One of the most dangerous parts of working about in a hookah lounge is walking with a tray of hot coals that you have to get from the kitchen. You have to make your way through the bar, weaving around customers and chairs. You have to be careful of bumps and don’t have too much time to deliver them. In busy bar service, the time and distance you have from a serious burn incident can be as wide as a few centimeters.

Charcoal that is 400–600 °C (750–1100 °F) is the most dangerous thing to have around in a hookah lounge. Delivering a hot plate or a steam wand is not dangerous to yourself and others. When charcoal packs comes into contact with the skin, it can leave a permanent mark. Alcohol makes the lounge a hot a dangerous environment and dare I say combustible.

This article is for the employers who prepare staff in the art of transporting hot coals from the kitchen to the side to service them at the table. We discuss (1) charcoal transport route, (2) anti-drop tools , and (3) burn prevention and response protocols . These methods are tried and proven to be effective and are currently in use.

Designing a Safe Charcoal Transport Route

A very dangerous part of the shisha preparation process is transporting hot coal from the burner to the hookah bowls. In fact, many of the most common accidents at a lounge caused by hot charcoal do not occur at the table. These accidents actually happen on the transport. Whether it is a server carrying a tray of coals that loses their balance, an unexpected collision with a guest, or even tripping over obstacles, the most common and dangerous part of transporting coal happens long before the coals reach the destination. The construction of a planned, designated transport route is the best safety improvement measure a lounge can implement.

1.1 Map Your Current Flow

Start by outlining your lounge floor plan and jot down the locations of:

• – Coals preparation area (burners, tongs, coal storage)
• – Every hookah station or table where coals are dropped off
• – The bar, waitstaff stations/stands, and POS terminals
• – Areas of high traffic (entrances, pathways to and from the restrooms, the edges of the dance floor)
• – Obstructions (e.g., steps, ramps, doorways, low hanging lights, or decorations)

Map out every possible route taken by the staff to transport hot charcoal. It is very likely that some of these routes will overlap with the main customer traffic flow. Mark these routes with a red “X”. These will be your primary danger zones.

1.2 Designate the Coal Transport Passage

After you locate hazardous areas within the facility, establish a designated coal transport passage . This is a defined, fixed pathway that every employee is required to observe whenever transporting live coals. Key design features may include:

• – Separation from customer pathways: The coal transport passage should follow the employee back-of-house pathways. If the passage must take a route across a customer front-of-house area, then it should be taken along a wall, rather than a central pathway.
• – Avoidance of sharp changes of direction: Each change of direction constitutes a potential trip hazard. Design the coal transport passage with as few changes of direction as possible, and optimally, a direct routing from the kitchen to the table zone.
• – Sufficient width: The passage should have a minimum width of 1.2 meters (4 feet) so that a coal transport server is able to pass an employee with minimal contact.
• – Non-slip surfacing: Conduct a corridor-wide survey to locate and treat surfaces. Non-slip floor treatments and mats should be placed at kitchen-to-bar transport passage points.
• – Sufficient illumination: The passage must be illuminated at all times.
• – Boundary marking: Corridors should be marked with floor tape, glow strips, or colored tiles to indicate boundaries. This serves to visually restrict passage for staff and customers during service time.

1.3 The Two-Person Relay System

For busy lounges, use the two-person relay system. The first staff member prepares the coals. The second staff member, also called the runner, takes the prepared coals to the table. This keeps the staff member that prepares the coals from being distracted by the other tasks that need to be done at the same time.

When going to the prep station, the runner should have no items in their hands. This includes drinks, napkins, or any other items. The runner should focus on the coal tray. This rule has caused a decline of over 60% in transport incidents in lounges that have implemented this rule.

1.4 Hot Coal Delivery and Time Blocking

An example of time blocking is designating specific and limited time slots for transporting hot coals. This is done by blocking off the busiest rush times. An example is the first 30 minutes of having a new table being seated. During this time, the new table gets the first coals to be set, and after this time, replacements are delivered to different tables by a runner every 20 minutes. This causes a runner to only make half of the usual trips required to service the lounge.

2.Anti-Drop Tools

An example of anti-drop tools are tools that prevent hot coals from coming into contact with customers. No matter how safe the route for coals is, without the tools the route loses its importance. The anti-drop tools are the primary safety barrier between a hot coal and a customer’s skin. These tools should be a priority for every lounge.

2.1 Deep-Tray Coal Carriers with Raised Rims

For the transport of charcoal, standard flat trays are extremely dangerous. Invest in coal carriers that have deep trays and raised rims (at least 3 cm / 1.2 inches tall). These trays are built so that even if the carrier is significantly tilted, the coals will not roll off the side. Look for the following:

• – stainless steel hookah construction (non-flammable, easy to sanitize)
• – Raised, inward-curved edges to hold coals in place
• – Heat-insulated handles or handles at least 15 cm away from the tray body
• – A non-slip base or silicone feet that keep the tray from sliding on surfaces

Linkup Hookah provides tooling solutions with professional-level stainless steel tongs and handling tools specifically designed for this. Refer to the custom stainless steel tongs collection to find tools with both ergonomic designs and commercial durability. The right tongs will lessen the possibility of coal slipping while it is being transferred from the burner to the tray to the bowl.

