ESH Handbook 2002

E S HENVIRONMENTAL

SAFETY & HEALTHHANDBOOK

2002 EDITION

The information contained in this booklet is purely advisoryand for the purpose of assisting contractors/employers in theareas of environment, safety and health. The content in thisbooklet does not purport to refer to or guarantee compliancewith regulations that may be applicable to such practices andconditions. This booklet should not be considered a definitivelisting of all regulations nor an absolute solution to allenvironmental, safety and health issues. Nike assumes noresponsibility for the implementation, management, orprocedures contained herein.

Nike, Inc.One Bowerman Drive

Beaverton, Oregon 97005-6453

Copyright © 2002 Nike, Inc.

All rights reserved.

Table of Contents

1. ESH Management ............................................... 1-1A. Management System ..................................... 1-1B. ESH Committee .......................................... 1-12C. Injury/Illness System Management .............. 1-15

• Incident/Accident Investigation System ... 1-16• Reporting Hazards ................................... 1-17• Evaluating Hazards .................................. 1-17• Correcting Hazards .................................. 1-18

2. Environmental Protection ................................... 2-1A. Air Emissions ................................................ 2-1B. Hazardous Waste ........................................... 2-9C. Polychlorinated Biphenyls (PCBs) ............... 2-14D. Wastewater .................................................. 2-16E. Solid Waste ................................................. 2-20F. UST ............................................................ 2-22G. AST ............................................................ 2-26H. Spill Response ............................................. 2-29

3. Chemical Management ....................................... 3-1A. Chemical Hazard Communication ................ 3-1B. Hazardous Material Labeling ......................... 3-1C. Restricted Manufacturing Substances (RMS) 3-9D. Storage, Handling, Distribution, Dispensing 3-11

4. Facilities and Maintenance .................................. 4-1A. General Work Environment .......................... 4-1

• Housekeeping ............................................ 4-1• Floors and Walls ........................................ 4-2• Stairs and Stairways ................................... 4-3• Exits .......................................................... 4-7• Illumination .............................................. 4-9

B. Ventilation .................................................. 4-14• Exhaust Ventilation .................................. 4-14• Fume Hoods ............................................ 4-18

C. Accident Prevention Signs and Tags ............. 4-21

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D. Machine Shop Safety ................................... 4-23• General Rules .......................................... 4-23• Bench and Pedestal Grinders .................... 4-24• Air Hoses, Tools and Compressors ........... 4-26• Fan Guards .............................................. 4-28• Portable and Powered Hand Tools ........... 4-28• Tool and Equipment Maintenance ........... 4-32• Ladder Safety ........................................... 4-45• Compressed Gas Cylinders ...................... 4-48

E. Contractor and Subcontractor Safety ........... 4-52F. Confined Spaces Protection ......................... 4-53G. Welding, Cutting and Brazing (Hot-Work) . 4-55

5. Industrial Health ................................................. 5-1A. Heat Stress Prevention ................................... 5-1B. Cold Stress Prevention ................................... 5-4C. Occupational Noise Exposure ........................ 5-7D. Ergonomics ................................................. 5-15E. Non-Ionizing Radiation (Ultraviolet (UV)

and Radio Frequency (RF) Radiation) ......... 5-23F. Bloodborne Pathogens ................................. 5-32G. Asbestos ...................................................... 5-35H. Occupational Exposure Limits ..................... 5-39

6. Emergency Preparedness and Response ............... 6-1A. Emergency Action ......................................... 6-1B. Fire Protection ............................................... 6-4

• Fire Protection Plan ................................... 6-4• Fire Protection Measures ............................ 6-7• Fire Brigades .............................................. 6-7• Fire Extinguishers .................................... 6-10

C. Medical Services and First Aid ..................... 6-18• General .................................................... 6-18• First Aid Kits ........................................... 6-20• Eyewash and Shower/Drenching

Equipment ............................................... 6-22

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7. Personal Protective Equipment ............................ 7-1• Job Attire ................................................... 7-1• Head Protection ......................................... 7-2• Eye and Face Protection ............................. 7-3• Hand Protection ........................................ 7-6• Foot Protection ........................................ 7-11• Respiratory Protection ............................. 7-11• Hearing Protection .................................. 7-17• Fall Protection ......................................... 7-19

8. Machine and Equipment Safety ........................... 8-1A. Motor Vehicle Operation and Forklifts .......... 8-1B. Energy Control (Lockout/Tagout) ............... 8-10C. Machine Guarding ...................................... 8-16D. Mills and Calenders .................................... 8-27E. Electrical Safety ........................................... 8-31F. Cranes, Hoists, Chains and Slings ............... 8-43

9. General Health .................................................... 9-1A. Dormitories ................................................... 9-1B. Clinics ........................................................... 9-6C. Canteens ..................................................... 9-11D. Sanitation .................................................... 9-15E. Drinking Water ........................................... 9-18F. Childcare Facility Management ................... 9-21

10. Sampling Equipment/Device Guidelines ........... 10-1A. 3M Organic Vapor Monitors (OVM) .......... 10-1B. Sound Level Metering Guidelines ................ 10-5

11. General Information, Weights and Measures ..... 11-1

1. ESH Management

A. Management System

1. ESH Policy

Contractors/employers are required to establish andmaintain an ESH policy statement that isdocumented, implemented and communicated to allemployees and addresses the following:

a. Appropriateness to the nature, scale and impactsof its activities, products or services.

b. Commitment to continual improvement andpollution prevention.

c. Commitment to comply with relevant ESHlegislation and regulations, and with otherrequirements to which the organization subscribes.

d. A framework for setting and reviewing ESHobjectives and targets.

e. Availability to the public.

2. ESH Aspects

a. The purpose of this section is to define the processby which contractors/employers identifysignificant ESH aspects of its activities, productsor services.

b. This process must take into account the cost andtime of undertaking the analysis and theavailability of reliable data.

c. Information already developed for regulatory orother purposes may be used in this process.

d. This section must address the degree of controlthe organization may have over the ESH aspectsbeing considered.

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1e. In documenting the ESH aspects/impacts

identification process, this section must addressthe following:

1) The criteria used to determine significance.

2) Applicable processes and operations of thecontractor/employer to be assessed (i.e., processflow charts).

3) Responsibilities for aspects/impacts identifica-tion.

4) Consideration of aspects/impacts under bothnormal and abnormal operating conditions.

5) How new or planned activities and processesare assessed.

3. Legal and Other Requirements

a. The purpose of this section is to define the processfor identification and access to legal and otherrequirements to which the contractor/employersubscribes.

b. This section must also describe the process ofmonitoring these requirements.

c. Things to look for:

1) This section must specifically identify theregulatory and other relevant ESH require-ments that apply to the contractor/employer(e.g., a listing and the name of the individualwho maintains the list).

2) This section must identify who is responsiblefor reviewing and analyzing draft and finalregulations/legislation and how their applica-bility is documented (e.g., procedural refer-ences).

ESH Management 1–3

13) This section must also address how these

requirements or changes to requirements arecommunicated to employees and management.

4. Objectives and Targets

a. The purpose of this section is to define the processthe contractor/employer uses to establish anddocument ESH objectives and targets.

b. This section must clearly provide the linksbetween the contractor’s/employer’s ESH aspects/impacts, ESH policy, and other commitments thecontractor/employer has made with regard to theenvironment.


1) This section must specifically address howobjectives and targets are set and approved bythe contractor/employer, and specifically howthey are to be documented, measured, reviewedand revised.

2) When establishing and reviewing its objectives,the contractor/employer must consider its legaland other requirements, its significant ESHaspects, its technological options, the financial,operational and business requirements, itscommitment to pollution prevention, and theviews of interested parties.

5. ESH Management Program

a. The purpose of this section of is to describe themanagement program the contractor/employerwill utilize to achieve its established ESHobjectives and targets.

b. Things to look for:

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11) This section must designate responsibility for

achieving objectives and targets at each relevantfunction and level.

2) This section must include the means andtimeframe by which the objectives and targetsare to be achieved.

6. Structure and Responsibility

a. The purpose of this section is to define specificroles, responsibilities and authorities thecontractor/employer has established to facilitate aneffective ESH management system.

b. This section must clearly designate theresponsibilities for implementation of thecontractor/employer management system.

c. It must identify the senior managementrepresentative(s) who have specific responsibilityand authority to:

1) Ensure the management system requirementsare established, implemented and maintained.

2) Report on the performance of the managementsystem to top management. This section mustinclude some discussion of how the contractor/employer is providing resources (human,financial, and technological) to support themanagement system.

7. Training, Awareness and Competence

a. The purpose of this section is to define how thecontractor/employer identifies training needs andimplements training programs.

b. These training programs ensure all employeeswhose work may cause a significant impact on theenvironment and/or the safety and health of


1employees are aware of their roles andresponsibilities and are competent to carry outtheir work activities as defined in the managementsystem.


1) This section must clearly describe the proce-dures (related to training) the contractor/employer has put in place to ensure itsemployees understand:

a) The importance of conformance with theESH policy.

b) The significant impact (actual or potential)of their work activities.

c) The consequences of deviating fromspecified operating procedures

8. Communication

a. The purpose of this section is to provide anoverview of the contractor’s/employer’s internaland external communication systems that supportthe ongoing implementation of the managementsystem.

b. The contractor/employer is required to establishand maintain procedures for internalcommunication between various levels andfunctions of the organization and fordocumenting and responding to communicationsfrom interested external parties.

c. This section of the manual must describe orprovide reference to the contractor’s/employer’smajor internal and external communicationsystems or procedures for:

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11) Communication of the contractor’s/employer’s

ESH policies, objectives, targets, and programs.

2) Communication of the contractor’s/employer’ssignificant ESH aspects and procedures forevaluating changes.

3) Communication of legal and other require-ments (i.e., Nike requirements).

4) Communication of operating procedures andcriteria for operations associated with signifi-cant ESH aspects.

5) Communication of emergency preparednessand response procedures.

6) Communication of procedures to monitor andmeasure key characteristics of its operationsand activities.

7) Communication of employee concerns andquestions.

8) Receiving, documenting, and responding torelevant communication from externalinterested parties (e.g., customers, the public).

9) Making the contractor’s/employer’s ESH policyavailable to the public.

10) Communication of ESH requirements tovendors, suppliers, and contractors/employers.

9. Documentation

a. The purpose of this section is to describe how thecontractor/employer establishes and maintainsinformation, in paper or electronic form, thatdescribes the core elements of the managementsystem, their interaction, and direction to relateddocumentation.


1b. All 17 elements of this standard must be described

or cross-referenced in this section.

10. Document Control

a. The purpose of this section is to describe thecontractor’s/employer’s document-control systemfor controlling all documents required by thestandard.

b. This section must address how managementsystem documents:

1) Can be located (i.e., are periodically reviewed,revised and approved by authorized personnel).

2) Are available at all locations where operationsessential to the effective functioning of themanagement system are performed.

3) Are properly removed from all points of use ormarked as obsolete as appropriate.

4) Are retained as necessary for legal or knowledgepreservation purposes when obsolete.

11. Operational Control

a. The purpose of this section is to describe how thecontractor/employer has identified thoseoperations and activities that are associated withthe identified significant ESH aspects.

b. This section must describe how the contractor/employer plans these activities, includingmaintenance, in order to ensure they are carriedout in line with its ESH policies, objectives andtargets.


1) This section must clearly describe how thecontractor/employer establishes and maintains

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1documented procedures to cover situations thatcould lead to deviations from the ESH policy,objectives and targets.

2) This section must describe how operatingcriteria is established, as well as the individualresponsible for the procedural activities.

3) This section must cover procedures related toidentifiable significant ESH aspects of goodsand services used by the contractor/employerand the process of communicating thoseprocedures and requirements to suppliers andcontractors/employers.

12. Emergency Preparedness and Response

a. The purpose of this section is to describe thesystem (procedures) the contractor/employermaintains to enable it to identify and respond topotential accidents and emergency situations, andfor preventing and/or mitigating the ESH impactsthat may result.

b. This section can be generally used to referenceemergency preparedness and response programsthe operation already has in place.


1) How the emergency preparedness and responseprocedures are reviewed and revised.

2) How the procedures are periodically tested(including drills).

3) Who is responsible for generating and main-taining procedures.

13. Monitoring and Measurement

a. The purpose of this section is to identify how thecontractor/employer establishes and maintains


1documented procedures to monitor and measurethe key characteristics of its operations andactivities that can have a significant impact on theenvironment and/or safety and health of theemployees.

b. This section must discuss how information isrecorded and performance tracked with regard toESH objectives and targets, and how the process isused to ensure that all equipment used inmonitoring and measurement is properlycalibrated and maintained.


1) This section must include specific proceduresin place for monitoring and measurement,including the process for periodic evaluation ofcompliance with relevant ESH legislation andregulations.

2) This section must discuss the required featuresof the monitoring and measurement proce-dures including individuals responsible forthese programs.

14. Nonconformance and Corrective and PreventiveAction

a. The purpose of this section is to define how thecontractor/employer identifies, investigates andresolves nonconformance in the ESHmanagement system.

b. This section must address how the contractor/employer has assigned responsibility and authorityfor these activities and how it records any changesto documented procedures resulting fromcorrective and preventive action.

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1c. Things to look for:

1) This section must include various means ofmeasuring, monitoring, auditing, self-assessingand other review systems that feed informationinto the corrective action system.

2) This section must reveal how managementensures that corrective and preventive actionshave been implemented and that there is asystematic follow-up to ensure effectiveness.

15. Records

a. The purpose of this section is to describe theprocess the contractor/employer uses to identify,maintain, and dispose of its ESH records.

b. This section describes the minimum requirementsfor ESH records generation, maintenance andretention procedures.

c. This section must also identify the records thatwill be used as objective evidence of thecontractor’s/employer’s conformance to therequirements of the management system.

d. Things to look for:

1) This section must include:

a) Who is responsible for determining whatrecords are required.

b) Who is responsible for filing and mainte-nance.

c) Guidelines for records management.

d) Location of comprehensive ESH recordslists.


116. Management System Audit

a. The purpose of this section is to describe theprocess the contractor/employer uses to evaluatethe effectiveness of the ESH Management System.

b. This section must describe the procedure used inthe management system evaluation and includehow the results are presented to seniormanagement.

c. This section must clearly describe the manage-ment system audit program responsibilitiesincluding:

1) Audit scheduling.

2) Audit scope.

3) Deficiency reporting.

4) Auditor requirements.

17. Management Review

a. The purpose of this section is to describe how thecontractor’s/employer’s top management reviewsthe ESH management system to ensure itscontinuing suitability, adequacy and effectiveness.

b. This section is intended to describe how seniormanagement will address changes to policy,objectives and targets, and other elements of themanagement system in light of managementsystem audit results or changing circumstanceswhich could effect the continual improvementprocess.

c. This section must clearly describe:

1) The frequency of the management review.

2) The individual responsible for initiating thereview.

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13) The scope of the review (e.g., audit results

(internal and external), complaints andinformation requests, corrective actionsummaries, objectives and targets).

4) How and where review results will be docu-mented.

5) Individuals on the review team.

B. ESH Committee

1. Formation and Membership

a. A committee composed of both employee andmanagement representatives will be established atthe facility.

b. All working shifts must be represented.

c. Representatives must serve a minimum one-yearterm.

d. The committee will select the chairperson.

2. Duties and Functions

a. The ESH committee’s function is to assistmanagement in developing and maintaining theessential elements of the environment, safety andhealth program. The committee will promoteawareness of and provide a means ofcommunicating environment, safety and healthissues and concerns between management andemployees. The ESH committee has the completesupport of senior management.

b. The committee will establish a written agenda toprescribe the order in which the committee’sbusiness will be addressed during the meeting.

c. The committee will evaluate the facility’senvironment, safety and health policies and


1procedures, and make written recommendationsfor change or adoption of new policies andprocedures. A reasonable time limit must beestablished for management to respond to therecommendations presented by the ESHcommittee.

3. Employee Involvement

a. ESH committee meetings will be held at leastmonthly. The meetings will be documented in theform of minutes. The minutes will be:

1) Posted where employees can read them.

2) Maintained for 3 years.

b. The ESH committee representatives may also electto review the minutes with their departments.

4. Incident/Accident Analysis

a. The committee will review any incidents/accidentsthat have occurred during the past month. Thecommittee will also determine if any accidenttrends are developing.

b. It may be necessary to invite the supervisor whoinvestigated an accident to attend the meeting toclarify questions concerning the investigationprocess.

5. Hazard Assessment and Control

a. The ESH committee will conduct environment,safety, and health inspections of the facilities,including the offices and grounds, at leastquarterly.

b. The inspections will be documented using anenvironment, safety and health inspectionchecklist.

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16. Training

The ESH committee members must be properlytrained in the following:

a. ESH committee duties and functions.

b. Hazard identification in the workplace.

c. The applicable Nike Code Leadership Standards(CLS) and any applicable local ESH requirements.

d. Techniques regarding incident/accident analysisand implementation of corrective actions.

7. Minutes Guidelines

a. The minutes must be:

1) Typed.

2) Brief, concise, and well-organized.

3) Distributed within 3 working days. (Thecommittee must develop a distribution list.)

b. Contents must include:

1) Title.

2) Date meeting was held.

3) Time meeting was opened or called to order.

4) Names and departments of members present.

5) Names and departments of members absent.

6) Names, titles, and organizations of guests.

7) Statements indicating that minutes of previousmeetings were read or acknowledged.

8) Unfinished business including report(s) and/orrecommendation(s) not acted on.


19) Recommendations completed since last

meeting.

10) New business.

11) New recommendations.

12) Remarks/comments.

13) Time adjourned.

14) Date and time next meeting to be held.

15) Signature of chairperson.

c. Style and format should best fit needs, or use theform provided.

C. Injury/Illness System Management

1. General Principles

a. Contractors/employers must prepare and maintainrecords of occupational injuries and illnesses.

b. Each contrator/employer must investigate everyinjury or illness that employees suffer inconnection with their employment, to determinethe means that must be taken to preventrecurrence.

c. Contractors/employers must follow the reportingprocedures listed on pages 1-20 through 1-22.

