT training, or EHS First Aid/CPR training may be substituted with proof of completion. All first aid training must be kept up to date and proof of certification is required.
Equipment-specific hands-on training will be provided by the designated ICTAS Fabrication Lab Coordinator (the ICTAS Facilities Assistant) or his/her designee.
Proper Use of the ICTAS Fabrication Laboratory
Personal Protective Equipment and the Buddy System
Appropriate personal protective equipment (PPE) must be worn when working in the ICTAS Fabrication Laboratory. Anyone not wearing appropriate PPE will not be allowed to work in the lab. Closed toed shoes are required in the fabrication laboratory (i.e. tennis shoes, boots, etc. which are in good condition). If you do not have the appropriate PPE for a specific procedure, please see either the ICTAS Facilities Assistant or the ICTAS Lab Facilities Manager. The Buddy System must be used at all times. This means that either the ICTAS Fabrication Lab Coordinator (a.k.a. the ICTAS Facilities Assistant) or an approved Fabrication Lab Representative is present at all times while work is conducted in the lab. There is to be a minimum of 2 people working in the lab at all times, with a maximum occupancy of 4 individuals. This includes at least one Fabrication Lab Representative (or Coordinator). Under no circumstances may powered equipment with high speed moving parts be taken from the Fabrication Lab into any other lab space or out of the building. All persons using powered equipment in the Fabrication Lab must be trained by the ICTAS Fabrication Lab Coordinator.
Safety Glasses
Safety glasses are REQUIRED in the Fabrication Lab at ALL times. Safety glasses must be worn when working with any type of power tools or powered equipment. Safety glasses and face shields must be worn during grinding, sanding, and polishing operations for all materials. Failure to do so may result in eye irritation, embedded metal/wood shavings, and/or blindness.
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If particles get into the eyes, flush at an eyewash station for 15 minutes. If you need safety glasses or a face shield for a particular task, please see either the ICTAS Facilities Assistant or the ICTAS Lab Facilities Manager.
Gloves
There is no “universal” glove suitable for all applications. For example, disposable latex gloves are commonly used and are inexpensive, but do NOT provide protection against chemicals or metals. Use the following glove types when working with the following chemicals:
1. Neoprene gloves for working with epoxies; 2. Butyl gloves for working with acetone; 3. Nitrile gloves for working with gasoline and resin systems.
Leather gloves are to be worn while handling materials (such as woods or metals) to provide protection against cuts, scrapes, splinters, etc. Gloves are NOT recommended for use while using the machines, as they can pose entanglement hazards. Gloves are available in the glass-front cabinet in the Fabrication Lab. If the boxes are empty, contact either the ICTAS Facilities Assistant or the ICTAS Lab Facilities Manager. To learn more about choosing the correct glove for an application or chemical, go to www.bestglove.com.
Respirators Any respiratory protection being used by anyone working in the ICTAS Fabrication Laboratory must be approved by Virginia Tech’s Environmental Health and Safety Department. Use of a nuisance dust mask does not require approval by EHS, as nuisance masks do not have a NIOSH approval number and are not considered “respirators”. Respirators are subject to compliance with OSHA’s Respiratory Protection Standard. The use of a respirator requires the following steps be taken:
1. A respiratory medical evaluation questionnaire must be completed and submitted to EHS. The questionnaire may be found online at http://www.ehss.vt.edu/detail_pages/document_details.php?s_document_title=inspe&document_id=452. Once complete, send the questionnaire to [email protected] for review.
2. Enrollment in the EHS Voluntary User Program is highly recommended. This program involves the review of Appendix D of the OSHA Respiratory Protection standard (29 CFR
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1910.134) and acknowledgement of that review by signature on an Informed Consent Form submitted to EHS.
3. Registration for an EHS one-hour respirator training class can be accessed by going to http://www.ehss.vt.edu/train.php. Scroll down to Respiratory Protection and choose the date and time that best suits your schedule.
4. Anyone needing a respirator must be fit tested to ensure that the particular respirator provides proper protection and seal. Fit testing will not be completed until the one-hour training class has been completed. Contact the EHS medical surveillance coordinator to schedule an appointment.
Filter cartridges used with respirators are selected by EHS based on exposure level. When a cartridge needs replacement, it should be replaced with the same cartridge recommended by EHS. Old cartridges and respirators that have not been properly cleaned and maintained must be discarded and replaced. All functioning half-face respirators must be cleaned after each use and kept in a sealed plastic container. If respirators are needed in the ICTAS Fabrication Lab, discuss with Autumn Timpano, ICTAS Lab Facilities Manager so that the procedure to be conducted can be evaluated.
Hearing Protection Ear plugs and/or ear muffs are recommended in areas where noise-producing power tools or machinery are used. If you are within 3 feet of someone and need to raise your voice to communicate, it is possible that you are in a hazardous noise area and should be using hearing protection. Hearing loss is permanent! Disposable ear plugs are available in the Fabrication Lab. If the ear plug container is empty, please contact either the ICTAS Facilities Assistant or the ICTAS Lab Facilities Manager. The ear plugs will be located in the glass-front cabinet.
