Compressed air is a safe, versatile form of energy that can provide power to a wide variety of high-powered tools in the workshop. Unfortunately, air compressors also present a significant source of danger in the shop when they aren’t operated correctly. When working with air compressors, you must be aware of your surroundings always and operate them correctly and safely.
*AIR COMPRESSOR WARNING*What are some common dangers of air compressors? Compressed air is powerful enough to cause severe physical injuries if misdirected or used without proper caution. Common dangers of air compressors include the following:
Tissue injury
Eye injury
Internal damage
Fire hazards
Electrical hazards
Explosions
Carbon monoxide
Noise
Tripping
Learning how to operate an air compressor safely can help you avoid these dangers. Keep reading to find out more about the dangers associated with air compressor operation and what you can do to prevent them.
9 Common Dangers of Air Compressors and How to Be Safe
There are many dangers that people face when using air compressors. With air compressors being a staple in many workshops and industrial places – and even the average DIY-ers project station – knowing how to avoid the dangers of air compressors is crucial. The following sections discuss the different air compressor hazards that you may face and how to avoid them.
Common Dangers of Air Compressors – Bodily Harm
When used as intended and in a functional state, air compressors are not a dangerous piece of equipment. However, if mishandled or suffering from malfunction, they can be one of the most hazardous pieces of equipment in the entire shop.
Compressed Air Pressure and Tissue Injury
You wouldn’t normally think of air as being powerful enough to break skin, but skin contusions and tissue injury are easily possible with the levels of air pressure generated by an air compressor.
The amount of air pressure necessary to break human skin is only 100 psi. While smaller compressors used to run household pneumatic drills and other small equipment rarely get over 90 psi, larger air
compressors such as those used in manufacturing or automotive repair equipment can reach air pressures of 150 psi or higher.
It isn’t odd to see someone playfully aim a blow dryer, hose spray attachment, or another piece of equipment projecting water or air towards a person because these elements are not seen as being dangerous when they come in contact with people. But if you add high pressure to air or water, you are left with a powerful force that can cause a ghastly accident if misdirected.
Compressed Air Pressure and Eye Injury
A severe potential injury involved with air compressors is their threat to the human eye—unlike skin, which requires 100 psi to be broken by the force of compressed air, a person’s eye can be accidentally blown from its socket at only 12 psi—this means that playfully aiming an air compressor’s output point at someone’s face could permanently blind them in an instant.
While most people know better than to point an air compressor at a person’s face on purpose, this accident can still happen if a strong stream air is deflected off of an objected at close range or at a person’s unprotected eyes. It can also occur if an air compressor is accidentally switched on by another person in the shop while it is being inspected at close range by another operator.
Situational awareness and communication while working around high-powered equipment like air compressors is an integral part of preventing tragic (and even deadly) industrial accidents related to high air pressure equipment.
Compressed Air Pressure and Internal Damage
Because most of our contact with generated air current in daily life is with low air pressure equipment such as fans, A/C units, or (at most) a leaf blower, many people don’t think of air as an element that is deadly in a workplace environment like fire or electricity. But air that has been compressed is capable of doing massive internal damage to the human body.
If high-powered air is introduced to the interior of the human body, it can cause the following deadly medical consequences:
Vascular air embolism: A vascular air embolism is when bubbles of air are introduced to the bloodstream, where they can cause sudden cardiac arrest or a stroke. A pulmonary embolism is a high-risk medical condition that can often lead to death.
Intestinal rupture: If high-powered air is introduced to the human body through the mouth, navel, or rectum, this air can quickly rupture the digestive tract once it makes its way into the intestines, leading to internal bleeding.
Like a blacksmith’s forge or a high-voltage welding unit, air compressors must be treated like the dangerous piece of equipment they are to avoid potentially causing a life-threatening injury in the workshop. It is the responsibility of workers, hobbyists, and employers to ensure that everyone who operates air compressors does so with an understanding of how dangerous they can be to the human body.
It is easy to underestimate the power that an air compressor is capable of producing. However, underestimating that power can easily lead to injury or death if air compressors are misused.
