Safety Zones & PPE by Area¶

Consolidated reference for all zone-based safety requirements at Scott Recycling. Replaces scattered safety information across multiple documents with a single print-and-post reference.

Audience: All employees, visitors, contractors, auditors

Format: This document is designed to be printed as a wall poster and posted at the entrance to each warehouse zone. The summary table and zone-by-zone tables are the critical content.

Related: - Workplace Safety — OSHA-level general safety guidance - Emergency Response — medical, fire, spill, weather - Environmental Compliance — CRT, battery, hazmat handling specifics - Daily Checklists — opening/closing procedures reference zones - ~/Desktop/sr-drafts/warehouse-layout-template.md — facility layout (template, not yet live)

Quick-Reference Table (Print This)¶

Zone	Code	Min PPE	Restricted?	Major hazards
Reception / Office	I	None	No	Minimal
Waiting area	—	None	No	Minimal
Customer drop-off counter	—	None	Public side only	Minimal
Receiving dock	A	Hard hat, hi-vis, steel-toe, safety glasses	No	Forklifts, falling pallets, traffic
Sorting area	B	Cut gloves, safety glasses, steel-toe	No	Sharp edges, broken glass, lifting
Tech bench	C	Safety glasses	No	Small sharp parts, ESD
Data destruction (shredder)	D	Hearing protection, safety glasses, cut gloves	Authorized only	Shredder noise + debris, sharp fragments
Weighted materials / scrap	E	Cut gloves, steel-toe, hi-vis, safety glasses	No	Sharp metal, heavy loads, falling pallets
CRT / hazmat storage	F	N95 minimum, cut gloves, safety glasses	Trained handlers only	Lead dust, battery acid, mercury, fire risk
High-value secure storage	G	Standard	Management access	Minimal — low hazard
Outbound shipping dock	H	Hi-vis, steel-toe, safety glasses	No	Dock traffic, lifting
Office / admin	I	None	No	Minimal
Break room	J	None	No	Minimal
Fleet / garage area	K	Safety glasses, steel-toe	No	Vehicle movement, lifted vehicles, fluids

PPE glossary:

Hi-vis = high-visibility vest or shirt, ANSI Class 2 minimum
Hard hat = ANSI Z89.1 Type 1 minimum
Safety glasses = ANSI Z87.1 minimum, side shields required
Steel-toe = closed toe + ASTM F2413 protective toe
Cut gloves = ANSI/ISEA 105 Cut Level A2 minimum, A4+ for sharp-metal work
Hearing protection = NRR 25+ earplugs or earmuffs (mandatory >85 dBA zones)
N95 = N95-rated respirator minimum (P100 for lead/mercury work)

Zone-by-Zone Detail¶

A. Receiving Dock¶

Purpose: Trucks arrive, material unloaded, initial intake weight captured, chain of custody begins.

Staffing: Warehouse receivers + forklift operators + occasional driver presence

Required PPE: - Hard hat (overhead hazard from loading / unloading) - Hi-vis vest (ANSI Class 2 minimum) - Steel-toe shoes (falling-pallet risk) - Safety glasses (debris, dust) - Cut gloves for handling sharp material

Hazards: - Forklift traffic (the #1 injury cause in recycling warehouses) - Falling loads during unloading - Slips / trips on dock surfaces (especially in wet weather) - Dock-edge falls (if dock leveler is not deployed) - Back strain from lifting

Hazard controls: - Dock plates / levelers deployed before any material movement - No pedestrians in the forklift swing radius while loading/unloading - Clear stop signs for forklift operators at corners and entrances - Floor marking delineating pedestrian walkways vs. forklift zones

Emergency equipment nearby: - First aid kit (mounted on wall) - Fire extinguisher (ABC class) - Eye wash station - Spill kit (for fluid leaks from trucks)

Emergency procedures: - Injury → call 911, then Dan; see Emergency Response - Forklift collision → stop all forklift activity, document, driver re-certification check - Fluid spill → contain with spill kit, call for cleanup help

B. Sorting Area¶

Purpose: Received material is sorted into categories (electronics / scrap / hazmat / refuse).