2. Injury/Illness Tracking and Records

a. Contractors/employers must maintain in eachfactory a log and summary of all injuries andillnesses (resulting in a fatality, hospitalization, lostworkdays, medical treatment, job transfer ortermination, or loss of consciousness) for thatfactory, and enter each event no later than 7working days after receiving the information.

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1b. Contractors/employers must establish a written

supplementary record of factors (incident/accidentreport form) that caused the injury or illness.

c. Contractors/employers must post an annualsummary of occupational injuries and illnesses.This posting will include the year’s totals, calendaryear covered, company/factory name,management signature, title and date. Thesummary must be posted by February 1 of eachyear and must remain in place until April 30 ofthe same year. If country law requires differentdates than those mentioned, then those dates mustbe met.

d. The log and summary, written supplementaryrecord, and the annual summary must be retainedin each factory for 5 years following the end of theyear to which they related.

e. Contractors/employers must apply theserequirements to all incidents involving factoryemployees, on-site vendors, and visitors, whichresults in personal injury or illness.

f. Contractors/employers must train all employees inthe incident/accident reporting procedures.

g. Contractors/employers must conduct an annualreview of this program to confirm that employeesare familiar with the incident/accident reportingrequirements and that the program is managedproperly.

3. Incident/Accident Investigation System

a. Supervisors must investigate an incident/accidentas soon as possible after the incident to preservephysical evidence and obtain witness statementswhile memories are fresh. The supervisor mustdetermine and record all facts surrounding the


1incident. Causes and effects must be analyzed todiscover the basic reason for the incident.Necessary action must be taken as soon as possibleto prevent recurrence of the incident.

b. The supervisor must complete the Supervisor’sIncident/Accident Investigation Report, with helpfrom the employee. Each section of the reportmust be thoroughly completed. It is importantthat the employee describe the incident in his orher own words and that the employee sign his orher name on the appropriate line.

c. The Incident/Accident Investigation Report mustbe completed for all incidents, even those thatdon’t result in an injury or illness claim.

d. A copy of the completed form must be sent toNike. The original must be maintained by thehuman resources department or clinic. If theincident results in a work related injury or illnessclaim, the insurance company needs to receive acopy of the report form.

4. Reporting hazards

a. Employees are expected and encouraged to reportany hazard that they believe exists in theworkplace. No reprisals will be taken againstemployees for reporting any condition they feelconstitutes an unsafe condition.

b. Employees must report hazards to their supervisor,department ESH committee representative, or amember of senior management. Employees mustreport hazards on forms provided.

5. Evaluating hazards

Facilities must use the following methods andprocedures to identify and evaluate workplace hazards:

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1a. Quarterly environment, safety and health

inspections conducted by the ESH committee.

b. Employee reports of unsafe or unhealthy workconditions and subsequent investigations andactions.

c. Investigation after an employee sustains an on-the-job occupational incident/accident.

d. Periodic environment, safety and health surveysconducted by environment, safety and healthconsultants employed by the location’s insurancecarrier.

6. Correcting hazards

a. Serious hazards (those with the potential to causedeath or serious physical harm to an employee)will be corrected immediately. All employeesexposed to this hazard will be removed from thearea. Employees assigned to correct the hazard willbe provided with all necessary safeguards,including personal protective equipment anddevices.

b. All other hazards will be corrected in a timelyfashion with times for correction being agreedupon by senior management and the departmentsupervisor. Protection may include temporarywork procedures or personal protectiveequipment.

c. In regard to a. and b. above, if warranted,administrative action will be taken to protect theenvironment, safety and health of affectedemployees prior to the correction. (For example,equipment violation, multiple-shift isolation, etc.)

d. Once a hazard is identified, the best course ofaction is to immediately eliminate the hazardous,


1unsafe condition. Since this is not always possible,the senior manager sometimes must rankidentified hazards by the potential for destructiveconsequences. Hazards that rank high in thepotential for both frequency (number ofaccidents) and severity must be addressed first.

• Critical—Any condition that requires immedi-ate action to correct.

• Potential—Any condition that, if left unat-tended, may cause harm.

7. Contractor/Employer Incident/Accident ReportingProcedures

a. Prior to initiating Nike procedures, factory mustidentify and comply with country law.

b. All incidents and accidents resulting in death,injury, or causing illness to employees and events(near-miss accidents) must be reported in order to:

1) Establish a written record of factors that causeinjuries and illnesses and events (near-misses)that might have resulted in death, injury orillness.

2) Maintain a capability to promptly investigateincidents and events in order to initiate andsupport corrective and/or preventative action.

3) Provide statistical information for use inanalyzing all phases of incidents and events.

c. This Incident/Accident Reporting System appliesto all incidences involving contract factoryemployees, on-site vendors, contracted third-partyemployees, and visitors that results in (or mighthave resulted in) personal death, injury or illness.

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2. Environmental Protection

A. Air Emissions


a. Emissions of toxic substances to the outsideatmosphere from production and non-productionsources (e.g., welding, painting, waste burning,etc.) are required to be controlled, minimized and/or eliminated whenever possible at owned andcontracted facilities.

b. Contractors/employers must be aware how thesesubstances can be emitted to the outsideatmosphere and how these emissions can andmust be controlled, minimized or eliminated in-accordance with Nike standards and applicablelocal requirements. The primary areas wherepotential air emission will be found are:

1) Solvent cleaning processes (Volatile OrganicCompound (VOC) emissions).

2) Dryers and curing ovens (VOC).

3) Painting and touch-up (VOC and OzoneDepleting Chemicals (ODC) emissions).

4) Boiler operations (Carbon Dioxide (CO2)

emissions).

5) Air conditioning equipment (Chlorofluorocar-bon (CFC) emissions).

6) Welding (CO2 and particulate emissions).

7) Grinding (particulate emissions).

8) Chemical storage and dispensing (VOC andODC emissions).

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9) General operations where respiratory protec-tion is required (all emissions).

10) Waste burning.

c. All emission sources must be addressed bydocumentation and physical controls or acombination of both.

1) Documentation Controls: Generally refer torequired operating procedures, inspections anddocumentation (see Section 2).

2) Physical Controls: Generally refer to physicalequipment (see Section 3).

2. Air Emission Documentation Controls

To achieve Nike’s air emission objective, each facilitymust be able to demonstrate they have the followingdocumentation controls in place:

a. Emission source inventory. The facility must haveavailable for inspection an inventory of allemission sources. The inventory must include:

Figure 2-1: Stackhead Designs

Environmental Protection 2–3

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1) Location of emission sources.

2) Types and quantities of pollutant emitted.

3) Air pollution control devices and removalefficiencies.

4) Permit numbers for emission sources andcontrol devices.

b. Asbestos Inventory. Contractor/employer mustmaintain an asbestos inventory that includes thelocation and type (friable versus nonfriable).

c. Chlorofluorocarbon (CFC)Inventory. Contractor/employermust maintain a CFC inventorythat includes:

1) Location and type of equipment.

2) Quantity and type of CFCs.

d. Ozone Depleting Chemical (ODC) Inventory.(Sample chemicals below.) Contractor/employermust maintain an ODC inventory that includes:

1) Location, type and quantity of ODCs.

2) Chart depicting ODC quantity versus month/year.

Table 2-1: Abbreviated ODC Table

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e. Routine inspections and maintenance.Contractor/employer must maintain a record ofinspections and maintenance for all pollutioncontrol devices to ensure their effectiveness.

3. Air Emissions Physical Controls

Processes that utilize volatile organic chemicals(VOCs) or emit other toxic substances must have airquality physical control devices installed, such as:

Figure 2-2: Fume Hood Cutaway


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Figure 2-3: Dust and Centrifugal Collector

a. Fume hoods and spray booths. Must be equippedwith pollution control devices.

b. Buffing and grinding equipment. Must beequipped with exhaust fans and bag-houses tocollect dust particles.

c. Pollution control equipment

1) Used filters must be replaced on a regular basis.

2) Used filters must be tested to ensure they arenot a hazardous waste prior to disposal.

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B. Hazardous Waste


a. Hazardous wastes from production and non-production sources are required to be controlled,minimized and/or eliminated whenever possible.Many countries have specific laws and regulationsthat regulate these substances and each facilitymust know these requirements.

b. A hazardous waste is generally defined by thefollowing characteristics:

1) It is a solid, liquid or gas substance that can nolonger be used and must be discarded.

2) It is flammable (flash point below 100 degreesFahrenheit (37.8 degrees Celsius).

3) It is corrosive (acids or oxidizers).

4) It is toxic (generally referred to as poisons).

5) It is explosive (easily ignitable with violentreaction).

6) It is radioactive.

c. The contractor/employer must be aware thathazardous wastes come from a variety of sourcesand that these wastes left uncontrolled canadversely impact human health and theenvironment. Hazardous wastes are required to becontrolled, minimized and/or eliminated in-accordance with Nike standards and localrequirements. The primary areas where hazardouswastes will be found are:

1) Solvent cleaning or materials preparation areas.

2) Spot cleaning areas (used rags).

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3) Painting operations (paint gun cleaners andpaint removers).

4) Maintenance areas (cleaners, light ballasts, usedbatteries, used hydrologic fluids, etc.).

5) Wastewater treatment sludges.

6) Empty solvent cleaning and wastewatertreatment chemical containers (e.g., drums and5 gallon (19 liter) cans).

7) Laboratory wastes.

8) Cooling tower chemicals.

9) Landscaping (pesticides and herbicides).

10) Used filters.

d. All hazardous waste sources must be addressed byDocumentation and Physical Controls andcombinations of both.



2. Hazardous waste Documentation Controls. To achieveNike’s hazardous waste management objective eachfacility must be able to demonstrate they have thefollowing administrative controls in place:

a. Hazardous waste inventory. The facility shouldhave available for inspection an inventory of allhazardous waste sources.

1) Waste streams are characterized as hazardous bylaboratory testing or process knowledge.

b. Hazardous waste reporting. The facility mustmaintain a hazardous waste reporting form.


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c. Hazardous waste handling procedures andtraining. The facility must have written proceduresfor hazardous handling, storage and disposal anddocumented employee training (includingemergency response and spill training).

d. Hazardous waste disposal facilities. The facilitymust maintain a list of disposal facilities used forall off site disposal including:

1) Date of disposal.

2) Location and name of disposal facility.

3) Name and quantity of waste disposed.

4) Tracking or shipping numbers as applicable.

e. Routine inspections and maintenance.Contractor/employer must maintain a record ofinspections for hazardous waste storage areas.

3. Hazardous Waste Physical Controls. Hazardous wastesmust have the following engineering controls in place:

a. Hazardous waste containers. The facility must usecontainers for hazardous waste (includingcontainers in satellite accumulation areas) thatmeet the following requirements:

1) Are appropriate for the waste being stored inthem (e.g., acids are not stored in metaldrums).

2) Are clearly labeled “Hazardous Waste.” (SeeFigure 2-4 next page.)

3) Are closed (except when adding hazardouswaste).

4) Ignitable wastes are bonded and grounded.(See Chapter 3, pages 17–22.)

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b. Designated storage areas that include thefollowing:

1) Impermeable floor surface (concrete or other).

2) Emergency response equipment (spill kits).

3) Covered or otherwise protected from rain orother elements.

Figure 2-4: Hazardous Waste Labels


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4) Secondary containment equal to 110 percentof volume of materials stored.

5) Separate areas for incompatible wastes (e.g.,acids and oxidizers).

6) Signage indicating storage of hazardous wastes.

7) Locking gate or door.

c. Designated satellite/workplace hazardous wasteaccumulation areas that include the following:

1) Clearly marked and designated as satellite/workplace hazardous waste accumulation area.

2) Must be at or near the point of generation.

Figure 2-5: Secondary Containment Unit

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C. Polychlorinated Biphenyls (PCBs)


a. The presence of PCBs can pose a significant threatto the environment and well being of employees.PCBs are typically found in capacitors,transformers and other electrical equipment and ifreleased, can contaminate air, soil and water.

b. PCBs have been used in many industrialapplications. Because of their insulatingproperties, chemical instability and relativeinflammability, they have been typically found inthe following:

1) Capacitors

2) Transformers

3) Electrical equipment

4) Plasticizers

5) Surface coatings

6) Inks

7) Adhesives

8) Flame retardants

9) Paints

c. All PCBs must be managed using Documentationand Physical Controls or a combination of both.




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2. PCB Documentation Controls

To achieve Nike’s management objectives, each facilitymust be able to demonstrate they have the followingdocumentation controls in place:

a. PCB survey. The facility must have available forinspection an inventory of all suspected PCB-containing equipment. Inventory will include butnot be limited to:

1) Lighting equipment (ballasts)

2) On-site transformers

b. Laboratory analyses of suspected PCB containingequipment.

c. If necessary, facility must develop PCB removalplan or develop procedures to manage PCB-containing equipment left in service, includingroutine maintenance and equipment inspections.

d. Facility must establish procedures to ensure allPCB-containing equipment that is removed fordisposal is removed to an approved disposalfacility; applicable employees must be trained onthese procedures.

e. Records of removal and disposal of PCBcontaining equipment must be maintained.

3. PCB Physical Controls

The following physical control must be in place:“Waste” light ballasts identified as PCB containingmust be accumulated separately from other solidwastes.

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D. Wastewater


a. Discharges of process and sanitary (people related)wastewater to the outside environment arerequired to be controlled, minimized and/ortreated at all owned and contracted facilities.Uncontrolled (untreated) discharges can have anadverse effect to both human health and theenvironment and are specifically regulated by bothNike standards and local/country requirements.

b. The contractor/employer must be aware of howcontaminated water discharges are emitted to theoutside environment and how these discharges canbe controlled, minimized and/or eliminated. Thetypical areas where wastewater discharges will befound are:

1) Solvent cleaning processes.

2) Outsole and midsole degreasers.

3) Compressor and boiler blow-down.

4) Cooling tower blow-down.

5) Sanitary systems (toilets, kitchens and canteensin factories and dormitories).

6) Wastewater treatment plant.

7) Laminating.

8) Mold shops.

9) Dyeing.

10) Outside cleaning.

11) Outside chemical storage areas.

12) Waste storage areas.


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13) Chemical dispensing areas.

14) Vehicle parking areas.

c. Documentation and Physical Controls orcombinations of both must address all dischargesources.



2. Wastewater Documentation Controls

To achieve wastewater objectives, each facility must beable to demonstrate it has the following administrativecontrols in place:

a. Discharge source inventory. The facility must haveavailable for inspection an inventory of alldischarge sources. The inventory must include:

1) Location of discharge points and dischargesources.

2) Types and quantities of pollutant discharged.

3) Water pollution control devices (wastewatertreatment plants, oil/water separators, etc.) andremoval efficiencies.

4) Permit numbers for discharge sources andcontrol devices as appropriate.

b. Discharge Sampling Plan. The facility mustmaintain a wastewater (including rain water)sampling plan that includes:

1) The locations and types of samples (includingsludge from wastewater treatment plants).

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2) Name of certified laboratory performing theanalyses.

3) Frequency of sampling.

c. Employee Training. Facility must ensureemployees operating wastewater treatmentequipment are properly trained and include thefollowing;

1) Training records and certifications.

2) Personal protective equipment.

3) Emergency operational control (shutdown)procedures.

d. Routine inspections and maintenance. Facilitymust maintain a record of inspections andmaintenance for all wastewater pollution controldevices to ensure their effectiveness

3. Wastewater Physical Controls

Processes where water and toxic substances directlyinteract and are discharged from the facility must haveone of the following wastewater engineering control inplace:

a. Wastewater Treatment Plant

Must be designed to meet discharge standards.

b. Oil/Water Separator

For operations where oil and gasoline are washeddown to drains.

c. Outside Drains and curbing. Rain water that mayinteract with materials and equipment storedoutside the facility must be managed by:

1) Diverting from running off the facility bycurbs, berms, or culverts.


2

Fig

ure

2-6

: Was

tew

ater

Tre

atm

ent P

roce

ss

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2) Collected in a drainage system that is separatefrom the process and sanitary wastewatersystem.

3) Tested prior to discharge.

E. Solid Waste


a. Solid wastes from production and non-productionsources are required to be controlled, minimizedand/or eliminated whenever possible.

b. The contractor/employer must be aware that solidwastes come from a variety of sources and thatthese wastes take resources to manage (money andtime) and can adversely impact the environment.Solid wastes are required to be controlled,minimized or eliminated in-accordance with Nikestandards and local requirements. Examples ofsolid waste are:

1) Packaging scrap (boxes, straps, pallets, wraps,etc.).

2) Cutting and trimming wastes.

3) Office waste (paper, boxes, etc.).

4) Cafeteria wastes.

5) Dorm wastes.

7) Maintenance wastes (waste oils, scrap metal,wood, empty containers, landscaping debris).

8) Production wastes (defective product, gloves,dust masks, empty containers, rags, etc.).

c. All solid waste sources must be addressed byDocumentation and Physical Controls or acombination of both.


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2. Solid Waste Documentation Controls

To achieve the solid-waste management objective,each facility must be able to demonstrate they havethe following documentation controls in place:

a. Solid waste inventory. The facility must haveavailable for inspection an inventory of all solidwaste sources.

b. Solid waste reporting. Contractor/employer mustmaintain a solid waste reporting form on amonthly basis that includes:

1) Total waste.

2) Disposed waste.

3) Recycled waste.

c. Routine inspections and maintenance.Contractor/employer must maintain a record ofinspections for solid waste storage areas.

d. Disposal method must be documented.

e. Solid waste disposal. The facility must maintain alist for solid-waste disposal that includes thefollowing:

1) Name of vendors collecting solid waste andremoving offsite.

2) Vendor permits that may be necessary for solidwaste disposal and/or recycling.

3) Date of disposal.

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4) Location and name of disposal facility.

