This is the place where all fun projects happen. It is where old furniture is fixed rather than replaced, when special shelves are built for hard-to-fit corners, when garden planters, benches, cabinets, and homemade gifts gradually get shaped.
However, it is also easy to become too comfy.
The workshop in the garage, shed, or basement feels rather cozy, creating an illusion that the upcoming task is somehow less serious. One might be doing nothing but sanding one board, trimming the edge of the worktable or making a single cut until dinner. Yet saw blade, drill bit, chemical finishing or a puff of dust do not differentiate between a professional workshop and a DIY one at home.
Safety protocol in the workshop does not lie in treating each and every DIY project like a formal procedure. It lies in creating a workshop in which the safer option is more convenient. When everything is prepared properly – tools, safety gear, space, and emergency gear – one will spend less time on dealing with arising issues and more time on working.
Here are seven protocols which will help one make any home workshop safer and more efficient.
Make PPE A Part of the Starting the Job
The easiest way to forget about protective equipment is storing it inconveniently.
If safety glasses are kept in a drawer, hearing protection is hanged at the other end of the garage, and gloves are hiding in a box behind the pile of scraps, it becomes very tempting to believe that the project will last just a minute. And that is how the smallest projects become those that one will complete without the necessary protective equipment.
Setup a simple PPE station in the entrance to the workshop or near the main workbench. It does not need to be fancy. Just a wall-mounted rack, labeled shelf, or a small cabinet will be enough. The important thing is that eye protection, hearing protection, gloves, and needed masks will be accessible before using any tool.
Eye protection is the first thing in this station.
DIYers usually believe that the ordinary prescription glasses are enough for workshop activities. Even though they might provide some protection, regular glasses are made for vision correction, not for protection. They might not protect one from the chips from a drill, debris from a cutting wheel or dust from the side.
Wearing goggles over regular glasses is a temporary solution, especially if one’s work is particularly dusty or splash heavy. But this approach has its own problems. Glasses with goggles can fog up, feel uncomfortable and limit the peripheral vision. When the eyewear becomes uncomfortable, one will be tempted to take it off the middle of the project.
There is another solution for the DIYers who wear glasses – prescription safety glasses. These glasses unite personalized prescription with a protective frame and lenses that are rated for impacts, thus offering both safe vision and comfort. While choosing safety glasses, make sure that they are marked according to ANSI/ISEA Z87.1 standards for the USA and the frame is suitable for the kind of work one is going to perform.
The point is not to wear all kinds of PPEs for every activity. The point is to ensure that the right equipment is used during the project that is risky.
Make Tools Impossible to Start Accidentally
Any workshop is not a place for a single person. One’s kids can come looking for a parent, one’s partner can require something from the garage, friends can borrow a tool, and even one can be distracted in the middle of the job.
Thus, tools should always be left in the condition in which they are impossible to start casually or unintentionally.
The unplugging of corded tools after the use is the easiest way to achieve this goal. It is especially important before changing blades, bits, or sanding discs, cleaning jams or adjusting the machine in proximity to the moving parts. The removal of the power source physically is much more reliable than remembering that the switch is off.
Many stationary tools such as table saws, band saws, and drill presses have removable safety keys. Remove the key and put it in the accessible place. It may seem like an insignificant step, but it will stop someone from switching on the machine that one does not know how to operate.
If one’s workshop is shared or may be accessed by kids, a lockable cabinet for the portable power tools may be a great idea. This measure does not need to feel restrictive or overprotective. It is just a recognition of the fact that drills, rotary tools, angle grinders and saws are not household tools which should be used without preparations.
The same principle applies to the batteries. Cordless tools should be kept without batteries prior to any maintenance, blade change or storage where kids might be able to access them. With battery-powered tool one may start using it accidentally if the trigger is pressed.
A safe workshop is not the place where everyone should remember what they should not touch. It is the place where one cannot accidentally start using something dangerous because of simple physical barriers.
Control Dust and Ffumes at the Source
Dust is one of the underestimated elements of workshop safety since it seems so usual. One sees a cloud when sanding, routing or cutting the wood, sweeps it and assumes that it is done.