First Aid Kits, Fire Extinguishers, and Eyewash Stations A first aid kit and fire extinguisher is located in the Fabrication Lab area. First aid kits and fire extinguishers are not to be blocked (by equipment, materials, etc.). All materials should be at least 3 feet away from the front of the kit or fire extinguisher. If a first aid kit is missing items, contact the ICTAS Lab Facilities Manager immediately. If the fire extinguisher is discharged for any reason, contact the ICTAS Lab Facilities Manager immediately. One eyewash station is located on the right side of the sink in the Fabrication Lab area.
Material Safety Data Sheets Any product which may pose a health or physical hazard must have a material safety data sheet (MSDS). MSDSs provide important information on particular products and must be kept in the red binder in the Fabrication Lab. If the product does not come with a paper copy of the MSDS,
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go online and search for the MSDS to download (ex. Google acetone MSDS). If you bring new chemicals into the Fabrication Lab, you must add the MSDS to the binder. If you are injured while using a chemical and need to go to the hospital, you or the person accompanying you must bring the correct MSDS or you may not be admitted!
Hazard Control Equipment guards are designed to keep the user safe during machine operation and should not be in any position where they do not protect the user. Guards should also never be removed any time the machine is running. Adjusting guards away from their protective position or removing them while a machine is in operation will result in permanent loss of Fabrication Lab access.
Housekeeping and Materials Storage The ICTAS Fabrication Lab is to be kept clean at all times. Debris is to be swept up and disposed of properly and any spills are to be cleaned off of the floor immediately to prevent slipping hazards. Packaging material and waste materials should be bagged and taken to the Waste Marshaling area in the loading dock. Aisles and walkways must be kept free of debris and obstructions and a clear path must be maintained to the exit. The entryway to the lab, fire extinguishers, and eyewashes must have unobstructed access at all times. Materials are to be stored in the provided cabinets and storage bins. All flammable substances must be stored in the flame retardant yellow flammable materials cabinet located under the workbench in the back of the lab. All flammable waste should be disposed of in plastic/polypropylene containers – not glass. No glass containers should be placed on the floor in the lab area. Any waste containers on the floor need to be in a secondary container to prevent spills/leaks. Store any cloth or paper rags, or other material that has been saturated with flammable or combustible liquids, in an approved metal can with a tight-fitting lid. Always remove/replace clothing that has become saturated with a flammable or combustible liquid – even if it is just a little. Saturated clothing can easily ignite if exposed to an ignition source, such as radiant heat, flame, or sparks. Empty chemical containers ready for disposal must be rinsed with water, de-labeled (either defacing or removing completely), and placed in broken glass containers. Full broken glass containers should be completely sealed with packaging tape and then placed in the trash receptacle in the Waste Marshaling area.
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No sharp objects should be placed in the trash. This could cause a hazard to the housekeeping staff removing trash. All sharp objects should either be placed in a red sharps container (if small) or boxed in a sturdy cardboard box and subsequently sealed for disposal. Grinders and drill presses must be plugged into a wall outlet, NOT into power strips. No daisy chaining of power strips or extension cords is allowed under any circumstances due to the potential fire hazard created. No food or drink is permitted in the Fabrication Lab at any time. Break rooms are provided throughout the building for the storage and consumption of food and beverages. If any equipment has frayed electrical cords, ask the ICTAS Facilities Assistant for a repair or replacement.
Worker Actions
The following are safeguarding aids that must be followed during the use of any machine or powered equipment in the ICTAS Fabrication Lab:
1. Leather gloves – Use leather gloves while handling materials (i.e. metals, woods, etc.) to prevent cuts, punctures, etc. Do NOT use gloves while using equipment to prevent entanglement hazards;
2. Holding tools – Use these to place and remove material to reduce point of operation hazards (i.e. pliers, appropriate gloves);
3. Push blocks – Use these to feed material into cutting blades to keep hands farther away from point of operation;
4. Warning signs – Read these before using any machine; they inform the user of the guards that are available and their proper use;
5. ON/OFF switches – Turn machinery off before leaving work area.
Mechanical Motion Hair and clothing can easily become entangled in machinery with moving parts. Rotating machine motion (circular motion) can cause scalping, amputation, and choking (e.g. grinders). Reciprocating machine motion (back/forth or up/down motion) can cause amputation or other injuries. Transverse machine motion (straight, continuous line motion) can result in impact or other hazards.
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Point-of-Operation Hazards Points of operation occur where material and machine meet; where work is being done on a part or component. Cutting (mechanical motion), punching (blanking, drawing, stamping), shearing (slide or knife), and bending have multiple point-of-operation hazards. Injuries due to point-of-operation hazards happen most often when the worker is not paying attention. These injuries can be prevented by proper use of guards, proper operation of the machinery, and attentive worker attitude.