3. Solid Waste Physical Controls

Solid wastes must have the following physical controlsin place:

a. Separate garages or bins for each waste (includingliquid wastes and recyclables).

1) Garages or bins must be covered.

2) Garages or bins must have adequate flooring(concrete or other impermeable surface).

3) Garages or bins must be secured with firesuppression equipment.

b. Solid wastes must be separated from liquid wastestorage.

c. Labeled and marked

1) Labels must indicate waste designation (e.g.,trash, recycle, etc.).

2) Signs must indicate that smoking is prohibited.

3) All labels and signs must appear in bothEnglish and the language of the employee.

F. Underground Storage Tank


a. The presence and use of underground storagetanks (USTs) can pose a significant threat to theenvironment. USTs are typically used for storageof fuels and other industrial chemicals that ifreleased can contaminate both the soil and groundwater. Appropriate control and management ofUSTs is required by Nike Code Leadershipstandards and local requirements.


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b. The contractor/employer must be aware that thereare various types of storage units that areconsidered to be “underground” storage tanks,these can include:

1) Bulk fuel storage tanks with more than 10percent of the tank located below ground level.

2) Vaults.

3) Material conveyance piping (70 percent ormore located below ground).

4) Sumps.

5) Trenches.

c. All USTs must be managed using Documentationand Physical Controls or a combination of both.



2. UST Documentation Controls

To achieve the UST management objectives, eachfacility must be able to demonstrate they have thefollowing documentation controls in place:

a. Records that indicate UST type, location, size,age, and contents.

b. Fill and overfill prevention procedures. Thefacility must have UST fill procedures available forinspection.

c. Certification of employee training. The facilitymust have available for inspection employeetraining records on proper tank management andspill response.

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d. Spill response procedures. The facility must haveappropriate spill response procedures available forinspection.

e. Periodic tank inspections. The facility mustinspect all USTs daily and document equipmentinspected and any necessary repairs or correctiveactions.

f. The UST must be tested annually to ensure tankis not leaking.

3. UST Physical Controls

USTs must have the following physical control devicesinstalled:

a. Secondary containment/protective barriers. AllUSTs must have secondary containment.

1) Must be capable of holding 110 percent of thestorage tank capacity.

Figure 2-7: Underground Storage Tank WithSecondary Containment Barrier


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2) Exposed UST components such as vent pipesand fill valves must have appropriate physicalbarriers to protect them from contact withvehicles and machinery.

b. Corrosion protection is added to unprotected steelUSTs.

c. Leak detection systems.

1) All USTs must have an operating leak-detection system. (See Figure 2-7 previouspage.)

2) Leak detection systems must be periodicallycalibrated.

d. Marking and labeling.

1) All USTs must have appropriate markings andlabels indicating tank contents and applicablehazards. (See Chapter 3, Section B, HazardousMaterials Labeling).

2) Vent pipes and other ancillary tank compo-nents must be labeled.

e. Spill response equipment. All USTs must haveappropriate spill response equipment locatedwithin 50 feet (15 meters) of all USTs, or asspecified by regulatory requirements. Equipmentincludes but is not limited to the following:

1) Alarms or other communication devices.

2) Booms and dykes.

3) Gloves, splash guards and other personalprotective equipment.

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G. Aboveground Storage Tanks


a. The presence and use of aboveground storagetanks (ASTs) can pose a significant threat to theenvironment. ASTs are typically used for storageof fuels and other industrial chemicals that, ifreleased, can contaminate soil, surface water andground water. Appropriate control andmanagement of ASTs is required by Nike CodeLeadership standards and local requirements.

b. The contractor/employer must be aware that thereare various types of storage units that areconsidered to be “aboveground” storage tanks.These can include but are not be limited to thefollowing:

1) Bulk fuel storage tanks.

2) Boiler fuel reservoirs.

3) Solvent baths.

c. All ASTs must be managed using Documentationand Physical Controls or a combination of both.



2. AST Documentation Controls

To achieve the AST management objectives, eachfacility must be able to demonstrate they have thefollowing documentation controls in place:

a. Records that indicate AST type, location, size, age,and contents.


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b. Fill and overfill prevention procedures. Thefacility must have AST fill procedures available forinspection.

c. Certification of employee/subcontractor training.The facility must have available for inspectionemployee training records on proper tankmanagement and spill response.

d. Spill response procedures. The facility must haveavailable for inspection appropriate spill responseprocedures.

e. Periodic Tank inspections. The facility mustinspect all ASTs weekly and document equipmentinspected and any necessary repairs or correctiveactions.

3. AST Physical Controls

ASTs must have the following physical control devicesinstalled:

a. Secondary containment/protective barriers. AllASTs must have secondary containment. (SeeFigure 2-8 next page.)

1) Must be capable of holding 110 percent of thestorage tank capacity.

2) Exposed AST and AST components, such aspiping and fill valves, must have appropriatephysical barriers to protect them from contactwith vehicles and machinery.

b. Tank fill and dispensing pipe must be locked at alltimes (except when in use).

c. Marking and labeling.

1) All ASTs must have appropriate markings andlabels indicating tank contents and applicable

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Figure 2-8: Aboveground Storage Tanks WithSecondary Containment Barriers


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hazards. (See Chapter 3, Section B, HazardousMaterials labeling.)

2) Piping and other ancillary tank componentsmust be labeled.

d. Spill response equipment. All ASTs must haveappropriate spill response equipment locatedwithin 50 feet (15 meters) of all ASTs or asspecified by regulatory requirements. Equipmentmust include but not be limited to the following:

1) Alarms or other communication devices.

2) Booms and dykes.

3) Gloves, splash guards and other personalprotective equipment.

H. Spill Response


a. Chemicals, oils and other potentially hazardousmaterials (Hazmat) are a part of many of themanufacturing and maintenance processes atowned and contracted facilities.

b. Contractors/employers must be aware that there isa potential for these chemicals, oils and potentiallyhazardous materials to be spilled. The facility mustalways be prepared to respond to such spills so asnot to adversely affect human health and/or theenvironment and to ensure that they are managedin-accordance with Nike standards and localrequirements. The primary areas where spills canoccur are:

1) Hazmat receiving areas.

2) Hazmat dispensing and storage areas.

3) Chemical cleaning processes.

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4) Maintenance areas.

5) Oil storage areas.

6) Waste water treatment facilities.

7) Anywhere Hazmat may be used.

c. All potential spills must be addressed byDocumentation and Physical Controls or acombination of both.


Figure 2-9: HazMat Storage Area


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2. Spill Response Documentation Controls

To achieve the spill response objective each facilitymust be able to demonstrate they have the followingdocumentation controls in place:

a. Spill response plan and procedures. The facilitymust have available for inspection a spill responseplan which designates the following:

1) Individuals responsible for coordinating spillresponse activities.

2) Alarms and warnings.

3) Evacuation procedures.

4) Area specific spill response procedures.

b. Spill response training. The facility must haveavailable for inspection spill response trainingrecords for all employees identified as spillresponders.

c. Spill corrective action form. The facility mustmaintain a record of spill causes and correctiveactions.

d. Periodic spill response drills. The facility musthave available for inspection records of periodicspill response drills.

3. Spill Response Physical Controls

a. Spill Control Stations.Facilities must have a spillcontrol station in place.Spill control stationsmust be located within50 feet (15 meters) of all

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potential spill sites and include but not be limitedto the following:

1) Personal protective equipment (see MaterialSafety Data Sheet) for recommended equip-ment).

2) Chemical absorbent.

3) Drain covers.

4) Waste receptacles (buckets, drums, etc.).

5) Decontamination procedures.

Figure 2-10: Spill Kit


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Figure 2-11: Spill Response Cart

3. Chemical Management

A. Chemical Hazard Communication

Programs must consist of the following items:

1. A survey of potentially hazardous materials found atfacilities.

2. A written procedure outlining methods for dealingwith potentially hazardous materials found onsite.This procedure must be available for employeeexamination.

3. Material Safety Data Sheets (MSDS) are informationdata sheets on each potentially hazardous material thatprovide basic data on the characteristics and potentialhazards associated with the material. These sheetsmust be readily accessible.

4. Labeling of containers of potentially hazardousmaterials to inform users of the contents and theirpotential hazards.

5. Employee training to acquaint employees with thepotential hazards associated with materials in theworkplace and the safe methods for working withthem.

B. Hazardous Material Labeling

There are three main systems of hazard warning labelsthat employees are likely to encounter: U.S. Departmentof Transportation (DOT), Hazardous MaterialIdentification System (HMIS®), and the National FireProtection Association (NFPA). Employees must beaware of each of these systems.

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1. The following is a partial listing of the morecommonly encountered DOT labels. DOT labelsmust be used on vehicles transporting hazardousmaterials and on containers used for transportation.

a. Explosives. Substances that willignite with a violent reactionand can cause massivedestruction.

Figure 3-1: Hazard Communications

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b. Non-Flammable Gas. Acompressed gas that will notreadily burn and is notpoisonous. It is hazardousbecause it is under pressureand/or it can suffocate a personwithin a confined space.

c. Flammable Gas. A gas that, atambient temperatureand pressure, forms aflammable mixture with air at aconcentration of 13 percent byvolume or less.

d. Poison Gas. Gases such aschlorine and anhydrousammonia that are poisonous tohumans or animals wheninhaled.

e. Flammable Liquid. Any liquidhaving a flash point below 100o

F (37.8o C). Excluded aremixtures of liquids havingcomponents with flash pointsof 100 o F (37.8 o C) or higher,if the total of these componentsmakes up 99 percent or moreof the total volume of the mixture.

f. Flammable Solid. A solid,other than a blasting agent orexplosive, that is liable to causefire through friction,absorption of moisture,spontaneous chemical change,or retained heat frommanufacturing, or that can be

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ignited readily and whenignited burns so vigorously andpersistently as to create aserious hazard.

g. Oxidizer and Oxidizing Agent.A substance that yields oxygenreadily to stimulate thecombustion (oxidation) oforganic matter.

h. Poison. A substance that isharmful to human health. Alsocalled toxic.

i. Radioactive. Material thatemits radioactive particles orrays, such as many of thematerials used in well loggingor for industrial radiography.

j. Corrosive. Causes visibledestruction or irreversiblealterations in living tissue bychemical action at the site ofcontact. Causes a severecorrosion rate in steel.

2. The Hazardous Material Identification System(HMIS®) is a registered trademark of the NationalPaint & Coating Association. The code numbers areon a scale of 0 for no hazard to 4 for high hazard.Labels are coded for degree of health hazard,flammability, and reactivity. Recommended personalprotective equipment (PPE) is written on the label atthe time the label is placed into service. The codes arepresented in Figure 3-2 facing page. The numbers onthe label (Figure 3-3 on page 3-6) were selected solelyfor illustration purposes.


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Figure 3-2 HMIS® Chart

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Figure 3-3: HMIS® Label


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Figure 3-4: NFPA Hazardous MaterialsClassification Chart

3. The National Fire Protection Association (NFPA)system is used in industrial plant and storage locationsto provide information for fire fighting and emergencyresponse personnel. The code numbers are on a scaleof 0 for no hazard to 4 for high hazard. The labels arecoded for degree of health hazard, fire hazard,reactivity, and special hazard. The numbers in Figure3-4 below were created solely for illustration purposes.(See also Table 3-1: Hazardous Materials Guide nextpage.)

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Table 3-1: NFPA Hazardous Materials Guide


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C. Restricted Manufacturing Substances (RMS)

1. General Principals

a. A number of chemicals are considered to beharmful to human health and the environementand are banned from being used at any phase ofthe manufacturing process at owned andcontracted facilities.

b. Contractors/employers must be aware that thesechemicals are not to be used at any time and eachfacility is responsible for ensuring that onlyapproved chemicals are used in accordance withNike Code Leadership standards and localrequirements. The primary areas where potentiallynon-approved chemicals will be found are:

1) Solvent-cleaning processes

2) Mixing rooms

3) Dye-preparation areas

4) Chemical storage areas

5) Maintenance areas

6) Rubber rooms

7) Molding areas

8) Painting/silk screening areas

9) Waste water pretreatment

c. Prevention of banned chemicals entering intoproduction and other processes can be effectivelyaddressed by Documentation Controls.


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2. Banned Chemicals Documentation Controls

To achieve the banned chemical use objective, eachfacility should be able to demonstrate they have thefollowing documentation controls in place:

a. Chemical Inventory. The facility should haveavailable for inspection a current inventory of allchemicals used on site. The inventory mustinclude:

1) Name and process where chemicals are used

2) Quantities used and stored on site

3) MSDS

4) Certification the chemicals are not on theapplicable RMS

b. Purchase Approval Procedure. The facility mustmaintain a procedure to review all requests fornew chemical purchases. The procedure mustinclude:

1) Review of MSDS

2) Cross-check of proposed purchase against theRMS

3) Chemicals approved for purchase list

4) Chemical requisition form

c. Routine Inspections. The facility must maintain arecord of inspections for all chemical storage areasto ensure all chemicals on site are not on theRMS.


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D. Chemical Storage, Handling, Distribution,Dispensing

1. Solvents and Cleaning Agents

a. Do not use gasoline or any other similarflammable materials for cleaning purposes.

b. Review cleaning agent container labels todetermine if contents are acceptable for theintended use.

c. Incompatible materials must be stored separately.

d. Cleaning agents must not be heated, or used onhot surfaces or near flames.

e. Place rags that have been used with cleaningagents in designated covered metal containersuntil they can be properly cleaned or disposed of.

f. Avoid skin contact with solvent liquids or inhalingvapors. Use nitrile, neoprene, or other suitablegloves to protect hands when using solvents andcleaning agents. If a cleaning agent or solventcomes in contact with the skin, clean the affectedarea with soap and water and apply a lotion toreplace the natural body oils.

g. Remove clothing that becomes contaminated witha cleaning agent as soon as possible. Clean skinwith soap and water to prevent a chemical burn.

h. Areas where cleaning solvents are used must bewell ventilated.

i. Fusible links on parts washers must not bemodified or bypassed.

[See Some Incompatible Chemicals next pages.]

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2. Electrical Bonding and Grounding

a. Before transfer or collection of flammable liquids,dispensing containers or process equipment mustbe properly grounded and bonded to a receivingcontainer.

b. Static electricity is generated by the contact andseparation of dissimilar material. For example,static electricity is generated when a fluid flowsthrough a pipe, or from an orifice, into a tank.The principal hazards created by static electricityare those of fire and exposure, which are caused byspark dischargers containing sufficient energy toignite any flammable or explosive vapors, gases, ordust which are present. Also, the shocking ofpersonnel may cause an involuntary reaction, suchas falling, which may lead to an injury.

c. A point of great danger from a static spark is theplace where a flammable vapor may be present in

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the air, such as an outlet of a flammable liquid fillpipe, a delivery hose nozzle, near an openflammable liquid container and around a tanktruck fill opening or barrel bunghole. A sparkbetween two bodies occurs when there is not agood electrical conductive path between them.Hence, grounding and bonding of flammableliquid containers is necessary to prevent staticelectricity from causing a spark.

d. The terms “bonding” and “grounding” often havebeen used interchangeably because of poorunderstanding of the terms. Bonding is done toeliminate the difference in potential betweenobjects. The purpose of grounding is to eliminatethe difference in potential between an object andthe ground. Bonding and grounding are effectiveonly when the bonded objects are conductive.Although bonding will eliminate a difference inpotential between the objects that are bonded, itwill not eliminate a difference in potentialbetween these objects and the earth unless one ofthe objects possesses an adequate conductive pathto earth. Therefore, bonding will not eliminate thestatic charge, but will equalize potential betweenthe objects bonded so that the spark will not occurbetween them.

e. When two objects are bonded, the charges flowfreely between the bodies and there is nodifference in charge.

f. An adequate ground will always discharge acharged conductive body and is recommended as asafety measure whenever any doubt existsconcerning a situation, or a governing authorityrequires it.


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g. To avoid a spark from discharge of static electricityduring filling operations, a wire bond should beprovided between the storage container and thecontainer being filled, unless the metallic pathbetween the container is otherwise present. Foradditional safety, it is advisable to have thebonding wire or one of the containers grounded.

h. Bonding and grounding systems should bechecked regularly for performance, especiallyelectrically. Preferably before each fill, the exposedpart of the bonding and grounding system shouldbe inspected for parts which have deterioratedbecause of corrosion or have otherwise beendamaged. Many companies specify that bonds andgrounds be constructed of bare, braided, flexiblewire because it facilitates inspection and preventsbroken wires from being concealed.

i. Figure 3-5 (next page) shows one method ofbonding and grounding a metal receivingcontainer.

3. Flammable Liquids

a. Proper storage and use of flammable liquids cansignificantly reduce the possibility of accidentalfires and injury to employees. The following areguidelines for handling flammable/combustibleliquids.

b. Definitions

1) Flammable Liquid—A liquid with a flashpointbelow 100° F (38° C).

a) Class IA—Flashpoint below 73° F (23° C)and boiling point below 100° F (38° C).

b) Class IB—Flashpoint below 73° F (23° C)and boiling point above 100° F (38° C).

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c) Class IC—Flash at or above 73° F (23° C)and below 100° F (38° C).

2) Combustible Liquids—A liquid having a flashpoint at or above 100° F (38° C).

3) Class II Combustibles—Flashpoint above 100°F (38° C) and below 140° F (60° C).

4) Class III Combustibles—Flashpoint at orabove 140° F (60° C).

Figure 3-5: Bonding and GroundingMetal Receiving Container


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a) Subclass IIIA—Flashpoint at or above 140°F (60° C) and below 200° F (93° C).

b) Subclass IIIB—Flashpoint at or above 200°F (93° C).

c. Responsibilities

1) Facility Management

a) Provide proper storage for flammableliquids.

b) Ensure proper training is provided toemployees who work with flammableliquids.

c) Ensure containers are properly labeled.

2) Supervisors

a) Provide adequate training in the use andstorage of flammable liquids.

b) Monitor for proper use and storage.

c) Keep only the minimum amount requiredon hand.

d) Ensure MSDS are current for all flammableliquids.

