General Shop Requirements

Everyone working at the STEM Coliseum must:

• Read, Understand, and review (with a parent/guardian) this document and return it to the coaches signed by both a parent/legal guardian and student.
• Successfully complete tool specific training or work under the direct supervision of a coach or mentor on any tool they have not been given prior “independent authorized user” status. If you are unsure of your pre-approval status, ask a mentor or coach first!
• Never work in the shop without at least one mentor present on site.
• Be appropriately dressed for working on machines; long pants, nothing loose
• Wear appropriate eye protection (safety glasses must have Z87.+ logo on them.)
• Report all accidents, however small, to the coaches or mentors immediately and then complete the electronic injury reporting form.
• Look out for posters with specific information on operating machines, unique hazards, and emergency policies.
• Not bring food or beverages into any shop areas.
• Respect all lock-out procedures and report unsafe equipment to a coach or mentor immediately.

Procedure to Handle Behavioral Safety Infractions

• 1st violation: Friendly, verbal reminder.
• 2nd  violation: Level I written warning sent and recorded for Coliseum records, loss of “independent authorized user” status until retrained to satisfaction of STEM. Student sign-off of training.
• 3rd  violation: Level II written warning sent and recorded for Coliseum records, no longer allowed to do work or compete at facility, followed by Coliseum staff retraining. Student sign-off of training.
•  Three Level I or two Level II  violations in one-month: loss of all facility  privileges for 1 week, followed by STEM Coliseum safety retraining and student sign-off
•  Remember that we are all responsible for safety, beyond the unsafe operator, you may also be assigned a safety violation if you were present while it occurred and did nothing to prevent it.

Personal Protective Equipment and Appropriate Attire 

1. No loose garments. Long sleeve shirts or coats must not be worn when working with rotating machinery. Long pants must be worn. Wear appropriate clothing for the job (e.g., do not wear short-sleeved shirts or short pants when welding). Roll and secure long sleeves. Do not wear highly flammable clothes.

2. Remove or secure anything that might get caught in moving machinery. No jewelry, rings, hanging earrings, neckties, chains etc. can be worn. Remove or secure hoodie drawstrings, all rings, wristwatches, necklaces, and other jewelry before operating machinery.

3. Hair or beards that are shoulder length or longer must be tied up and secured (not hanging), or in a hat or hair clip.

4. Always wear closed‐toe shoes in the shop to protect feet and toes. Leather shoes are preferred. Sneakers are allowed, but not recommended.

5. Eye protection must be worn whenever in the workshop spaces, especially when working on or near any machine creating eye hazards. All safety eyewear must have side protection and be stamped “Z87+” to confirm that they follow ANSI Z87.+ protective eyewear for high impact.

6. Additional protection using face shields may be necessary while working in the metal or wood areas and if flying particles are expected during the machining process. Welding eye and face protection must be appropriate for the work being conducted. Welding spectators without proper protective equipment will be removed from the area.

7. Hand protection in the form of suitable gloves should be used for handling hot objects, glass, or sharp‐edged items.

8. Do not wear gloves while operating rotating machinery. Holding objects with a rag near moving machinery is also not permitted. Gloves, rags, etc. can be easily caught in machines that are in motion, pulling the operator into the equipment.

Shop Housekeeping

 9. Each user is expected to clean up after themselves. Clean up any mess. Wipe up any spilled liquids. Pick up materials. Sweep up dust and debris. Keep the work area clean. Keep the floor free of scraps and oil.

10. All machines and surroundings must be cleaned after use. Keep the floor around machines clean, dry and free from trip hazards. Do not allow chips to accumulate.

11. Before you leave the shop each day all tools must be returned to the toolbox, the machine cleaned and wiped down and the floor swept. Leave 10‐15 minutes for cleanup.

12. No rags may be used near working machines. If cleaning is necessary, use paper towels.

13. A brush, hook, or special tool is preferred for removal of chips, shavings, etc. from the work area. Never use your hands to clean cuttings – they are sharp and often very hot. Clean up the work area using a brush and dustpan.

14. Never use compressed air guns to clean clothing, hair, or aim the gun at another person. Never press air gun to anyone’s skin for risk of causing an embolism.

15. Avoid excessive use of compressed air to blow dirt or chips from machinery to avoid scattering chips. Compressed air used for cleaning work areas, such as work benches, table saws, and drill presses, must not exceed 30 psi at the outlet, statically or dynamically, and is only permitted with effective chip guarding or personal protective equipment to protect the operator and other employees from flying debris. Do not use the compressed air hose to blow chips off machinery unless there is a safety nozzle that reduces the pressure to below 30 psi. Vacuum the machine and sweep the floor area of any remaining chips.