Proper Code of Conduct The following safety rules and procedures are to be followed at all times:
1. This facility is for project-related work only – NOT for personal use. 2. Reckless behavior such as horseplay, throwing objects, etc. is not allowed. 3. Loose clothing, jewelry, neck ties, and scarves should not be worn in the ICTAS
Fabrication Lab. Remove and store them in a secure location before entering the Fabrication Lab.
4. Long hair must be tied back and secured prior to entering the Fabrication Lab; long facial hair must be covered while using power equipment.
5. Do not leave project related items in the Fabrication Lab for an extended period of time. Remove them as soon as possible.
6. No food or drinks are allowed in the Fabrication Lab at any time. 7. No unauthorized persons are allowed in the Fabrication Lab. Do not let someone into
the Fabrication Lab if they do not have access. Doing so will cause you to lose your access to the Fabrication Lab and possibly to the building.
8. Requests for tours or visitors need to be routed through the ICTAS Facilities Staff. 9. Tools may not be removed from the Fabrication Lab. 10. Shop users must abide by all applicable OSHA and VIOSH safety regulations. If you
cannot do a job safely in this lab, don’t do it. If you are unsure about the safe operation of a tool or any aspect of a task, ask for help.
11. No one who is under the influence or is otherwise impaired by medication, controlled substances, illegal substances, or alcohol may be in the Fabrication Lab.
12. Fabrication Lab users must use appropriate Personal Protective Equipment – protect your eyes, face, and hearing!
13. All Fabrication Lab users must wear safety glasses while in the lab. 14. Keep fingers clear of the point of operation; never use a rag/cloth near moving
machinery. 15. Never use your hands to clean shavings or cuttings. 16. All machines must be operated with their guards and shields in place. 17. Users must keep floor around machines clean, dry, and free from trip hazards.
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18. Extension cords must be 14 gauge wire or heavier; do not daisy chain extension cords (connect multiple cords).
19. Please contact the ICTAS Lab Facilities Manager before storing paints, solvents, or chemicals in the Fabrication Lab. Take care to ensure incompatible chemicals are not stored together. An MSDS is required for any glue, oil, chemical, or solvent used in the lab and must be stored in the MSDS binder provided.
20. Fabrication Lab users may bring small hand tools (non-powered) or supplies from outside to use in the shop only after obtaining express written approval from the ICTAS Fabrication Lab Coordinator or his/her designee. ICTAS assumes no responsibility for any lost or stolen items brought into the facility.
21. Should you or your group use certain hand tools frequently, your group is strongly encouraged to purchase these hand tools (non-powered) with group money to keep in your labs.
22. Users must report any problems, spills, broken equipment, etc. to ICTAS Facilities ([email protected]) without delay.
23. Users must report all accidents to their supervisor and to the ICTAS Lab Facilities Manager immediately.
Fabrication Lab Potential Hazards
Potential Injuries a. Scalping (due to hair getting caught in moving machinery) b. Loss of fingers (coming into contact with any cutting or shearing machinery) c. Bruising d. Cuts e. Burns
Severe Injuries a. Amputations b. Lacerations c. Eye injuries d. Punctures
Impact Hazards An impact hazard is caused by flying debris or by reciprocating high speed machinery and can result in:
a. Bruising b. Broken skin c. Loss of eyesight d. Broken bones
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Examples of impact hazards include the following:
• Grinder throwing work piece due to being incorrectly secured. • Not securely clamping work pieces on the CNC mill, resulting in the part being propelled
across the room.
Entanglement Hazards Most machines in the Fabrication Lab use rotating motion. Rotating parts can instantly catch loose clothing, hair, and jewelry, and cause the following:
a. Amputations b. Scalping c. Choking/asphyxiation d. Cuts and scrapes
Sharp Object Hazards Blades and drill bits have sharp edges. Proper handling of bits and blades is necessary to avoid the following:
a. Cuts b. Punctures c. Loss of fingers
Carefully follow directions on band saws while installing new blades. Use proper chuck side for the mill to avoid injuries and parts with poor tolerances.
Hazardous Areas for Injuries Due to Physical Contact a. Nip Points – Parts on parallel axes that rotate in opposite directions or against
stationary objects (most common). b. Shear Points – Cutting blades move past a stationary point. c. Pinch Points – Body parts can be caught between moving and/or stationary
parts. d. Point of Operation – Area on a machine where work is being done. e. Power Transmission Equipment – All parts that transmit energy and motion.
Injuries Due to Potential (Stored) Energy Potential, or stored, energy is dangerous because the impending motions are sudden and are not expected. Carefully examine lockout/tagout procedures to prevent injuries from accidental start-up or unexpected energizing.
a. Unexpected start-up of machinery – Example: Computer numeric control (CNC) processes.
b. Hydraulic/Pneumatic and electrical energy release – Examples: Hydraulic presses, grinders, band saws.
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c. Wires or cables under high tension – Example: Pulleys. d. Frayed or damaged electrical cords due to presence of high electrical voltages
causing potential differences.
Guarding Devices
Machine Guards Guards are available to assist in keeping the operator safe and should be in place any time the machine is in operation. Removing guards from any equipment during operation will result in loss of ICTAS Fabrication Lab access privileges. Some typical machine guards and their uses are listed below:
1. Fixed or enclosed – These guards are a permanent part of the machine, contain no moving parts, and prevent everything but the work piece from reaching the point of operation.