3) Employees

a) Follow all storage and use requirements.

b) Report deficiencies in storage and use tosupervisors.

c) Immediately report spills to supervisors.

d. Hazard Control

1) Engineering Controls

a) Properly designed flammable storage areas.

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b) Ventilated storage areas.

c) Grounding straps on drums and dispensingpoints.

2) Administrative Controls

a) Designated storage areas.

b) Limited amount of flammable liquids in useand storage.

c) Employee training.

d) Limited and controlled access to bulkstorage areas.

e) Posted danger, warning and hazard signs.

e. Substitution

Flammable liquids sometimes may be substitutedby relatively safe materials in order to reduce therisk of fires. Any substituted material should bestable and nontoxic and should either benonflammable or have a high flashpoint.

f. Storage and Usage of Flammable Liquids

Flammable and combustible liquids requirecareful handling at all times. The proper storage offlammable liquids within a work area is veryimportant in order to protect personnel from fireand other safety and health hazards.

1) Storage of Flammable liquids should be inNFPA approved flammable storage lockers. Donot store other combustible materials nearflammable storage areas or lockers.

2) Bulk drums of flammable liquids must begrounded and bonded to containers duringdispensing. (See Figures 3-6 and 3-7 followingpages.)


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Figure 3-6: Examples of Bonded and GroundedMetal Receiving Containers

3) Portable containers of gasoline or diesel are notto exceed 5 gallons (19 liters).

4) Safety cans used for dispensing flammable orcombustible liquids should be kept at points ofuse.

5) Appropriate fire extinguishers are to bemounted within 75 feet (22.86 meters) ofoutside areas containing flammable liquids,and within 10 feet (3 meters) of any insidestorage area for such materials.

6) Storage rooms for flammable and combustibleliquids must have explosion-proof lightfixtures.

7) Bulk storage of gasoline, diesel, or oil are keptin above ground tanks. Tank areas are diked tocontain accidental spills. All tank areas must bedesignated no smoking, no hot work, no openflame areas.

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Figure 3-7: Examples of Bonded and GroundedMetal Receiving Containers


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8) No flames, hotwork, or smoking is permittedin flammable or combustible liquid storageareas.

9) The maximum amount of flammable liquidsthat may be stored in a building are:

a) 20 gallons (76 liters) of Class IA liquids incontainers

b) 100 gallons (378 liters) of Class IB, IC, II,or III liquids in containers

c) 500 gallons (1,893 liters) of Class IB, IC,II, or III liquids in a single portable tank

10) Flammable liquid transfer areas are to beseparated from other operations by distance orby construction having proper fire resistance.

11) When not in use, flammable liquids must bekept in covered containers.

12) Class I liquids must be used only where thereare no open flames or other sources of ignitionwithin the possible path of vapor travel.

13) Flammable or combustible liquids must bedrawn from or transferred into vessels,containers, or portable tanks within a buildingonly through a closed piping system, fromsafety cans, by means of a device drawingthrough the top, or from a container orportable tanks by gravity through an approvedself-closing valve that is bonded and grounded.Transferring by means of air pressure on thecontainer or portable tanks must be prohibited.

14) Maintenance and operating practices must bein accordance with established procedureswhich will tend to control leakage and preventthe accidental escape of flammable or combus-

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tible liquids. Spills must be cleaned uppromptly.

15) Combustible waste material and residues in abuilding or unit operating area must be kept toa minimum, stored in covered metal recep-tacles, and disposed of daily.

16) Rooms in which flammable or combustibleliquids are stored or handled by pumps musthave exit facilities arranged to prevent occu-pants from being trapped in the event of fire.

17) Inside areas in which Class I liquids are storedor handled must be heated only by means notconstituting a source of ignition, such as steamor hot water.

g. Cabinets

Not more than 120 gallons (454 liters) of Class I,Class II, and Class IIIA liquids may be stored in astorage cabinet. Of this total, not more than 60gallons (227 liters) may be Class I and II liquids.Not more than three such cabinets (120 gallons(454 liters) each) may be located in a single firearea except in an industrial area. (See Figure 3-8next page.)

h. Containers

The capacity of flammable and combustible liquidcontainers will be in accordance with Table 3-2 onpage 3-26.

i. Storage Inside Buildings

Where approved storage cabinets or rooms are notprovided, inside storage will comply with thefollowing basic conditions:


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1) The storage of any flammable or combustibleliquid must not physically obstruct a means ofegress from the building or area.

2) Containers of flammable or combustibleliquids must remain tightly sealed except whentransferred, poured or applied. Remove onlythat portion of liquid in the storage containerrequired to accomplish a particular job.

3) If a flammable and combustible liquid storagebuilding is used, it will be a one-story building

Figure 3-8: Storage Cabinet

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devoted principally to the handling and storingof flammable or combustible liquids. Thebuilding will have 2-hour fire-rated exteriorwalls having no opening within 10 feet (3meters) of such storage.

4) Flammable paints, oils, and varnishes in 1 or 5gallon (3.8 or 19 liter) containers, used forbuilding-maintenance purposes, may be storedtemporarily in closed containers outsideapproved storage cabinets or room if kept atthe job site for less than 10 calendar days.

Table 3-2: Recommended Storage Containers


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Figure 3-9: Storage Locker Ventilation Fans

j. Ventilation

Every inside storage room will be provided with acontinuous mechanical exhaust ventilation system.To prevent the accumulation of vapors, thelocation of both the makeup and exhaust airopenings will be arranged to provide, as far aspractical, air movement directly to the exterior ofthe building and, if ducts are used, they will notbe used for any other purpose. (See figure 3-9below.)

4. Facilities and Maintenance

A. General Work Environment

1. Housekeeping

a. Each employee is responsible for goodhousekeeping practices.

b. Work areas must be maintained in an orderlymanner.

c. Tools and equipment must be stored when not inuse.

d. Work areas, walkways, and stairways must be keptfree of slipping/tripping hazards.

e. All spills must be promptly cleaned up.

f. Exits must be kept free of obstructions.

g. Access to emergency equipment (air packs, fireextinguishers, etc.) must be kept free and open atall times.

h. All places of employment must be kept clean tothe extent that the nature of the work allows.

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Figure 4-1: Cluttered Shop Floor

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i. The floor of every workroom must be maintained,so far as practicable, in a dry condition. Wherewet processes are used, drainage must bemaintained and false floors, platforms, mats, orother dry-standing places must be provided, wherepracticable, or appropriate waterproof footgearmust be provided.

j. To facilitate cleaning, every floor, working place,and passageway must be kept free from protrudingnails, splinters, loose boards, and unnecessaryholes and openings.

k. All aisles, emergency exits, fire extinguishers,eyewash/shower stations, etc., must be kept clear(a minimum of 3 feet (0.9144 meters) of eitherside) of product storage, material storage, forktrucks and pallet jacks (temporary andpermanent) at all times.

l. Storage areas are kept orderly at all times.

m. Smoking is not permitted inside buildings and/orwithin 50 feet (15.24 meters) of material storage.This includes all offices, rest rooms, productionfloor, storage areas, coolers, etc. Smoking ispermitted outside in designated areas. To preventfires and keep the grounds neat and orderly, allcigarette/cigar ashes and butts are to be disposedin the provided butt cans or ashtrays only.

2. Floors and Walls

a. A standard railing and toeboard must guard everyfloor opening. The railing must be provided on allexposed sides (except at entrance to stairway). Forinfrequently used stairways where traffic across theopening prevents the use of fixed standard railing(as when located in aisle spaces, etc.), the guardmust consist of a hinged floor opening cover of

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standard strength and construction and removablestandard railings on all exposed sides (except atentrance to stairway).

b. Every wall opening from which there is a drop ofmore than 4 feet (1.22 meters) must be guarded.

c. Every open-sided floor or platform 4 feet (1.22meters) or more above adjacent floor or groundlevel must be guarded by a standard railing on allopen sides except where there is entrance to aramp, stairway, or fixed ladder. The railing mustbe provided with a toeboard if a person can passbeneath the open sides, if there is movingmachinery, or there is equipment with whichfalling materials could create a hazard.

d. Every flight of stairs having 4 or more risers mustbe equipped with standard stair railings orstandard handrails.

e. A standard railing must consist of top rail,intermediate rail, and posts, and must have avertical height of 42 inches (106.68 centimeters)nominal from upper surface of top rail to floor,platform, runway, or ramp level. The top rail mustbe smooth-surfaced throughout the length of therailing. The intermediate rail must beapproximately halfway between the top rail andthe floor, platform, runway, or ramp. The ends ofthe rails must not overhang the terminal postsexcept where such overhang does not constitute aprojection hazard.

3. Stairways and Elevated Work Surfaces

a. Fixed stairs must be provided for access from onestructure level to another where operationsnecessitate regular travel between levels, and foraccess to operating platforms at any equipment

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that requires attention routinely duringoperations. Fixed stairs must also be providedwhere access to elevations is daily or at each shiftfor such purposes as gauging, inspection, regularmaintenance, etc., where such work may exposeemployees to acids, caustics, gases, or otherharmful substances, or for which purposes thecarrying of tools or equipment by hand isnormally required. (It is not the intent of thissection to preclude the use of fixed ladders foraccess to elevated tanks, towers, and similarstructures, overhead traveling cranes, etc., wherethe use of fixed ladders is common practice.)Spiral stairways shall not be permitted except forspecial limited usage and secondary accesssituations where it is not practical to provide aconventional stairway. Winding stairways may beinstalled on tanks and similar round structureswhere the diameter of the structure is not less than5 feet (1.52 meters).

b. Fixed stairways shall be designed and constructedto carry a load of 5 times the normal live loadanticipated but never of less strength than to carrysafely a moving concentrated load of 1,000pounds (373 kilograms).

c. Fixed stairways must have a minimum width of 22inches (56 centimeters).

d. Fixed stairs must be installed at angles to thehorizontal of between 30 degrees and 50 degrees.Any uniform combination of rise/treaddimensions may be used that will result in astairway at an angle to the horizontal within thepermissible range.

e. All treads must be reasonably slip-resistant and thenosings must be of nonslip finish. Welded bar


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Figure 4-2: Runs and Risers for Stairs

Figure 4-3: Safe Angles for Ladders,Stairs and Ramps

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grating treads without nosings are acceptable,providing the leading edge can be readilyidentified by personnel descending the stairwayand provided the tread is serrated or is of definitenonslip design. Rise height and tread width mustbe uniform throughout any flight of stairsincluding any foundation structure used as one ormore treads of the stairs.

f. Stairway platforms must be no less than the widthof a stairway and a minimum of 30 inches (76.2centimeters) in length measured in the directionof travel.

g. Standard railings must be provided on the opensides of all exposed stairways and stair platforms.Handrails must be provided on at least one side ofclosed stairways, preferably on the right sidedescending.

h. Vertical clearance above any stair tread to anoverhead obstruction must be at least 7 feet(2.134 meters) measured from the leading edge ofthe tread.

i. Employees must not climb onto vessels, tankroofs, etc., without safeguards (planking, scaffolds,etc.). Working from any surface over 4 feet (1.22meters) above adjacent floor or ground requiresguardrails or that employees use safety belts.

j. Where guardrails are installed, toe boards must beprovided if a person can pass beneath the opensides or where falling materials can create ahazard.

k. When on stairways or elevated work surfaces,employees must avoid carrying loads that extendabove eye level or otherwise obstruct vision.


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4. Exits

a. Every building or structure must be provided withexits of kinds, numbers, location, and capacityappropriate to the individual building or structure,with due regard to the character of the occupancy,the number of persons exposed, the fire protectionavailable, and the height and type of constructionof the building or structure, to afford alloccupants convenient facilities for escape.

b. In every building or structure exits must be soarranged and maintained as to provide free andunobstructed egress from all parts of the buildingor structure at all times when it is occupied. Nolock or fastening to prevent free escape from theinside of any building must be installed.

c. Every exit must be clearly visible and the route toreach it must be conspicuously indicated in such amanner that every occupant of every building orstructure who is physically and mentally capablewill readily know the direction of escape from anypoint, and each path of escape, in its entirety,must be so arranged or marked that the way to aplace of safety outside is unmistakable.

d. Any doorway or passageway not constituting anexit or way to reach an exit, but of such acharacter as to be subject to being mistaken for anexit, must be so arranged or marked as tominimize its possibleconfusion with anexit and the resultantdanger of personsendeavoring toescape from firefinding themselvestrapped in a dead-

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end space, such as a cellar or storeroom, fromwhich there is no other way out.

e. Adequate and reliable illumination must beprovided for all exit facilities.

f. In every building or structure ofsuch size, arrangement, oroccupancy that a fire may notitself provide adequate warningto occupants, fire alarms must beprovided where necessary towarn occupants of the existenceof fire so that they may escape,or to facilitate the orderlyconduct of fire exit drills.

g. Every building or structure,section, or area thereof of suchsize, occupancy, andarrangement that the reasonablesafety of numbers of occupants may beendangered by the blocking of any single means ofegress due to fire or smoke, must have at least 2means of egress remote from each other, soarranged as to minimize any possibility that bothmay be blocked by any one fire or otheremergency conditions.

h. Every required exit, way of approach, and way oftravel from the exit into the street or open space,must be continuously maintained free of allobstructions or impediments to full immediate usein the case of fire or other emergency.

i. Every automatic sprinkler system, fire detectionand alarm system, exit lighting, fire door, andother item of equipment, where provided, must becontinuously in proper operating condition.


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5. Illumination

a. The purpose of industrial lighting is to provideillumination in quality and quantity sufficient forsafety and to enhance visibility and productivitywithin the work environment. It is essential toinvestigate and to understand the task, theenvironment, the lighting and theirinterrelationships.

b. Luminance is frequently the one controllablefactor in task visibility. Luminance resulting fromthe light on the task and its surroundings may becontrolled by varying the amount and distributionof light. Luminance needed to see well is usuallymany times what is necessary for merediscernment. Higher luminance may compensatefor deficiencies in the other contributing factors.

c. Example of Illuminance Selection

1) Suppose a machine shop is to be relighted. Thesupervisor, with consultation with the depart-ment, determines the following:

a) Worker Age: Young (under 40).

b) Demands: Workers are under pressure tomaintain close tolerances on die production.Speed and accuracy are considered impor-tant, but not critical, to production.

2) The supervisor then follows this step-by-stepprocedure:

a) STEP 1. Define the visual task. Here, thesupervisor uses the information obtained ina) and b) above.

b) STEP 2. Find an illuminance category.Here, the supervisor refers to Table 4-2

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Tab

le 4

-1 A

an

d B

: Illu

min

ance

Val

ues

, Mai

nta

ined

, in

Lu

x fo

r a

Co

mb

inat

ion

of

Illu

min

ance

Cat

ego

ries

an

d U

ser,

Ro

om

an

d T

ask

Ch

arac

teri

stic

s


4

(page 4-12) to find an illuminance categoryof “E” under “Machine Shops,” in thesubhead “medium bench or machine work.”

c) STEP 3. Determine the illuminance on taskcategory by cross referencing “E” and theappropriate weighting category in Table 4-1B (above).

d) STEP 4. Refer to Table 4-1A (GeneralLighting Throughout Room) (facing page).

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Table 4-2: Recommended IlluminanceCategories for Industrial Interiors

Area/Activity ............................................. Illuminance CategoryClothing Manufacture (see Sewn Products)

Receiving, opening, storing, shipping .................................. DExamining (perching) ........................................................... ISponging, decating, winding, measuring ............................. DPiling up and marking ......................................................... ECutting ............................................................................... GPattern making, preparation of trimming, piping, canvas andshoulder pads ...................................................................... EFitting, bundling, shading, stitching .................................... DShops .................................................................................. FInspection ........................................................................... GPressing ............................................................................... FSewing ................................................................................ G

Leather ManufacturingCleaning, tanning and stretching, vats ................................. DCutting, freshing and stuffing ............................................. DFinishing and scarfing ......................................................... E

Leather WorkingPressing, winding, glazing ................................................... FGrading, matching, cutting, scarfing, sewing ....................... G

Machine ShopsRough bench or machine work ........................................... DMedium bench or machine work, ordinary automaticmachines, rough grinding, medium buffing and polishing .. EFine bench or machine work, fine automatic machines,medium grinding, fine buffing and polishing ...................... GExtra-fine bench or machine work, grinding, fine work ...... H

Materials HandlingWrapping, packing, labeling ................................................ DPicking stock, classifying ..................................................... DLoading, inside truck bodies and freight cars ....................... C

Sewn ProductsReceiving, packing, shipping ............................................... EOpening, raw goods storage ................................................ EDesigning, pattern-drafting, pattern grading andmarkermaking ..................................................................... FComputerized designing, pattern-making and grading,


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digitizing, marker-making, and plotting .............................. BCloth inspection and perching ............................................. ISpreading and cutting (includes computerized cutting) ....... FFitting, sorting and blunding, shading, stitch marking ........ GSewing ................................................................................ GPressing ............................................................................... FIn-process and final inspection ............................................ GFinished goods storage and picking orders ........................... FTrim preparation, piping, canvas and shoulder pads ............ FMachine repair shops .......................................................... GKnitting .............................................................................. FSponging, decating, rewinding, measuring .......................... ELeather working (see Leather working)Shoe manufacturing (see Shoe manufacturing)

Shoe Manufacturing—LeatherCutting and stitching cutting tables ..................................... GMarking, buttonholding, skiving, sorting, vamping,counting .............................................................................. GStitching, dark materials ...................................................... GMaking and finishing, nailers, sole layers, well beatersand scrafers, sluggers, randers, wheelers, treers, cleaning,spraying, buffing, polishing, embossing ............................... F

Shoe Manufacturing—RubberWashing, coating, mill run compounding ........................... DVarnishing, vulcanizing, calendering, upper and solecutting ................................................................................ DSole rolling, lining, making and finishing processes ............. E

Textile MillsFinishing

Fabric preparation (desizing, scouring, bleaching,singeing, and mercerization) ......................................... DFabric dyeing (printing) ................................................ DFabric finishing (calendering, sanforizing, sueding,chemical treatment) ..................................................... Ea

Inspection .................................................................. Ga,b

aSupplementary lighting should be provided in this space toproduce the higher levels required for specific seeing tasksinvolved.

bColor temperature of the light source is important for colormatching.

