[Type here]

Rensselaer Motorsport Shop Rules

Team Leaders
Advisor: Kaitlyn Lounsbury (518) 526-5805
Team Leader: Tim Rice (339) 203-2234
Facilities and Safety Manager: Henry Chickering (508) 740-2499
Commented [H1]: and the rest of em too

Table of Contents Commented [KL2]: Insert Table of Contents

Contents
Table of Contents .................................................................................................................................... 1
General Emergencies and Injuries............................................................................................................ 1
Disclaimer ............................................................................................................................................... 2
General Safety Practices .......................................................................................................................... 2
Cleanliness and Shop Courtesy ................................................................................................................ 4
Machines and Power tools ...................................................................................................................... 5
Welding ................................................................................................................................................... 5
Chemical ................................................................................................................................................. 6
Composites ............................................................................................................................................. 7
Dynamometer ......................................................................................................................................... 8
Electronics............................................................................................................................................... 8
Faculty .................................................................................................................................................... 9

General Emergencies and Injuries

Report all injuries and emergencies to team leaders. If leaders are not immediately available,
report to other shop members.. If an injury or hazard needs prompt attention:

Call Public Safety at campus phone: (518) 276-6611

Use emergency action by calling: 911

1
[Type here]

In case of fire or hazardous chemical spill evacuate the premises immediately and call public
safety.
Evacuation is the goal - fire extinguishers are intended for shop egress only.

a. Do not attempt to move an injured person unless there is imminent danger to life.b. Do
not attempt to clean up any blood or bodily fluids, under any circumstances. Call Public
Safety.

c. First-aid kits and fire extinguishers are located in the shop and it is good practice to
become familiar with their locations.

d. The eye wash and shower station is located outside of the cage. When facing the cage door it
is to your right. The shower is painted bright orange.

e. If a harmful situation seems present when entering the shop (excessive vapors, smoke, heat,
smells, etc.) leave immediately and do not attempt to remedy the situation. Contact the
appropriate authorities listed above.

Following an emergency or injury, the Facilities and Safety Manager, Henry Chickering must be
notified. If the injury requires medical attention, a Rensselaer Incident Report must be generated
and submitted within 24 hours of the injury being sustained. Additional near-accidents should be
logged internally with the Facilities and Safety Manager.

Disclaimer
It is the responsibility of every team member to read and abide by these rules. A member is not allowed
to work in Bumstead Garage until he or she has completed the SOE and MANE Safety quizzes, and
submitted the 100% scores to the team Safety Manager. These will be made available through LMS and
must be completed at the beginning of each semester. It is the responsibility of the member to contact
the Safety Manager to obtain the quizzes.

Team members entering Bumstead Garage agree to follow the rules laid out in this Manual, posted
outside of the Cage area, in accordance with SOE, MANE, and EH & S.

At any point in time, if a team member is acting unsafely, they may be removed from the shop by a
member of Team Leadership.

General Safety Practices

2
[Type here]

The following rules apply to any and all work done in the shop. Any person(s) not following proper
safety practices must amend their behavior or will be asked to leave. The shop will only be
opened with two people present. One or more of which are required to be a current or former
team leader.

a. DO NOT OPERATE ANY MACHINES if your abilities are impaired for any reason (personal
illness, lack of sleep, drugs or alcohol).
b. Use of tobacco products, alcohol, and illegal substances is prohibited in and on the grounds
surrounding Bumstead garage.
c. Cell phone use is permitted in shop areas, but not allowed while operating a machine or
power tool.
d. Long hair, loose clothing, neckties, dangling jewelry, hoodie strings or headphone cords
must be removed or pulled back when in the shop.
e. Safety glasses with side shield protection must be worn in the shop area at all
times. Persons not wearing safety glasses will be asked to leave. Glasses with OSHA
approved (shatterproof) lenses and side shields are permitted.
f. Open-toed shoes (high heels, sandals, flip-flops) are not allowed in the shop. Only closed-
toed shoes are allowed. Shoes with open tops (ballet flats may be subject to this rule at the
discretion of the Facilities and Safety Manager.)
g. Hearing protection is strongly recommended for louder projects.
h. Wear gloves when appropriate – for heat or cut protection. Gloves are never appropriate
when operating a rotating tool or machine, including a grinding wheel, mill, or lathe.
i. The use of a respirator is strictly regulated. No work should be planned that requires the
use of a respirator. Note that an N95 particle mask is considered a respirator under the
Rensselaer Respiratory Protection Program.