16. Storage: Return tools to their correct storage place. Don't store tools, supplies or spare parts on benches, tables, or in the aisle or on the floor where they become tripping hazards. Keep all flammable materials away from heaters and welding areas to prevent fire. Grease, oil, paint, and solvents should be stored in a closed metal container. Gasoline must be stored in a plastic can with self‐closing lid. Flammable and combustible liquid in excess of 1 gallons (total load) shall be stored in an acceptable or approved flammable storage cabinet. Supplies and equipment should be stored in an area designed specifically for them.

Behavior

 17. A safe attitude will protect you and others. Think, practice, and develop good safety habits. If you cannot do a job safely in this shop, don’t do it. There are limits to what we can build here.

18. Think through the entire job before starting. Ask for help if you have questions.

19. No smoking, eating, or drinking in the shop. Do not bring food or snacks into the shop.

20. Respect the rights and property of other students. Be thoughtful and helpful to other students in the shop.

21. Respect your shop staff. They are highly trained individuals and are looking out for your safety.

22. Horseplay, running, yelling, and or fighting is absolutely forbidden in the shop.

23. Always keep your eyes on your fingers, ears tuned to the sound of the machine, and nose tuned to the smell of smoke. Avoid distractions. Keep your mind on your work. Talking or listening to the radio while running machinery can lead to accidents. Stop working and turn off the power tool you are working with if distracted by something or someone. Never look away from your work when operating a power tool. Never cross your arms when using a manual or automated tool.

24. Earphones or headphones to listen to personal music devices are prohibited within the shop.

25. Never work when you are impaired. Do not operate power tools when you are ill, taking strong medications, or fatigued. Do not drink alcoholic beverages before or during work in the machine shop area. Do not work in the shop if you are tired or in a hurry – this almost always ruins the work, and often results in injury due to carelessness.

26. Ensure the safety of yourself and others by being aware of your surroundings. If you see someone committing an unsafe act, report it to the supervisor immediately. As the machine operator you are responsible for the safety of the people in your immediate area. It is your responsibility to look around and be sure that everyone within your range is wearing safety glasses/welding helmets, etc.

Machine/Tool Use 

27. Do not use equipment until you have received appropriate instruction and feel comfortable operating it.

28. Follow all special rules and regular safety procedures while using the equipment. Guidelines are posted near unique pieces of equipment.

29. If you’re unsure about the safe operation of a tool or any aspect of a job – ask for help! You are not authorized to use equipment on which you have not had appropriate instruction.

30. Use equipment and tools for their intended use. Do not use a tool or attachment for something it was not designed to do. Select the correct bit, cutter, grit, or grinding wheel, etc for the material with which you are working. This saves time and improves the quality of work and reduces the risk of mishap.

31. Know the machine. Before using any tool, read the operator's manual, or comparable literature including the specific information posted in the shop, to learn the applications, limitations, and potential of each power tool. Never use a tool unless trained to do so.

32. Know the emergency-stop switch location(s). Remember where the switch is located so you can turn off the machine quickly.

33. Inspect all tools and machinery before each use and replace or repair if parts are worn or damaged. Inspect screws, nuts, bolts and movable parts to make sure they are tightened. Repair tools only if you are trained to do so. Never repair a tool with the power energized to it, including pneumatic pressure or potential energy stored in springs etc.

34. Check the power cords and plugs on portable tools before using them. Make sure the cord will not become caught or angled. The cord should be flexible, but not easy to knot. Clean the cord regularly and inspect the grounding connections.

35. Machine guards must be kept in place while operating equipment, when appropriate. If machine guards need to be adjusted or removed under special circumstances, permission must be granted by a coach or mentor. Once the task is completed, machine guards must return to their original position.

36. Make sure the machine work surface is clean, unobstructed, and ready for use.

37. Before starting a machine, always check it for correct setup and always check to see if the machine is clear by operating it manually, if possible.

38. Keep your fingers clear of the point of operation of machines by using special tools or devices, such as push sticks, hooks, pliers, etc. Keep your hands away from sharp tools.

39. Never use a rag near moving machinery. Use paper towels if necessary.

40. If a machine, tool, or other piece of equipment breaks or operates improperly, stop using it and report the problem to the supervisor immediately. LOCK OUT the tool by tagging it and zip tying the end plug so that it can’t be powered up until coach or mentor inspection is possible. Do not use broken or damaged equipment. If it sounds odd, it’s likely not working properly. Students are not to attempt to make repairs to tools or equipment. Hiding or concealing broken tooling only slows the replacement of that piece of tooling, so it won’t be there next time you need it.

