Reprinted from the ACJ - February, 1997
I read the other day that the most dangerous sport in the world is Mountain Climbing. I'm guessing it is not the mountain "climbing"that is dangerous but the mountain "falling" that causes most of the problems. With the variety of surface conditions as well as the ice and snow, the potential for slips and falls is very real. Using that same rational, I am sure that the second most dangerous sport must be carrying groceries from the car to the house up an ice covered driveway. Holding a large radiator to your chest and traversing the slick shop floor from the test tank to the repair bench, paint booth, or back to the car must rank up there as well.
Slips and falls account for about 10 % of all workplace injuries. 1500 deaths each year are attributed to falls at work, and not all of those workers are professional Bungee jumpers. The majority of fall accidents occur in the construction industry. The next category of workers most susceptible to slips and falls are production and repair people, followed closely by second rate boxers taking a dive.
Unlike the nice soft mat, and hefty paycheck greeting those palookas, a shop floor is not forgiving. I have also found that not that many radiator shops have a good "cut man" in their corner. So let's be proactive here and try to prevent wipe outs before they occur.
The most prevalent slip hazard in the shop is water. It may be ice and snow or rain water. It may be water spilled from the boil out or test tank, but it can also be condensation on a cold shop floor on a humid day. Second to water, chemicals cause the most spills. In our quest to be the trend setter for American industry, radiator shops have two of the worst chemicals for contributing to nose dives.
Antifreeze is about as slick as a common chemical gets. Mix two parts antifreeze with one shop floor and let the ice dancing begin. Another less obvious chemical hazard is zinc chloride (ZnCl2). Zinc chloride tends to absorb water. Where there was a small pile of powdered flux a minute ago, now is a puddle of mildly corrosive soup waiting for a swimmer.
That is a great one-two punch. First you fall on your head on the concrete floor, then you realize you are soaking in chemicals.
Grease, oil, soap and mud can also play a contributing role. The floor surface itself is another factor in fall frequencies. Metal surfaces such as platforms, stairs, and ladders are the worst. Followed by smooth concrete, followed by a Honky Tonk dance floor on 10 cent beer night.
The best way to attack this problem is from a standing position. Take a walk around the shop and look for problem areas. Snow squeaking in under the garage door, spills from the test tank, oil and grease left by the customers car, roof leaks, banana peels, etc. Talk with your coworkers. Pay attention when they tell you the story of how they almost broke their neck carrying a large core while performing a backshop ballet. Think seasonally. Winter is the worst time but spring rains also create problems. Try to anticipate hazards rather than reacting after an accident. It is easier to say "watch out!" than "boy, I bet that hurt".
There are many solutions to slip and fall hazards. A rough floor surface is the best solution. Epoxy or paint coatings with grit distributed throughout are excellent for this, but non-slip strips on the floor or stairs work as well. Use non slip mats in front of tanks or other areas that are always wet. These mats are usually raised and allow water to flow through thus keeping a good footing surface for the worker. Be sure to clean these mats periodically. Don't wait until the grease and dirt have filled up the holes and you are standing on a mound of goo instead of a mat. Non-slip shoe soles or overshoes that provide a grip are nice. Use signs to remind the vertically challenged of areas that are especially bad.
As with all shop safety equipment and procedures, they don't work if you don't use them. Train your employees in the slip and fall hazards present. I find this training easier to do prior to an accident occurring, but it does prove very effective, if not timely, to tell a person to be careful as they lie face down in a pool of coolant.
Instruct the folks in how to handle themselves on slippery surfaces. Keep your balance, always keeping at least one foot firmly under you. Move slowly and deliberately to accomplish this. Carry any loads as low as possible. This lowers your center of gravity, preventing falls. An additional benefit is that if you fall, you land on the load rather than it landing on you.
Teach them to watch themselves on stairs and ladders. Probably, the most important fall prevention procedures is to clean up spills as they occur. Better to do this with a rag now, than with the back of your shirt after taking a Brody.
With slips and fall accidents costing industry 11 million lost work days annually it is an often overlooked but notorious workplace hazard. Planing ahead, providing protection and training can go a long way toward keeping your business and your coworkers on their feet. It may be more dangerous to climb Kilamonjaro than to work in a rad shop, but at least they have the Sherpas to carry the radiators.
The above article was written by David M. Brown, Chief Engineer of Johnson Manufacturing Company, Inc. and is published by JOHNSON with the expressed approval of the National Automotive Radiator Service Association and the Automotive Cooling Journal. Other reproduction or distribution of this information is forbidden without the written consent of JOHNSON and NARSA/ACJ. All rights reserved.
JOHNSON MANUFACTURING COMPANY
114 Lost Grove Road / PO Box 96 / Princeton, Iowa 52768-0096
Phone 563-289-5123 or Fax 563-289-3825