j. Be aware of your surroundings and peers to avoid bumping into someone working a
machine; no running in the shop.
k. A 2-pronged outlet or transfer attachment is never appropriate for a 3-pronged hookup,
as this eliminates the ground needed for the tool or appliance.
l. Heavy-duty (outdoor) extension cords are permitted if inspected and the casing is intact
(no cuts or exposed wiring), and may not be used longer than 1 day (not permanent).
m. Light-weight (indoor) extension cords may not be used, under any circumstances.
n. Computers and other electronics may be plugged into surge protector strips for extended
times.

o. It is advised that backpacks and coats go in the office or outside of the cage while one is
at Bumstead.

3
[Type here]

p. If a medical supply or first-aid item is low, empty or missing, inform a member of the
leadership or Facilities and Safety Manager. Commented [H3]: title

Cleanliness and Shop Courtesy

a. Regulatory codes require an open shop floor and 36” of free space around circuit
breakers. When leaving the shop, ensure the floor is free of clutter and that no items are
left in or around the taped zones for circuit boxes. A clear path to the breakers must be
maintained at all times.
b. All flammable or combustible liquids, aerosols, paints, or organic compounds must be
stored in the marked cabinets.
c. Do not vandalize shop furniture/items, treat all tools as if they were your own –
replacement affects everyone else using the tool. Report a broken tool to the Facilities
and Safety Manager so it can be replaced. He will perform the necessary tag-out to Commented [H4]: title

remove the tool from service. Commented [H5]: lol

d. If the shop is missing a tool or runs out of a material, inform the Facilities and Safety also gendered wording wOAh
Manager. Commented [H6]: title

e. All tools and materials should be returned to their designated locations when work is
finished.

f. Calipers are precision measuring devices, not tools, and should always be cleaned and put
away when they are no longer in use.
g. Drill bits go back in the correct drawer, use calipers to measure the bit from land to land
(the shank of the bit is not the size of the hole it drills) if you’re not sure of size.
h. If you do not know where a tool goes, ask a team member.
i. Tools do not belong in pockets and should not leave the shop.
j. Clean up work stations before your departure at the shop at the end of the day.
k. Shop cleanups are scheduled at the discretion of the Facilities and Safety Manager or
Facilities and Safety Manager. Attendance is mandatory for all full members. If a full Commented [H7]: title

member cannot attend a shop cleanup they should contact (email, slack, text) the
Facilities and Safety Manager with the reason why they cannot attend. Commented [H8]: title

l. Doing personal or school projects at the shop is encouraged, but keep in mind that team
members working on racecar projects have priority on machines and shop space.
Members are expected to spend the majority of their time in the shop working on projects
for the team. If a member is in violation of this they may be asked to leave. Commented [H9]: how do say better

m. Backpacks and coats should not be left in the shop. Leave them outside the cage or in the
office area.
n. Liquid spills may present a slip danger.

4
[Type here]

Machines and Power tools

Unless you have been fully trained by our team, do not attempt to use the machines or adjust
them in any way. If you want to be trained on machines, ask someone to train you.

Many hazards exist in a machine shop. You are expected to exercise caution at all times, and think
before every action. Your behavior affects the entire team.

Commented [H10]: this isnt how we do it

a. A machine may not be left running unattended. Turn off machines when leaving. its basically "recieve informal training and then rip it. ask questions
as you have them"
b. Do not distract people operating machines, which include speaking to them. If you must
talk, bring machinery to a complete stop first. But idk if thats okay with anyone else....
Its better than what you get in processees so I dont really think its
c. Only one person is allowed to operate a machine at a time. Additional assistance, such as wrong

spraying coolant on a part, is allowed if the assistance is wanted by the machine operator. Commented [H11]: this seems a bit overkill...
Commented [H12]: this is needed sometimes so having it say
d. Powered projects may not be left running alone. Should long-term testing be required, it "only one person" seems like it could get us in trouble over bullshit
must be arranged in advance of the planned work. The work must be discussed on a case-
also the wording is a bit funky
by-case basis, and given permission from the Facilities and Safety Manager.
e. When using any machinery or power tool, including the lathe, mill, or drill press, do not
put your hand in the proximity of the rotating machinery or work piece until it has stopped
spinning
f. Manufacturer-recommended safety precautions and machine-specific practices must be
followed when operating certain power tools. This includes using guards for open-disk
rotating machinery, such as an angle grinder.
g. Fabrication or modification of pressure vessels by student, staff, or faculty is not allowed.
Use of commercially available pressure vessels within their manufacturer-rated
operational range is allowed. .

