DIY Safety Check Workbook

DIY SAFETY CHECK

WORKBOOK

FIRST AID

HORIZON SOLUTIONS, A REXEL BANNER

Are You Risking Safety Violations?

Our collection of workplace safety checklists can help protect your employees and
ensure you meet basic standards.

Safety is critical in every industry, at every workplace. This workbook provides sample
safety checklists that can be used during internal safety inspections to identify potential
hazards. These tools will help you evaluate your current situation and prevent future
incidents and injuries.
Our safety workbook is by no means all-inclusive. You should skip pages that don’t apply
to your facility and supplement pages to address topics specific to your operations. You
should always refer to OSHA standards for complete, specific regulations that may apply
to your work situation and environment.

“It has been estimated that employers pay almost $1 billion per week for direct
workers’ compensation costs alone.” – OSHA

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Checklists: REXELUSA.COM

Building Conditions Page 5
Confined Spaces Page 6
Electrical Safety Page 7
Emergency Exit Regulations Page 10
Eyewash Stations Page 13
Fall Protection Page 15
Fire Safety Page17
First Aid Page 18
Hazard Communication Page 19
Machinery Tools and Equipment Page 21
Material Handling and Storage Page 22
Personal Protective Equipment (PPE) Page 24
Scaffold and Ladder Page 26

Select the checklists that apply to you. You’ll also find blank pages at the end of this
workbook. Use those pages to create your own lists, as needed.

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HORIZON SOLUTIONS, A REXEL BANNER

OSHA reports “businesses spend $170 billion a year on costs associated with
occupational injuries and illnesses expenditures that come straight out of company profits.
But workplaces that establish safety and health management systems can reduce
their injury and illness costs by 20 to 40 percent. In today’s business environment,
these costs can be the difference between operating in the black and running in the red.”

– OSHA

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Building Conditions

People should be able to move in, out, and around your facility safely in all conditions.

⬜ Doorways: Non-exit doorways clearly marked.
⬜ Evacuation Signage: Building evacuation drawings with exits, pathways, and

emergency gathering space clearly marked (see Emergency Exit Regulations).

⬜ Exterior Roof Access: Rooftop maintenance requirements met.
⬜ Fire Doors: Doors to equipment rooms and storage marked and in good

working order.

⬜ Seasonal Safety Plan: Documented seasonal safety plan for walkways,

entries, and stairs.

⬜ Trip Hazards: Stairways, aisles, and access ways kept clear of trip hazards

and not used for storage (see Fall Protection).

“15% to 20% of all workers compensation costs are due to slips, trips and
falls” – OSHA

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HORIZON SOLUTIONS, A REXEL BANNER

Confined Spaces

Working in confined spaces requires proper planning and frequent evaluation to ensure
worker safety.

⬜ Inspection: Rescue retrieval equipment inspection performed annually by a

competent person.

⬜ Permit: Permits are required for certain types of confined space programs.

⬜ Plan: Written rescue plan.

⬜ Records: Employee training record.

⬜ Testing: Gas detection equipment bump tested and calibrate.

What is a confined space?

“OSHA uses the term ‘permit-required confined space’ (permit space) to describe a
confined space that has one or more of the following characteristics: contains or has the
potential to contain a hazardous atmosphere; contains material that has the potential
to engulf an entrant; has walls that converge inward or floors that slope downward and
taper into a smaller area which could trap or asphyxiate an entrant; or contains any other
recognized safety or health hazard, such as unguarded machinery, exposed live wires, or
heat stress.” – OSHA

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Electrical Safety

Electricity is a wonderful thing; it can also cause serious injuries and death if not
controlled, monitored, and properly contained.

⬜ Assessment: Electrical arc hazard assessment completed with one-line

drawing and audited within five years.

⬜ Boundaries: At each electrical hazard, the floor must be marked with correct

boundaries or clearly labeled entry distances must be on the panel label.

⬜ Document: Capture and retain the following information:

⏹ What is the age and condition of existing service entrance equipment?
_____________________________________________________

⏹ How many points of power distribution are there? _________________
____________________________________________________

⏹ Have there been any previous electrical studies? __________________
__________________________________________________

⬜ Electric and Control Panels: Panels must be unobscured and

unobstructed, providing full access.

⬜ Electrical Studies: Maintain a database of electrical studies and one-line

diagrams and audit and update them at least every five years.

Note: Thermographic testing of electrical sources and switching equipment on a regular basis can prevent
possible fires, arc flashes or arc blasts, equipment failure and production downtime.

