Tag: eye protection

Compressed Air Safety in Industrial Environments: Key Risks and Best Practices

Published on by Neal RakerLeave a comment

Compressed air powers tools, equipment, and cleaning processes in many facilities—but it can also cause serious injuries, damage equipment, and disrupt operations when used improperly. Here is a concise look at the main hazards and the practices that reduce risk.

Common compressed air hazards

  • High-pressure injection and flying debris: Air blasts can propel chips and dust into eyes and skin; air can also enter the body through cuts or openings and cause life-threatening injury.
  • Excessive noise: Blow-off and open pipes can exceed safe sound levels, contributing to permanent hearing loss and making communication harder.
  • Whipping hoses and failed fittings: A loose or damaged hose can detach and strike workers with significant force.
  • Contaminants in the air stream: Oil, water, and particulates can affect product quality, degrade tools, and create health risks in certain applications.

OSHA note: blow-off pressure limits

OSHA Standard 1910.242(b) requires compressed air used for cleaning to be reduced to less than 30 PSI at the nozzle when dead-ended (blocked), and to be used with effective chip guarding and appropriate PPE. Meeting this requirement is a baseline for a safe compressed air program.

Many facilities meet these standards by using engineered nozzles and safety air guns (for example, from EXAIR or similar manufacturers) that limit dead-end pressure, reduce noise, and improve blow-off efficiency.

Best practices checklist

  • Use engineered nozzles/air guns: Replace open pipes and improvised nozzles; choose designs that limit dead-end pressure and reduce noise.
  • Control debris: Use chip guards/shields and direct blow-off away from people and walkways.
  • Manage hoses: Secure connections, route hoses to prevent kinks and trip hazards, inspect routinely, and use whip checks where appropriate.
  • Wear the right PPE: Eye protection is essential; add hearing protection where noise is elevated; use gloves/protective clothing as the task requires.
  • Follow safe procedures: Never point compressed air at anyone or use it to clean clothing; depressurize lines before maintenance; train operators and post clear signage.
  • Maintain the system: Keep filters/dryers/lubricators serviced and repair leaks to improve safety and reduce energy waste.

The Bottom Line

Compressed air is essential—but it is not risk-free. When you pair OSHA-aligned pressure control with engineered tools, hose management, PPE, training, and routine maintenance, you reduce injuries, cut down time, and keep operations running safely.

Neal Raker, Application Engineering Manager
nealraker@exair.com

Compressed Air Safety Dos and Don’ts

Published on by Russ BowmanLeave a comment

In the Navy, it was a universally accepted fact that NOTHING onboard the ship was “sailorproof.” Regardless of how it was designed, what it was made of, how many interlocks, mechanical stops, automatic shutoffs, etc., something had, any & all of those features could be overridden (by accident or on purpose) and cause a wide range of chaos, and/or damage, and/or injury. That’s why training and procedures are so important.

It’s the same in any civilian/corporate industry too – any device, tool, instrument, machinery, etc., can be inherently dangerous if it’s not used properly. And “used properly” for a LOT of those includes personal protective equipment, commonly known as PPE.

In the United States, the Occupational Safety & Health Administration (OSHA) publishes a couple of standards relevant to the safe use of compressed air:

Standard 1910.242(b) applies to the use of compressed air for cleaning. It states “Compressed air shall not be used for cleaning purposes except where reduced to less than 30 p.s.i. and then only with effective chip guarding and personal protective equipment.”

  • Do wear eye protection, at a bare minimum, in regard to the personal protective equipment, no matter what. If the debris you’re blowing off is sharp or jagged, a full face shield & long sleeves are likely called for as well.
  • Don’t operate a blowoff device in a manner where the static pressure at the outlet of the nozzle will reach or exceed 30 p.s.i. If you’re using an engineered product like an EXAIR Super Air Nozzle, it’s perfectly fine to use a higher air supply pressure than that. They’re designed so that the outlet pressure won’t exceed 30 p.s.i. no matter what the supply pressure is.
EXAIR engineered Air Nozzles, like the Model 1100 Zinc Aluminum Super Air Nozzle shown here, discharge the compressed air flow through a series of holes, recessed between an array of fins. This means that there’s always a relief path for the airflow, so the outlet pressure cannot reach a dangerous level.