Welding
Unless you have been fully trained by our team, do not attempt to use the welder or adjust it in any way.
If you would like to be trained to weld, ask the pertinent team member.

a. Always weld with the fume hood on.

b. Do not weld while wearing polyester, nylon or other plastic-based fabrics, as they may
melt to the skin and produce burns. This includes tennis shoes or other footwear made of
these materials, leather boots or shoes are recommended.
c. Never bother someone who is welding. This is dangerous not only to them but everyone
in the fabrication area. Wait until their mask is up to ask them a question.

5
[Type here]

d. Do not watch weld arcs, or their immediate reflections, without eye protection of at least
shade 10 (as dark as a welding mask). Failure to protect your eyes will result in their
damage or loss.
e. Do not handle or move any welding equipment or piece (object being welded on) without
explicit instruction to do so from their fabricator. They could be hot or fragile.
f. Carbon fiber conducts electricity and is poisonous when burnt. Special precautions must
be followed when welding near carbon fiber. Ask an experienced welder for further
information.
g. Coated metals are not allowed to be welded in the shop (e.g. galvanized, zinc coated).
Thoroughly remove the coating if you wish to weld them.
h. Do not weld any component (or car) that is wired or instrumented in any way. This will
lead to damage to expensive components, or catastrophic and dangerous cross-
grounding.
i. If you empty an argon tank, tell the Facilities and Safety Manager or team welder. Commented [H13]: title

j. Once you have finished with the welder, untangle all of the cables and wrap them up
neatly away from traffic areas.
k. Shut off welder, completely close argon tank, and turn off fume hood when done welding.
l. If you have been fully trained by our team, you are welcome to practice welding under
the following circumstances:
a) The welder you are using is not needed to work on racecar components
b) We are not rationing welding supplies (tungsten, filler rod, argon) Commented [H14]: these are lifted directly from our "posted
on the cage" shop rules, funny.

Chemical
a. You should know how to use a chemical safely and dispose of it properly whenever using
one. Review the specific SDS and Laboratory Chemical Hygiene Plan for proper disposal
procedures. The right time to figure out how to prepare for and use a chemical is before
ordering it. The Facilities and Safety Manager must be notified prior to purchase. Commented [LKR15]: title

b. Safety Data Sheets (SDS) are available on line through MSDSonline

at www.msdsonline.com. A copy of the sheet is also available in the shop.
c. All chemicals must be clearly labeled by content, written in their full name in English. An
abbreviated, chemical formula or molecular structure label does not satisfy this
requirement.
d. Volatile, flammable, and other toxic or odor-producing chemicals must be stored in the
designated cabinets.
e. Do not drain-dispose any chemical without first consulting Environmental Health & Safety
(EH&S).

6
[Type here]

f. To reiterate, no chemicals should be used that require the use of a respirator.

g. Oil soaked rags or rags with any type of solvent are to be disposed of in proper containers.
Do NOT dispose of these items in regular trash containers.
h. Hazardous or regulated materials such as batteries, computer components, and chemical
reagents must be disposed of properly. Notify the Facilities and Safety Manager if dealing Commented [H16]: title
with their disposal.
i. All chemical and material hazards, including spills and incidental events, are to be dealt
with in accordance with the Hazardous Materials Contingency Plan drawn up by
Rensselaer. Commented [H17]: we need to get a copy of this I guess

Composites
In addition to being subject to the Chemical policy above composites have the following rules:

a. Do not begin a layup before presenting its purpose and your plan to the appropriate team Commented [H18]: titles?
Design Leads ?
leader. It is a lengthy process, so be sure to schedule a time and location to work. When
leaving a layup, provide a note that includes: contact information, timeframe expected
for the composite to set, your expected return time, and any other important notes about
the layup.