2.2 Heat-Resistant Gloves – The Right Kind of Gloves

Many lounges offer generic kitchen oven mitts when handling coal. This is a poor decision, as oven mitts are designed only for the dry heat of an oven. They don’t take into account the radiant and conductive heat of charcoal embers. If an ember lands on an oven mitt, it will smolder through the fabric in a matter of seconds. The only mitts that should be used are the following:

• – Kevlar mitts for intermittent contact rated for over 500 °C
• – Silicone mitts with extended cuffs that cover wrists
• – Mitts designed for handling hot embers, as opposed to miscellaneous kitchen use

Instruct employees to check mitts before every shift. Any sign of a thin or worn area increases the risk of a 2nd degree burn for employees. Mitts should be immediately discarded at the first sign of wear.

2.3 Tray Covers and Mesh Screens

For lounges with tight space or with stair access, it may be easiest to use trays that come with mesh covers or wire screens that are fitted. These enclosures do contain the coals if the tray is upset and allows the coals to radiate. Some higher-end versions have a locking latch. The few seconds it takes to lock the cover is nothing compared to the disaster that can happen from a tray of coal spilled in a crowded area.

2.4 The Drop-Proof Tongs Technique

Even the best tongs are only as good as the technique used. Train employees on the “three point grip” for carrying a single coal.

• – Point 1: Grip the coal at the widest, not the edges.
• – Point 2: Keep the arm of the tongs parallel with the ground, as opposed to angled.

Point 3: Keep a steady, strong grip – do not loosen the grip mid-carry.

During training, practice the transfer motion using the cold coals until it is engrained as muscle memory. Staff should be trained to be able to pick up, carry, and place a coal while not looking at their hands.

2.5 Choosing the Correct Burner Minimalizes Handling Risk.

The kind of burner you pick can help minimize risk on staff to handle the hot coals. Electric burners that heat the coals uniformly and predictably yield coals that are less likely to break or be uneven, meaning that there are less coals that staff must handle. Linkup’s electric charcoal burners provide consistent, rapid ignitions that help lower the amount of time the staff are exposed to the dangerous heat.

Check the electric charcoal burner collection for commercial use. Check the electric charcoal burner collection for commercial use.

3.Burn Prevention and First Response Protocol

No matter what precautionary measures are set, it is realistic to expect that there will be burns from a dropped coal, brushing against a hot HMD, and a customer reaching for a drink too soon. Prevention is the main focus, but a burn response protocol is essential to minimize risk of damages and injuries.

3.1 Proactive Prevention: The Five-Second Rule — Reversed

In the shisha sector, the Five-Second Rule mindset is common among the employees. That is, Grab it before it burns me. This is absolutely incorrect. The coconut shell charcoal used in shisha burns for more than 30-45 mins and reaches and maintains a temperature of 400 °C. Thus, it can be on the receiving end for less than half a second and inflict a second degree burn. The employees should be trained on the following:

• – Never pick/enclose in the bowl a lit coal that has been burning for less than 5 mins. If it has been burning for 5 mins, it is at its peak temperature and extremely dangerous to handle.
• – Never handle coals with your fingers or touch the coals even if you are just making a minor adjustment to the coals in the bowl.
• – Always have a mindset that the coal’s temperature is at its peak and can burn you at that moment. You can check the actual temperature of the coal using an infra-red thermometer.

3.2 Zone Based Risk Management

The lounge can be divided into 3 risk zones. Each zone should require a different standard of employee behavior.

• – Red Zone (prep area): This has the highest concentration of the most dangerous items (hot coals). This zone should have the mandatory use of PPE gears including gloves, long-sleeves, as well as covered, non-slip shoes. Only employees trained in handling of coals should be allowed here.
• – Yellow Zone (transit corridor): This zone contains coals that are being carried or transported. Employees should have an ‘eyes forward’ posture, should not use phones or carry out other tasks. Employees should be urged away from the corridor.
• – Green Zone (table service): This zone will have coals sitting in a Heat Management Device (HMD) on a bowl. Employees in this zone can carry out their normal duties. However, they should have a

3.3 Customer Safety Briefing— Subtle but Effective

While at a bar, customers are typically talking and are generally unaware of the hot items on the table. Use a gentle safety prompt while serving:

When putting a new coal on the HMD say, “Fresh coal— the bowl is very hot for the next few minutes. Please clear the area of sleeves and hair.”

Ensure that hookah stands are away from walkways so that passing customers do not bump into the bowl.

Use a small tent card on the table that has a warning:

“Caution: Hot surface on your hookah.”

3.4 Immediate First Response for Charcoal Burns.

The faster a burn is treated, the better. Post the following protocol in the kitchen and staff area. Train every employee on this protocol during onboarding and review quarterly.

Step 1 — Remove the source: Use tongs to remove any coals or hot items that are in direct contact with the victim’s skin. Do not use your bare hands to do this.