2. Interlocked – These guards prevent operation of the machine unless the guards are in place.
3. Adjustable – These guards are moveable by the operator to allow various sizes of material to be used on a single machine. These are the most common and include machinery such as band saws and grinders.
4. Self-Adjusting – These guards open as a work piece is advanced through the machine, keeping the point of operation only large enough to accommodate contacted material.
Other Safeguarding Devices 1. Presence sensing (optical, electromechanical) 2. Gates (moveable barrier) 3. Lockout/Tagout – Ensuring that all hazardous energy sources of a machine have
been de-energized and secured in a positive manner.
Cleaning Fabrication Lab Equipment and Facility
1. Large equipment will be cleaned and maintained by the ICTAS Fabrication Lab Coordinator. He/She will disengage electrical power to a machine before cleaning to avoid accidentally starting it before cleaning it and will use lockout/tagout measures as necessary.
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2. Fabrication Lab users must remove cutting tools and hand tools before cleaning an area. Users must also take out drill bits and lower saw blades or guards completely before cleaning to reduce the chance of injury.
3. Clean chips and debris from tools. 4. Users must return tools and unused supplies to their original locations in the Fabrication
Lab before leaving the lab. 5. Users are responsible for cleaning Fabrication Lab surfaces and floors if their work has
generated debris. A broom and dust pan for coarse debris and a shop vacuum for finer dust will be provided.
6. Users must report missing, broken, or damaged tools to ICTAS Facilities.
In Case of Emergency In case of an emergency (injury, chemical spill, fire, etc.), assess the severity of the situation and act appropriately. When in doubt, call 911 and then contact the ICTAS Fabrication Lab Coordinator or ICTAS Lab Facilities Manager. The Fabrication Lab is equipped with a fire extinguisher, eyewash station, fire blanket, first aid kit, and telephone. NOTE: Should you need to call 911, dialing 911 on your cell phone will direct you to the Town of Blacksburg emergency response. You will need to let them know you are on the Virginia Tech campus and need Virginia Tech emergency response. If you dial 911 from a Virginia Tech phone, you are directly routed to the VT Police Department.
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Appendix A: A Death in the Lab - Real Life Hazards
Published online 18 April 2011 | Nature 472, 270-271 (2011) | doi:10.1038/472270a
A Death in the Lab
Fatality adds further momentum to calls for a shake-up in academic safety culture.
Richard Van Noorden
Fellow students hold a vigil for Yale undergraduate Michele Dufault. THE YALE DAILY NEWS
In the early hours of 13 April, undergraduate students working at Yale University's Sterling Chemistry Laboratory made a shocking discovery. There in the lab's machine shop was the dead body of 22-year-old undergraduate student Michele Dufault, her hair tangled in a lathe. She had apparently died of asphyxiation in an accident described by Richard Levin, president of Yale in New Haven, Connecticut, as a "true tragedy".
Within days, federal health and safety officials had started to investigate. Details are scarce, but it is already clear that Dufault was not inexperienced with the equipment; she had taken a training course and had used the lathe safely many times before, according to fellow physics student Joe O'Rourke. She was, however, working late at night and probably alone (a speculation that Yale would not confirm) — circumstances that were not unusual at the machine shop, says O'Rourke.
Around the United States, laboratory directors and safety officers immediately checked their own policies on working practices in machine shops. But the accident has also heightened wider concerns about the ever-present tension between research freedom and safe working conditions in academia. And it underscores the slow pace of change since another high-profile laboratory fatality led to similar soul-searching less than three years ago.
In late 2008, 23-year-old research assistant Sheharbano Sangji sustained horrific burns in a lab fire at the University of California, Los Angeles (UCLA), and died of her injuries 18 days later. Sangji's death — in very different circumstances from Dufault's — resulted in federal fines for the university and a rapid toughening of safety policies there. On 30 March, UCLA unveiled its latest safety initiative: a new Center for Laboratory Safety, which is billed as the first in the
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United States to measure the effectiveness of safety policies and develop ways to improve scientists' approach to safety. More widely, Sangji's accident acted as a lightning rod for demands to improve standards across the United States.
Sheharbano Sangji (left) and Michele Dufault. FACEBOOK
Yet for all this attention, health and safety experts say that they have not seen a significant shift in the behaviour of bench scientists or the attitudes of lab heads, who are in the best position to improve safety culture. "It's very difficult to change principal investigators' attitudes," says James Gibson, UCLA's director of environmental health and safety. All too often, researchers in laboratories around the country still work alone, and without proper supervision or protection. "In many cases, academic freedom is more important than safety," says Jim Kaufman, president of the Laboratory Safety Institute in Natick, Massachusetts.
Chemical focus
Although such concerns apply across academia, accidents in chemistry laboratories have drawn the most scrutiny in recent years. A year after Sangji's death, Preston Brown, a graduate student in chemistry at Texas Tech University in Lubbock, lost three fingers of his left hand during a dangerous experiment. Brown was grinding up chunks of nickel hydrazine perchlorate — using a hundred times the recommended amount — when it detonated.
