Garage Construction Project

Main Floor Safety Manual

9 min read

Purpose & Scope

This manual summarizes the site-specific risks, controls, and operating procedures for anyone working on the main level of the garage. It focuses on the period between the current build stage (foundation poured with embedded utilities) and the final fit-out with permanent MEP systems. Treat it as the minimum standard; always layer in task-specific job hazard analyses, PPE, and permits when outside contractors or specialty equipment are involved.

Space Overview

  • The main floor is a 24’×40’ auto-repair and fabrication bay with a radiant slab, planned 2-post lift, and mechanical room infrastructure routed through the slab conduits (content/20-Design/Interior/Air and Battery Tool Strategy.md:8-11).
  • Key floor design features include a level third bay for the lift while the other two bays slope into a shared center drain, so expect pitching surfaces and wet areas any time the doors open (content/index.md:71-73).
  • Radiant heating PEX, fiberglass rebar, and multiple conduits (sewer, gas, water, electrical, data) are encased in the slab, with thickened pads in the lift bay; damaging the concrete risks critical systems (content/index.md:37-44).
  • The ceiling height is 10 ft, which limits lift raise height and leaves little tolerance for tall loads, ladders, or overhead storage additions (content/20-Design/Interior/Lift.md:17-22).

General Safe Work Practices

  • Maintain a clean floor: sweep grinding dust, wipe up hydraulic fluid, and keep snowmelt contained so that slopes toward the drain do not turn into slip hazards.
  • Control ignition sources around fuel-fired heaters, diesel storage, and natural-gas piping.
  • Require eye/hand protection for all tool work, plus hearing protection when compressors, sanders, or grinders run.
  • Enforce a “hands off” policy for energized panels, gas valves, and generator interlocks unless a qualified person is present.

Structural & Embedded Systems

Radiant Slab and Embedded Utilities

  • Assume every bay contains radiant tubing except the two 4’×4’ PEX-free pads reserved for the lift columns; keep anchors, saw cuts, and core drills within documented safe zones only (content/20-Design/Interior/Lift.md:8-23).
  • Use non-destructive locating (as-built PEX sketches, thermal camera preheat, or cover plates) before drilling, and log new penetrations so future crews can avoid the same spots.
  • The slab temperature sensor conduit and utility sleeves run toward the mechanical room; protect these stubs during material handling and avoid using them as tie-down points (content/index.md:37-44).

Floor Drainage & Grade

  • Mark the change from the level lift bay to sloped bays so rolling toolboxes or creepers do not drift unexpectedly (content/index.md:71-73).
  • Keep drain grates clear of grinding swarf and ice; clogging forces meltwater to spread across the work area, increasing slip risk and corrosion.

Overhead Envelope

  • With a 10 ft ceiling, crane hooks, light fixtures, and future ceiling storage must preserve at least 6 ft 8 in walking clearance; confirm that any temporary hoists or lumber storage stay clear of the planned lift rise envelope (content/20-Design/Interior/Lift.md:17-22).

Electrical Safety

Service Equipment

  • The garage will host a 200 A breaker panel fed by 200 A-capacity conductors but initially protected by a 100 A breaker at the house, routed through its own trench from the southwest house corner; only licensed electricians should touch this system and all trenching must honor NEC burial depths, grounding, and conduit requirements (content/20-Design/Interior/Electrical Planning.md:10-33; content/50-Build/Utilities & Conduits.md:22-64).
  • Maintain the required working clearance (minimum 3 ft) in front of the panel planned for the mechanical room to avoid blocking access for shutdowns or inspections (content/50-Build/Mechanical Room.md:8-33,76-83).

Receptacles, Cords & Controls

  • All 120 V garage outlets are specified as GFCI-protected, with tamper-resistant receptacles at 12–18 in height (48 in over benches) to protect against shock when floors are wet (content/20-Design/Interior/Electrical Planning.md:34-38,45-48).
  • Where cabinets or equipment block an outlet, fit removable caps, blank plates, or in-use covers so metal debris cannot bridge the contacts; inspect behind shelving on a set schedule (content/20-Design/Interior/Electrical Planning.md:50-61).
  • Dedicated 20 A circuits at the workbench are earmarked for high-density battery charging; label outlets per tool platform so crews do not overload a single branch (content/20-Design/Interior/Air and Battery Tool Strategy.md:26-30).