41. If you have made an adjustment to a piece of equipment and can’t get it reset to normal settings, report to the shop supervisor.

42. Used materials should not be used on machines without permission. If used lumber is recycled, it must be thoroughly checked for nails, defects, screws, bearings, etc.

43. A hard hammer should not be used to strike a hardened tool or any machine part. Use a soft faced hammer. 

44. When working with metal, wood, or plastics, secure the materials with clamps or in a vise to keep it from moving.

45. Securely clamp down all work pieces in chop saw, drill press and milling machine. This will prevent work from being lifted or spun around with the cutters. Use all guards that are available and be wary of points of contact with rotating cutters and chucks.

46. Work only at operating speed. Do not use a power tool before it has reached operating speed or while it is coming to a stop. Never force a tool by applying too much pressure. Let each tool work at its own speed without forcing it. Once a power tool has been turned off, allow it to coast to a stop. Never force an object into moving parts to stop a machine. Never put down a moving power tool. When cutting, run the tool for the entire cut, including the down cut and up cut if applicable.

47. Keep tools clean and in good repair. Always clean up power tools before putting them away.

48. Avoid using tools that are or appear to be in disrepair. Use power tools only for their intended functions.

49. Always turn off and unplug a power tool before adjusting, oiling, cleaning, or repairing it; attaching an accessory; or changing bits, blades or grinding wheels. Before adjusting or changing bits or cutters, disconnect the power cord to avoid accidentally touching the switch and possible injury when the tool starts. Unplug or lockout tools when not in use.

50. Unplug tools by pulling directly on the plug end. Jerking on the cord can cause damage to the tool.

51. Do not leave a machine running unattended, unless intended as it is designed. Make sure all moving parts have come to a complete stop before you put the tool down, leave the work area or before you make minor adjustments.

52. Use a ground fault circuit interrupter when working with portable power tools near water.

53. Use safe blades. Never use cracked or kinked saw blades. Keep saw blades sharp and properly set. Never use a saw blade with missing or damaged teeth.

54. Personal power tools may not be brought from home for use in the machine shop unless they have been inspected by the Machine Shop Supervisor for safe operation.

55. Do not machine, grind, or cut any radioactive or other solid toxins like PCB boards. Unsure? Check the materials SDS (Safety Data Sheets).

56. Do not leave keys on chucks of lathes, drill presses, and milling machines. The key can be thrown out with great force when machinery is turned on. This also applies to wrenches used to tighten the cutting tools into the spindles of the milling machines.

57. Clean and replace tools where you found them. All tools must be returned to their proper place after use. The toolboxes and cabinets are organized according to the character of their contents. People expect to find tools in their ‘usual’ locations, so clean and replace everything where it belongs when you’re finished.

58. Stack and store projects neatly in assigned areas labeled with your name and date.  

Chemicals, Cleaners, Solvents, and Hazardous Materials

 59. If you have not worked with a particular material before, check the Safety Data Sheets (SDS) for any specific precautions to be taken while working with the material. Also, ask the shop personnel before cutting any unusual material.

60. Heavy sanding and grinding should only be done in well‐ventilated areas and with dust collection systems on.

61. Follow all appropriate precautions when working with solvents, paints, adhesives, or other chemicals. Use appropriate protective equipment.

62. Used rags, especially oily and greasy ones, must be kept in a covered, marked container. Rags must be a safe distance from the welder and other sources of ignition. Always store oily rags in an approved metal container.

63. No welding, cutting or brazing or work that produces noxious vapors may occur in the shop unless it has ventilation designed for this.

64. Handle fiberglass and insulation materials with care. Its particles can irritate the skin, eyes, and respiratory system.

65. Know what you are soldering with. Lead solder is toxic and must be collected as hazardous waste. We do not use lead solder in any electronics or robot building process.

66. Dispose of solvents, cleaners, chemicals, and other hazardous materials of any kind in the proper containers.

Accidents and Facility Emergencies

 67. All accidents must be reported to the coach or mentor immediately. Complete the electronic accident form at the earliest time from injury occurrence.

68. Do not attempt to remove foreign objects from the eye or body. If chemicals get in the eye(s), wash eye(s) for 15 minutes in an open flow of water before getting medical treatment.

69. Know the emergency numbers! Call the town emergency services @ 911 for medical or other emergencies.

70. Shop fires can be any one or a combination of three fire classes: Class A, ordinary combustibles; Class B, combustible liquids; and Class C, fires in live electrical equipment. Class D fires are flammable solids (e.g., magnesium). ABC Class extinguishers are in the shop. Everyone should be familiar with its location and know how to use it in case of emergency.  Students should not try to put out any significant fire, focus on notification and safe evacuation.