How to Prevent Bodily Harm While Using Air Compressors
To avoid a deadly injury while using air compressors in the workshop, observe the following rules of conduct:
Never deliberately point an air compressor output at another person in the shop under any circumstances, regardless of whether it is currently being operated.
Do not operate an air compressor without protective equipment such as gloves and safety goggles.
Be aware of the risk of bodily harm while using air compressor equipment and treat it with caution, working carefully and slowly in the shop to avoid accidents. Always use situational awareness to avoid accidentally aiming an air compressor at another person in the shop.
Air compressor safety to avoid bodily harm involves treating the air compressor like the high-powered piece of machinery it is, rather than a toy. As long as air compressors are treated with respect, they can be one of the most valuable tools in the workshop.
Common Dangers of Air Compressors – Fire Hazards
Like many other pieces of equipment in a workshop environment, one of the most common dangers associated with air compressors is their ability to start a fire inadvertently. This can be the result of several problems:
Oil leaks in the air compressor system: Since oil is flammable, an oil leak in the air compressor system can lead to a fire if exposed to sparks, either from an electrical short in the air compressor system or from associated workshop activities such as welding.
A high-pressure explosion: Because the air in an air compressor itself is highly flammable and highly pressurized, any combustion caused by a malfunction in the air compressor system can lead to a fiery explosion.
An electrical short: Electrical shorts in the air compressor system cause arcs of electricity that can ignite nearby flammable materials or combustible liquids and gases in the workshop environment. Electrical shorts can cause a fire, whether someone is in the workshop at the time or not.
Direct exposure to combustible or flammable materials: The heat generated from an air compressor can catch fire if flammable materials are left near the machine.
There are many ways you can prevent a fire hazard in the workshop related to the air compressor system. The most important thing is to make sure that the workshop is clutter-free and that there are no potentially combustible or flammable materials left near the air compressor area.
The second most important thing is to make sure that all air compressor equipment is maintained to prevent defects that increase the risk of fire. Do not operate an air compressor that is leaking oil, has a known electrical fault, or is in a position to overheat.
Here are some other methods you can use to ensure fire safety in the workshop while using air compressors:
Install a smoke and carbon monoxide detector in the workshop.
Make sure that there are fire extinguishers available in the workshop in case of an explosion or fire.
Inspect all air compression equipment before use, every single time it is operated. Assess the workshop for fire hazards and remove them before starting up the air compressor.
The threat of an air compressor related fire is rare, but the consequences are potentially tragic. Make sure to follow strict safety protocols while operating air compressors to prevent an accident.
Common Dangers of Air Compressors – Electrical Hazards
Air compressors are an electrical piece of equipment in the workshop, which means they contain many of the same dangers as other electrical pieces of equipment such as generators or table drills. Electrical dangers involving air compressors come in two primary forms: electrocution and fire hazard.
The threat of electrocution with an air compressor is relatively low, provided that the air compressor is operated carefully. However, maintenance of the air compressor is essential for preventing electrical shorts and other malfunctions that could potentially injure the operator or spark a fire.
Electrical fires are one of the most dangerous risks in a workshop since workshops are typically adjacent to residential or communal areas, so these fires can spread and trap others. Electrical fires can also occur in the middle of the night, leading to injury or massive property damage and loss.
How to Prevent Electrical Danger While Using Air Compressors
Remaining clear of the dangers involving air compressors and electricity mostly involves following some common–sense rules around the workshop that apply to all electrical equipment, such as:
Do not operate the air compressor with any of its electrical panels or covers opened to expose the wiring underneath.
Avoid wet conditions. Don’t operate an air compressor in a wet area, which might cause electricity to travel and electrocute the operator.
Make sure that the air compressor is only operated from an electrical outlet that has been grounded. Without proper grounding, the air compressor is at risk of electrical shorts and fire.
The air compressor’s power cord should be regularly inspected for fraying before operation to help prevent the risk of an electrical short. If the cord is damaged, it should be replaced or repaired.
Do not attempt to service, break down, or clean the air compressor system unless it is unplugged from a power source.
Using non-conductive gloves such as welding gloves can prevent stray shocks in case of an electrical malfunction in the air compressor.
If you encounter a person in the workshop who is being shocked, immediately shut off the breaker to remove the source of power or—if unavailable—grab the nearest non-conducive material and get them off the circuit.