Standard 1910.95(a) isn’t exclusive to the use of compressed air, but since the discharge of a high pressure gas to atmospheric pressure can create quite a racket, noise levels associated with the use of compressed air often exceed exposure limits published in this standard.

  • Do protect your ears, same as you do your eyes. This one is near & dear to me, because my Dad lost a significant amount of his hearing in his early 40’s as a result of occupational noise exposure, and I saw first-hand what an impact that has on quality of life…for him, and frankly, for us too. There are a number of ways to do this, and the National Institute of Safety & Health (NIOSH) ranks them in order of effectiveness in their Hierarchy of Controls.
  • Don’t make earplugs, earmuffs, headphones, etc., the first and only line of defense. Don’t get me wrong; they work GREAT when the right ones are used properly…”right” and “properly” being the key words there.
  • So, DO make selection, training, and enforcement of their usage a high priority if the source of the noise cannot be:
    • Eliminated – this can be a toughie, because whatever’s making the noise is very likely there for a reason.
    • Substituted – this is a much more common, and still highly effective method, as engineered products like EXAIR manufactures can dramatically lower noise levels while maintaining the effectiveness of compressed air usage.
Examples of some sound levels we’re all familiar with, and how some EXAIR products compare favorably.

In closing, my last dos & don’ts are: Do heed OSHA’s safety standards, so you don’t get a hefty fine for endangering yourself or the folks you work with. Frankly, if they catch you before anyone gets hurt, you got off light. If you’d like to find out more about how EXAIR Intelligent Compressed Air Products can improve safety with your compressed air usage, give me a call.

Russ Bowman, CCASS

Application Engineer
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Chip Shields, OSHA, And You

Published on by Russ BowmanLeave a comment

Safety is a key part of our culture at EXAIR Corporation.  We have regularly scheduled, all-hands required, safety training on a number of topics.  Our Order Entry team can likely tell you as much about our lockout/tagout procedures as our Machinists can.  Nobody even thinks about entering The Shop without safety glasses, and it’s not just because of the signs.

We pay attention to these…

…so we don’t ever have to use this.

OSHA 1910.242(b) states that “Compressed air shall not be used for cleaning purposes except where reduced to less than 30 p.s.i. and then only with effective chip guarding and personal protective equipment.“ (emphasis mine)  All EXAIR Intelligent Compressed Air Products are engineered to meet the requirements of the first part (30psi outlet pressure to prevent dead ending…we’ve written about that numerous times, including here, here, and here) and we can also provide pre-installed devices to satisfy the second part:  the EXAIR Chip Shield.

Any EXAIR VariBlast or Heavy Duty Safety Air Gun can come fitted with a Chip Shield, and any Soft Grip Safety Air Gun, except for those with Stay Set Hoses, can as well.  Safety Air Guns with Back Blow Nozzles automatically come with a Chip Shield. The principle is simple: a clear polycarbonate (so you can still see what you’re doing) round disc slips over a short (or long if you want) pipe extension between the gun & the nozzle.  It’s fitted with a rubber grommet so you can position it to where it’s most effective – sometimes that might be closer to the part being blown off; sometimes it may be back a little closer to the operator.

EXAIR Safety Air Guns are available, from stock, with Chip Shields.

If you already have an air gun that’s doing the job, you can easily add an EXAIR Chip Shield to it.  They’re made to fit a wide range of extension diameters, and can even come with the extension if you need it.  We also stock a number of adapter fittings; if you know what threads your air gun has (or if you can send us some photos) we can quickly & easily spec those out for you.

Convenient and inexpensive “thumb guns” with cross drilled nozzles (left) are compliant with the first part of OSHA 1910.242(b). Fitting one with an EXAIR Chip Shield (center) makes it compliant with the second part. A Model 1102 Mini Super Air Nozzle (right) makes it quiet & efficient.

