Sheet metal workers face many well-known occupational threats, but some are less obvious or often overlooked. Maintaining a complete awareness of the risks is the first step to addressing them. That is especially true since many accident investigations show multiple failures contributing to the catastrophic outcomes. Besides putting employees at risk, unaddressed shortcomings can lead to hefty fines and unwanted media attention, which could make it harder for employers to attract and maintain workers. What must safety managers know, and how should they mitigate the risks?
1. Cart accidents
The extraordinary weight and size of some sheet metal pieces can pose significant dangers, especially as people attempt to move them in bulk or without their colleagues' assistance. In one October 2024 incident, 1,400 pounds of sheet metal fell onto a worker as he tried to move it with a company-made cart.
An investigation revealed that the tool did not meet occupational safety standards and that people made it with a furniture dolly, metal frame and plywood. Additionally, the affected company had not developed adequate employee procedures for moving sheet metal on mobile carts, and the injured team member had no training in the task.
Another 2024 incident elsewhere killed a worker who was moving sheet metal with a cart. Those looking into the matter said the 22-year-old apprentice was transferring the material when the wheel caught on an uneven surface edge and caused the cart to tip over onto him. When emergency responders arrived at the scene, the worker was in cardiac arrest and had life-threatening crush injuries. Although those attending to him took the man to the hospital, he eventually died there.
These examples emphasize the importance of prioritizing safer ways of transferring sheet metal. Improvements could be as simple as establishing processes where multiple people must operate carts to guide and keep them stable. However, it is even better if safety managers explore options such as conveyors that reduce manual movement.
2. Occupational lung diseases
Sheet metal workers have high rates of occupational lung diseases due to the likelihood of inhaling material dust, metalworking fluids and other potentially harmful substances. Since the harm can increase over time, people may only begin showing symptoms once they have worked in the industry for decades.
Fortunately, increased awareness of the hazards has encouraged safety managers and other decision-makers to change processes and minimize worker risks. For example, coil coating is an automated process that uniformly applies colors to metal. The associated machinery has real-time control mechanisms that dispense the paint quickly and accurately.
People handling paint or other sheet metal finishing products by hand should always wear the appropriate respirators or other recommended protection. However, the ongoing push to automate processes when possible may put more distance between the workers and harmful substances, minimizing the threat of occupational lung diseases.
Additionally, industrial facilities may have environmental sensors that can detect the presence of harmful chemicals and alert supervisors when the conditions become too dangerous. That improved visibility enhances proactiveness and elevates safety.
It is also beneficial for workplaces to maintain atmospheres where workers feel comfortable about reporting lung issues linked to their tasks. For example, irritant-induced occupational asthma symptoms appear within a day of initial exposure, making it potentially easier to pinpoint the cause.
The sooner affected sheet metal employees can tell their managers about new lung symptoms, the easier it will be to alter their working arrangements if needed. However, individuals must feel comfortable in industrial settings to take that step.
3. Bodily damage
Sheet metal workers are also at risk of accidents such as severed or lost body parts. These often occur when people get their limbs trapped inside or between sheet metal processing machines. Ongoing employee training provides valuable information that people must resist making near-automatic movements — such as reaching into a piece of equipment to retrieve something that has fallen into it. Additionally, appropriately placed signage can improve spatial awareness, reminding people they are near dangerous machines.
Safety managers should also review the required personal protective equipment. Well-fitting protective gloves can prevent or reduce the severity of finger injuries. Machines should also have guards that stop workers’ body parts from getting too close to the parts that could hurt them.
Establishing procedures for people to follow before using industrial machinery can significantly reduce the risks. An apprentice at an Australian sheet metal plant had seven fingers severed while operating a guillotine. Investigators concluded that he accidentally bypassed a safety measure while cutting the galvanized material. However, while they found the employer did not cause the incident, its preventive measures were insufficient.
Although company representatives visually checked equipment each month, those examinations did not include looking at the protection indents in the guillotine’s metal guard.
The metal manufacturer lacked documented operating procedures, meaning there was no prestart checklist for machine operators. Moreover, those examining what happened said such preliminary procedures may have allowed someone to identify that nothing covered the blade operating area to safeguard the worker.
Thorough inspection procedures and preliminary operating steps can prevent bodily harm by raising people’s awareness. However, effective measures for reporting issues to the appropriate parties are also needed.
4. Mental health difficulties
Although many manufacturing workers deal with challenging work environments, those faced by sheet metal workers frequently include long hours, tight deadlines and intensive physical demands. These aspects can collectively reduce employees’ mental well-being, making them more likely to experience anxiety, depression and other issues.
Sometimes, issues begin after a person gets injured on the job and needs to take painkillers to manage the condition. The sudden loss or reduction of previous abilities can remind people of their fragility and negatively impact their mood.
Additionally, research indicates that construction industry and sheet metal workers are at a higher risk of suicide than their counterparts in other fields. Getting access to the appropriate resources is also not always straightforward. Some people may perceive seeking help as a sign of weakness or worry about the stigma attached to mentioning their mental health struggles.
However, some organizations — including the Sheet Metal and Air Conditioning Contractors' National Association — have responded with dedicated campaigns to connect workers with the assistance they need and emphasize there is no shame in utilizing help.
Sheet metal workers have long known the physical risks associated with their roles. However, it is time for them to recognize how mental health challenges can be equally threatening, especially since many people suffer in silence.
Take sheet metal safety seriously
These dangers illustrate the importance of regularly auditing industrial workplaces to identify and address sheet metal-related threats. Additionally, when you demonstrate a willingness to hear employee feedback about identified issues or new safety procedures, workforce members will realize everyone plays a vital role in accident prevention.
