OHS in Timber and Sawmill Workshops

Sawmill safety: from log to dry timber

Timber is the raw material of furniture and wood product manufacturing, and timber is produced by sawing logs in a sawmill, stacking and drying them. Sawmill safety is therefore not the safety of a single machine but of a chain in which a heavy, irregularly shaped material is moved, cut and stored from start to finish. Woodworking businesses in Bursa, above all in the İnegöl Furniture and Woodworking Specialised OIZ (organised industrial zone) and the surrounding workshops, are either a link in this chain or its customer.

Stage	Main hazard	Typical incident	Basic measure
Log unloading and yard	Rolling, crushing	A log slipping as a binding strap is released	Chocks, safe unloading zone, pedestrian separation
Band saw and carriage	Cutting, trapping	Removing sawdust from the saw by hand, being struck by the carriage	Adjustable guard, perimeter guarding, lockout
Edging and cross-cutting	Cutting, kickback	A workpiece being thrown on a circular saw	Riving knife, push stick
Timber stack	Collapse, falls	A stack collapsing while being picked up by forklift	Level ground, regular sticking, height limit
Drying kiln	Heat, humidity, confined space	Entering a kiln with fans running or at high temperature	Isolation, cooling and ventilation, door that opens from inside

Log handling and the log yard

During log handling, logs rest against each other; the movement of a single log can set the whole pile in motion. Therefore:

When a lorry is unloaded, binding straps are released from the side opposite the one where the load could fall, and while a vehicle controlling the load is ready.
In the unloading and stacking zone, the side towards which logs could roll is marked as a prohibited zone; no one stands between a log and a vehicle or wall.
Logs on the ground are secured with chocks or wedges and stored on level ground wherever possible.
In areas where a log grapple or forklift operates, pedestrian routes are physically separated. For planning, see our article on the forklift and pedestrian traffic plan in warehouses, and for the operator's start-of-shift check, our article on the forklift operator's daily check.

In the winter months, mud and ice increase slipping in the log yard; ground conditions and suitable work footwear should be checked separately in this period.

Cutting timber with a band saw

In band saw timber sawing, the log advances towards the saw on a carriage. The risks are concentrated in the saw itself, the carriage travel area and saw maintenance:

Saw guard: Except for the section needed for cutting, the saw blade and wheels must be enclosed. The guard at the cutting zone is adjusted to the height of the log; a guard left in its highest position leaves most of the blade exposed.
Carriage travel area: Trapping gaps form between the log carriage and fixed structures. The carriage travel area is enclosed with fencing or guardrails; the operator does not intervene on the log without leaving the control position.
Sawdust and jammed pieces: While the saw is running, sawdust is not removed by hand and jammed pieces are not pushed by hand. The machine is stopped and the blade is allowed to come to a complete stop.
Blade change and tension adjustment: These jobs are done with the power isolated and lockout-tagout (LOTO) applied. A band saw blade can break; wheel covers must be strong enough to contain a broken blade.
Saw sharpening: For grinding machine guards and eye protection during sharpening and deburring, see our article on grinding machine safety.

Cross-cutting and edging sawn timber on a circular saw is a separate risk group; our article on circular saw and planer safety gives detailed information on kickback, the riving knife and push sticks.

Timber stacking: collapsing stacks and snapping straps

Timber stacking is the basis of drying and storage, but its balance is easily upset. For stack safety:

The stack is built on firm, level ground with even bearers.
Stickers between layers are placed in a vertical line, directly above the bearers. Misaligned stickers bend the stack and set it up to collapse.
Stack height is determined in the risk assessment according to the stack base, the ground and the forklift or loader used, and is marked on site.
Sufficient aisles are left between stacks for forklifts and pedestrians; workers do not climb onto stacks.
Package straps are under tension; when cut, they whip. The strap is cut from the side with suitable shears, and no one stands in front of the package.

For block stacking and pallet rules, see our article on block stacking and pallet rules.

Drying kilns: heat, humidity and confined space

In drying kilns, timber is dried with hot, humid air. The inside of a kiln is dangerous because of high temperature, humidity, running fans and large doors that close:

Before entering the kiln, heating and fans are stopped and locked out; the kiln doors are opened for ventilation and the internal temperature falls to a workable level.
The kiln door is not closed without checking that no one is left inside; an arrangement allowing it to be opened from inside is provided.
The ventilation conditions and entry arrangements of the kiln are assessed against confined space criteria; see working in confined spaces.
If the kiln is heated by a steam boiler, the boiler is subject to periodic inspection at least once a year under Annex III of the Regulation on Work Equipment; from 1 January 2027, steam boilers will be inspected by accredited equipment inspection bodies. For details, see steam boiler safety.

Boilers burning wood waste and sawdust silos also carry fire and dust explosion risks; see dust explosion risk.

Sawmill noise and wood dust

Sawmill noise levels are high when band saws, circular saws and planers run together. The Regulation on Noise defines three thresholds: at the lower action value of 80 dB(A), hearing protection is made available; at the upper action value of 85 dB(A), wearing hearing protection is mandatory and hearing tests are carried out; and the limit value of 87 dB(A), taking into account the effect of hearing protection, may not be exceeded under any circumstances. We plan noise measurements with authorised laboratories and enter the results into the risk assessment; for the measurement approach, see our article on workplace noise measurement, and for choosing protection, our article on hearing protector selection and SNR.

Wood dust is the second major health risk. Work involving hardwood dust is listed as a carcinogenic process in the Regulation on Carcinogenic or Mutagenic Substances, and its limit value is 5 mg/m³. For dust extraction systems and dust measurement, see our article on wood dust and dust collection.

Sawmill checklist

Is the log unloading zone marked and are pedestrian routes separated?
Are the band saw and wheel guards in place and the cutting guard adjusted?
Is the carriage travel area enclosed?
Is there a written lockout instruction for blade changes?
Has a stack height limit been set and marked on site?
Is there a kiln entry instruction and a door arrangement that can be opened from inside?
Are noise and dust measurements up to date; is hearing protection being worn?

As Bursa Sistemer, in our OHS specialist service we enter this chain stage by stage into the risk assessment at sawmills and woodworking workshops in Bursa and the surrounding provinces, and we plan and follow up the periodic inspections of steam boilers and lifting equipment with authorised persons and bodies. For other sector-specific risks see our furniture page, and for our service arrangements in İnegöl our İnegöl OSGB page.

Frequently Asked Questions

Can sawdust be cleared while the band saw is running?

No. Sawdust and jammed pieces are removed with a brush or suitable tool, not by hand, after the machine has been stopped and the blade has come to a complete stop. Blade changes and maintenance are done with lockout-tagout.

How high should a timber stack be?

There is no fixed height in the legislation. The height is determined in the risk assessment, taking into account the condition of the ground, the stack base, the sticking arrangement and the forklift or loader used, and is marked on site.

Is noise measurement mandatory in a sawmill?

In workplaces where noise may reach the action values, measurement is part of the risk assessment. Measurement is carried out by authorised laboratories; if the upper action value of 85 dB(A) is exceeded, wearing hearing protection is mandatory and workers' hearing is tested.

Is a drying kiln a confined space?

Depending on its size, ventilation and entry arrangements, a kiln may meet the criteria for a confined space. This is assessed in the risk assessment; in all cases, entry into the kiln should be governed by a written instruction.

What training is given to sawmill workers?

Every worker receives induction training before starting work, followed by basic OHS training according to the hazard class. The topic of job- and workplace-specific risks is delivered face to face in hazardous and very hazardous workplaces; the band saw, log handling and kiln entry are part of this topic. Forklift users additionally need a forklift operator certificate.