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B. Ventilation

1. Exhaust Ventilation

a. Exhaust ventilation systems are classified in 2generic groups: General Exhaust System and LocalExhaust System.

b. The general exhaust system can be used for heatcontrol and/or removal of contaminants generatedin a space by flushing out a given space with largequantities of air. When used for heat control, theair may be tempered and recycled. When used forcontaminant control (the dilution system),enough outside air must be mixed with thecontaminant to reduce the average concentrationto a safe level. The contaminated air is thentypically discharged to the atmosphere. A supplysystem is usually used with a general exhaustsystem to replace the exhausted air.

c. Dilution ventilation systems are normally used forcontaminant control only when local exhaust isimpractical, as the large quantities of tempered

Figure 4-4: Direction of Air Flow


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replacement air required to offset the air exhaustedcan lead to high operating costs.

d. Local exhaust ventilation systems operate on theprinciple of capturing a contaminant at or near itssource. It is the preferred method of controlbecause it is more effective and the smaller exhaustflow rate results in lower heating costs comparedto high flow rate general exhaust requirements.The present emphasis on air pollution controlstresses the need for efficient air-cleaning deviceson industrial ventilation systems, and the smallerflow rates of the local exhaust system result inlower costs for air-cleaning devices.

e. Local exhaust systems are comprised of up to 4basic elements: the hood(s), the ductsystem(including the exhaust stack and/orrecirculation duct), the air-cleaning device and thefan. The purpose of the hood is to collectcontaminants generated in the air stream directedtoward the hood. A duct system must then

Figure 4-5: Inlet and Exhaust Locations

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Table 4-3: Range of Capture Velocities

Figure 4-6: Branch Entry

transport the contaminated air to the air cleaningdevice, if present, or to the fan. In the air cleaner,the contaminant is removed from the air stream.The fan must overcome all the losses due tofriction, hood entry, and fittings in the systemwhile producing the intended flow rate. Figure 4-6 below shows examples of good and poor branchentry designs.


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Figure 4-7: Exhaust Monitoring

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2. Fume Hoods

a. Testing Fume Hoods

1) A performance test to determine the operatingcondition of a fume hood must be conductedperiodically. The test procedure outlined herepresumes a bench-type laboratory hood. Ifother types of hoods are used, some modifica-tion of the test procedure may be required. The

Figure 4-8: Fume Hoods


4

performance test does not constitute anengineering investigation of what the causesmay be for poor performance of the fume hoodor of ways to improve performance. However,the performance test could be used as an aid tosuch an investigation.

2) Generally, the toxicity level of the work donewithin the hood will determine the hood facevelocities and the total amount of the exhaustair. Materials of little or no toxicity need facevelocities only sufficient to maintain controlunder normal operating conditions. As toxicitylevels rise, the face velocity should be increasedto assure control. The recommended velocitiesfor different toxic levels range from 80 FPM(24.38 MPM) to 130 FPM (39.62 MPM).Generally, 100 FPM (30.48 MPM) is satisfac-tory for most applications [Note: a Class Blaboratory fume hood with a minimum averageface velocity of 100 feet per minute (FPM)(30.48 meters per minute) would have about1000 to 1300 cubic feet per minute (CFM) (305to 396 cubic meters per minute (CMM)) of airexhausted through the hood. The equation for thiscalculation is Q = AV, where Q is air volume inCFM; A is face in square feet; and V is facevelocity in FPM]. The facility must specifywhat level of performance is required for eachhood. The tests must be in agreement withthe toxicity level of the work to be performedin the fume hood and the safety standardsestablished by the facility.

3) General activity in the facility must be normal.Air currents in front of the hood must bereduced or eliminated if possible. Conduct thetest with the normal hood apparatus in place

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and operating. The following list is typical ofthe test devices needed to perform smoke tests:

a) Smoke candles, ½ minute

b) Smoke tubes

c) Titanium tetrachloride

d) Cotton swabs

b. Smoke Test Procedure

1) To determine that a positive air flow is enteringthe hood over the entire face, take a completetraverse of the hood face with either:

a) Titanium tetrachloride on a cotton swab.

b) A smoke candle.

c) A smoke tube.

2) Use a smoke tube, a smoke candle, or swab astripe of titanium tetrachloride on pieces oftape to produce the necessary amount of smokeat the following test locations: (1) along bothsides, the top and the work surface of the hoodabout 6 inches (15 centimeters) behind and inparallel to the hood face, (2) along the backpanel and the baffle of the hood, and (3)around any equipment in the hood. Verify thatall smoke is carried to the back of the hood andexhausted. The hood fails the test if visiblesmoke flows out the front of the hood. Reverseair flows or dead air spaces are not permitted.

3) With the sash open, ignite a smoke candlewithin the hood enclosure to observe theexhaust capacity of the hood. All smoke shouldflow quickly and directly to the back of thehood and be exhausted. Set the candle on the


4

work surface and close the sash. With the sashclosed, the hood must have enough air to diluteand exhaust the smoke. The hood fails the testif visible smoke flows out the front of the hood.Reverse airflows or dead air spaces are notpermitted.

4) Place a pan of hot water in the center of thework area and add enough chunks of dry ice tothe hot water to form a large volume of heavywhite smoke. All smoke should flow directly tothe back of the hood and be exhausted. Thehood fails the test if visible smoke flows out thefront of the hood. Reverse airflows or dead airspaces are not permitted.

C. Accident Prevention Signs and Tags

1. Signal Word. The word or words that designate adegree or level of hazard seriousness. The signal wordsfor product safety signs are DANGER, WARNING,and CAUTION.

a. DANGER: Indicates an imminently hazardoussituation which, if not avoided, will result in deathor serious injury. This signal word is to be limitedto the most extreme situations.

b. CAUTION: Indicates a potentially hazardoussituation which, if not avoided, may result inminor or moderate injury. It may also be used toalert against unsafe practices.

Note: DANGER or WARNING must not beconsidered for property-damage accidents, unlesspersonal injury risk appropriate to these levels isalso involved. CAUTION is permitted forproperty-damage-only accidents.

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Figure 4-9: ANSI Tag Warnings


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Table 4-4: Color Table

D. Machine Shop Safety

1. General Rules

a. Keep shop areas clean and orderly.

b. Place junk, scrap, and waste in containers orspecialized areas for proper disposal.

c. The shop area must be properly lighted.

d. Fire protection equipment effective for thepotential hazards must be readily accessible. Referto Chapter 6, Emergency Preparedness &Response.

e. Appropriate first aid equipment must be provided,stocked, and readily available. Employees mustknow the locations of this equipment. Refer toChapter 6, Emergency Preparedness & Response.

f. Personal protective equipment (PPE) must beprovided as needed. Such equipment must be

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properly maintained. Refer to Chapter 7, PersonalProtective Equipment.

2. Bench and Pedestal Grinders

a. Use appropriate eye protection when usinggrinders.

b. Grinders must be equipped with tool/work restsadjusted to clear the abrasive wheel by not morethan 1/8 inch (3.17 millimeters).

c. Adjust the tongue guard so that clearance is nomore than ¼ inch (6.35 millimeters).

d. In addition, protective shield guards must beprovided on grinders and the grinding wheel mustbe rated for at least the RPM of the motor.

e. Powered Abrasive Wheel Tools

1) Powered abrasive grinding, cutting, polishing,and wire buffing wheels create special safetyproblems because they may throw off flyingfragments.

Figure 4-10: Bench/Pedestal Grinder


4

2) Before an abrasive wheel is mounted, it mustbe inspected closely and sound- or ring-testedto be sure that it is free from cracks or defects.To test, wheels should be tapped gently with alight non-metallic instrument. If they soundcracked or dead, they could fly apart inoperation and so must not be used. A soundand undamaged wheel will give a clear metallictone or “ring.” (See Figure 4-12: Ring Test nextpage.)

3) To prevent the wheel from cracking, the usermust be sure it fits freely on the spindle. Thespindle nut must be tightened enough to holdthe wheel in place, without distorting theflange. Follow the manufacturer’s recommen-dations. Care must be taken to assure that thespindle wheel will not exceed the abrasivewheel specifications.

4) Due to the possibility of a wheel disintegrating(exploding) during start-up, the employee mustnever stand directly in front of the wheel as itaccelerates to full operating speed.

The hood or gap adjustment must be kept ¼ inch (6.35millimeters) from the wheel and must be adjusted for wear.

Figure 4-11: Grinder Hood Adjustment

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5) Portable grinding tools need to be equippedwith safety guards to protect workers not onlyfrom the moving wheel surface, but also fromflying fragments in case of breakage.

6) Powered Grinder Safety Precautions

a) Always use eye protection.

b) Turn off the power when not in use.

c) Never clamp a hand-held grinder in a vise.

3. Air Hoses, Tools, and Compressors

a. Air hoses must be raised over aisles and work areasto prevent tripping hazards.

b. Eye protection must be worn when using an airtool for cleaning.

c. Do not use more than 30 psi (pounds per squareinch) (11.2 ksi (kilograms per square inch)) whenusing an air tool for cleaning. A sign must beposted stating that 30 psi (11.2 ksi) is themaximum pressure allowed.

d. Do not dust off clothing with compressed air.

Figure 4-12: Ring Test


4

e. Hoses must be kept clean and stored in a mannerthat protects them and maintains their goodcondition when not in use.

f. Air compressor and air receiver tanks must beequipped with spring-loaded pressure relief valves.These valves must be tested. Block valves must not

Figure 4-13: Air Nozzle with Dead-end Safety Tip

Figure 4-14: Acceptable Methodsfor Use of Compressed Air

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be placed between the air receiver tank and thepressure relief valve.

g. Drain liquid accumulation from air tanksperiodically.

h. Automatic starting compressors must have awarning sign stating that the unit startsautomatically.

NOTE:

Pressure relieving valves and gauges must be ratedand set at air receiver manufacturer’s specifications.

4. Fan Guards (Exposure of Blades)

When the periphery of the blades of a fan is less than7 feet (2.13 meters) above the floor or working level,the blades must be guarded. The guard should haveopenings no larger than ½ inch (1.27 centimeters).(See Figure 4-15 below.)

5. Portable Hand Tools and Powered Hand Tools

a. Hand tools are non-powered. They includeanything from sledges to wrenches. Appropriate

Figure 4-15: Some Types of Fan Guards


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personal protective equipment (e.g., safetygoggles, gloves, etc.) must be worn, due to hazardsthat may be encountered while in use.

1) Tools must be examined, kept clean andfunctional, and repaired (if necessary) prior touse. Unrepairable tools must be removed fromservice and destroyed.

2) Tools must be used only for the purpose forwhich they are designed.

3) An employee must assume a safe and stableposition before applying pressure to a toolhandle, to avoid losing balance or falling if thetool should slip.

4) Holders must be used when striking chisels,punches, rods, stakes, etc., to prevent handinjuries. Eye protection must be worn whenstriking tools are used. (See Figure 4-16 below.)

5) “Mushroomed” or expanded heads of impacttools such as chisels and sledgehammers mustbe dressed (filed off ) as needed. (See Figure 4-17 next page.)

6) A hammer must not be struck against anotherhammer.

Figure 4-16: A Striking Holder

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7) Adjustable crescent wrenches must not be usedif a box or open-end wrench of the correct sizeis available.

8) Jaws on adjustable crescent wrenches must betightened around fitting/nut and the forceapplied on the side with the stationary jaw.(See Figure 4-18 below.)

9) Wrenches must be pulled instead of pushedwhen possible.

10) Handles of sledges, hammers, mauls, and thelike must be securely wedged into the heads.Wooden handles must not be painted becausepaint causes handles to be slick and hidescracks and other defects. Cracked or splithandles must be replaced; they must not betaped.

b. Power Tool Precautions

1) Power tools can be hazardous when improperlyused. There are several types of power tools,based on the power source they use: electric,pneumatic, liquid fuel, hydraulic, and powder-actuated.

Figure 4-17:MushroomedStriking Tool

Figure 4-18:Crescent WrenchDirection of Force


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2) The following general precautions must beobserved by power tool users:

a) Never carry a tool by the cord or hose.

b) Never yank the cord or the hose to discon-nect it from the receptacle.

c) Keep cords and hoses away from heat, oil,and sharp edges.

d) Disconnect tools when not in use, beforeservicing, and when changing accessoriessuch as blades, bits and cutters.

e) All observers must be kept at a safe distanceaway from the work area.

f ) Secure work with clamps or a vise, freeingboth hands to operate the tool.

g) Avoid accidental starting. The worker mustnot hold a finger on the switch button whilecarrying a plugged-in tool.

h) Tools must be maintained with care. Theymust be kept sharp and clean for the bestperformance. Follow instructions in theuser’s manual for lubricating and changingaccessories.

i) Be sure to keep good footing and maintaingood balance.

j) The proper apparel must be worn. Looseclothing, ties, or jewelry can become caughtin moving parts.

k) All portable electric tools that are damagedmust be removed from use and tagged “DoNot Use.”

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6. Tool and Equipment Maintenance

a. Guards

1) Hazardous moving parts of a power tool needto be safeguarded. For example, belts, gears,shafts, pulleys, sprockets, drums, chains, orother reciprocating, rotating, or moving partsof equipment must be guarded.

2) Guards, as necessary, must be provided toprotect the operator and others from thefollowing:

a) Point of operation

b) In-running nip points

c) Rotating parts

d) Flying chips and sparks

3) Safety guards must never be removed when atool is being used. For example, portablecircular saws must be equipped with guards.An upper guard must cover the entire blade ofthe saw. A retractable lower guard must coverthe teeth of the saw, except when it makescontact with the work material. The lowerguard must automatically return to thecovering position when the tool is withdrawnfrom the work.

Figure 4-19: Retractable Safety Guard


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b. Pulleys

1) Exposed parts of pulleys 7 feet (2.13 meters) orless above the ground, floor or workingplatform must be guarded. (See Figure 4-20below.)

c. Shafting

1) All horizontal, vertical or inclined shafting 7feet (2.13 meters) or less above the ground,floor or working platform must be guarded.

Figure 4-21: Shaft Guards

Figure 4-20: Combination Beltand Pulley Guard

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2) Shafting under benches or tables must becompletely enclosed.

3) Projecting shaft ends within 7 feet (2.13meters) of the working surface must havesmooth, rounded edges and must not projectmore than half the diameter of the shaftbeyond the end of the bearing, unless the shaftend is guarded by a non-rotating casing.

4) Unused exposed keyways less than 7 feet (2.13meters) above the working surface must befilled, covered or guarded.

d. Couplings, Collars, and Clutches

1) Clutches, collars, cut-off couplings and clutchpulleys with projecting parts need guards if anypart is 7 feet (2.13 meters) or less above theworking surface. (See Figure 4-22 below.)

e. Gears, Sprockets, Friction Drives

1) As a general rule, gears and sprockets should becompletely enclosed. (See Figure 4-23 nextpage.) Exceptions are gears and sprockets ininaccessible places. They need not be guardedif they have extension lubrication fittings or

Figure 4-22: Coupling, Collar, Clutch Guards


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systems that can be serviced from the meshpoint of gears and sprockets.

2) Sprockets, open-web gears and friction drivesneed guarding to prevent accidental contact.

f. Band Saws

1) Band saw wheels must be completely enclosedor guarded, except the part between the guideroll and the table.

2) The down travel guard from the upper wheelto the guide must be made of heavy metal andadjusted so the blade will travel within theangle or channel.

Figure 4-23: Gear, Sprocket, Friction Drive Guards

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3) The guard must come to within ½ inch (1.27centimeters) of the stock being cut.

4) Band saws must have tension-control devices.

g. Crosscut and Ripsaw.

1) The contractor/employer must provide eachcircular crosscut saw and ripsaw with a hoodthat covers the saw at all times at least to thedepth of the teeth, and that adjusts itselfautomatically to the thickness of the materialbeing cut. It is important that the hood remainin contact with the material at the point wherethe stock meets the saw. (See Figure 4-25

Figure 4-24: Band Saw Guarding


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below.) In addition, the exposed parts of thesawblade under the table must be guarded.

2) A spreader slightly thicker than the saw diskand slightly thinner than the saw set or kerfshould be used on circular ripsaws, exceptwhen grooving, dadoing, or rabbetting.

3) Anti-kickback devices are recommended forcircular ripsaws. A pusher stick must beprovided and used.

4) The contractor/employer must provide apositive means of shutting off power to all

Figure 4-25: Table Saw Guarding

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woodcutting machinery while repairs andadjustments are made. Power and operatingcontrols must be within easy reach of theoperator.

Figure 4-26: Overhead Circular Saw Guarding

Figure 4-27: Grinder Guarding


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h. Safety Switches

1) The following hand-held powered tools are tobe equipped with a momentary contact “on-off” control switch: drills, tappers, fastenerdrivers, horizontal, vertical and angle grinderswith wheels larger than 2 inches (5 centime-ters) in diameter, disc and belt sanders,reciprocating saws, saber saws, and othersimilar tools. These tools also may be equippedwith a lock-on control provided that turnoffcan be accomplished by a single motion of thesame finger or fingers that turn it on.

2) The following hand-held powered tools may beequipped with only a positive “on-off” controlswitch: platen sanders, disc sanders with discs 2inches (5 centimeters) or less in diameter;grinders with wheels 2 inches (5 centimeters)or less in diameter; routers, planers, laminatetrimmers, nibblers, shears, scroll saws andjigsaws with blade shanks ¼-inch (6.35millimeters) wide or less.

