Safety in metal fabrication shops begins by making employee health and well-being a priority. According to the U.S. Bureau of Labor Statistics, more than 16,000 workers are seriously hurt and 50 are killed every year in fabricated metal product manufacturing. From October 2022 to September 2023, OSHA issued $12.4 million in citations to metal fabrication facilities.
OSHA has specific regulations for safe operations in metal fabrication. Knowing how to keep your shop compliant with OSHA regulations can prevent injuries, save lives, and protect your company’s bottom line.
Here are the top five OSHA citations with the highest penalties in fabricated metal product manufacturing for the 2022-23 reporting period. By reviewing and addressing these — and the complete list of citations — you can reduce costly worker injuries, avoid fines, and prevent shutdowns resulting from inadequate safety measures:
1 General requirements for machine guarding ($2,602,654 in fines).
OSHA regulations require machine guarding to protect operators and employees from hazards at the point of operation, as well as ingoing nip points, rotating parts, flying chips, and sparks. Examples of guarding methods include barrier guards, two-hand tripping devices, and electronic safety devices. See DWC’s Machine Guarding Fact Sheet.
2 The control of hazardous energy ($1,685,127 in fines).
The lockout/tagout process outlines practices and procedures for disabling machinery or equipment to prevent the release of hazardous energy. See DWC’s Lockout/Tagout Fact Sheet.
3 Powered industrial trucks ($693,315 in fines).
Proper use of material handling equipment is crucial to avoid injuries and costly citations. Training employees to use powered industrial trucks correctly is vital to creating safe work practices at metal fabrication shops. See DWC’s Powered Industrial Truck Inspection Checklist.
4 Hazard communication ($627,528 in fines).
Hazard communication remains a top priority for all industries. Compliance with the Hazard Communication Standard, including the Global Harmonized System (GHS) of Classification and Labeling of Chemicals, is essential for manufacturers using hazardous chemicals. A written Hazard Communication Program is mandatory, and awareness of compliance deadlines is crucial. See DWC’s Hazard Communication Fact Sheet.
5 Respiratory protection ($573,909 in fines).
Respirators are often needed to protect workers from exposure to airborne chemicals, toxic gases, or inhaling grit, dust, and metal fumes. A proper exposure assessment, protection levels, physician approval, employee training, and documented respirator programs are vital for compliance. The most common violation in this area for metal fabrication facilities is for hexavalent chromium safety. See OSHA’s Respirator Quick Card and Hexavalent Chromium publication.
Metal fabrication shops can ensure OSHA compliance and create a safer work environment by addressing these key OSHA citations. DWC safety professionals can help your company with OSHA-authorized employee training or free, on-site consultation to ensure OSHA compliance. For more information, visit www.TxSafetyatWork.com or call 800-252-7031, option 2.