The trouble is that the finest dust particles stay in the air for the longest time. It can accumulate not only in the workshop but also on the surface and stay suspended in the air one breathes long after turning off the tool.
The best way to deal with the dust is to catch it as close to the tool as possible. Attach a dust extractor or a shop vacuum to saws, sanders, routers and other tools that can be hooked up. A vacuum hooked up to the tool will usually catch dust better than the air cleaner which works throughout the room.
However, it does not mean that an air cleaner can be skipped. Workshop air cleaner can be used to remove the dust that got past the source extraction during a longer session of sanding or using several tools. The most effective system uses both: capturing the dust at the source and filtering what stays in the room.
Materials matter too. The softwood, hardwood, plywood, MDF, insulation materials, drywall compound and old painted surfaces all produce different kinds of dust. Particularly MDF produces very fine dust when cut or sanded, so the use of proper dust extraction and respiratory protection can be reasonable.
And, finally, finishes, stains, adhesives, paints and solvents bring in a new problem: fumes.
Opening a door or window is better than nothing, but it is not always enough for substances which produce strong vapors. When applying coatings and chemicals, use them in well-ventilated area and follow the instructions regarding ventilation, protective equipment and drying time. Whenever possible, use an exhaust system which removes the air to the outside instead of just circulating it in the room.
Having a neat workshop feels great, but having an efficient dust removal system is far more than good housekeeping. The system keeps one healthy, clears the vision and prevents fine dust to spread beyond the workshop.
Arrange the Workshop According to One’s Movement
Workshops accidents happen not necessarily because of something that happens right at the edge of the tool. People get hurt while tripping over a cable, reaching awkwardly across the board or bumping into a workbench while controlling a long board.
The workshop arrangement should reflect the way one works.
First, one should consider machines which require plenty of space. A table saw, mitre saw or a planer requires not only space around the machine, but also in front of and behind it, if one wants to work with a long piece of material. Think about the source of the board, its path and destination once it is cut.
There should not be any twisting, stretching or squeezing between obstacles while holding the board against the cutting edge. If one finds oneself balancing a board on one’s knee, lifting one end of it above some tool or maneuvering through the narrow passage, then the arrangement of the workshop needs to be reconsidered.
Most frequently used machines should be located close to the main workbench. Heavy machines should be stored low to facilitate and make it safer to lift them. Extension wires should be kept in order and their condition should be checked periodically.
Floor markers might be useful in the case of large garage workshops. There is no need to organize it in the manner of a factory. A tape line on the floor can act as a reminder of the zone where one should not stay while the tool is working, especially near those with kickback, moving stock and flying debris.
Lighting is the element of the room layout as well. The workshop should have enough light to allow one to see cutting lines, drill marks and the condition of the material. Overhead light is great, but the focused light near the workbench will help one see details much better. The poor lighting encourages one to get closer, awkwardly hold the workpiece and make rash judgments.
The safest workshop is the one which feels calm and uncluttered. Having enough space to walk and clearly-defined space for every tool and equipment allows one to work without hurry.
Use a Short Pre-flight Check Before Every Power-tool Task
The pre-flight check may sound like a formal step, but it only takes a couple of minutes.
Before switching on the tool, one should take a pause and look at the setup. Are the cord, battery and cables in good condition? Is the guard in place? Is the blade, bit or the cutting accessory suitable for the material? Is the workpiece clamped in the right place?
Such checks can detect the most easily missed problems.
One can incorporate such checks into the routine of using power tools:
The tool, plug and the cable are in good condition.
Guards, shields and other safety features are installed and work.
The blade, bit or the disc is in good condition and tight.
The workpiece is supported and, if possible, clamped instead of being held.
No loose sleeves, jewelry and long hair on.
The workshop floor is clear enough to move comfortably.
PPE is on before starting the tool.
One does not need a checklist taped to the tool. The goal is to develop the mental habit.
