Facility Maintenance Checklist

Apply LOTO per 29 CFR 1910.147 before opening any panel. Trip-test breakers per the panel schedule, verify each circuit's labeling matches the load it serves, and thermal-image high-amperage breakers (200A+) for hot spots. Mismatched panel schedules are a recurring NEC 408.4 finding.

Walk the production floor and MCCs looking for cracked insulation, damaged conduit, missing knockouts, and green corrosion at terminations. Pay attention to flex conduit at machine guards — vibration loosens connections over time.

NFPA 101 requires a 30-second functional test monthly and a 90-minute discharge test annually. Log results — AHJ inspectors will ask for the log on a Joint Commission or fire marshal visit.

NFPA 110 monthly exercise: 30 minutes minimum at no less than 30% nameplate kW. Check coolant, oil, fuel level, battery voltage, and ATS transfer time. No-load runs alone wet-stack the engine and don't satisfy code.

Ground-resistance check on the main grounding electrode (target under 25 ohms per NEC 250.53). Spot-check bonding on machine frames, paint booths, and any solvent-handling equipment where static is an ignition risk.

Note MERV rating and date on each new filter. For dust collectors serving combustible dust processes, follow NFPA 652 — ruptured cartridges are a deflagration risk. Log differential pressure before and after change.

Look for separated joints at flex connections, sagging hangers, and damaged insulation. In welding or grinding areas, check for accumulated dust on top of duct runs — a fire load that's easy to miss from floor level.

Compare each zone sensor against a calibrated reference thermometer. Climate-controlled production zones (paint, assembly with adhesives, electronics) should be within ±1°F of setpoint; recalibrate or replace drifted sensors.

Coil cleaning, refrigerant charge check, and amp draw on compressor motors. Document refrigerant added per EPA Section 608 — leak rate over 20% on commercial refrigeration triggers a repair-or-retire decision within 30 days.

Monthly visual: gauge in green, pin and seal intact, accessible, signage visible, mounted at correct height. Initial and date the inspection tag. Annual maintenance and 6/12-year hydrostatic tests are tracked separately by the licensed servicer.

Notify the monitoring company before testing to avoid a false dispatch. Test pull stations on a rotating basis, verify horn/strobe coverage, and check sprinkler control valve position and tamper switches per NFPA 25. Log all readings.

Log a corrective action in the CMMS or QMS with the deficiency, root cause, owner, and target close date. Life-safety findings get a 30-day SLA and require effectiveness verification before closure — don't close on retraining alone.

Walk the floor confirming HazCom GHS labels on secondary containers, NFPA 704 diamonds on bulk storage, exit egress signage, and PPE requirement signs at entry points to designated areas. Confirm SDS access (binder or terminal) within reach of the work area.

Verify posted maps reflect the current floor layout (a common gap after equipment moves), assembly points are clear, and warden assignments are current. Update the EAP per 29 CFR 1910.38 if any process or layout changed since the last review.

Walk restrooms, breakrooms, and process water lines. Photograph any active leaks, mineral staining at threaded joints, or pinhole corrosion on copper. Ceiling tile staining is the usual tell for slow leaks above the floor.

Annual backflow tests by a certified tester are usually required by the local water authority — confirm test tags are current. Verify line pressure at the gauge nearest the meter; adjust the PRV if outside the 40–80 psi target.

Pour water down trap primers to confirm seal. Pull strainers on production-area drains and clear chips, swarf, or food debris depending on the site. Roof drains and scuppers should be cleared before the rainy season — backed-up drains are a structural load risk.

Setpoint at 120°F for handwashing fixtures (scald risk above 120°F per ASSE 1070); 140°F+ where required for sanitation. Lift the TPR valve briefly to confirm it discharges. Look for sediment at the drain valve — a flush is due if discharge is rusty.

For sites with cooling towers, DI systems, or process water treatment, log conductivity, pH, and biocide residual. Inspect any oil storage covered by the SPCC plan — secondary containment integrity, drainage valve closed, no sheen.

Look for new cracks wider than 1/8", differential settlement at column bases, and spalling at floor joints under heavy machinery. Mark and date any crack so growth can be tracked at the next inspection.

Operate every overhead door through a full cycle, listening for grinding rollers or a binding chain. Test photo-eye reversal. Dock levelers, pit edges, and trailer-restraint interlocks are common sources of pinch and crush incidents.

Walk the roof for ponding, blistered membrane, lifted seams, and debris around drains. Photograph any flashing damage at curbs, vents, and HVAC penetrations. Coordinate with EHS for fall-protection tie-off before stepping onto the roof.

Tag any racking with damaged uprights, loose footplates, or missing safety pins — RMI guidelines require red-tag and offload of damaged frames. Check painted aisle lines, machine-guarding fasteners, and pedestrian barriers in forklift zones.