71. In the event of a facility-wide emergency, such as chemical spills, fire, active security risks, or violence, secure your safety first, then help those immediately around you.  Never reenter the facility once evacuated. Notify an adult of your concerns. Evacuation regrouping zones:

·       When at ME Mall, evacuate to the large pine tree across the parking lot near the old Sears Building,

·       when at FHS, evacuate across the road from the rear shot parking lot outside of the greenhouse area.

Safe Robot Lifting, Handling, Transportation, and Field Access

72. To protect team members from muscle strains and other injuries as they transport the robot between the pits and the competition area, we strongly recommend team members use a cart.

73. Always follow recommended practices for lifting, handling, and transportation of robots. By practicing these safety techniques, your team members will also develop a quick, fluid routine.

•        Ensure all transporters wear appropriate PPE (safety glasses at a minimum are required.)

•        Make sure the robot is safe to move:

·       Are all parts of the robot secured?

·       Relieve all stored energy and open the main circuit breaker on the robot. Stored energy can include many forms including electrical, mechanical, hydraulic, pneumatic, chemical, thermal or other sources in machines and equipment that can be hazardous.

•        Always lift the robot with at least two people, three to four preferred.

•        Before lifting, hold a short discussion to determine the direction and path you will be lifting.

•        Ensure that the areas and paths are clear of debris and hazards.

•        During the Lift

·       Appoint someone to coordinate the lift to make sure you are all ready to begin.

·       Each lifter should place his/her feet close to the robot and adopt a balanced position.

·       All persons should lift at the same time using proper body mechanics, these include:

·      Lift with your legs, keeping your back straight.

·      Do not twist your body- use your feet to turn your entire frame if you need to turn.

·      Use proper hand holds to grasp the robot and make sure you have a safe, secure lift point before starting the lift.

·      Bend your knees to a comfortable degree and get a good handhold. Maintain normal spinal curves.

·      Tighten your stomach muscles and commence lifting the robot, using your leg muscles if you are lifting the robot up from the floor.

·      Keep the robot close to your body, and coordinate lift speed with the others.

·      Make sure the cart is stable and will not roll, coordinate correct placement of the robot on the cart.

74. Lead the cart with a team member who can ensure the safety of those in the path of the travel area.

75. Always use the gate opening when entering/exiting the playing field. Climbing over the railing is Prohibited.

Battery Safety 

76. Batteries contain acid. This substance, H2SO4, is a corrosive, colorless liquid that will burn your eyes, skin, and clothing.

You can find emergency handling and first aid procedures on the SDS (Safety Data Sheets), along with proper protection for handling cracked or damaged batteries, and information on disposal of the battery.

77. Any battery that is visibly damaged in any way is dangerous and unusable. Don’t take a chance- don’t use it!

78. Periodically inspect your batteries for any signs of damage or leaking electrolyte. Remember that a dropped battery may be cracked, but the crack may not be visible and might eventually leak electrolyte.

79. When a battery electrolyte leak occurs:

•        Neutralize it by pouring the sodium bicarbonate on all wet surfaces. The sodium bicarbonate itself is not dangerous and will react with the acid in the electrolyte leaving a safe residue that can be disposed of in a conventional manner such as rinsing with water.

•        Follow emergency handling instructions of the SDS and notify a mentor.

•        Put on gloves before handling the battery.

•        Place the battery in a leak-proof container for removal.

•        Be sure to neutralize any acid on the gloves before removing and storing them.

•        Seek medical attention if skin contacts any chemicals.

•        Properly dispose of the battery, which is now a hazardous material.

80. Safe battery charging and handling requires you follow the following practices

•        Keep the battery-charging area clean and orderly.

•        Place your battery charger in an area where cooling air can freely circulate around the charger.

•        Properly ventilate any battery charger to dissipate heat.

•        Do not short out the battery terminals. If metal tools/parts contact the terminals simultaneously, it will create a direct short circuit. This may cause high heat to develop in the battery terminal/part/tool area and the battery could explode. To avoid the possibility of shorting out the battery terminals and creating a hazardous situation it is required to cover all exposed battery terminals and connections with appropriate insulating material such as electrical tape or tubing.

•        When inserting the battery into the battery rack, always have the terminals up (at the top)

•        Never attempt to disassemble batteries or battery housing to prevent accidental puncture.

•        Never use tools to remove a stuck battery as they may puncture the battery.

 81. Lithium-ion batteries are particularly prone to overheating and fire during charging and use. Only charge a lithium-ion battery with its manufacturer’s provided charger. Beware of hot batteries and remove them from charging or use immediately. Never charge a traditional sodium battery with a Lithium-Ion battery charger.