Backup Power System

  • A weatherproof 50 A (240 V) inlet, manual interlock, and four-wire feeder let a portable tri-fuel inverter generator back-feed essential loads; never connect or disconnect unless the generator is outside with exhaust directed away from doors (content/20-Design/Interior/Backup Generator Plan.md:32-56).
  • Standard operating sequence: move the generator at least 5–10 ft from the building, plug into the 50 A inlet, connect the natural-gas hose, start the unit, shift the interlock to generator mode, and shed non-essential loads before energizing circuits; reverse the steps when utility power returns (content/20-Design/Interior/Backup Generator Plan.md:48-56,113-118).
  • Label the exterior gas quick-connect “Emergency Generator Gas Port,” leak-test fittings after every hookup, and keep cords/hoses in weather-protected storage to avoid damage (content/20-Design/Interior/Backup Generator Plan.md:59-87,131-135).

Mechanical, Heating & Ventilation

Mechanical Room Controls

  • The mechanical room will host the boiler, radiant manifolds, panel, mini-split provisions, and low-voltage gear; all penetrations (gas, condensate, flue, line sets) must honor manufacturer clearances and be coordinated before framing (content/50-Build/Mechanical Room.md:8-103).
  • Boiler activation depends on locked-in framing, electrical service, and natural-gas service, so plan temporary heat carefully and never attempt DIY tie-ins to house utilities (content/50-Build/Mechanical Room.md:16-73).

Temporary Diesel Heaters

  • Two 8 kW VEVOR diesel air heaters mounted on fire-safe pads inside the garage will supply heat until permanent systems run; their combustion intake/exhaust pass through a cement-board window insert sealed with high-temp products (content/20-Design/Interior/Temporary Heating (Winter 2025-26).md:10-59,81-88,105-124).
  • Keep combustibles clear of the intake/exhaust, verify the downward exhaust slope, and inspect seals weekly for leaks; any exhaust odor inside requires immediate shutdown and troubleshooting (content/20-Design/Interior/Temporary Heating (Winter 2025-26).md:14-59,81-88).
  • Run both heaters on high 30–60 minutes before work, then drop to mid once target temperature is reached; limit door cycles and add oscillating fans to destratify air (content/20-Design/Interior/Temporary Heating (Winter 2025-26).md:66-78).
  • Install and periodically test CO alarms, stage a Class B/C extinguisher nearby, and store diesel or kerosene in approved containers away from sparks (content/20-Design/Interior/Temporary Heating (Winter 2025-26).md:81-88).

Permanent HVAC Planning

  • The long-term plan pairs a gas-fired radiant slab with a Mitsubishi Hyper-Heat outdoor unit feeding a garage cassette and upstairs head; protect reserved wall and ceiling penetrations so the future linesets, condensate drains, and electrical disconnect can be installed per the routing plan (content/20-Design/Interior/HVAC Strategy.md:13-24).

Heavy Equipment & Tooling

Two-Post Lift Bay

  • The lift bay relies on a 6 in, 4,000 PSI slab with rebar and PEX exclusion pads; keep documentation of the column centerlines and anchor torque specs once the model is finalized (content/20-Design/Interior/Lift.md:8-29).
  • Because the ceiling is only 10 ft, plan low-profile arms/ramps for vehicles with side pipes and set hard stops for tall SUVs; post the maximum safe lifting height at the bay entrance (content/20-Design/Interior/Lift.md:17-23).

Compressed Air & Battery Systems

  • Continuous-duty air tools (dual-action sanders, die grinders, HVLP guns) demand 8–15+ CFM at 90 PSI, so the planned 60–80 gal, two-stage compressor must have adequate electrical supply, vibration isolation, and clearance for cooling (content/20-Design/Interior/Air and Battery Tool Strategy.md:15-19,26-29,142-146).
  • Plan for ceiling hose reels between lift columns, quick-connects at each bay, drip legs, and ball valves before every drop; routinely drain condensate and keep reels retracted to prevent trip hazards (content/20-Design/Interior/Air and Battery Tool Strategy.md:26-30,129-140).
  • Mark the regulator/filter combinations above the workbench (paint/spray zone) and keep coalescing filters serviced so oil carryover does not contaminate coatings (content/20-Design/Interior/Air and Battery Tool Strategy.md:129-137).
  • Battery charging cabinets must be ventilated and labeled by platform to avoid mixing packs or overloading circuits; include a thermal runaway plan (sand bucket, extinguisher) nearby (content/20-Design/Interior/Air and Battery Tool Strategy.md:26-30,145-146).