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HORIZON SOLUTIONS, A REXEL BANNER

⬜ Extension Cords: These cords should only be for temporary use and kept

off walkways, away from hazards, and properly protected.

⬜ Ground-Fault Circuit Interrupter Outlets: GFCI outlets must be in

place within six feet of any water source.

⬜ Labeling: Complete electrical panel and equipment labeling.

⬜ Lockout/Tagout: There must be a written program and properly marked

equipment. A visual backup is recommended. All procedures must be clearly
marked.

⬜ Personal Protective Equipment: Required FR and Cal-rated PPE must be

available to employees (see Personal Protective Equipment).

⬜ Records: Training records for every employee who could be exposed to arc

flash/blast.

⬜ Responsibilities: Identify and qualify the people responsible

for safety, maintenance, and efficiency of the electrical distribution sytem.
____________________________________________________

It is required that any temporary use electrical outlets be GFCI protected during construction.

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⬜ Security: Exterior panel locked.
⬜ Training: Electrical workers are required to have training every three years.

Between 2012 and 2016, 739 workers died after being exposed to electricity—
that’s nearly three deaths a week. – NFPA

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HORIZON SOLUTIONS, A REXEL BANNER

Emergency Exit Regulations

Despite our best efforts, emergencies can and will occur. That’s why it’s important to
have a proper, compliant plan in place.

Emergency Action Plan:

⬜ Plans should be posted and clearly marked (see OSHA checklist of

developing an EAP).

Illumination:

⬜ Means of egress require proper, reliable illumination.

⬜ Emergency and exit lights must be functional and always in proper

operating condition.

⬜ Emergency and exit lighting systems must provide illumination for at least 60

minutes.

Routes:

⬜ Exit routes must be free of explosives and flammable materials, including

seasonal decorations.

⬜ Routes should be kept clear, even during maintenance and construction work.

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Signage:

⬜ Direction of travel to exit or discharge must be apparent. Signs must be

posted indicating direction to nearest exit.

⬜ A line of sight to an exit sign must always be clearly visible. If the line of sight

to the exit must be obscured, post clear signs that lead the way.

⬜ Doorways along the exit route that do not have exit ports should be clearly

marked “Not an Exit” or with the purpose of that door.

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HORIZON SOLUTIONS, A REXEL BANNER

Testing and Documentation:

⬜ All emergency and exit lighting systems must be inspected monthly and

tested annually.

⬜ Exit illumination and signs require a functional test for a minimum of thirty

seconds.

⬜ Be certain that all emergency fire equipment is in good, working order.
⬜ All testing and inspection should be documented.

In 2010, a retail chain faced $233,500 in proposed fines, chiefly for exit access
and fire and crushing hazards. – OSHA

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Eyewash Stations

Often overlooked in many facilities, emergency eyewash stations play an important role
in the safety of workers.

⬜ 10 Seconds: A station must be a minimum ten-second walk from eye

hazards.

⬜ 15 Minutes: Stations must provide a 15-minute flush of tepid water at .04

gallons per minute flow rate.

⬜ Activation Valves: They must be of the “stay open” type and only closed

through a secondary action.

⬜ Clear Path: A clear path of travel from hazards to the eyewash stations.

⬜ Inspection Tags: The inspection tag should be visible with date and

signature of the inspector.

⬜ Inspections: A complete anual inspection is required (flow rate, water

temp, valve and spray head condition).

⬜ Mounted Stations: Stations must be mounted so that the flush area is

a minimum of 33” from the ground, but not more than 53” from the ground.

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HORIZON SOLUTIONS, A REXEL BANNER

⬜ Portable Units: Portable units should be cleaned and have the water

checked weekly.

⬜ Signage: A clearly visible sign is required to identify each eyewash station.
⬜ Spray Heads: The spray heads must be protected from airborne debris and

not require a separate action to remove the protective caps (activating the
spray should remove the caps).

⬜ Water Temperature: Plumbed units should have a mixing valve to provide a

water temperature between 60 and 100 degrees Fahrenheit.

In 2018, Eye and Face Protection was #10 on OSHA’s list of most frequently
cited violations. – OSHA

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Fall Protection

From minor stumbles to major drops, slips, trips and falls account for tens of thousands
or injuries and deaths each year.

⬜ Inspection: Equipment must be regularly inspected by a competent person

with the date documented.

⬜ Ladders: Use only proper ladders or portable steps to access high shelves or

cabinets (see Scaffold and Ladder).

⬜ Program: There must be a written fall protection program that is regularly

reviewed.

⬜ Plan: Written rescue and retrieval plan.
⬜ Records: Fall protection training records for employees.