We can provide a Chip Shield for most any device with a threaded fitting. I couldn’t find a way to re-use the non-OSHA-compliant nozzle that came with this gun (thank goodness.)

Another example of a larger air gun fitted with a more powerful cross drill nozzle (left) that can be made totally OSHA compliant with an EXAIR Chip Shield (center.) An EXAIR High Force Super Air Nozzle (right) keeps the power, while reducing noise level and compressed air consumption (right.)

Since 1983, EXAIR Corporation has been manufacturing quiet, safe, and efficient compressed air products for industry (emphasis mine.)  If you have concerns or questions about safety in regard to your compressed air use, call me.

Russ Bowman
Application Engineer
EXAIR Corporation
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Compressed Air and Safety

Published on by John BallLeave a comment

Warning

Compressed air is generally considered the fourth utility in industrial, commercial and back-yard settings.  It is used to power pneumatic equipment, cleaning surfaces, conveying materials, etc.  The compressor reduces the volume inside a chamber to increase the pressure.  The compressed air typically is contained in a reservoir tank for distribution to pneumatic equipment and devices.  Since air is a compressible fluid it has stored energy; and, if not used properly, it can be hazardous.  Most people perceive compressed air as harmless, but this is untrue.  It can be very dangerous.  Here are some potential risks when using compressed air:

  1. If the air pressure against the skin becomes greater than 30 PSI, air can penetrate through the membrane and cause an embolism which could be fatal.  The term used is Dead-End pressure, any end-use nozzle or blowoff product cannot exceed 30 PSI dead-end pressure.
  2. Hearing damage can occur from exposure to loud noises from compressed air exhausting from pneumatic equipment or devices.
  3. Proper use of Safety Air Guns and Safety Air Nozzles is a must. They should not be modified or tampered with.  For example, tying the trigger on an air gun for continuous blowing or modifying the nozzle to get a different blowing pattern.
  4. Compressed air can generate high velocities which can shoot chards of debris. The accelerated fragment can injure any part of the body even from bounce-back.
  5. If the air pressure is higher than the recommended rating for the equipment, uncontrolled eruptions can occur which can send broken pieces everywhere.
  6. When air hoses or lines are laying on the floor, near pinch points, or degrades from the environment, a break can occur causing unrestrained hose “whipping”.

Some safety precautions can be followed in your area when using compressed air products.  They may seem basic, but they are commonly overlooked.

  1. Verify that all compressed air components are rated to be used for the maximum line pressure.
  2. Use shut-off valves nearby to isolate the system from the main compressed air line.
  3. Have general inspection on your compressed air system to check for pipe degradation, leaks, faulty pneumatics, etc.
  4. When you go to repair items attached to the compressed air line, make sure to use proper lockout procedures to isolate and remove the hazardous energy.
  5. Remember that compressed air is not a toy and use proper PPE when required.
  6. If any pneumatically operated product is damaged, remove it from service and either repair it or replace it.

EXAIR Products

In 1970, Occupational Safety and Health Administration, OSHA, was enacted by the Department of Labor.  This organization was created “to ensure safe and healthful working conditions for working men and women”.  They created a set of laws and standards that they enforce with heavy fines and reoccurring visits if not followed.  The Department of Labor lists these laws under title 29 in the Code of Federal Regulations (CFR).  For general industry, these safety regulations are under part 1910 of 29 CFR.  To give a few examples, 29 CFR 1910.242b gives the explanation about dead-end pressure.  Under 29 CFR 1910.95a shows the maximum allowable noise exposure.  The reason that I noted these two OSHA standards as they are commonly overlooked with Safety Air Guns, and commonly fined by OSHA for improper nozzles.

Safety is everyone’s responsibility, and EXAIR products can be a key.  If you would like to discuss how to improve your workplace, you can contact an Application Engineer at EXAIR.     Because hazards and fines can be detrimental to your company when it comes to compressed air safety.

John Ball
Application Engineer

Email: johnball@exair.com
Twitter: @EXAIR_jb

 

Photo: Attention Warning Sign by Peter-Lomas.  Creative Commons: CCO