b. When working with resin, wear eye protection, gloves, long pants and long sleeves. Check
the SDS of the resin before use to ensure proper Personal Protective Equipment (PPE),
and always work in an area with good ventilation.
c. Be aware of the pot life of the resin you are working with, and proceed accordingly.
Always mix resin and hardener to the proper ratio, if you do not know the ratio, consult
its data sheet, the manufacturer, or a team leader.
d. When cutting/sanding cured layups, always work under an engineering controlled particle
hood, wear eye protection, and cover any exposed skin. Always wet out the sanding
surface to cut down on freed dust particles.

e. If you are running the vacuum pump, you are responsible for checking pressure, oil, etc.
regularly. Notify others working in the area that you are running the pump.
f. Do not shut or unplug vacuum pump before consulting the person running it.
g. Change vacuum pump oil regularly.
h. DO NOT leave/store other projects or scrap in the composite corner.
i. Return all tools, tape, vacuum putty, resin, etc. to their home after use.
j. Clean mixing cups, reusable mixing sticks and spatulas properly after each layup.
k. If a material is running low or is out (gloves, carbon, resin, bagging, peel ply, etc.), notify
the Facilities and Safety Manager. Commented [H19]: title

7
[Type here]

Dynamometer
a. While the car is running on the dyno, everyone in the engine dyno area should
be wearing hearing and eye
b. Stay out of the dyno area unless you have permission from the engine group
leader. We need to be able to move quickly around the car if something goes
wrong.
c. Be alert for signs of issues. If you see anything of concern inform the engine
group leader or current calibrator.

Electronics
a. To reiterate, safety glasses must be worn at all times, including soldering. Avoid flicking
the soldering iron to remove excess material.
b. When working on high voltage (24V or greater) all members of the shop must be aware
and keep their distance. This is similar to when members are welding.
c. High voltage work must be approved by the team advisor .
d. High voltage gloves and rubber mats must be used at all times when working on exposed
high voltage elements and accumulators. Commented [H20]: we dont have these, the "one hand" rule
(H) works perfectly well here. also dont be an idiot applies.
e. Synthetic fiber-based clothing (such as polyester) may not be worn when working with
high voltage. Additionally, conductive jewelry (rings and watches) must be removed.
f. You must ground your lines before working with high voltage systems.
g. Do not work on electronic circuits when power is on, unless it is absolutely necessary. Low
power analog and digital circuitry (i.e. ≤ 250 mA) is the ONLY exceptions to this rule
provided the power supply or battery is fused at 1 amp or less. Commented [H21]: this sounds reasonable but IDK if you could
consider troublehsooting the car harness to be in violation of this
h. Use the one-handed rule (only one hand touching circuit at any given time) when working given that sometimes you do it when the car is on and when the car
is on you can draw like 200,000 mA of current when you are
on active circuits. Electric currents of less than 50-100 milliamps can cause death. running the starter motor.
i. A battery may not be left charging alone, for any reason. No exceptions.
j. Batteries and power supplies must be fused appropriately to ensure safety of the
operator.
k. All batteries must be manufacturer labeled and their battery chemistry (type) listed.
l. Any batteries not of the standard consumer type (e.g. AA, AAA, C, D, 9v, 6v lantern
battery, etc.) must be approved by the team advisor or a faculty member. This includes
the Lithium-based battery types: “Lithium”, “Li-po”, “Li-Ion”, “Lithium-Polymer”, “MnO2-
Li”, etc. Commented [H22]: again, we run our own shop and make our
own educated decisions. this seems unreasonable
m. Never charge a battery without first knowing the specific precautions and procedures to
take for its chemistry and power source. NEVER attempt to charge a non-rechargeable
battery.

8
[Type here]

n. Capacitors (electrolytic and large) hold their charge for several hours. Be sure they are
discharged with an insulated clip lead before working on the circuit.
o. Semiconductors and other circuit components may become hot when in use, exercise
caution when removing them from an operational circuit.

Faculty

Kaitlyn Lounsbury – Team Advisor, Associate Advancement Officer

Location: HAH 2nd Floor
Email: Lounsk2@rpi.edu
Office: (518) 276-4132
Cell: (518) 526 5805

Randy McDougall – Technical Manager, Safety Specialist

Location:,JEC 1201
Email:mcdour@rpi,edu
Office: (518) 276-2391

Leon Golinski – Maintenance Mechanic, Lead/On-Site Caretaker

Location: Bumstead Garage, 2368 Burdett Ave.
Email: golinl@rpi.edu
Office: (518) 276-6238
Cell: (518) 376 0792