Staffing: Sorters (trained in 3-photo sort process)

Required PPE: - Cut gloves (Level A2 minimum, A4+ for work with broken CRT or sharp metal) - Safety glasses - Steel-toe shoes - Dust mask (optional, for dusty loads)

Hazards: - Sharp edges on metal, broken plastic, broken glass - CRT glass shards (lead contamination risk) - Sudden sharp surprises when moving piles - Repetitive motion strain - Lifting strain

Hazard controls: - Sorting tables at ergonomic height (avoid bending) - Cut-resistant gloves always, even for "just one item" - Two-person lifts for anything over 50 lbs - Regular break rotation to reduce repetitive strain

Emergency equipment nearby: - First aid kit - Eye wash station

C. Tech Bench¶

Purpose: Laptops, desktops, phones, tablets tested, graded, wiped, refurbished or parted out.

Staffing: Tech processors (trained in laptop / phone / desktop SOPs)

Required PPE: - Safety glasses (flying parts when disassembling) - ESD strap (optional, for sensitive component work)

Hazards: - Small sharp parts (screws, heat sinks, broken plastic) - Battery incidents (swollen lithium-ion batteries from old laptops — never continue to use a swollen battery, isolate immediately) - Eye strain from close work - RSI / carpal tunnel from repetitive hand work

Hazard controls: - Good lighting (task lights at each station) - Battery isolation protocol for damaged batteries (non-combustible container, remove to hazmat zone) - Magnetic parts trays - Rotation of tasks to avoid overuse injury - Anti-fatigue mats at workstations

Emergency equipment nearby: - First aid kit - Eye wash station - Burn kit (if soldering is done) - Battery fire containment container (ideally Class D extinguisher)

D. Data Destruction (RESTRICTED)¶

Purpose: Hard drives, SSDs, phones, tablets destroyed per NIST 800-88. Chain of custody critical.

Staffing: Authorized destroyers only (per HIPAA Compliance Policy)

Required PPE: - Hearing protection (shredder is loud — >85 dBA) - Safety glasses with side shields - Cut gloves - Steel-toe shoes - Dust mask (drive shredding produces fine dust)

Hazards: - Shredder ingestion — the #1 hazard. Never reach into a running shredder. Use push sticks for fed material. - Flying debris from shredder - Noise-induced hearing loss - Dust inhalation - Electrical hazards - Chain-of-custody break (different kind of hazard — compliance, not physical)

Hazard controls: - Lockout/tagout (LOTO) for any shredder maintenance - Two-person rule for destruction operations (one operator + one witness per chain-of-custody SOP) - Shredder interlocks enforced (never bypassed) - Push sticks and safety guards in place - Dust extraction / vacuum active during shredding - Access control (locked cage, authorized badge only)

Emergency equipment nearby: - First aid kit - Eye wash station - Fire extinguisher (dust + electrical = Class C) - Emergency shutoff / kill switch for shredder - LOTO kit

Emergency procedures: - Shredder entanglement → hit emergency stop IMMEDIATELY, then 911, do NOT attempt extraction - Dust inhalation → remove to fresh air, 911 if breathing is affected

E. Weighted Materials / Scrap¶

Purpose: Scrap metal separated, weighed, staged for sale to commodity buyers.

Staffing: Warehouse material handlers

Required PPE: - Cut gloves (Level A4+ for sharp metal) - Steel-toe shoes - Hi-vis vest - Safety glasses - Hard hat (when working near overhead material handling)

Hazards: - Sharp metal (#1 cut source in recycling) - Falling / shifting piles of heavy material - Forklift traffic (if material is moved by forklift) - Back strain from lifting - Crush injuries from pallet / bin movement

Hazard controls: - Pile heights limited to prevent tipping - Floor scale leveled and maintained - Clear paths between bins - Cut gloves always — no exceptions - Baler LOTO if baler is in use

Emergency equipment nearby: - First aid kit - Fire extinguisher

F. CRT & Hazmat Storage (RESTRICTED)¶

Purpose: CRTs, batteries (Li-ion, NiMH, lead-acid), mercury lamps, refrigerants held until shipped to downstream processor.