Unusually, the US Chemical Safety Board (CSB) — a body that usually investigates large industrial accidents such as refinery explosions — stepped in. For the first time ever, it said it would review academic laboratory safety. At an August 2010 meeting of the American Chemical Society in Boston, Massachusetts, CSB chairman Rafael Moure-Eraso said that the board had gathered media reports of around 120 university chemistry laboratory accidents since 2001, and concluded that "safety practices at US universities leave a lot to be desired".
Chemistry labs have been a particular focus of concern because the most dangerous procedures in other sciences tend to have more detailed safety protocols, says Peter Reinhardt, head of environmental health and safety at Yale University. "Using radioactive materials or biological materials is much more stringently regulated," he told Nature (speaking before Dufault's accident). "The big gap is hazardous chemicals in laboratories."
Rick Danheiser, an organic chemist at the Massachusetts Institute of Technology in Cambridge who chairs the chemistry department's health and safety committee, agrees that some labs' safety standards are too lax. But "there are chemistry departments with very strong safety programmes, and there's a whole range of laboratories in between", he says.
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Neal Langerman, who runs the consulting company Advanced Chemical Safety, based in San Diego, California, is more strident about the extent of the problem. "I have come to the conclusion that most academic laboratories are unsafe venues for work or study," he wrote in a 2009 opinion column in the Journal of Chemical Health and Safety. He now says that, despite the recent accidents, he has not noticed a significant change in chemists' attitude to safety.
US scientists are undeniably much safer today than before swathes of occupational health legislation arrived in the 1970s, along with a new watchdog agency, the federal Occupational Safety and Health Administration (OSHA). Further improvements came in 1991, when OSHA stipulated that each chemistry lab should prepare a 'chemical hygiene plan' — effectively a handbook detailing safety protocols and emergency procedures — although these requirements are rarely enforced by inspections.
The US Bureau of Labor Statistics says that the rate of recordable incidents in scientific research and development services has fallen from 2.1 per 100 full-time employees in 2003 to 1.2 in 2009. But the government does not track major accidents or near misses specifically in academic laboratories. "Anecdotally, most people agree that university labs have more frequent and more frequently serious accidents than industry," says Dorothy Zolandz, director of the National Academies Board on Chemical Sciences and Technology.
Researchers often point out that industry is in a better position than academia to keep safety standards high because it has a clear hierarchy of power, fewer inexperienced students, and accountability to management. One of the clearest difference lies in lone working: surveys by the American Chemical Society last year suggest that 70.5% of faculty and 52.1% of graduate students often or occasionally work alone in laboratories, something that is forbidden in industry.
Safety officers and experienced chemists say that good laboratory safety relies on far more than regular inspections. What's key, says Tom Welton of Imperial College London, is that the group's research leader accepts unequivocal responsibility for the safety of everyone doing science in the laboratory, building a culture where researchers instinctively have safety foremost in their minds.
Evidence presented at a US National Research Council meeting on laboratory safety in November 2010 backs up Welton's point. Ron Zanoni, manager of occupational safety at international chemicals giant Arkema, based in Colombes, France, showed a 2004 survey that found case injury rates ranging from 7.8 to 0.8 per year at Arkema's various US sites. The differences correlated well with working relationships and top-down leadership engagement at different sites, Zanoni says. Improving safety leadership at labs with poor records had reduced injury rates by 2007.
“Changing the culture is really going to be a long-term challenge.”
As UCLA has found, it can be hard to change researchers' mindsets, even after a death on campus. Over the past two years, the university has ramped up laboratory safety regulations, training and inspections. But Nancy Wayne, a physiology professor on the board of the new laboratory safety centre, says researchers at UCLA do not always appreciate the tougher regime, sometimes seeing environmental inspectors as 'police', rather than partners in
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improving standards. "Changing the culture is really going to be a long-term challenge," says Gibson. Some professors, he says, have even questioned the need for flame-resistant lab coats — a bitter irony given the circumstances of Sangji's accident.
She was using a syringe to draw reactive t-butyl lithium from a bottle when it burst into flames, setting her clothes alight. She was not wearing a lab coat. Since then, the California Division of Occupational Safety and Health has agreed fines with UCLA of around US$70,000 for safety violations. Sangji's supervisor, Patrick Harran, declined Nature 's request for an interview. The Los Angeles district attorney is still reviewing Sangji's case, and has not yet decided whether to press criminal charges against either Harran or UCLA. If this resulted in a conviction, "the rules change completely right then and there", says Langerman. "All of a sudden, if you hurt somebody badly, you may face felony charges."
In the United Kingdom, the threat of legal action has proved to be a powerful incentive for change. Around 25 years ago, an explosion in a chemistry laboratory at Sussex University in Brighton shot a piece of metal into a student's abdomen. The student eventually recovered, but the government's Health and Safety Executive prosecuted Sussex University for negligence. The episode had a profound effect on safety standards in Britain, says Welton. Today, British researchers are required to write down risk assessments before every experiment, something that is not required in the United States.