Good examples of non-conducive materials that work in a pinch are extension cords,
soled shoes (kick their hand away from the source of the shock), a wooden handle, or a plastic tarp.
Immediately call 911 or other emergency services.
When operating heavy–duty electrical equipment in the shop, the most important thing is to make sure that equipment is adequately maintained and is operated per the manufacturer’s instructions. Ensure that an electrical outlet’s output is compatible with an air compressor’s electrical requirements before plugging it in to prevent potentially dangerous electrical malfunctions.
Common Dangers of Air Compressors – Explosions
Another serious risk of working with air compressors is the threat of the air compressor tank or the air compressor tool itself exploding as a result of the high-pressure environment it is operated under.
Explosions in the air compressor system can result from a variety of causes such as the following:
A weakened air tank
A damaged or disabled safety pressure valve
A spark from an electrical short near flammable materials
An exploding air compressor not only serves a danger to any nearby operators from the resulting shrapnel or fire, but it also serves as a more significant fire hazard since an air compressor explosion has the potential to spin out of control quickly, depending on what kind of environment the air compressor is being operated in.
Several workshop practices can be put into place to help avoid air compressor explosions. Here are some of the things that can be done to prevent them:
Air compressors should be kept more than twenty feet away from any flammable aerosol that is being sprayed in the workshop.
The safety air pressure valves on an air compressor should never be tampered with, rigged, or removed. All air compressor repairs should ideally be undertaken by an experienced professional who specializes in air compressor repair to prevent accidental damage to the machine or injury to the operator.
Air compressors require consistent ventilation to prevent overheating, which is a risk for both fire and explosions. Always make sure the air compressor’s ventilation system is unobstructed, and the air compressor is operated in ambient temperatures that do not lead to overheating.
Air compressor tanks, valves, and hoses should be regularly inspected for rust or other defects that could potentially cause the air compressor to blow out. Aging or damaged components should be repaired or replaced as needed. Damaged tanks should always be replaced outright.
Attachments should not be added to the air compressor that exceed the pressure requirements of the compressor itself. Make sure all hoses, fittings, and replacement parts have a PSI rating that is equal to or exceeds the PSI rating of the air compressor system.
Be sure to gradually bleed air from the system before performing service or maintenance to prevent large fluctuations in air pressure within the system.
Preventing an explosion when using air compressors mainly comes down to safe workshop practices and following the instructions on how to use the compressors. Treating the equipment with a lack of respect or trying to alter it without adequate experience are two scenarios that can have tragic consequences when it comes to air compressors.
Common Dangers of Air Compressors – Carbon Monoxide
Electrical air compressors pose a risk for fire and explosions, but gas-powered air compressors pose their own set of safety risks. One serious risk is the risk of carbon monoxide poisoning if a gas-powered air compressor is used in an enclosed space. Carbon monoxide is generated by the burning of fuel and by combustion engines.
Air compressors can be used safely indoors, but gas-powered air compressors should not be used without adequate ventilation to prevent the build-up of carbon monoxide. Carbon monoxide is a colorless, tasteless, odorless gas that can quickly cause the following symptoms in a matter of minutes:
Disorientation
Headache
Nausea
Unconsciousness
Coma
Death
Carbon monoxide is also dangerous because it is a threat to workshops that are attached to residential homes by conventional ventilation systems. Many people are accidentally poisoned by carbon monoxide in their sleep. Garages and workshop areas are another common location associated with carbon monoxide poisoning since they are often enclosed and house gas-powered equipment, such as heaters and air compressors.
The most significant risk associated with carbon monoxide poisoning in the workshop with air compressors is that by the time a person realizes that they’ve been poisoned by carbon monoxide, they are often too sick and mentally confused to remove themselves from the room before passing out. This quickly leads to hypoxemia and death from oxygen deprivation.
Because of the annoying noise associated with air compressors, other people in the workshop area or household may not stop to check on the air compressor operator until it’s far too late to help. Even if they do manage to discover a person who is poisoned by carbon monoxide, the carbon monoxide can quickly affect potential rescuers as well once it has built up in an enclosed space.
