Tools are designed with safety in mind. It's your job to keep it in mind.

First Off ... in the words of our favorite Master Woodworker...

Before we use any power tools, let's take a moment to talk about shop safety. Be sure to read, understand, and follow all the safety rules that come with your power tools. Knowing how to use your power tools properly will greatly reduce the risk of personal injury. And remember this: there is no more important safety rule than to wear these — safety glasses.   Norm Abram

Horror Stories:

Do you want a little firsthand information about workshop safety? Try joining a woodworkers' association in your area. In the group I joined years ago, the big culprit was the jointer--that is, until I listened to the stories. It turned out that the fellow with a few abbreviated fingers was trimming a 4-in.-long workpiece. He knew the piece was too short--that's why he didn't use a push stick. Another woodworker with a similar condition owes it all to fatigue--working too long on a deadline job--without the jointer guard in place.

And the near misses are just as terrifying. Like the time a stick being ripped on a table saw penetrated the wall behind the operator. Then there was the guy that installed the wrong knives in a jointer and they careened into space seconds after the machine was started. That was me. I had the foresight to stand back as the machine came up to speed.

While the stories seem endless, you don't have to become a character in one. With a little common sense, basic knowledge and the right protective gear, your hours in the shop can be enjoyable and productive--and safe.

It's All In Your Head:

We all enter woodworking with good instincts--we don't want to get hurt. What we lack, in the beginning, is knowledge about what the tools can and can't do and how they get the job done. Once you learn, for example, that a circular saw blade exerts a force on the workpiece, it stands to reason that the workpiece must be held in a way that resists that force–or it's going to move fast. This is why work must be held against a radial-arm saw fence. If it's not, the saw blade will put it there pretty quick.

Tools and machinery are predictable–they always respond in the same way to you, and to the job. We, on the other hand, get tired and, frankly, we're all just a little more emotional than your average single-phase induction motor. If you knew that every day at 3 pm your table-saw arbor would start to wobble, you'd probably stop using the tool around 2:45, right? Then, why is it that at 4:30, after no lunch and having worked straight through the day, you're setting the fence for one last rip? Face it, you've lost your edge, but your carbide-tipped blade hasn't.

Fatigue isn't the only culprit. Anger and depression–in fact, any emotion that takes control–can get you into trouble. Finally, don't even think about going into the shop if you've had a drink or are taking medication that affects your concentration.

While government agencies such as the Occupational Safety and Health Administration (OSHA) and the National Institute of Occupational Safety and Health (NIOSH) have a hand in industrial safety regulations, home workshops are on their own. However, government and industry studies can and do affect the safety equipment we use.

Protection for your eyes is probably the most immediate and obvious concern. Workshop eye protection comes in three forms: glasses, goggles and full-face shields. Because most eye injuries result from small flying particles, glasses or goggles are a good choice. However, where there's a risk of larger flying objects, a face shield may be more effective.

Ordinary eyeglasses are not enough. According to a study conducted by the Bureau of Labor Statistics, of eye injuries reported while wearing some type of eye protection, 42 percent of the respondents were wearing glasses without side shields. With side shields, the number drops to about 13 percent. However, only 6 percent of the workers with injuries while wearing eye protection reported using goggles. Face shields rank better than simple glasses, but less effective than goggles–a good reason to wear safety glasses or goggles with a face shield. The overwhelming lens material choice is polycarbonate. When choosing safety glasses, check that the lens is labeled for safety use.

Unlike eye injuries, the workshop risk to your hearing is subtle. Hearing loss from exposure to the noise of power equipment occurs slowly and may take years to become apparent. And, the loss is permanent.

Statistically, noise levels of about 85 dBA and up will, over time, negatively affect your hearing. For a rule of thumb, have someone speak to you from 3 ft. away while a machine is on. If the person needs to speak loudly or shout, you should have ear protection.

Standard ear protectors take the form of muffs or plugs, and devices that have been tested are given a noise reduction rating (NRR). This rating indicates, under laboratory conditions, the noise reduction on the decibel scale that the equipment provides. In practice, effectiveness is considerably less. The important thing is to make sure that your ear protection has an NRR rating that indicates it has been tested. As for choosing plugs or muffs, pick the one you're more likely to wear. In extreme cases, wear both.

Working in your home shop also poses dangers to your respiratory system. Although much of the sawdust you create is visible, it's what you can't see that's cause for concern. Particles smaller than 10 microns (one-one-hundredth of a millimeter) can pass through the filtering system in your nose and throat and end up in your lungs. And, certain woods contain compounds that may trigger allergic reactions.

The most common defense against airborne dust is a simple, disposable face mask. Avoid so-called nuisance masks–single-layer masks that trap particles only about 10 microns and larger. Instead, choose a multi layered mask or cloth mask that's designed to handle fine dust.

Finishing products may give off vapors that can also pose a danger. The first strategy against these contaminants is good cross ventilation. However, where there is an excessive buildup of fumes, a reusable cartridge-type respirator equipped with filters suitable for paint and organic vapors can provide basic protection. And with the proper filters, a respirator can also be used to protect against dust.

With all masks and respirators, it's important that they fit securely against the face. In cases where facial hair interferes with the seal, some workers opt for an air helmet or powered air-purifying respirator (PAPR). This device has a battery-powered fan and a set of filters that clean the air before it reaches the helmet.

Finally, every shop should be equipped with a first-aid kit just in case anything goes wrong. In addition to the standard array of bandages, a good first-aid manual is a must. With it, you can handle simple accidents yourself, and keep serious problems stable until help arrives.

You may also want to consider taking a First Aid course...stop by your local Ambulance squad building, Firehouse or try the YMCA. This is a course that may save your life, also consider a CPR course. Jason

Illustrations by George Retseck Published in the May 1997 issue.

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