Compressed air incidents can happen without warning and may involve high-pressure air, flying debris, hose whip, equipment failure, or air injection injuries. Quick, organized emergency response helps reduce the severity of injuries and prevents additional hazards. Every worker should know how to safely isolate compressed air systems, summon emergency assistance, and protect themselves and others during an incident.
This toolbox talk reviews the actions to take during a compressed air emergency and the importance of prompt reporting and emergency medical care.
Why This Matters
- Compressed air systems store significant energy that can be released suddenly.
- Air injection injuries can appear minor but require immediate medical evaluation.
- Rapid isolation of the air supply helps prevent additional injuries.
- Prompt emergency response minimizes the consequences of equipment failures.
- Prepared workers respond more safely and effectively during emergencies.
Common Hazards
- Hose whip caused by failed couplings or fittings.
- Air injection injuries from high-pressure air contacting the skin.
- Flying debris striking workers.
- Equipment failure or ruptured hoses.
- Uncontrolled release of compressed air.
- Eye injuries from airborne particles.
- Slips, trips, or falls during emergency situations.
- Delayed reporting of injuries or equipment failures.
Safety Checklist
Before Work Begins
- Review emergency procedures for compressed air equipment.
- Know the location of emergency shutoff valves and air isolation controls.
- Verify first aid supplies and emergency communication equipment are readily available.
- Inspect hoses, fittings, regulators, and safety devices before use.
- Ensure workers understand how to report emergencies and summon medical assistance.
- Wear the required PPE for compressed air operations.
If an Emergency Occurs
- Stop work immediately and isolate or shut off the compressed air supply if it is safe to do so.
- Keep workers away from damaged or uncontrolled pressurized equipment.
- Call for emergency medical assistance when injuries are serious or when an air injection injury is suspected.
- Provide first aid only within the limits of your training while waiting for emergency responders.
- Do not restart or reuse damaged compressed air equipment until it has been inspected and approved for service.
- Report the incident according to company procedures and preserve the area for investigation when appropriate.
Crew Talking Points
- Where are the emergency air shutoff valves located?
- How do we contact emergency medical services from this worksite?
- What should you do if a hose begins whipping or equipment fails?
- Why do air injection injuries always require immediate medical evaluation?
- Who is responsible for reporting compressed air incidents?
- Speak up immediately if you notice damaged equipment or an emergency situation developing.
Stop Work If
- A hose, fitting, or compressed air component fails or becomes uncontrolled.
- A worker suffers an air injection injury, eye injury, or other serious injury.
- Compressed air equipment cannot be safely isolated.
- Pressure control devices fail or the system becomes unstable.
- Required emergency procedures cannot be carried out safely.
- You believe continued operation presents an immediate danger to workers.
Final Reminder
Compressed air emergencies require immediate action. Stop work, isolate the air supply if it is safe to do so, protect others from additional hazards, and obtain prompt medical attention for all serious injuries—especially suspected air injection injuries. Never place yourself at risk while responding to an emergency, and never return damaged equipment to service until it has been properly repaired and inspected.
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