"I think that it will take a professor being punished, perhaps unfairly, to really engender change on the part of academia overall," says chemical-safety blogger Chemjobber, an industrial synthetic organic chemist in the United States. But funding agencies could also play a part. The CSB, for example, is considering recommending that grant applications should contain specific safety-training requirements.
"I think in the long run, the CSB recommendations, a possible new OSHA lab standard, and input from the American Chemical Society will result in a modification of the regulatory climate," says Langerman. But scientists should not wait for those changes before taking the initiative on safety, he adds.
"Members of the academic community have unique freedoms that are denied to industry," he says. "They then have a unique responsibility to behave in a manner that supports the freedom they are given."
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Appendix B: First Aid for Cuts and Puncture Wounds For Minor Cuts:
1. Wash your hands with soap or antibacterial cleanser to prevent infection. 2. Wash the cut thoroughly with mild soap and water. 3. Use direct pressure to stop the bleeding. 4. Apply antibacterial ointment and a clean bandage that will not stick to the wound.
For Minor Punctures:
1. Wash your hands with soap or antibacterial cleanser to prevent infection. 2. Use a stream of water for at least 5 minutes to rinse the puncture wound, then wash
with soap. 3. Look (but do NOT probe) for objects inside the wound. If found, DO NOT remove – go to
the Emergency Room. If you cannot see anything inside the wound, but a piece of the object that caused the injury is missing, also seek medical attention.
4. Apply antibacterial ointment and a clean bandage that will not stick to the wound. DO NOT:
• Do NOT assume that a minor wound is clean because you can’t see dirt or debris inside. Wash it.
• Do NOT breathe on an open wound. • Do NOT try to clean a major wound, especially after the bleeding is under control. • Do NOT remove a long or deeply embedded object. Seek medical attention. • Do NOT probe or pick debris from a wound. Seek medical attention.
Call 911 if:
• The bleeding is severe, spurting, or cannot be stopped (for example, after 10 minutes of pressure).
• There is impaired function or feeling from the cut. • The person is seriously injured.
Seek Medical Attention Promptly if:
• The wound is large or deep, even if the bleeding is not severe. • You think the wound might benefit from stitches (the cut is more than a quarter inch
deep, on the face, or reaches bone). • A cut or puncture is caused by a rusty object. • You step on a nail or other similar object. • An object or debris is embedded – Do NOT remove it yourself. • You have not had a tetanus shot within the last 10 years.
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Appendix C: First Aid for Blood Loss & Open-Injury Bleeding Considerations:
• Always seek emergency assistance for severe bleeding or if internal bleeding is suspected internal bleeding can rapidly become life threatening.
• Serious injuries don’t always bleed heavily, and some relatively minor injuries (for example, scalp wounds) can bleed quite a lot. People who take blood-thinning medications or who have a bleeding disorder may bleed excessively and quickly because their blood does not clot properly. Bleeding in such people requires immediate medical attention.
• Direct pressure will stop most external bleeding and is the most important first aid step. • If possible, always wash your hands before giving first aid to someone who is bleeding. • Try to use disposable gloves when treating someone who is bleeding. Gloves should be
in every first aid kit. • Although puncture wounds usually don’t bleed very much, they carry a high risk of
infection. Seek medical care to prevent tetanus or other infection. • Abdominal and chest wounds can be very serious because of the possibility of severe
internal bleeding. They may not look very serious, but can result in shock. Seek immediate medical care for any abdominal or chest wound. If organs are showing through the wound, do not try to push them back into place. Cover the injury with a moistened cloth or bandage and apply only very gentle pressure to stop the bleeding.
Symptoms of Shock
• Confusion or decreasing alertness • Clammy skin • Dizziness or light-headedness after an injury • Paleness • Rapid pulse, increased heart rate • Shortness of breath • Weakness
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Appendix D: Call 911 If Bleeding Is Severe Or If Shock or Internal Bleeding Is Suspected
1. Calm and reassure the victim. The sight of blood can be very frightening. 2. Lay the person down. This reduces the chances of fainting by increasing blood flow to
the brain. When possible, raise up the part of the body that is bleeding. 3. Remove any obvious loose debris or dirt from a wound. If an object becomes stuck in
the body, DO NOT remove it. Place pads and bandages around the object and tape the object in place.
4. Put pressure directly on an outer wound with a sterile bandage, clean cloth, or even a piece of clothing. If nothing else is available, use your hand. Direct pressure is best for outside bleeding, except for an eye injury.
5. Maintain pressure until the bleeding stops. When it has stopped, tightly wrap the wound dressing with adhesive tape or a piece of clean clothing. Place a cold pack over the dressing. Do not peek to see if the bleeding has stopped.
6. If bleeding continues and seeps through the material being held on the wound, do not remove it. Simply place another cloth over the first one while awaiting medical attention.
