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702 Effective Accident Investigation
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Surface Cause Analysis

The surface causes of accidents are the unique hazardous conditions and unsafe or inappropriate behaviors that occur during the sequence of events, contributing in some way to the accident.

Unguarded lower blade and arbor end of radial saw. Source: OSHA.

Hazardous Conditions

Let's look at some characteristics and examples of hazardous conditions:

  • Are unique things or objects that are somehow defective or unsafe
  • Employee physical or psychological conditions such as fatigue or stress
  • May also be unique defects in processes, procedures or practices
  • May exist at any level of the organization
  • Are the symptoms of deeper root causes

Hazardous conditions may exist in any of the categories below.

  • Materials
  • Machinery
  • Equipment
  • Tools
  • Chemicals
  • Environment
  • Workstations
  • Facilities
  • People
  • Workload
  • Equipment: Malfunctioning or poorly maintained forklifts leading to potential collision or tipping hazards.
  • Machinery: Unshielded moving parts on conveyor belts that can cause entanglement injuries.
  • Tools: Worn-out or damaged power tools that may overheat, short-circuit, or cause electric shocks.
  • Chemicals: Improper storage of flammable liquids that increases the risk of fire or explosion.
  • Facilities: Poorly lit stairways or walkways that increase the likelihood of slips, trips, and falls.
  • Electrical Systems: Exposed wiring or overloaded circuits that pose a significant risk of electrical fires.
  • Confined Spaces: Limited ventilation in confined spaces that can lead to oxygen deficiency or the buildup of toxic gases.
  • Pressure Vessels: Faulty pressure relief valves on boilers or tanks that could result in explosions.

Knowledge Check Choose the best answer for the question.

6-5. You are conducting a surface cause analysis related to a recent accident. Where should you look for potential hazardous conditions?