3) Other hand-held powered tools such as circularsaws having a blade diameter greater than 2inches (5 centimeters), chain saws, andpercussion tools without positive accessoryholding means must be equipped with aconstant pressure switch that will shut off thepower when the pressure is released.

i. Electrical Safety

1) To protect the user from shock, tools musteither have a three-wire cord with ground andbe grounded, be double insulated, or bepowered by a low-voltage isolation transformer.Three-wire cords contain two current-carryingconductors and a grounding conductor. One

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end of the grounding conductor connects tothe tool’s metal housing. The other end isgrounded through a prong on the plug.Anytime an adapter is used to accommodate atwo-hole receptacle, the adapter wire must beattached to a known ground. The third prongmust never be removed from the plug.

2) Double insulation is more convenient. Theuser and the tools are protected in two ways: bynormal insulation on the wires inside, and by ahousing that cannot conduct electricity to theoperator in the event of a malfunction.

3) Electric Power Tool General Safety Practices:

a) Electric tools must be operated within theirdesign limitations.

b) Gloves and safety footwear are recom-mended during use of electric tools.

c) When not in use, tools must be stored in adry place.

d) Electric tools must not be used in damp orwet locations.

e) Work areas must be well lighted.

Figure 4-28: Typical 120 Volt Branch Circuitwith Correct Wiring


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4) Unqualified and Qualified Persons

a) Unqualified persons. Employees whose jobassignments require them to be close toexposed parts of electrical circuits at 50 voltsor more must be trained in and familiarwith any electrically related safety practicesnot specifically addressed in this standardbut which are necessary for their safety.

b) Qualified persons. Employees permitted towork on or near exposed energized partswho perform electrical work must betrained to recognize the hazards associatedwith their work environment and useappropriate procedures and protectiveequipment to minimize the risk of anaccident or injury. Work supervisors mustverify the qualifications and training of allelectrical workers before they are permittedto perform electrical work. Qualifiedemployees must, at a minimum, be trainedin and familiar with the following:

• The skills and techniques necessary todistinguish exposed live parts from otherparts of electric equipment.

• The skills and techniques necessary todetermine the nominal voltage of exposedlive parts.

• The clearance distances specified and thecorresponding voltages. (See Table 4-5next page.)

• The safety-related work practices requiredby Nike’s Electrical Safety CLS.

• Techniques necessary to de-energizeelectrical systems, identify live parts of

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equipment, and determine the nominalvoltage of exposed live parts and clearancedistances.

• Procedures for locking out and taggingenergized electrical circuits and equipmentsafely. See Nike’s Control of HazardousEnergy CLS.

• National Electrical Code (NFPA 70).

• National Electrical Safety Code (ANSI/IEEE C2).

• Use of personal protective grounds.

• Use of testing and measuring equipment.

Table 4-5: Minimum Depth of Clear WorkingSpace at Electric Equipment


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• Safety plans and work-authorizationdocuments.

• Use and care of personal protectiveequipment.

• Hazard categories and personnel require-ments.

j. Pneumatic Tools

1) Pneumatic tools are powered by compressed airand include chippers, drills, hammers, andsanders. There are several dangers encounteredin the use of pneumatic tools. The main one isthe danger of getting hit by one of the tool’sattachments or by some kind of fastener theworker is using with the tool. Eye protection isrequired and face protection is recommendedfor employees working with pneumatic tools.Working with noisy tools such as jackhammersrequires proper, effective use of hearingprotection.

2) When using pneumatic tools, employees are tocheck to see that they are fastened securely tothe hose to prevent them from becomingdisconnected. A short wire or positive lockingdevice attaching the air hose to the tool willserve as an added safeguard.

3) A safety clip or retainer must be installed toprevent attachments, such as chisels on achipping hammer, from being unintentionallyshot from the barrel.

4) Screens must be set up to protect nearbyworkers from being struck by flying fragmentsaround chippers, riveting guns, staplers, or airdrills.

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5) Compressed air guns must never be pointedtoward anyone. Users must never “dead-end” itagainst themselves or anyone else.

k. Hydraulic Power Tools

1) The fluid used in hydraulic power tools mustbe an approved fire-resistant fluid and mustretain its operating characteristics at the mostextreme temperatures to which it will beexposed. The manufacturer’s recommendedsafe operating pressure for hoses, valves, pipes,filters, and other fittings must not be exceeded.

l. Jacks

1) All jacks—lever and rachet jacks, screw jacks,and hydraulic jacks—must have a device thatstops them from jacking up too high. Also, themanufacturer’s load limit must be permanentlymarked in a prominent place on the jack andmust not be exceeded.

2) A jack must never be used to support a liftedload. Once the load has been lifted, it mustimmediately be blocked up.

3) Use wooden blocking under the base ifnecessary to make the jack level and secure. Ifthe lift surface is metal, place a 1-inch (2.54centimeter) thick hardwood block or equiva-lent between it and the metal jack head toreduce the danger of slippage.

4) To set up a jack, make certain of the following:

a) The base rests on a firm level surface.

b) The jack is correctly centered.

c) The jack head bears against a level surface.

d) The lift force is applied evenly.


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5) Proper maintenance of jacks is essential forsafety. All jacks must be inspected before eachuse and lubricated regularly. If a jack issubjected to an abnormal load or shock, itmust be thoroughly examined to make sure ithas not been damaged.

6) Hydraulic jacks exposed to freezing tempera-tures must be filled with an adequate antifreezeliquid.

7. Ladder Safety

a. General

1) Ladders must be examined for defects beforeeach use. Defective ladders must be removedfrom service and reported to the appropriatesupervisor.

2) Wooden ladders must not be painted. Painthides cracks and other damage.

3) When climbing or descending a ladder,employees must face the ladder and have freeuse of both hands. Employees must grasp siderails and not rungs with their hands.

4) Employees must not carry objects or tools intheir hands while ascending or descendingladders. Tools must be carried in a sackstrapped over the shoulder or otherwise securedto the person or hoisted by an appropriatemethod.

b. Portable Ladders

1) Employees must only use ladders that havelabels showing that the ladders conform toappropriate ANSI or equivalent Standards.

2) Metal ladders must not be used for electrical

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work or where they may contact electricalconductors. Special nonconductive ladders(approved wooden, fiberglass, etc.) are availablefor electricalmaintenancework.

3) Employeesmust not leanfrom a ladderto reach work;the ladder mustbe reposi-tioned.

4) Straight andextensionladders mustextend 3 feet(0.9 meters)beyond the topresting pointwhen used forclimbing onto

Figure 4-29: Proper Position of Straight andExtension Ladders


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Figure 4-30: Proper Position of Straight andExtension Ladders

a platform. The upper portion of an extensionladder must be secured (“lashed”) or the ladderheld by another person. The base of the laddermust be placed away from the wall ¼ theworking-height distance of the ladder. (SeeFigures 4-29 previous page and 4-30 below.)

5) A folding stepladder must not be used in astraight closed position.

c. Fixed Ladders

1) Employees must not climb a permanently fixedladder longer than 20 feet (6.1 meters) unlessthe ladder is equipped with a cage or theemployee uses a fall protection device. Employ-ees must report ladders that do not meet theseconditions to the appropriate supervisor.

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8. Compressed Gas Cylinders

a. Handling

1) When necessary to move compressed gascylinders, a cart or other mechanical deviceespecially designed for that purpose must beused. Cylinders may also be rolled on thebottom edge, but never dragged.

2) Cylinders handled by hoisting equipment mustbe carried in a cradle or similar device and caretaken to prevent their being dropped. Slings,ropes, or an electromagnet must never be usedto move cylinders.

3) Cylinders must never be dropped or allowed tostrike each other violently.

4) Cylinders must never be used for any purposeother than to contain the gas for which thecylinder was designed.

5) Empty cylinders must be marked or labeled“EMPTY.” Valves must be tightly closed andthe valve protection caps replaced.

6) Cylinders to be transported must be loadedand secured in an upright position, unlessspecifically designed for horizontal service.

7) Valve protection caps must never be used forlifting the cylinder.

8) Cylinder valves must be kept closed with thevalve protection cap in place during handling.

b. Use

1) Acetylene cylinders must be used in a securedand upright position.

2) Valve protector caps must be kept on cylinders


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except when the regulator is attached or thecylinder is connected to a manifold system.

3) Threads on a regulator or union must corre-spond to those on the cylinder valve outlet.Connections must not be forced.

4) A cylinder of compressed gas must never beused without a pressure-reducing regulatorattached to the cylinder valve.

5) Regulators and pressure gauges must only beused with the gases for which they are designedand intended.

6) The cylinder valve must always be closedbefore attempting to stop leaks.

7) Sparks, molten metal, electrical currents,excessive heat, or flames must not be permittedto come in contact with the cylinder orattachments. This includes propane oracetylene torches and space heaters.

8) Oil or grease must never be used as a lubricanton valves or attachments to oxygen cylinders,since oil and oxygen under pressure can be afire hazard. Also, oxygen regulators must notbe handled with oily or greasy hands or gloves.

9) Cylinder contents must never be used forpurposes other than those for which they wereintended.

c. Examination

1) Compressed gas cylinders must bear allmarkings and be hydrostatically tested asrequired.

2) Cylinders must be examined for signs ofcorrosion or other damage.

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3) Leaky or damaged cylinders must be reportedand taken out of service immediately. Theymust be removed to a safe location andobserved until safely depressurized. They mustbe marked or labeled “DAMAGED.”

d. Storage

1) Oxygen cylinders must not be stored within 20feet (6.1 meters) of fuel gas cylinders orcombustible/flammable materials (especially oilor grease), unless protected by a noncombus-tible barrier at least 5 feet (1.52 meters) highhaving a fire resistance rating of at least ½hour.

2) Cylinders, both empty and full, must be storedand secured in an upright position, unlessdesigned for horizontal use. Cylinders must besecured with a chain or by some other accept-able means and kept in a safe, dry, well-

Figure 4-32: Compromised and NormalCompressed Gas Cylinders

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ventilated place that is not exposed to heat orthe direct rays of the sun.

3) Cylinders must be mounted and used in afashion that will prevent the bottoms frombecoming corroded or otherwise damaged.

4) Acetylene cylinders must not be placed in ahorizontal position.

5) Cylinder valves must be kept closed duringstorage with the protective valve caps in place.

6) Compressed gas cylinders must not be acceptedfrom the supplier unless they are properlylabeled and have protective valve caps in place.

E. Contractor and Subcontractor Safety

1. Contractors/subcontractors are expected to:

a) Inform their employees of the site emergencyaction plan and of the known potential fire,explosion, or toxic release hazards related to theirwork and the process.

b) Conduct operations in such a manner thatconstitutes no potential hazard to employees,property, or the environment.

c) Provide the designated contractor/subcontractorwith reports of hazards presented by thecontractor’s work or identified during thecontractor’s work.

d) Report to the contractor/subcontractor allaccidents, injuries, and significant near-missesoccurring at the worksite.

e) Conduct investigations of incidents involvingcontractor/subcontractor employees, equipment,or processes.


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f ) Comply with all safety policies and procedures aswell as those of their own organization.

g) Satisfy all federal, state, local, and countryregulations and have written safety programs andprocedures, as required.

h) Provide and maintain all required personalprotective equipment (PPE), safety equipment,and instrumentation necessary to perform theirwork effectively, efficiently, and safely.

i) Train their employees in the proper use ofequipment and safe performance of their jobs.

j) Conduct appropriate industrial hygienemonitoring and, if requested, provide copies of theresults.

F. Confined Spaces Protection

1. Definition

a. Confined spaces are spaces that:

1) Are large enough and configured such that anemployee can bodily enter and perform work.

2) Have limited or restricted means for entry andexit.

3) Are not intended for continuous humanoccupancy.

b. A permit-required confined space is a confinedspace that has one or more of the followingcharacteristics:

1) Contains or could contain a hazardousatmosphere.

2) Contains a material that could engulf anentrant.

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3) Has an internal configuration that could trapan entrant or cause asphyxiation.

4) Contains a recognized health/safety hazard.

2. Employees assigned topermit-required confinedspace operations must betrained in safe entry andemergency procedures andbe periodically retrained asan entrant, entrysupervisor, attendant, orrescue team member. Theymust have a thoroughknowledge andunderstanding of theirequipment and thepotential hazards that exist.

3. The atmosphere in theconfined space must betested for oxygendeficiency, flammability,and toxicity before entry.The atmosphere must alsobe continuously monitoredas feasible throughout theconfined space operation.

4. No one must enter apermit-required confinedspace unless a ConfinedSpace Entry Permit has beencompleted and posted.

5. Appropriate personalprotective equipment (PPE)must be used.


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G. Welding, Cutting, and Brazing

1. General Guidelines

a. Welding must be performed by welders who arequalified in the type of welding they are toperform.

b. Welders are responsible for the maintenance oftheir equipment and for the protection and safetyof people in the immediate work area.

Figure 4-33: Confined Spaces

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c. The welder and the welder’s helper must use theproper protective clothing and eye protection asrequired by applicable regulations for the jobbeing performed.

d. Fire extinguishers must be available for fire controlat all welding operations.

e. All persons must stand to one side of anycompressed gas cylinder regulator gauge whenpressure is being applied to the regulator.

f. When a welder is cutting or welding on a pipe, noperson must be in front of or near the open pipeend.

g. Welding or cutting operations must not beperformed in a confined space until the area hasbeen tested for oxygen level, toxics, andflammables and the appropriate permits have beenposted. Consult the facility’s local work permitsrequirements for further information.

h. Ventilation or respiratory protection may berequired while welding or burning under certainconditions, including, but not limited to:

1) On stainless steel, galvanized, or coatedmaterials, such as, but not limited to, paintsthat contain lead or mercury.

2) With fluxes or other materials containingfluorides.

3) Inside a confined space.

4) Where ventilation is inadequate.

5) In an oxygen-deficient atmosphere.

i. Steel drums, barrels, or other closed tanks orvessels that have contained volatile liquids or gasesmust be thoroughly steam cleaned, filled with


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water, or made safe by other approved methodsbefore the cutting or welding torch is applied.(Mechanical drum cutters must be used wheneverfeasible.)

j. A physical examination of the immediate workarea must be completed prior to initiating hotwork, to determine that no hazardous conditionsexist.

k. When welding in a hazardous area, theatmosphere must be continuously monitored towarn of any dangerous changes in the atmosphere.

Figure 4-34: Oxyfuel Gas Welding Unit

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2. Oxyfuel Gas Welding

a. Oxygen and fuel gas hoses must be protected fromflying sparks and hot slag. They must be examinedfrequently for leaks, wear, and loose connections.Immediate action must be taken to replacedamaged or worn hoses and to correct unsafeconditions.

b. The hose on oxyfuel welding units must be rackedwhen not in use. Master valves on oxygen and fuelgas cylinders must be closed and the pressure bledfrom regulators and hoses after use.

c. Torches must be examined frequently for leakyvalves and damaged nozzles and tips.

d. The cylinder valve must be closed immediately if ahose catches fire.

e. Spark igniters must be used to light weldingtorches. Matches and cigarette lighters must notbe used for this purpose.

f. Flashback arrestors (check valves) must beprovided to prevent the flame from passing downthe hose into the fuel gas system.

3. Arc Welding

a. Welders using arc welding equipment mustprovide a protective screen around the arc whenpracticable and advise persons in the surroundingarea not to look at the arc without appropriate eyeprotection. Refer to Chapter 7, General (Eye &Face, Head, Foot and Hand Protection).

b. Suitable precautions must be taken to avoid shockfrom arc welding equipment:

1) Do not stand in water while arc welding.

2) Use proper protective equipment, such as


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Figure 4-35: Hot Work Warning Tag

rubber boots and rubber pads, if performingarc welding in wet or high humidity condi-tions.

3) Do not dip energized (“hot”) electrode holdersin water.

c. Do not use cables with damaged insulation orexposed conductors. If it is necessary to repairdamaged cable, the repaired section must have aninsulating quality equal to that of the originalcable. Never make splices within 10 feet (3meters) of the electrode holder.

d. Protect cables from vehicular traffic or otherhazards that may subject them to being cut orpinched.

e. Turn off arc welding equipment when not in use.

5. Industrial Health

A. Heat Stress Prevention

1. Probably the most elementary factor of environmentalcontrol is contol of the thermal environment in whichpeople work.

2. In all cases, the objective is the prevention of heatstroke, which is life threatening and the most seriousof the heat-related disorders.

3. The following charts are designed to assist in assessingand counteracting the affects of heat stress.

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Industrial Health 5–3

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B. Cold Stress Prevention

1. Fatal exposures to cold in the workplace have almostalways resulted from accidental exposures involvingfailure to escape from low air temperatures or fromimmersion in low-temperature water.

2. The most important aspect of life-threateninghypothermia is a fall in the deep-core bodytemperature. The intent is to prevent the deep bodytemperature from falling below 36° C (96.8° F) andto prevent cold injury to body extremities.


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C. Occupational Noise Exposure


This section helps facilities identify noise hazards inthe workplace and protect employees by means ofengineering controls and hearing protection devices.

2. Terms

a. Noise is measured in units of energy called“decibels” (dB). OSHA requires noise to bemeasured according to a weighted scale, “A.”Therefore, the noise levels discussed in this sectionwill be expressed in “dBA.”

b. Representative noise samples are expressed as aneight hour time-weighted average (“8 hr. TWA”).The general thresholds the facility must follow arethe “Action Level” (AL) of 85 dBA over an 8 hr.TWA and the “Permissible Exposure Limit” (PEL)of 90 dBA over an 8 hr. TWA.

Note: Because these thresholds are based upon aneight-hour exposure, the allowable dBA willdecrease if the facility work shifts exceed eighthours (e.g., 10 hr. = PEL 88.39 and AL 83.39, 12hr. = PEL 87.08 and AL 82.08).

c. A loss of hearing of 25 dBA at certain frequencies(2000, 3000, and 4000 Hz) is termed a “standardthreshold shift” (STS).

3. Scope

This section applies if any of the facility employees areexposed to occupational noise levels equal to or greaterthan 85 dBA over an 8 hr. TWA.