Staffing: Trained hazmat handlers only

Required PPE: - N95 minimum respirator (P100 for any CRT handling or mercury work) - Cut gloves (Level A4+) - Safety glasses with side shields - Steel-toe shoes - Chemical-resistant gloves for acid (lead-acid batteries)

Hazards: - Lead dust from CRTs — most CRTs contain leaded glass; broken CRTs release lead particulate - Lithium battery fire — damaged / swollen Li-ion batteries can spontaneously ignite; fire can be severe and self-sustaining - Mercury from broken lamps - Battery acid from lead-acid batteries - Hazmat exposure from mixed chemical spills - Storage duration violation (regulatory, not physical — but tracked in sr_ewaste_compliance)

Hazard controls: - Segregated storage per material type (never mix Li-ion with lead-acid with CRTs) - Fire-safe container for Li-ion batteries - Secondary containment (spill tray) under battery storage - Lead-dust cleanup with wet wipes, never dry sweep (releases particulate) - Mercury spill kit on-hand (not general spill kit — mercury-specific) - Access control — trained handlers only - Storage duration tracking via sr_ewaste_compliance module (10-month warning / 11-month critical / 12-month violation thresholds) - Ventilation — hazmat zone should be ventilated separately from general warehouse

Emergency equipment required: - Eye wash station - Emergency shower - First aid kit - Mercury spill kit (specifically, not just general spill kit) - Battery-fire-specific extinguisher (Class D or specialty Li-ion fire suppressant) - Chemical spill kit - Phones for emergency calls

Emergency procedures: - Li-ion battery fire → evacuate zone, call 911, do NOT use water (water + lithium = violent reaction), use Class D or specialty extinguisher if trained - Mercury spill → evacuate, notify trained responder, use mercury-specific kit, VENTILATE, notify TDEC per reportable quantity rules - Battery acid spill → neutralize with the battery acid spill kit, dispose per hazmat protocol - Lead dust exposure → remove affected employees, wet-clean the area, medical monitoring per OSHA lead standard

G. High-Value Secure Storage (RESTRICTED)¶

Purpose: CPUs, RAM, phones, SSDs, and other high-theft-target items stored behind physical access control.

Staffing: Management access only

Required PPE: - Standard (safety glasses recommended when handling lots of small items)

Hazards: - Minimal physical hazard - Theft risk is the primary concern (not a safety hazard but a business one) - Inventory discrepancy / shrinkage

Hazard controls: - Locked cage with camera coverage - Access log (who entered, when, why) - Daily inventory count - Separation of duties (whoever places inventory ≠ whoever counts)

H. Outbound Shipping Dock¶

Purpose: Final packing, labeling, loading onto outbound carriers.

Staffing: Shipping / logistics staff

Required PPE: - Hi-vis vest - Steel-toe shoes - Safety glasses - Cut gloves (for packing sharp items)

Hazards: - Dock edge falls - Forklift / pallet jack traffic - Lifting injuries - Strain from repetitive packing

Hazard controls: - Dock levelers deployed before loading - Visual checks before backing trucks in - Ergonomic packing stations - Lift-assist equipment for heavy items

I, J. Office / Break Room / Restrooms¶

Purpose: Administration, CSR work, employee personal time

Hazards: Minimal (general office hazards — electrical, ergonomic, slips)

Required PPE: None

Special Topics¶

Lockout/Tagout (LOTO)¶

Required for maintenance on ANY powered equipment:

Shredder (data destruction)
Baler (scrap metal)
Conveyor (if installed)
Forklift charger
Air compressor
Any equipment with stored electrical, hydraulic, pneumatic, or mechanical energy

LOTO procedure summary (full version in Workplace Safety):

Notify affected employees
Shut down equipment normally
Isolate energy sources (unplug, breaker off, valve off, bleed hydraulics)
Apply lock and tag
Verify isolation (try to start — should NOT run)
Perform maintenance
Reverse: remove LOTO, restore energy, test, notify employees

Only LOTO-trained employees may perform LOTO. Contractors must use their own LOTO per our LOTO rules.

Hot Work Permit¶

Required for ANY open flame, welding, torch cutting, grinding, soldering:

Signed permit from Dan or facility manager
Fire watch during and 30 minutes after work
Fire extinguisher within arm's reach
Area cleared of flammables (minimum 35-foot radius)
Sprinkler system operational
Time-limited permit (specific day, specific area)

Hot work is prohibited in or near CRT/hazmat zone, battery storage, or any area with combustible dust accumulation.

Forklift Operations¶

Certified operators only. Forklift certification required per OSHA 1910.178.

Pre-use inspection daily
Speed limit: 5 mph in indoor areas
Horn at corners and blind spots
No passengers on forks
No raising loads above shoulder height while moving
Park with forks down, key out, parking brake set
No forklift operation in CRT/hazmat or data destruction zones (foot traffic only in those zones)

Respirator Program¶

Required for: - CRT handling (lead dust) — P100 minimum - Mercury work — P100 + vapor cartridges - Battery acid cleanup — chemical cartridges - Paint / solvent application — vapor cartridges - Welding fume — specific to the metal being welded

Respirators must be: - Fit-tested per OSHA 1910.134 (before first use, annually thereafter) - Medically evaluated (before first use) - Properly cleaned and stored between uses - Replaced per manufacturer schedule

Voluntary use of dust masks (non-respirators) is permitted in dusty areas without formal program requirements, but supervisors should monitor for respiratory issues.

Fall Protection¶

Not currently required at Scott Recycling facilities based on typical work heights, but:

Required if working from heights >4 feet without guardrails
Required for any rooftop work — only contractors perform rooftop work, not employees
Required for high-bay shelving work if shelving exceeds 4 feet

Confined Space¶

Scott Recycling does not routinely work in confined spaces, but:

Tank cleaning, vault work, crawl spaces → confined space permit + attendant + air monitoring
Contractors who enter confined spaces bring their own program
Employees do NOT enter confined spaces without formal training + permit system

Training & Certification¶

Each zone has specific training requirements:

Zone	Training required	Refresh cadence
A — Receiving	Forklift (for operators), PPE, loading safety	Annual
B — Sorting	Material handling, cut prevention, back safety	Annual
C — Tech bench	Laptop / phone / desktop SOPs, ESD handling	Annual
D — Data destruction	HIPAA, NIST 800-88, shredder operation, LOTO	Annual
E — Weighted materials	Material handling, back safety, commodity grading	Annual
F — CRT/hazmat	Hazmat handling, respirator, lead/mercury safety, `sr_ewaste_compliance`	Annual + initial
G — Secure storage	Inventory control, cage access	Initial only
H — Outbound	Packing, shipping, dock safety	Annual
I, J, K — Office/break/fleet	General safety orientation	Initial

Training records tracked in Odoo hr_skills module. New hires complete role-specific training before working independently in their zone.

Incident Reporting¶

Any zone-specific incident must be reported per Emergency Response Procedures:

First: safety — get people out of harm's way
Call 911 for injuries, fires, fatalities
Call Dan after 911
Document — photos, witnesses, timeline
Preserve the scene until authorized to clean up
File incident report within 24 hours
OSHA notification within 8 hours for fatalities, 24 hours for hospitalizations / amputations / loss of eye
Debrief within 48 hours — root cause, preventive action

Enforcement¶

Safety rules are non-negotiable. Violations follow Disciplinary Procedures:

First violation (minor): verbal warning, retrained
Second violation or major violation: written warning
Third violation or severe violation: final warning / suspension
Egregious violation (deliberate unsafe act, bypassing LOTO, refusing PPE): immediate termination

Review & Updates¶

Annually — full review of zones, PPE, hazards
Triggered — any incident, new equipment, new material stream, regulatory change

Last review: 2026-04-14 (initial consolidation) Next review: 2027-04 or upon incident