The best way to prevent carbon monoxide poisoning is to operate air compressors in an open–air environment or an indoor environment with reliable ventilation. All workshops and residential areas should also be outfitted with carbon monoxide detectors since many other common household appliances can also lead to dangerous levels of carbon monoxide if they malfunction.
Common Dangers of Air Compressors – Noise
It isn’t as dramatic as some of the other dangers involved with air compressors, but the noise levels that air compressors operate at are generally considered dangerous to human hearing. The more powerful an air compressor is, the more likely it is to be loud—most air compressors range between 40 and
90 decibels.
People who operate lower-powered air compressors or those that are designed to be deliberately quiet may not be at serious risk. However, for those people who operate industrial air compressor units, hearing damage is a severe threat. Hearing damage and loss occurs at 85 decibels or higher. Unfortunately, the cumulative hearing loss as the result of noise exposure may not be completely
evident until later in life, where it can cause serious quality of life issues.
This means that repeated exposure to the noise generated by an air compressor without protective equipment such as earplugs can lead to life-long hearing problems such as deafness (partial/total) or chronic tinnitus (constant perceived ringing noise in the ears).
Preventing noise damage from an air compressor is as easy as wearing earplugs or industrial ear muffs for hearing protection while operating loud machinery. This is protective equipment that should be readily available in the workshop area already if you’re operating other heavy equipment, such as drills.
Common Dangers of Air Compressors – Tripping
Like noise, the tripping hazard associated with air compressors isn’t one of the more gruesome dangers, but it’s one of the ones that you’re more likely to run into as a daily operator of an air compressor system. Chances are you’ll run into many more techs who have tripped and fallen in the workshop than you will ones who have survived an electrical shock or an air compressor explosion.
While a broken arm from tripping over an air compressor hose may not as dramatic as having your eyeball blown out of its socket by one, it’s still bound to be very inconvenient if it happens, especially if using heavy workshop equipment is how you make your living. Falling accidents can also be deadly in and of themselves. Falls are the second most common form of death related to unintentional injury next to car crashes.
Since air compressors are often operated around hard concrete or cement floors and sharp or pointy metal objects such as jutting workbenches corners and alignment racks, it’s crucial to keep air compressors in mind as a trip hazard. The potential for being badly injured while tripping in a workshop (especially if carrying a tool) is much higher than it is for tripping elsewhere.
Preventing a nasty trip while working with air compressors in the workshop is as simple as cleaning up after yourself. Making sure that all air compressor hoses are put away between uses or are stored on a wall hook will not only prevent someone from tripping on them, it will also allow operators to carefully inspect their hoses before and after each use to catch potential problems.
Can an Air Compressor Kill You?
The answer is yes, an air compressor can absolutely kill you. The pressures that are generated by an air compression system can cause life-threatening injuries, including the following:
Blindness
Skin contusions
Internal bleeding
Vascular air embolism
In fact, in 2018, this highly publicized case from Japan covered the death of a 46-year-old worker in a manufacturing plant after his coworker shot air from an air-compressor down the back of his pants as a joke. This ill-fated prank led to the death of the worker from internal hemorrhaging related to the high-powered air that had been forced into his body.
The young man who caused Akio Ishimaru’s death did not understand the common dangers presented by air compressor operation or how powerful these machines are while in use, which is why learning about how to prevent these kinds of accidents in any workshop where air compressors are operated is
crucial to saving lives.
Air compressors are a very powerful form of machinery, and misusing them can lead to death in a matter of minutes. This is why they should be treated with the same amount of respect as a high-voltage generator or any other high-risk piece of workshop equipment.
Safe operation of air compressors is generally not dangerous, but they are easy to underestimate. To avoid death, workers who operate air compressors should completely understand what they are capable of doing to the human body.
Avoiding Air Compressor Danger is About Prevention
Air compressors are a force to be reckoned with. However, they don’t have to be dangerous in your workshop as long as you make sure to follow basic air compression safety procedures, keep a tidy workshop, and treat your equipment with the respect it deserves. Almost all workshop accidents can be prevented by using common sense and caution while operating heavy machinery.
As long as you are meticulous about air compressor safety and recognize the potential dangers that air compressors can present, there’s no reason you should ever have to deal with an air compressor related accident in your workshop or home.