4. Identification of Hazardous Noise

a. The facility will arrange for representative noisemonitoring to be performed of all workers

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suspected of being exposed above 85 dBA over an8 hr. TWA. Regardless of who performs themonitoring, affected workers are allowed toobserve the monitoring, if interested.

b. Additional monitoring will be performedwhenever there is a change in productionprocesses, layout, or equipment which maysignificantly increase employees’ exposure to noise.

c. A sound level meter will be used to identify noisyareas in the facility. To determine worker TWAexposures, however, an audiodosimeter will beused. The results of that monitoring willdetermine who is included in the HearingConservation Program, what the attenuationfactor of their hearing protectors must be, andwhether the facility must investigate engineeringcontrols.

d. The sampling strategy must consider workermobility, noise variations over time, and officepersonnel who enter the production areasroutinely.

e. The calibration of all noise monitoringinstruments (sound level meters, audiodosimeters,etc.) should be verified for accuracy immediatelybefore and after all readings.

f. The facility will inform each worker who, as aresult of the monitoring, is believed to be exposedat or above 85 dBA over an 8 hr. TWA.

g. As mentioned previously, if employees worklonger than eight hours (i.e., overtime,compressed work week, etc.), then the permissibleexposure limit and the action level are loweredhours (e.g., 10 hr. = PEL 88.39 and AL 83.39, 12hr. = PEL 87.08 and AL 82.08). The facility


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should refer to Table 5-1 below to estimate thepermissible exposure limits to noise under suchcircumstances.

h. In no event is a worker ever allowed to be exposedto a noise level equal to or greater than 115 dBA.(See Figure 5-1 below.)

Figure 5-1: Permissible Noise Exposure

Table 5-1: Permissible Exposure Limits

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5. Provision of Hearing Protection

a. The facility will provide hearing protectors for allworkers exposed above the action level and requirehearing protection use by all workers exposedabove the permissible limit (see Chapter 7, Section7).

b. The facility will provide a variety of hearing-protection devices so that workers may select thosethat are most comfortable and easy to use.However, employees must not use protectivedevices that do not afford sufficient attenuation(see Chapter 7, Section 7).

6. Audiometric Testing

a. Because hearing loss is permanent, it is critical todetect it as soon as possible so corrective actioncan prevent further damage. To identify hearingloss in its early stages, the facility should requireall workers who are exposed above the action level(85 dBA over 8 hr. TWA) to participate inaudiometric testing. This test will be available atno cost to workers.

b. The baseline audiometric exam must be given toworkers as close as practicable to the time of hire,and in no event more than six months later. Allworkers will be given audiometric examsaccording to a regular annual schedule.

c. For the test to be valid, it is important thatworkers avoid noise for at least 14 hours prior tothe exam. Where that is not practicable, workerswill be given redundant hearing protectors (i.e.,plugs and muffs) to minimize the likelihood of atemporary hearing loss confounding theaudiogram.


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d. The facility will arrange for each worker’s annualaudiogram to be compared to the correspondingbaseline audiogram. In this manner, hearing losscan be detected before it becomes severe.

e. As mentioned previously, a loss of hearing of 25dBA at certain frequencies (2000, 3000, and 4000Hz) is termed a “standard threshold shift” (STS).If an STS is identified, the facility will notify theaffected employee, in writing, within 21 days andmay require that the worker be retested within 30days (from the date the medical professionalevaluated the audiogram) to verify the accuracy ofthe test.

f. All workers who experience a persistent STS willbe referred to a specialist to determine the cause ofthe hearing loss. If occupational exposure isidentified as a contributing factor to the hearingloss, then the facility will evaluate the effectivenessof the current hearing protectors, and retrain theaffected employee in the proper fit and use of theprotectors. The facility will ask the examiner todetermine if the most recent audiogram resultsshould be used as a baseline for future hearingtests.

g. If the STS is not persistent, then the facility willinform the affected employee of this fact.

h. The facility must verify that any potential providerof audiometric testing follows all applicablestandards.

7. Hearing Protector Effectiveness

a. Two factors determine whether a hearing-protection device protects an individual’s hearing:

1) The device is appropriate for the level ofexposure.

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2) The device is used properly.

b. The facility will only provide hearing-protectiondevices which have a Noise Reduction Rating(NRR) readily available. This NRR will be used toestimate the effectiveness of the device.

c. Maximum Noise Levels. The maximum amountof noise a person can be exposed to safely ismeasured by the duration of the exposure and theintensity of the noise. The Permissible NoiseExposure graph (Figure 5-1, page 5-9) showspermissible exposures (dBA) to continuous noise(workers should never to exposed to continuousnoise at levels greater than 115 dBA).

d. The adequacy of hearing protection should bedetermined using the formula:

e. Typically, figure a 50% safety factor in calculatingthe field attentuation of hearing protectionbecause many workers do not wear the protectionproperly:

f. When choosing hearing protection for workers,keep the above evaluation in mind and rememberthat hearing protection must be fitted and wornproperly and conscientiously to be of value.

g. For workers exposed above the PEL (PermissibleExposure Limit), hearing protection mustattenuate noise to below 90 dBA. If an STS


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(Standard Threshold Shift) has been experienced,attenuation provided must be below 87 dBA.Double protection should be considered for anyjobs where attenuation is not below 90 dBA,especially if audiograms indicate a hearing loss.Double protection offers an additional 5 decibelattenuation. As an example, if a worker uses plugswith an NRR of 29 and a muff with an NRR of23, calculate using the highest NRR and applyingthe 50% factor, then add 5 dB for the protectorwith the lower NRR:

h. Because the effectiveness of the hearing-protectiondevice is a function of the noise exposure level, itwill be re-evaluated whenever the noise levelincreases substantially (i.e., increases 3 dBA ormore).

8. Training

a. The facility will conduct training at orientation,annually, and whenever the facility has reason tobelieve there have been deviations from theprocedure.

b. This general training will cover at least thefollowing subjects:

1) This program and its requirements.

2) The effects of noise on hearing.

3) The purpose of hearing protectors.

4) The benefits and limitations of various modelsof hearing protectors.

5) How to select, fit, use, and care for hearingprotectors.

6) The purpose of audiometric testing.

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c. All training should be documented.

9. Record Keeping

a. If audiometric testing reveals a loss of hearing of25 dBA or greater by comparing the baselineaudiogram with the most recent test, the case willbe listed on the ESH log of occupational injuriesand illnesses as an “illness.” Notice that thisthreshold differs from the criterion for a standardthreshold shift.

b. Cases of hearing loss need to be recorded onlyonce for every time an additional 25 dBA loss isconfirmed. That is, if a worker suffers a 25 dBAloss one year, then another loss the next yearwhich is less than 25 dBA, the case needs to berecorded only in the first year. However, if at alater time, another 25 dBA loss is detected, asecond entry should be made on the log.

c. All audiometric tests for all workers will bemaintained by the facility for at least the durationof the worker’s employment plus 30 years.

d. All noise exposure measurements (i.e., sound-levelsurveys, audiodosimetry, etc.) will be retained forat least 30 years from the date they wereconducted.

10. Program Availability

This hearing conservation program and its trainingmaterials are available to the following parties:

a. Employees of the facility.

b. Contract employees on facility property and theiremployees.


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D. Ergonomics

1. Definition

Ergonomics is an applied science that concentrates onthe human factors involved in the design of a processor product.


a. The goal of ergonomics is to:

1) Reduce occupational injury and illness.

2) Improve productivity and work quality.

3) Reduce absenteeism.

b. The objective of ergonomics is to design worktasks so they are within limitations.

3. Back Injury—Low Back Pain

a. Most back injuries occur because the worker:

1) Uses his or her back muscles for something themuscles cannot tolerate.

2) Is not flexible enough to meet the requiredrange of motion.

3) Had to compensate for a large mid-section.

4) Experiences inflammation caused by excessiveuse of the back muscles.

b. To avoid back injury the employee should focuson:

1) Exercises to strengthen the muscles of the back.

2) Obtaining training on lifting techniques andproper use of back muscles.

3) Using stretching exercises for the upper legsand lower back prior to beginning work.

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4) Maintaining appropriate body weight.

5) Using back resting techniques and endurancetraining.

4. Lifting Procedures

a. Planning

1) Plan the lift and identify the path to be takento be sure it is clear of obstructions.

2) Examine the object for sharp corners, slipperyspots, or other potential hazards.

3) Employees are not to lift an object they are notsure is within their physical ability. Whenunsure, use a lifting device (cart, hand truck,etc.) or get help.

4) If possible, do not set an item on the ground ifit must be picked up again.

5) Avoid unnecessary bending or reaching. Donot reach over or around items blocking theobject to be lifted.

b. Lifting

1) Lift comfortably. Alwaysuse a material handlingdevice whenever necessary.

2) Stand close to the loadwith your feet spreadapart about shoulderwidth, with one footslightly in front of theother for balance.

3) Squat down bending atthe knees (not yourwaist). Tuck your chin


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while keeping your backas vertical as possible.

4) Place the lead hand (thehand on the side of thelead foot) to the front ofthe item. Placing thetrailing hand to the rear,tilt the item forward andslide the trailing handunderneath.

5) Get a firm grasp of the objectbefore beginning the lift.

6) Keep the load to the front,and bring it close to thebody’s center of gravity (nearthe waist).

7) Begin slowly lifting with yourlegs by straightening them.Never twist your body duringthis step—pivot with yourfeet.

8) Once the lift is complete,keep the object as close to thebody as possible. As the load’scenter of gravity moves awayfrom the body, there isdramatic increase in stress tothe lumbar region of the back.

9) Be sure the view is notblocked by the item, thencarry the load to the desiredlocation carefully.

10) When placing an item on a desk top, counter,or shelf, place the lead or forward edge (the

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edge away from the body) on the surface andpush the item into position. Be sure there isroom for the item, with nothing to interferewith its placement.

11) When placing an item on the ground, bend atthe knees. Place the forward edge down first.Slide both hands to the rear and clear of thebottom, then set the rear end down.

c. Team lifting

1) When team lifting, establish a leader andfollow his or her instructions and signals.

2) Make sure everyone understands the plan(where and how the object will be moved) andany signals to be used. Be sure all persons lift,lower, and carry the item at the same time.

3) Lower the object slowly. Place one end downfirst, then the other. Be sure all hands are outfrom underneath the item.

4) Back belts, if worn, are to be loosened whennot engaged in lifting.

5. Computer Workstations

a. Repetitive movements, such as keyboarding andusing a mouse, combined with restrictive posture,can cause injuries commonly known as repetitivestress injuries.

b. To help prevent repetitive stress injuries, clearenough room to work efficiently and placematerials or supplies where they don’t interferewith your movements. Be sure to arrange yourwork area so that you can face the display andkeyboard directly, without having to twist yourbody. (See VDT Selection and Set-up Checkliston pages 5-21 and 5-22.)


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c. If overhead lighting is uneven or insufficient, usetask lighting to shed light on hard copy or high-use areas of your desk to minimize eyestrain.

d. If you use the telephone often, don’t cradle itbetween your neck and shoulder. See if a headsetcan be adapted to your phone, or try a receivershoulder rest.

e. Making the right ergonomic adjustments to yourchair, keyboard, and display are important too. Ifyou find it uncomfortable or painful in any way,alter your position slightly.

f. Breaks and Stretches

1) Remember to get up and move aroundperiodically. If you type continuously, a goodrule of thumb is to do other tasks for 10minutes every 2 hours.

2) The following exercises can help you releasemuscle tension and reduce the risk of aches andpains. Do stretches gently. Don’t do any stretchthat causes pain. Hold each stretch 15 to 20seconds.

a) Shoulder rolls—Gently roll shoulderforward, up and drop back. Do slowly andrhythmically 5 to 10 times.

b) Finger Stretch—Gently open and closehand, stretching fingers while hand is in theopen position.

c) Trap Stretch—Sit on hands to help stabilize.Tip head down as if looking in your shirtpocket. Hold.

d) Pyramid Stretch—Start with hands inpyramid position. Keeping shouldersrelaxed, raise palms together overhead.

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Slowly bring arms down, staying together,until you feel a good stretch on the under-side of your forearms.

e) Side Bending—Lower ear toward shoulder.Repeat other side.

f ) Shoulder Blade Pinch—Rotate arms toback, pinching shoulder blades together.Palms will naturally rotate back—let them.

g) Hug Stretch—Grasp arm at elbow. Pull armforward and across body as if you arehugging somebody.

h) Chin Tuck—Keeping head level, slide chinback making a double chin. Hold 2 secondsand release.

i) Hand Stretch—Make gentle fist. Openhand at first joint keeping fingers bent.Open hand, straightening fingers all theway.


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5

E. Non-Ionizing Radiation (Ultraviolet (UV) andRadio Frequency (RF) Radiation)

1. UV Radiation

a. UV has the highest photon energy range.Penetration is limited—target organs are the skinand cornea. UVA or Near UV are those UVfrequencies “near” the visible frequencies and mayalso effect the lens. UVB or Actinic UV, the mid-frequencies, are the most damaging. UVC, or “FarUV,” or “Vacuum UV” (i.e., UV wavelengths <200 nm, which are “far” from the visiblewavelengths), have photon energies in excess of 12eV, but are quickly absorbed in air. (See Figure 5-2below.)

b. Protective measures (e.g., welding goggles) areneeded. The ACGIH/TLV curve is most stringentat 270 nm, and limits near UV to 1 mW/cm2;based on protection against sunburn (erythema),actinic skin, and conjunctivitis and photokeratitis(welder’s flash). Also, concern for skin cancer;most cases caused by sun. UV also causesincreased skin pigmentation (tanning). Intenseacute exposures, and possibly less intensecumulative exposures can cause cataracts.

c. UV is more hazardous because the symptoms aredelayed (no immediate sensation of being overexposed). Effects are exaggerated for skin, whichhas been photosensitized by agent such as coal tar

Figure 5-2: Electromagnetic Spectrum

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products, by photoallergens, or by certain diseases(e.g., erythropoietic porphyria).

d. Common UV sources are the sun, mercury vaporand quartz lamps (black lights), welding arcs, andUV lasers.

e. Measurement. Radiometer or light meter (photo-cell with a sensitive volt meter) with UV filters toselect desired wavelengths provide irradiancereadings in mW/cm2.

f. UV Safety Precautions

1) Identify all UV light sources at the facility.These may include lights used in mercury-vapor lamps, etc.

2) Ensure that all UV lights are fully covered orenclosed.

3) Have warning signs posted in UV hazard areas.

4) Turn off UV lights whenever workers removePPE or during maintenance activities.

5) Ensure workers are protected (i.e., eyes, skin)from indirect stray UV light. Equipment sealsshould be intact.

6) Ensure glasses and/or goggles are specificallydesigned to protect workers from UV light.

7) Ensure UV lamps are approved for the purposeand manufacturer’s guidelines are beingfollowed.

2. RF Radiation (Heat Sealers)

a. Radio Frequency (RF) radiation sealers generate,by means of electronic circuitry, oscillating fieldsof electric and magnetic energy. RF sealersgenerally operate within the band of frequencies


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from 10–70 MHz (a megahertz is one millioncycles per second), although most of the sealersoperate at normal frequencies from 10–40 MHz.A few used for plastics operate at frequencies ashigh as 300–400 MHz. RF electromagneticenergy emitted from an RF sealer is considerednon-ionizing radiation by virtue of its frequencyand energy. (See Figure 5-3 below.)

b. Control of the emission of RF energy from RFsealers should rely on the application of properlydesigned and installed shielding material. Theshielding should be placed on or around theequipment so as to minimize exposure due toemissions of stray RF energy. All shielding shouldbe properly grounded. Shielding conductors

Figure 5-3: RF Heat Sealer

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should be used for conveying RF current, andpath impedence should be minimized by usinggood conductor materials.

c. To minimize the risk of adverse health effects,radiofrequency (RF) fields as well as induced andcontact currents must be in compliance withapplicable guidelines (e.g., CNIRP, ANSI,ACGIH). Reduction in RF exposures can beaccomplished through the implementation ofappropriate administrative, work practice andengineering controls. The following outlines theprincipal elements of an RF Protection Programand examples of the RF measurements necessaryto implement the program elements.

1) Element 1. Utilization of RF source equipmentwhich meets applicable RF and other safetystandards when new and during the time ofuse, including after any modifications.

a) Manufacturers of RF source equipment areresponsible for making equipment thatcomplies with applicable standards, and forproviding information on the hazards ofoperating and servicing equipment. Theinformation must be sufficient to alert theend user of potential hazards and necessarycontrols applicable to using the equipment.Manufacturers are therefore required tomake detailed RF emission measurements oftheir products. Appropriate RF surveyresults should be provided to the end userfor comparison purposes.

b) The users should conduct RF “screening”measurements of equipment emissions afterinstallation, major maintenance, and anymodifications that could affect RF emis-


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sions. Significant deviations from previousmeasurements should be resolved.

2) Element 2. RF hazard identification andperiodic surveillance by a competent personwho can effectively assess RF exposures.

a) Screening measurements are normallysufficient to identify potentially hazardousRF areas that will require some controlstrategy, such as to determine where a fenceshould be located. More complex measure-ments are necessary if the employer intendsto allow exposures to employees approach-ing RF standards. For example, detailedmeasurements are necessary if whole-bodyand/or time-weighted averaging of expo-sures are necessary to bring exposures intocompliance.

b) RF fields can induce currents in nearbyconducting objects, such as a metal barrieror fence used to restrict access to RF hazardareas. These must be evaluated to ensurethey do not constitute RF shock.