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HORIZON SOLUTIONS, A REXEL BANNER

⬜ Slip, Trip, and Fall Hazards:

⏹ Keep walkways, stairways, and paths clear of debris and refuse
⏹ Be sure rugs or matting is secure with edges and corners flat on the floor
⏹ Winter ice should be addressed immediately
⏹ Water and spills should be cleaned up or the area marked off until cleared

⬜ Stairways: Handrails on stairways should be in place and firmly mounted.

Fall Protection was #1 on the list of most frequently cited OSHA standards in
2018. Fall Protection – Training Requirements was #8. – OSHA

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REXELUSA.COM

Fire Safety

Fire can spread easily, causing massive destruction in its path. A comprehensive program
can prevent fires and mitigate damage.

⬜ Fire Extinguishers:

⏹ Placed within 150 feet of each other, depending on types of flammables
⏹ Display current inspection tags
⏹ Surrounded by clear signage
⏹ Wall mounted for clear, easy access

⬜ Fire Suppression Systems: Facility systems should be inspected within the

last 12 months.

⬜ Penetrations: Wall, floor, and ceiling penetrations must be sealed.

⬜ Sprinklers: Sprinkler head clearance (18” minimum to products below).

⬜ Storage: Flammable/explosives stored in rated cabinets with proper signage

and marking (see Hazard Communication).

In 2017, there were 1,319,500 fires, resulting in 3,400 deaths, 14,670 injuries,
and $23 billion in losses – U.S. Fire Administration

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HORIZON SOLUTIONS, A REXEL BANNER

First Aid

Much of this workbook is designed to prevent injuries, but injuries can and will happen.
It’s a good idea to have first-aid supplies and properly trained employees.

⬜ Response Time: Note the approximate local EMT/Fire response time.

_____________________________________________________

⬜ First-Aid Kits: Onsite first aid materials should be organized, conveniently

located, and maintained.

⬜ Automated External Defibrillators: If AEDs are onsite, who is trained to

use them? ____________________________________________ _
_____________________________________________________

⬜ Records: Training record should be kept for responders.

“There are 220,000 victims of sudden cardiac arrest per year in the United States;
about 10,000 sudden cardiac arrests occur at work. Waiting for the arrival of emergency
medical system personnel results in only 5 - 7% survival. Studies with immediate
defibrillation have shown up to 60% survival one year after sudden cardiac arrest.”
– OSHA

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Hazard Communication

Part of preventing accidents, incidents, and injuries is properly communicating hazards
and risks.

⬜ Abatement and Containment: There must be a comprehensive program

in place.

⬜ Hazmat Spill Response: There should a trained response team, if required.
⬜ Labeling: Hazardous materials and hazmat must be labeled using the

Globally Harmonized System (GHS).
⏹ GHS written documentation
⏹ Employee training record for GHS

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HORIZON SOLUTIONS, A REXEL BANNER

⬜ Program: A written hazard communication program, including a complete

chemical list and file of Safety Data Sheets (SDS) for chemicals used
and stored in the facility.

⏹ SDS accessible to all employees, visitors, and contractors for review upon
request

“Hazard Communication Standard, General Industry was the #2 most
frequently cited violation in 2018.” – OSHA

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Machinery, Tools, and Equipment

Working with any type of machine, tool, or equipment requires training and focus.
Putting safeguards, signage, and best practices in place will protect everyone.

⬜ Cords: Machine and tool power cords in good condition, properly wired, and

safely routed.

⬜ Labeling: Electrical, hydraulic, pneumatic, heat, gas, and steam energy

sources should be clearly labeled with isolation devices.

⬜ Machine Safety:

⏹ Determine what machine safeguarding specification is being used so that
the correct machine audit can be completed

⏹ Machine guarding in place, fastened to floor or machine
⏹ Emergency stops on each working side of each machine

“Employee exposure to unguarded or inadequately guarded machines is prevalent in
many workplaces. Consequently, workers who operate and maintain machinery suffer
approximately 18,000 amputations, lacerations, crushing injuries, abrasions, and over

800 deaths per year.” – OSHA

Machine safety and maintenance of equipment relies heavily on a required Lock out / Tag out program with individual
procedures for each piece of equipment. Audits and training of maintenance workers is required annually.

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HORIZON SOLUTIONS, A REXEL BANNER

Material Handling and Storage

From ergonomic strains to caught-between or dropped-from-above accidents, material
handling and storage incidents are a common cause of workplace injuries.

⬜ Eyewash Stations: Required near battery charging stations (see Eyewash

Stations).

⬜ Hazard Communication: Forklift battery maintenance area marked for

explosive gas and fire, respiratory, and eye hazards.