7. If the bleeding is severe, take steps to prevent shock. Keep the injured body part completely still. Lay the person flat, raise the feet about 12 inches, and cover the person with a coat or blanket. However, DO NOT move the person if there has been a head, neck, back, or leg injury, as doing so may make the injury worse.
8. DO NOT apply a tourniquet to control bleeding, except as a last resort. If continuous pressure hasn’t stopped severe bleeding, a tourniquet may be used until medical help arrives or bleeding is controllable.
a. Apply to the limb between the bleeding site and the heart; tighten so that bleeding can be controlled by applying direct pressure over the wound.
b. To make a tourniquet, wrap strips of bandage material around the limb several times. Tie a half or square knot, leaving loose ends long enough to tie another knot. A stick should be placed between the two knots. Twist the stick until the bandage is tight enough to stop the bleeding and then secure it in place.
c. Check the tourniquet every 10 to 15 minutes. If the bleeding becomes controllable (manageable by applying direct pressure), release the tourniquet.
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Appendix E: Standard Operating Procedure for Drill Press
Insert SOP here.
Drill Press Safety Guidelines
1. Run drill at correct RPM for diameter of drill bit and material. Ask for the correct RPM. 2. Always hold work in a vise or clamp to the drill table. 3. Use a correctly ground drill bit for the material being drilled. 4. Use the proper cutting fluid for the material being drilled. 5. Remove chips with a brush – never by hand. 6. Ease up on drilling pressure as the drill starts to break through the bottom of the
material. 7. Don’t use a dull or cracked drill. Inspect the drill before using. 8. Don’t drill with too much pressure. 9. Always try to support part on parallels or a backing board when drilling through
material. 10. Never place taper shank tools such as large diameter drills or tapered shank reamers in
a drill chuck. Only straight shank tools such as standard drills can be clamped in chucks. 11. Always clean drill shank and/or drill sleeve and spindle hole before mounting. 12. Remove taper shank tools from spindle or sleeve with a drill drift and hammer. 13. Never try to loosen the drill chuck while the power is on. 14. Lower the drill spindle close to the table when releasing the drill chuck or taper shank
drill to reduce the chance of damage should they fall onto the table. 15. Never clean a machine while it is in motion! 16. If the drill binds in a hole, stop the machine and turn the spindle backwards by hand to
release the bit. 17. When drilling a deep hole, withdraw the bit frequently to clear chips and lubricate the
bit. 18. Always remove the drill chuck key or the drill drift from the spindle immediately after
using it. 19. Wear safety eye protection while drilling. 20. Let the spindle stop of its own accord after turning the power off. Never try to stop the
spindle with your hand. 21. Plexiglass and other brittle plastics can be difficult to drill. Ask for advice on drill and
coolant selection when drilling these materials.
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Appendix F: Standard Operating Procedure for Grinder
Insert SOP here.
Grinder Safety Guidelines
1. Special training is required before using the surface grinder. Ask the ICTAS Fabrication Lab Coordinator to demonstrate proper use.
2. Abrasive wheel machinery shall not be operated without the appropriate guards in place.
3. Tool rests on bench or pedestal grinders shall be set no more than 1/16 inch from the wheel.
4. Never use a wheel that has been dropped or received a heavy blow, even though there may be no apparent damage. Such wheels may be weakened or unbalanced enough to fly apart on startup.
5. Stand to one side when starting a grinding machine. Damaged wheels will sometimes fly apart, and this is most likely to happen when the machine is being started. Stand to the side so that you will not be in-line with the debris.
6. Do not grind on side of wheel unless wheel is specifically designed for such use. 7. Do not use excessive pressure while grinding. On surface grinder, do not exceed 0.0005
inch downfeed at any time. 8. Immediately report to the ICTAS Fabrication Lab Coordinator any cracked, broken, or
otherwise defective wheels. 9. Have the ICTAS Fabrication Lab Coordinator or a Fabrication Lab Representative mount
and balance new wheels. 10. Keep the grinding wheel dressed. Dressing a small amount frequently is better than
having to dress a lot later and will allow the wheel to cut faster, cooler, and with a better surface finish. Dressing is cleaning and smoothing the surface of the grinding wheel.
11. Hold work securely while grinding. Use the tool rest to support the work when off-hand grinding on bench or pedestal grinders.
12. Do not grind aluminum. Aluminum dust is explosive. Check with the ICTAS Fabrication Lab Coordinator or the ICTAS Lab Facilities Manager if aluminum must be ground.
13. Wear either goggles over safety glasses or a face shield and safety glasses when grinding on bench or pedestal grinders.
14. If a magnetic chuck is being used on the surface grinder, make sure it is holding the work securely before starting to grind.
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Appendix G: Standard Operating Procedure for Power Saw
Insert SOP here.
Power Saw Safety Guidelines
1. Unplug the tool before making any adjustments. 2. Before using any power tool, inspect it to make sure the cord is not damaged in any
way, that the ground pin is intact, and that the blade is sharp and undamaged. 3. Do not use the saw in a wet area. 4. Keep your head out of the path of particles thrown out by the blade. Wear eye
protection. 5. Disconnect the power cord before cleaning, changing blades, or making any
adjustments. 6. When it is necessary to raise the guard for certain types of cuts, use the guard lever. 7. Never wedge, wire, or otherwise jam the guard to prevent it from working. This is a
particularly dangerous practice and will cause your permission to work in the Fabrication Lab to be revoked immediately!