However, it is also worth noting that one should pay attention to the electrical equipment. The workshops in the garages, sheds or basements are often exposed to dampness, spills or changing temperatures. Using the ground-fault circuit interrupter may reduce the risk of electrical accident in these places, but it does not replace the inspection of one’s equipment before use.
One should never use the tools with damaged cords, cracked housing or loose switches. The tool which needs repairs should be taken out of use until it is fixed or replaced. Trying to finish “the one last cut” with a defective tool is never worth the risk.
Treat Finishes, Solvents and Oily Rags as Fire Hazards
Many workshop fires start after the project seemed to be completed.
Oil-based stains, varnishes and certain finishes can create heat during their curing process. Rags soaked with these products become hazardous when they are left in a pile, thrown into a regular trash can or put in a plastic container.
The safest way is to follow the product label precisely and discard the rags in accordance with the local regulations. In many cases, it means that one has to put them in an approved metal can with a tight lid until they are properly disposed of. Some products may require putting the rags outdoors to dry. What is crucial is that they should never be casually gathered in the workshop.
One should store flammable liquids in their original containers with tightly closed lids. These containers should be stored away from potential ignition sources, direct sunlight and places where they could be overturned. One should not leave the cans of these liquids opened on the workbench while working on something else and not consider the strong smell just a nuisance. The presence of strong fumes may indicate that better ventilation is needed.
This is yet another reason to keep the workshop clean. Sawdust, wood shavings and paper towels can provide the additional fuel for the fire. Regular sweeping and removal of waste materials will not only make the workshop more pleasant to work in, but will reduce the materials that could become the fuel for the fire.
Make emergency supplies easy to access
The workshop emergency station does not need to be impressive. It only needs to be obvious, accessible and supplied with the items needed to address the problems most likely to occur in the workshop.
As a minimum, one should mount a fire extinguisher nearby the exit, not hiding it in the cupboard or behind the equipment. A multipurpose extinguisher may be common for the workshops where wood, electrical equipment and finishing products are worked with, but it is worth consulting the extinguisher rating and local guidelines for one’s particular workshop.
A well-equipped first aid kit should be easy to find as well. Adhesive bandages may be useful, but more practical supplies for the workshop would include sterile gauze, wound dressings, adhesive tape, disposable gloves, burn gel or burn dressings, and trauma shears.
Especially one has to pay attention to the eye emergencies. In case of dust, debris, and chemical splash, it is crucial to react promptly. Therefore, it is useful to always have clean water or any eyewash solution at hand and know where the nearest sink is located before starting a project which requires using finishes, solvents or producing a lot of dust. Immediate flushing is much better than looking for supplies once the substance gets into one’s eyes.
And finally, it is important to always have one’s cell phone charged and easily accessible in the workshop. If one works alone, it is logical to tell somebody about the usage of more dangerous equipment, especially in case of long-term projects involving ladder, saws or chemicals.
The use of the emergency supplies is only useful if they are easily accessible. Therefore, one has to make sure that the way to emergency supplies is clear and regularly check their expiration date and replace whatever was used.
A Safer Workshop Is a More Productive Workshop
None of these protocols is designed to frighten anyone. These are just the ways of minimizing the small risks which may arise from the regular use of tools.
Proper equipment station means that one will have protective devices always close to hand. Power control helps to prevent accidental starts. Dust extraction and ventilation clean the air. Rational layout provides enough space for movement. Regular checks help to detect the problems with the equipment before they result in injuries. Proper storage of chemicals and rags minimizes the fire risks. Emergency supplies provide the feeling of security when something unexpected happens.
In other words, all this creates a working system.
One will not need to stop every ten minutes to think about safety since it will already be embedded into the system of one’s workspace. The tools will be in their proper place. The safety glasses will be easily available. The floor will be clean. The workpiece will be clamped. The dust extraction will be turned on before the first cut.
This will not be a slow DIY but a smarter DIY.
The best home workshops are not those which have the most expensive equipment. It is those which provide an opportunity to create, repair and experiment with confidence. Once the workspace is arranged to protect oneself from the most frequent risks, one can devote more time to enjoying the project.