⬜ Loading Docks:

⏹ Guarding is required at 48” height when the leading edge is exposed
(no truck and door is open)

⏹ Plate lift areas can be a permit-required confined space

⬜ Mezzanines: Must have kick plates, railing heights, and gates at access

points.

⬜ Pallet Racks: Must be marked for total load.

⬜ Stacking Heights: Floor markings, safety gates, and signage stating

maximum stacking heights.

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Construction’s Fatal Four

In 2017, 20% of work-related deaths were in the construction industry.
Eliminating the Fatal Four would save 582 workers’ lives in America every year, here’s how
that breaks down.

– OSHA

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HORIZON SOLUTIONS, A REXEL BANNER

Personal Protective Equipment (PPE)

Protective gear can not only prevent injuries, but it can also save lives—and it does every
day. PPE should fit well and be appropriate for the work performed.

⬜ Employees: Annual fit testing and training record for each employee.

⬜ Eyewear:

⏹ RX and standard, ANSI Z7 approved
⏹ Face shields at appropriate locations

⬜ Hand Protection:

⏹ Recent survey
⏹ Proper application of current technology

⬜ Hazard Controls: Engineered hazard controls to alleviate hazards.

⬜ Head Protection: Required for overhead cranes, gantry cranes, etc.

⬜ Hearing Protection: Proper noise reduction rating (NRR) for protections

and a written hearing conservation program.

⬜ Prevention: Administrative controls to keep workers from hazard exposure.

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⬜ Protective Clothing: In place for environmental, chemical, and mechanical

hazards.

⬜ Respiratory Protection: If required, adequate protection should be

available as part of a written respiratory program.

⬜ Signage: Clearly mark areas where PPE is required.
⬜ Testing: Annual audiometric and air quality testing to ensure effective

protection.

⬜ Training: When any PPE is provided, there must be training for its proper

use and limitations.

According to the Bureau of Labor Statistic, in 2017 there were:

⏹ 2.8 million non-fatal workplace injuries and illnesses—that’s 7,671 a day
⏹ 5,147 fatal workplace injuries—that’s 99 deaths a week

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HORIZON SOLUTIONS, A REXEL BANNER

Scaffold and Ladder

Ladder Conditions:

⬜ Ladder safety training for employees.

⬜ Ladder labels and markings in place.

⬜ Ladders tethered when stored.

⬜ Fixed vertical ladder annual inspection. (These ladders should no longer use

cages as fall arrest)

⬜ Two workers to handle extension ladders.

⬜ Safety climb systems must be installed at 24 feet or higher fixed vertical

ladders (FLV).

Scaffold Assembly Instructions:

⬜ Labels for weight and height restrictions.

⬜ Qualified person to inspect assembly.

⬜ Guarding in place.

⬜ Documented training for affected workers.

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OSHA Top 10 Most Frequently Cited Violations

for Fiscal Year 2018 (Oct. 1, 2017, to Sept. 30, 2018)

1. Fall Protection
2. Hazard Communication Standard
3. Scaffolding, General Requirements
4. Respiratory Protection
5. Control of Hazardous Energy (Lockout/Tagout)
6. Ladders
7. Powered Industrial Trucks
8. Fall Protection–Training Requirements
9. Machinery and Machine Guarding
10. Eye and Face Protection

– OSHA

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HORIZON SOLUTIONS, A REXEL BANNER

Safety Prevention and Training

As an employer, you must identify hazards in your workplace and take steps to eliminate
or minimize them. Workplace safety training provides your employees with the knowledge
and skills they need to protect equipment, facilities and, most importantly, each other.
Safety not only ensures that all your workers return home safe and healthy every day—it
increases brand reputation, improves efficiency and worker morale, and ultimately saves
you money.
If you want to start a safety program or boost an existing one, give us a call at
(800) 724-4750. We have safety specialists, authorized OSHA Outreach Instructors on
staff, and offer a range of resources to support you as you develop a more efficient and
safer workplace.

⏹ Safety products
⏹ Safety training and prevention
⏹ Safety audits and remediation

Contact a Safety Specialist today to learn more about our workplace safety
solutions: [email protected].

Customize Your Workbook: Use the following blank pages to create your own checklists.
These pages will help you make this workbook your own and improve the safety of your
facility.

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Checklist Name:

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Checklist Name:

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Checklist Name:

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Email: [email protected] www.Rexelusa.com

©2023 Horizon Solutions, a Rexel Banner. All Rights Reserved. All supplier trademarks are the property of their respective owners. – 01/06/2023