8. Wait until the saw stops before lifting it from a cut. 9. Before setting the saw down, make sure the guard is closed, as the blade may still be
turning. 10. Don’t pull the saw backwards in a cut if you can avoid it. 11. Use the proper blade for the type of cut to be made. 12. Do not use the cord to move or drag the saw. 13. Do not use the power hand saw for cuts if you cannot keep a firm and secure grip on the
saw and the material being cut. A hand saw is still the best for some kinds of work and is often faster.
14. Before cutting small work pieces, the ICTAS Fabrication Lab Coordinator should be consulted.
15. Adjust the depth of cut 1/8” greater than the material thickness.
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Appendix H: Safety Guidelines for Working with Solvents, Resins, and Other Chemicals
1. Learn about the chemicals that you are planning to use before opening them. Read the instructions and Material Safety Data Sheet. Consult the ICTAS Lab Facilities Manager if you have any questions.
2. Use water-based cleaners instead of solvents where possible. 3. Avoid skin contact. Wear appropriate gloves. 4. Work in a fume hood if possible. Respirators are available when necessary. The ICTAS
Lab Facilities Manager can work with you to get the necessary paperwork for respirator fitting with EHS.
5. Do not use solvents around hot metal surfaces and flames. 6. Do not smoke or light flames in areas where solvents are used and stored. 7. Report and clean up any spills immediately. Call the ICTAS Lab Facilities Manager. 8. Do not pour any chemicals down the drain. Waste containers will be made available
upon request. 9. Only use solvents in well ventilated areas. Do not work with solvents in confined,
unventilated areas. 10. Do not drink alcoholic beverages or take medications containing alcohol before or
during working with solvents. Alcohol in the bloodstream sometimes causes synergistic reactions with various solvents that can lead to loss of consciousness and even possibly death.
11. Report any ill effects and skin disorders to the ICTAS Lab Facilities Manager. 12. Develop and maintain good personal hygiene habits. Remove protective equipment and
wash thoroughly after contact with solvents. 13. Fumes from paints, solvents, adhesives, and the abrasive cut-off saw can drift around
the lab. Work to minimize these problems. 14. Mix resins in small batches.
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Appendix I: Standard Operating Procedure for CNC Mill
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Appendix J: Standard Operating Procedure for Metal Brake
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Record of Training & User Agreement Name: Principle Investigator: User Initials ICTAS Facilities
Initials Date
I have taken the EHS Machine Shop Safety class, received certification, and presented documentation to the ICTAS Lab Facilities Manager
I have received an orientation to the fabrication lab from the ICTAS Fabrication Lab Coordinator or his/her designee
I am aware of the hazards associated with the fabrication lab equipment and agree to follow all safety regulations learned in training, orientation, and as posted
I have been given the opportunity to ask questions regarding the information provided to me
I am aware of the proper use of all equipment I will use in the Fabrication Lab and know where to find specific instructions in the Fabrication Lab manual
I am aware of proper response to accidents/emergencies in the Fabrication Lab
I agree to use the required Personal Protective Equipment that is appropriate for my tasks, including safety glasses for all uses
I agree to use the Fabrication Lab only during its designated hours
I agree to use the Fabrication Lab only in the presence of another trained individual – either the ICTAS Fabrication Lab Coordinator or a designated Fabrication Lab Representative
I agree to report any problems, spills, or broken equipment to ICTAS Facilities immediately
I agree to report any accidents to my supervisor and the ICTAS Lab Facilities Manager immediately
I will not share my Fabrication Lab access with anyone, nor will I open the lab for use by unauthorized personnel
I agree to obtain approval from the ICTAS Fabrication Lab Coordinator or his/her designee before bringing in outside tools/supplies for use
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I have taken the EHS Chemical Safety training, received a score of 84% or better, and presented documentation to the ICTAS Lab Facilities Manager
I agree to provide MSDS in the Fabrication Lab for any chemicals or products I might use
I will clean up after each use of the Fabrication Lab, using posted safety precautions
I have demonstrated proficiency in and am authorized to use the following equipment in the ICTAS II Fabrication Lab:
Equipment User Initials ICTAS Fabrication Lab Coordinator Initials Date
Band Saw
Vacuum Former
Drill Press
Sander/Grinder
CNC
3-D Printer
Laser Cutter
Metal Brake
I understand that if I violate any of the ICTAS Fabrication Lab Rules of Use, I may be permanently barred from using it and shall be subject to discipline, including but not limited to access termination and/or a Conduct Referral. User Signature: Date: PI/Supervisor Signature: Date: I verify that the above named user of the ICTAS Fabrication Lab is appropriately informed and trained to safely use the facility. Lab Facilities Manager: Date: Fabrication Lab Coordinator: Date:
