Safety Audit Checklist for Countertop Fabrication Shops
What Is a Fabrication Shop Safety Audit?
A safety audit is a systematic review of your shop's compliance with OSHA regulations, industry safety standards, and internal safety policies. For countertop fabrication shops, the primary hazards include respirable crystalline silica dust, heavy material handling (slabs weighing 400-1,200 lbs), rotating machinery, wet floors, and noise exposure. OSHA penalties for stone fabrication violations regularly exceed $10,000 per citation, and serious silica violations can reach $150,000+.
TL;DR: Safety Audit Priorities
- Silica dust compliance is OSHA's top enforcement target for stone fabrication shops
- OSHA fines for silica violations range from $16,000 to $160,000 per citation in 2026
- The average fabrication shop injury costs $38,000 in medical, lost time, and insurance impact
- Conduct formal safety audits quarterly with monthly spot checks
- Workers' comp premiums decrease 15-25% for shops with documented safety programs
- Every employee needs silica exposure training regardless of their role
- This checklist covers OSHA's most-cited standards for stone fabrication
Complete Safety Audit Checklist
Section 1: Silica Dust Compliance (OSHA 1910.1053)
- Written silica exposure control plan on file and current
- Wet cutting methods used on all stone cutting operations
- Water flow verified and adequate on CNC, bridge saw, and hand tools
- Dust collection systems operational and maintained
- Respirable dust monitoring conducted per OSHA schedule
- Monitoring results documented and available to employees
- Employees at or above Action Level (25 ug/m3) identified
- Employees at or above PEL (50 ug/m3) have medical surveillance
- Respiratory protection program in place for affected employees
- Respirators properly fitted (fit testing documented annually)
- Housekeeping prevents dry sweeping of silica-containing dust
- Warning signs posted in areas where silica is present
- Employee silica training completed and documented annually
Section 2: Machine Safety
- All CNC machines have functional emergency stop buttons
- Bridge saw guards and covers in place and operational
- Lockout/tagout (LOTO) procedures written and posted
- LOTO locks and tags available at each machine
- LOTO training documented for all employees who operate or service machines
- Router and grinder guards in place
- Overhead crane inspected annually by certified inspector
- Crane capacity posted and visible
- Crane operators trained and certification documented
- Forklift inspected daily and operators certified
- All power tools inspected and in good repair
- Ground fault circuit interrupters (GFCI) on all outlets near water
Section 3: Personal Protective Equipment (PPE)
- Safety glasses available and required in all fabrication areas
- Hearing protection available (required above 85 dB -- most fab shops exceed this)
- Cut-resistant gloves available for material handling
- Steel-toe boots required and worn by all shop floor staff
- Respirators available and fit-tested for all employees in silica areas
- Back support belts available for heavy lifting tasks
- Face shields available for grinding operations
- PPE condition inspected regularly and replacements available
- PPE requirements posted at all entry points to fabrication area
Section 4: Material Handling
- Slab handling procedures documented (minimum 2-person for manual handling)
- A-frame racks rated for slab weight and not overloaded
- A-frame racks secured to floor or wall to prevent tipping
- Suction cups and carrying clamps inspected before each use
- Lifting equipment (crane, forklift) weight capacity not exceeded
- Clear aisles maintained (minimum 28" width per OSHA)
- Floor surfaces clean and free of slip hazards (slurry, water, debris)
- Anti-slip mats placed in frequently wet areas
- Proper lifting techniques trained and reinforced
Section 5: Electrical Safety
- Electrical panels accessible (36" clearance maintained)
- No frayed or damaged electrical cords in use
- Extension cords not used as permanent wiring
- GFCI protection on all outlets in wet areas
- Electrical panel directories current and labeled
- No open junction boxes or exposed wiring
- Portable tools double-insulated or grounded
Section 6: Fire Safety
- Fire extinguishers mounted, accessible, and inspected monthly
- Fire extinguisher annual inspection tags current
- Emergency exit routes posted and unobstructed
- Exit signs illuminated and visible
- Flammable materials (adhesives, solvents) stored in approved cabinet
- Welding/cutting operations performed with fire watch
- Evacuation plan posted and practiced annually
Section 7: Environmental Compliance
- Water recycling system operational and maintained
- Wastewater discharge meets local permit requirements
- Settling tanks cleaned on schedule
- Stone waste disposed of per local regulations
- Chemical storage secondary containment in place
- Safety Data Sheets (SDS) available for all chemicals
- Spill kits available and employees trained on use
Section 8: Training and Documentation
- New employee orientation includes safety training
- Silica awareness training documented for all employees annually
- Machine-specific training documented for each operator
- First aid/CPR trained staff on-site during all shifts
- OSHA 300 Log posted during required period (Feb 1 - April 30)
- Near-miss and incident reports filed and reviewed
- Safety committee meets monthly (required in some states)
- Emergency contact numbers posted
- First aid kit stocked and accessible
Audit Frequency and Scoring
| Audit Type | Frequency | Who Conducts | Duration |
|---|---|---|---|
| Full safety audit | Quarterly | Safety officer or outside consultant | 2-4 hours |
| Monthly spot check | Monthly | Shop manager | 30-60 minutes |
| Daily walk-through | Daily | Shift supervisor | 10-15 minutes |
| Post-incident review | After any incident | Safety officer + management | 1-2 hours |
Score each checklist item as: Pass, Minor Finding (correctable within 1 week), or Major Finding (immediate action required). Any item related to silica compliance or immediate physical danger should be classified as Major.
Common OSHA Citations for Stone Fab Shops
| Violation | Average Fine | Fix Cost | How Often Cited |
|---|---|---|---|
| Silica exposure above PEL | $16,000-$160,000 | $2,000-$15,000 | Very frequently |
| No written silica plan | $16,000-$50,000 | $500-$2,000 | Frequently |
| Missing machine guards | $5,000-$16,000 | $200-$1,000 | Frequently |
| No LOTO procedures | $5,000-$16,000 | $500-$2,000 | Moderately |
| Inadequate PPE program | $5,000-$16,000 | $500-$3,000 | Moderately |
| Electrical hazards | $5,000-$16,000 | $200-$2,000 | Moderately |
FAQ
How often should a fabrication shop conduct safety audits? Full audits quarterly, monthly spot checks, and daily supervisor walk-throughs. This three-tier approach catches issues at different scales and frequencies.
What is the biggest OSHA risk for countertop fabrication shops? Respirable crystalline silica exposure. OSHA has made stone fabrication a specific enforcement priority. Fines for silica violations can exceed $150,000 per citation and willful violations can reach much higher.
Do I need an outside consultant for safety audits? Not required, but recommended for the first audit and annually thereafter. An outside consultant brings fresh eyes and expertise on current OSHA enforcement priorities. Between outside audits, internal quarterly reviews maintain compliance.
What does a written silica exposure control plan need to include? Tasks that involve silica exposure, engineering controls used (wet methods, ventilation), work practices, respiratory protection, medical surveillance procedures, and employee training records. OSHA provides a sample plan that can be adapted.
How much does workers' comp cost for fabrication shops? Countertop fabrication carries an Experience Modification Rate (EMR) that heavily influences premiums. Shops with documented safety programs and low incident rates can see premiums 15-25% below the industry average.
What should I do if I find a major safety violation during the audit? Correct it immediately or shut down the affected operation until it can be corrected. Document the finding, the corrective action, and the completion date. A known hazard that is not corrected becomes a willful violation if OSHA inspects -- and willful violations carry the highest fines.
Are there safety requirements specific to installation work? Yes. Installation crews need to follow construction industry standards (OSHA 1926) when working on job sites, which include fall protection, scaffolding standards, and site-specific hazard awareness.
How do I track safety training for employees? Maintain a training matrix showing each employee, each required training topic, completion date, and next due date. Keep sign-in sheets and training materials on file for at least 3 years.
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Sources
- OSHA -- Respirable Crystalline Silica Standard (29 CFR 1910.1053)
- OSHA -- Stone Fabrication National Emphasis Program
- Natural Stone Institute -- Safety guidelines for stone fabrication
- National Safety Council -- Workplace injury cost data
- ISFA -- Safety standards for surface fabrication
- Bureau of Labor Statistics -- Injury and illness data for manufacturing