Fuel & Utility Management

  • Non-electrical utilities (3 in sewer, natural gas, water, low-voltage) share a second trench from the house to the mechanical room; dig permits and locate tickets are mandatory before any excavation near these runs (content/50-Build/Utilities & Conduits.md:66-90).
  • The natural-gas quick-connect for the generator must supply ~120 kBTU/hr via at least ¾ in piping and may require the utility to upsize the house meter/regulator; coordinate load studies with DTE before adding new gas-fired appliances (content/20-Design/Interior/Backup Generator Plan.md:59-87).
  • Diesel heaters consume ~0.2–0.3 L/hr, so track remaining fuel, keep containers capped, and purge heaters monthly at full output to prevent soot buildup (content/20-Design/Interior/Temporary Heating (Winter 2025-26).md:10-33,81-88).

Work-Zone Guidance

  • Bay 1 (west): plan dual quick-connects and note the sloped floor—chock rolling stands when doors are open (content/20-Design/Interior/Air and Battery Tool Strategy.md:129-133).
  • Bay 2 (center/lift): ceiling hose reels and post-mounted quick-connects near columns mean you must keep the column base area clear and protect hoses from being pinched by lift arms (content/20-Design/Interior/Air and Battery Tool Strategy.md:129-133).
  • Bay 3 (east/workbench): regulator/filter combos serve paint and tire work; enforce “no grinding near finishing tools” and keep short leader hoses tidy to prevent surface damage (content/20-Design/Interior/Air and Battery Tool Strategy.md:129-134).
  • Exterior service point: a valved, UV-rated quick-connect supports driveway work—winterize it when freezing temps hit to keep the line from bursting (content/20-Design/Interior/Air and Battery Tool Strategy.md:133-135).

Emergency Preparedness

  • Stage Class B/C extinguishers near the heaters, compressor, and workbench, plus a Class D extinguisher if magnesium grinding is planned.
  • Install CO alarms in the garage and the adjacent house to guard against heater or generator backflow (content/20-Design/Interior/Temporary Heating (Winter 2025-26).md:81-88; content/20-Design/Interior/Backup Generator Plan.md:59-87).
  • Label every breaker, gas valve, drain cleanout, and quick-connect; note emergency shutoff locations on the wall and in the project binder (content/20-Design/Interior/Backup Generator Plan.md:131-135).
  • Maintain clear egress paths at doors and windows even when staging materials for framing or insulation work.

Operating Checklists

Daily Start-Up

  1. Inspect floors, drains, and hose reels; remove ice, water, or debris.
  2. Test CO alarms and confirm extinguishers are charged weekly.
  3. If using diesel heaters, verify the window insert seals, run both units on high for 30–60 minutes, then drop to maintenance power (content/20-Design/Interior/Temporary Heating (Winter 2025-26).md:66-78,105-124).
  4. Unlock the panel area and confirm circuits you plan to use are labeled.

Generator Deployment

  1. Move generator outdoors ≥5–10 ft from the structure, connect the 50 A cord and gas hose, then start it (content/20-Design/Interior/Backup Generator Plan.md:48-53).
  2. Switch the interlock to generator mode, shed non-essential loads, and monitor amperage via the planned CT monitor (content/20-Design/Interior/Backup Generator Plan.md:54-119).
  3. Reverse the sequence when utility power returns and document runtime hours.

Shutdown

  1. Power down tools, let heaters purge, and disconnect generator hoses/cords.
  2. Drain compressor tanks and drop legs; hang hoses and cords.
  3. Lock out the panel area and mechanical room if no qualified person remains.

Continuous Improvement

  • Revisit this manual whenever new equipment (e.g., permanent boiler, mini-split, ceiling storage) comes online. Update hazard sections and checklists to reflect as-built conditions, and log revisions in the project documentation system so every crew member works from the latest guidance.

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