Step 2 — Cool the burn: Treat the burn with cool water (do not use cold, ice water) for a minimum of 10 minutes.

Step 3 — Cover loosely: To cover the burn, use a clean, sterile, non-stick dressing.

Step 4 — Assess severity: Dial emergency services if the the burn is larger than 3 cm or if the burn is on the victim’s hands, face, feet, genitals or on a person who is not able to treat the burn.

Step 5 — Documenting the Incident

Once an incident occurs, the following details must be logged in the accident log: a description of the incident, the individuals who were involved, and the first aid that was provided, in addition to any subsequent care. This information is important for insurance and liability concerns.

Each lounge needs to have at least one fully equipped burn first aid kit that is accessible to the staff. Supply the kits with sterile saline, non-stick dressing, elastic bandages, burn specific first aid, and gloves. Restock used kits and check them every month.

4. Staff Training: Turning Protocols Into Habits

For safety protocols to be effective, staff must be made to practice them. Construct a training regimen that ensures the staff internalizes it.

4.1 The Pre Shift Safety Briefing

The shift manager is required to do a safety briefing before each shift that should be no longer than two minutes. It should cover the following: 1) the coal corridor, 2) the safety rail and why its there, 3) two person relay, and 4) gloves and tong check.

4.2Quarterly Burn Drill

Once per quarter, the staff must run a drill that is simulative of a burn incident. The goal: for a staff member to ‘accidentally’ drop a tray of burning coals as to test how quickly and in what order the following steps are accomplished and then evaluate the time it took. 1) Creation of a safety perimeter to protect staff and customers, 2) First aid treatment of the burn victim, 3) Return to safety to check for coals, 4) Documentation of the incident. 3 minutes is the goal to accomplish all four.

4.3 New Staff Certification

New employees aren’t allowed to transport hot coals alone until this certification is completed:

• – They must pass a written test about burns and a first response test with a score of 90% or higher.
• – They must use the three-point grip to carry coals. This will be done with cooled coals.
• – They must transport coals three times while being supervised, and there must be no safety rule violations.
• – They must complete a safety protocol form.

These must be kept for the employee’s duration of employment plus one year. This is for liability and for insurance.

5. Recommended Equipment from Linkup Hookah

For these safety protocols to work, Linkup Hookah is recommended. They provide lounges with supplies and equipment, and for our safety protocols, this equipment is useful.

Custom Stainless Steel Tongs Collection

How we suggest tongs provide a design for an unbeatable grip for coals and hit the safety and durability marks.

They come in a variety of grip styles, and they come in a variety of sizes for the coals.

Tongs and tools collection.

Electric Charcoal Burners

Linkup Hookah’s electric charcoal burners reduce the safety risks associated with handling lit coals with a transit time of less than one minute. These continue to serve safely during our busy times, and they are designed to be used for the entire duration of the business.

Shop electric charcoal burners.

Heat Management Devices (HMDs)

High-end examples of HMDs, like the Kaloud Lotus III or Alpha FNX, contain the coals and minimize the chances of coal contact. With coals contained, HMDs have additional safety features—most importantly, in lounges with limited space between tables. Linkup has HMDs from all of the primary brands.

HMD Options at Linkup Hookah

6. Monthly Charcoal Safety Audit Checklist

At the beginning of each month, perform a safety protocol check with the following items:

• – Designated coal transport corridor is marked and not blocked.
• – Corridor lighting is checked and is not dim or burnt out.
• – Deep-tray coal carriers are not cracked or warped and are in good condition.
• – Inspected gloves are heat resistant and have no worn spots. They are to be replaced if damaged.
• – Tongs are stored at the prep station and are clean and in good condition.
• – Burn first-aid kits are stocked and have not expired.
• – The burn protocol poster is in staff and kitchen areas.
• – Staff have completed this week’s pre- shift safety briefings.
• – Unsanctioned staff were not handling coals.
• – The incident log was reviewed and is current.

10/10 Score – Excellent The items were addressed and no items were left unchecked. These items have a zero-tolerance policy for taking shortcuts.

Safety is a System

Coal handling safety is critical in shisha lounges to avoid serious hazards. Professional lounges use operational safety systems to manage coal as opposed to treating it as a training checklist item. On the other hand, shisha lounges without coal system safety learn through experience.

Three critical components make up a safe coal management system. First is a coal transportation system that minimizes coal to customer interaction. Second is a fall protection system that provides a means to prevent coal from falling. Third is a burn and injury prevention and response system. Each coal safety system component has a huge cost associated. This cost is significantly less than the cost of a serious burn injury, which has the potential to ruin a business.

It would benefit everyone in management to take a good hard look at the coal safety systems in your lounge and the path taken during the transport of coal. The systems should be walked, tools should be examined, and staff should be questioned about response to system failures. The gaps shown by your staff response will show the system most in need of priority.

For safe coal handling devices like deep transport systems and coal management tools, visit Linkup Hookah. Linkup Hookah sells to lounges that trust prevention the safety and quality of their business.