3) Element 3. Identification and control of RFhazard areas.

a) Controlling exposure time and the distancebetween the RF source and the operator areimportant in maintaining workers' expo-sures below recommended levels. Whennecessary due to excessive leakage, “RFhazard areas” must be identified to alertworkers of areas that are not to be occupiedduring RF application. The location of thehazard areas must be based on exposuremeasurements made during maximum fieldgeneration and duty factor (i.e., ratio of RF

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“on” time during any 6-minute period,assuming intermittent exposure).

b) Access to RF hazard areas should becontrolled with standard Lockout/ Tagoutprocedures (see Chapter 8, Section B) toensure workers are not occupying theseareas during the application of RF energy.

c) The RF hazard areas must be clearly markedwith appropriate signs, barricades, floormarkings, etc., such that any worker whohas access to the facility will be alerted notto occupy the hazardous locations. Signsmust be of standard design and shape (ref.ANSI C95.1), and of sufficient size to berecognizable and readable from a safedistance.

d) Screening measurements can be used todetermine where to locate signs to alertworkers approaching an RF hazard area,including the appropriate warning messageon the sign (e.g., Notice, Caution, Danger).

e) Compliance with the evacuation of hazardareas prior to RF application must bestrictly enforced. For example, workers maybe reluctant to follow a procedure whichrequires an RF sealer operator to first loadthe sealer, step back 6.5 yards (2 meters) toget outside the RF hazard area prior toactivating the RF energy, and then walkback to unload the sealer.

4) Element 4. Implementation of controls toreduce RF exposures to levels in compliancewith applicable guidelines (e.g., ANSI,ICNIRP), including the establishment of safework practice procedures.


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a) Reliance on averaging is normally notrecommended when establishing basiccontrol strategies because it obligates thefacility to conduct “measurement” ofemployee activity to ensure the averaging isapplicable, such as timing an employee'saccess inside an area which cannot beoccupied for 6 minutes without exceeding

Figure 5-4: Radio-Frequency Radiation HazardWarning Symbol

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the allowable time-weighted exposure.Where possible, controls should be estab-lished under the assumption that standardsare not time-weighted, i.e., assume thestandards are ceiling limits which are not tobe exceeded.

b) Measurements are necessary during thedevelopment of work practices to ensure thepractices are effective in preventing excessiveexposures. Detailed measurements arerequired if exposures are approachingguideline limits as discussed above.

c) Appropriate work practices must befollowed during the repair and maintenanceof RF equipment. Occasionally, cabinetpanels must be removed by service person-nel to allow access for maintenance. Failureto replace a panel properly may result inexcessive RF leakage. RF screening measure-ments can be used to determine whichpanels can be removed during operation(assuming other hazards, such as electricalshock, are controlled), and to ensure theshielding is reinstalled properly.

d) Detailed measurements must be made bythe manufacturers of RF personal protectiveequipment (PPE) to show its effectivenessand limitations. Limited measurements arenecessary by the user to ensure the PPE isapplicable and effective for the specificworksite conditions.

5) Element 5. RF safety and health training toensure that all workers understand the RFhazards to which they may be exposed themeans by which the hazards are controlled.


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a) Measurement of worker exposures isnecessary so that this information can beprovided as part of employee hazardtraining.

b) The scope of training, including reviews ofpotential biological effects, will be depen-dent on measure exposure levels.

6) Element 6. Worker involvement in thestructure and operation of the program and indecisions that affect their safety and health, tomake full use of their insight and to encouragetheir understanding and commitment to thesafe work practices established.

RF screening measurements should be made inthe presence of workers to facilitate under-standing and confidence in the program.

7) Element 7. Implementation of an appropriatemedical surveillance program.

a) RF measurements are necessary to deter-mine the need and scope of medicalsurveillance. For example, medical surveil-lance may consist of reporting the occur-rence of RF burns or the sensation of non-routine heating as a means of identifyingpotential problem areas.

b) A medical exam may be appropriate for“accidental” exposures defined as anexposure above some measured trigger level.

8) Element 8. Periodic (e.g., annual) reviews ofthe effectiveness of the program so thatdeficiencies can be identified and resolved.

Periodic RF screening measurements arenecessary to ensure conditions have not

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changed and that the RF Protection Programcontinues to be effective in preventing excessiveRF exposures.

9) Element 9. Assignment of responsibilities,including the necessary authority and resourcesto implement and enforce all aspects of the RFProtection Program.

a) Although this element does not directlyrequire RF measurements, it is included forcompleteness of the list of RF Programelements.

b) Without the commitment to the Program,as demonstrated by the assignment ofnecessary responsibility, authority andresources, the previous elements will not beeffective.

d. As described above, a variety of RF measurementsare necessary for an effective RF ProtectionProgram. Usually RF screening measurements areadequate unless control strategies allow exposuresapproaching RF limits. Detailed RFmeasurements are required of manufacturers ofRF products to document their effectiveness andlimitations. The effectiveness of the RF ProtectionProgram depends primarily on a facility’sunderstanding and commitment to the listedprogram elements, rather than on sophisticatedRF survey equipment or measurement procedures.

F. Bloodborne Pathogens

1. “Universal precautions,” as defined by the U.S.Centers for Disease Control, are a set of precautionsdesigned to prevent transmission of humanimmunodeficiency virus (HIV), hepatitis B virus


5

(HBV), and other bloodborne pathogens whenproviding first aid or health care. Under universalprecautions, blood and certain body fluids of allpersons are considered potentially infectious for HIV,HBV and other bloodborne pathogens.

2. Each contractor/employer having employees who mayhave skin, eye, mucous membrane, or parenteralcontact with blood or other potentially infectiousmaterials as a result of performing their professionalduties must establish a written exposure control plandesigned to eliminate or minimize exposure.

3. Methods of Compliance

a. Universal precautions must be observed to preventcontact with blood or other potentially infectiousmaterials. All body fluids must be consideredpotentially infectious.

b. Engineering and work practice controls.

c. Personal Protective Equipment (PPE).

4. Housekeeping

a. Contractors/employers must ensure that theworksite is maintained in a clean and sanitarycondition. The contractor/employer mustdetermine and implement an appropriate writtenschedule for cleaning and method ofdecontamination based upon the location withinthe facility, type of surface to be cleaned, type ofsoil present, and tasks or procedures beingperformed in the area.

b. All equipment, environmental and workingsurfaces must be cleaned and decontaminatedafter contact with blood or other potentiallyinfectious materials.

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5. Persons trained in first aid/CPR must also be trainedin avoiding exposure to bloodborne pathogens. Useuniversal precautions when there is a possibility ofbeing exposed to other people’s body fluids.

6. First aid kits/body fluid barrier packs must beavailable for those providing first aid. These packsinclude, but are not limited to, CPR mouth barriers,disposable latex gloves, and eye protection.

7. Contractor/employer mustprovide proper means of disposalfor materials that are consideredregulated medical wastes(biohazards). Bags or containersmarked with the biohazardsymbol must be handled bydesignated employees only.

8. Sharps Disposal Containers

a. Use the criteria below forevaluating theperformance ofcontainers for disposingof sharp objects (i.e.,sewing needles, razorblades):

1) Functionality—Containers should remainfunctional during their entire usage (i.e., theyshould be durable, closable, leak resistant ontheir sides and bottom, and puncture resistantuntil final disposal).

2) Accessibility—Containers should be accessibleto workers who use, maintain, or dispose ofsharp devices. They should be convenientlylocated and portable within the workplace, ifnecessary.


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3) Visibility—The following should be plainlyvisible to the workers who use the containers:the container, the degree to which it is full, theproper warning labels, and the color coding ofthe container.

b. Disposal of non-contaminated sewing needles, asan accepted practice in the United States, is toclose the lid of the sharps container, wrap it induct tape, and throw it into the trash.

c. Syringes/hypodermic or other contaminatedneedles should be disposed of in the same type ofcontainer, but the method of disposal is different.A biowaste vendor may be used or, in some cases,hospitals accept needles and incinerate themonsite. Contact your local waste hauler for moredetails.

G. Asbestos

Each facility should identify and manage asbestosmaterials in place. The facility should control the releaseof hazardous asbestos fibers through education, training,and communication to all personnel. The removal ofasbestos containing material (ACM) should be donewhenever feasible.

1. Definitions: The following definitions will be usedthroughout this section:

a. Asbestos Containing Material (ACM): Anymaterial containing more than 1% asbestos.

b. Friable Asbestos Material: Any materialcontaining more than 1% asbestos by weight thathand pressure can crumble, pulverize, or reduce topowder when dry.

c. Presumed Asbestos Containing Material(PACM): Thermal system insulation and surfacing

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material found in buildings constructed no laterthan 1980.

2. Information and Training

An awareness training course should be required forall facility employees and/or contractor supervisorswho perform work within or adjacent to facilitieswhere ACM/PACM are present. The contractor’s/employer’s supervisor is responsible for passing theinformation on to his/her employees. The trainingwill include the following:

a. The health affects of asbestos.

b. Locations, signs of damage and deterioration ofACM/PACM.

c. Proper response to fiber release episodes.

Figure 5-5: Exposed Asbestos Pipe Wrap


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d. Housekeeping requirements.

3. Hazards Communication

The facility should communicate the hazards ofasbestos to personnel who work in or adjacent to areascontaining asbestos:

a. Identify the presence of ACM/PACM at theworksite.

b. Notification should be in writing and personalcommunication, between facility employees/contractors concerning the presence of PACM andACM.

c. All friable asbestos materials should be labeled.

d. Any ACM/PACM that is disturbed should bereported immediately to the supervisor.

Figure 5-6: Asbestos Warning Sign

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4. Removal of Asbestos

There are two scenarios for the removal of ACM/PACM:

a. Planned removal—This ACM/PACM removal isrequired because of facility maintenance in thearea or new construction requiring the removal ofthe material. The project engineer in charge of theasbestos removal contractor/employer must becontacted and the material must be moved.

b. Minor emergency clean-up/removal—This ACM/PACM is removed because a small amount ofmaterial has come loose or needs to be moved forimmediate work.

1) If the minor emergency occurs during normalworking hours, contact the engineer in chargeof the asbestos removal contractor/employer.

2) If the minor emergency occurs after normalworking hours, the facility supervisor should becontacted immediately. The facility supervisorwill barricade the area to restrict access. Thefacility supervisor/foreman will contact themaintenance personnel on call, and the facilityengineer in charge of the ACM/PACMremoval contractor/employer. The ACM/PACM removal contractor/employer willremove the ACM/PACM.

5. Disposal

All ACM/PACM must be disposed of in an approvedlandfill.

6. Recordkeeping

a. The information kept in the asbestos files is asfollows:


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1) Asbestos abatement supervisor’s log sheet.

2) Verbal notification memo.

3) Government required reports.

4) Bulks sample reports.

5) Monthly contractor/employer reports onasbestos abatements performed.

6) Contractor/employer location monitoringresults and list of personnel in area.

7) Tracking documents (for hauling ACMs to alandfill).

b. These documents must be kept by the facilityengineer in the engineering files until completionof the project.

H. Occupational Exposure Limits

1. Requirements: Exposure Limits

a. Contractors/employers must abide by the morerestrictive of the country legal requirements, theAmerican Conference of Governmental IndustrialHygienists (ACGIH) Threshold Limit Values(TLVs), or US Occupational Safety and HealthAdministration (OSHA) Permissible ExposureLimits (PEL).

b. The occupational exposure limits, listed in Table5-2 next page, are defined as guidelines for bestmanagement practices. These limits representconditions to which employees can be exposed toon a regular basis without adverse health effects.

c. Occupational exposure limits are the maximumaverage air concentration that most employees canbe exposed to for an 8-hour work day, 40-hour

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work week for a working lifetime (40 years)without experiencing significant adverse healtheffects. A very small percentage of individualsexperience some discomfort or adverse healtheffects at or below the exposure limit because ofwide variation in individual sensitivities or pre-existing conditions. When employees work a shiftlonger than 8 hours per day, the exposure limit

Table 5-2: Occupational Exposure Limits


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must be adjusted (lowered) to prevent theemployee from overexposure.

d. Occupational Exposure Limits for hazardous aircontaminants must be listed on the material safetydata sheets (MSDS) for each product in use.

e. In the absence of either quantitative legal or Nikerequirements, quantitative guidelines will be set byNike CRC, giving consideration to consensusguidelines and other relevant information.

f. Exposure limits will be periodically evaluated. Seethe Indoor Air Quality Management Plan belowfor more information regarding when, where, andhow to sample.

2. Indoor Air Quality Management Plan

a. Contractors must develop and implement awritten Indoor Air Quality Management Plan.This plan must include the following elements:

1) A description of the plan and a functionaloverview of the day-to-day operation. Thissection must contain a detailed description ofthe site, the location of buildings and whatstructures and organizations are covered by theplan.

2) A communications strategy that describes howthe various departments within the factory willcommunicate, and the roles and responsibilitiesof each group.

3) A methodology for responding to factory/building air quality complaints.

4) A building-by-building specific plan to manageair quality. Each building plan will contain thefollowing components:

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a) A general description of the building and itsfunction, including work activity, numberof occupants, hours of operation, weekenduse, tenant requirements, and known aircontaminants released into the workenvironment.

b) A single line schematic or as-built construc-tion (blueprints) documents, which locatemajor building systems equipment and theareas they serve.

c) A written plan for maintenance of buildingsystems that is preventive in scope and isbased on the equipment manufacturers’recommendations. It will describe theequipment to be maintained, who willmaintain it and the schedule for mainte-nance.

d) Methodology for the use of site-specific,area or spot air purification technology tomanage air quality for sensitive individualsor problematic areas.

5) A building-specific baseline testing andevaluation plan. The evaluation plan orassessment must include:

a) Identification of potentially hazardousmaterials encountered or in use.

b) Establishment of how the substance couldenter the body (i.e., inhalation, ingestion,etc.).

c) Identification of the potential health effects.

d) Examination of the work environment:

• Review of available process flow charts.


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• Controls in place (ventilation, enclosures,personal protective equipment).

• Observations and odors.

• Assessment of worker complaints andclinic admissions data.

• Past air sampling results.

e) Identification of workers exposed and thedegree of exposure.

6) Based upon the results of the evaluation/assessment survey, air quality monitoringshould be conducted to determine the level ofexposure and potential health risk to employ-ees.

7) Contractors must train employees on thefollowing:

a) Familiarize employees with the plan and theoperational components therein.

b) Notify employees of the potential airbornehazards and their sources in their workplace(see Chemical Hazard CommunicationCLS).

c) The nature and extent of risks to health(both acute and chronic).

d) Reasons for the control measures and theirproper use.

e) The correct use, maintenance and limita-tions of safety equipment and facilities.

f ) The need for personal air sampling,biological monitoring and medical surveil-lance.

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g) The importance of good housekeeping andpersonal hygiene.

h) The results of monitoring.

i) Procedures for employee concerns andcomplaints.

j) Procedures for emergency releases of toxicchemicals.

8) Recordkeeping

a) Contractors must keep a suitable record ofany monitoring carried out for the purposeof this standard.

b) Employee exposure records will be keptuntil the employee leaves the job and for 30years thereafter.

c) Area monitoring records must be kept for atleast 5 years.

6. Emergency Preparedness& Response

A. Emergency Action

Contractors/employers must establish an action planand procedures for the orderly and coordinatedevacuation of, or sheltering within, all factory buildingsin the response to all emergencies (i.e., fire, tornado,typhoon, tsunami, bomb threat, flood, earthquake,hurricane, gas leaks, power outages, water failures).

1. Contractors/employers must develop and implement awritten emergency action plan, to include:

a. Emergency escape procedures.

b. Emergency escape route assignments.

c. Procedures to be followed by employees whoremain to operate critical plant operations beforethey evacuate.

d. Procedures to account for all employees afteremergency evacuation has been completed.

e. Rescue and medical duties for those employeeswho are to perform them.

f. The preferred means of reporting fires and otheremergencies.

g. Names or regular job titles of persons ordepartments who can be contacted for furtherinformation or explanation of duties under theplan.

2. The contractor/employer must establish an employeealarm system, to include:

a. The employee alarm system must provide warningfor necessary emergency action as called for in the

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emergency action plan, or for reaction time forsafe escape of employees from the workplace orthe immediate work area, or both.

b. The employee alarm must be capable of beingperceived above ambient noise or light levels by allemployees in the affected portions of theworkplace. Tactile devices may be used to alertthose employees who would not otherwise be ableto recognize the audibile or visual alarm.

c. The employee alarm must be distinctive andrecognizable as a signal to evacuate the work areaor to perform actions designated under theemergency action plan.

d. The employer must explain to each employee thepreferred means of reporting emergencies, such asmanual pull box alarms, public address systems,radio or telephones.

e. The contractor/employer must post emergencytelephone numbers near telephones, employeenotice boards, and other conspicuous locationswhen telephones serve as a means of reportingemergencies. Where a communication system alsoserves as the employee alarm system, allemergency messages must have priority over allnon-emergency messages.

f. The contractor/employer shall establishprocedures for sounding emergency alarms in theworkplace.

g. Maintenance and testing

1) The contractor/employer must ensure that allemployee alarm systems are maintained inoperating condition except when undergoingrepairs or maintenance.

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2) The contractor/employer must ensure that atest of the reliability and adequacy of non-supervised employee alarm systems is madeevery 2 months. A different actuation devicemust be used in each test of a multi-actuationdevice system so that no individual device isused for two consecutive tests.

3) The contractor/employer must maintain orreplace power supplies as often as is necessaryto assure a fully operational condition. Back-upmeans of alarm, such as employee runners ortelephones, shall be provided when systems areout of service.

4) The contractor/employer must ensure that theservicing, maintenance and testing of employeealarms are done by persons trained in thedesigned operation and functions necessary forreliable and safe operation of the system.

h. Manual operation

1) The contractor/employer must ensure thatmanually operated actuation devices for use inconjunction with employee alarms are unob-structed, conspicuous, and readily accessible.

3. If the employee alarm system is used for alerting firebrigade members, or for other purposes, a distinctivesignal for each purpose must be used.

4. The contractor/employer must establish in theemergency action plan the types of evacuation to beused in emergency circumstances (i.e., fire, explosion,and major hazardous material incident, bomb threats,etc.). A take-shelter procedure is required for severeweather.

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5. Training

a. Before implementing the emergency action plan,the contractor/employer must designate and traina sufficient number of persons to assist in the safeand orderly emergency evacuation of employees.

b. The contractor/employer must review the planwith each employee covered by the plan at thefollowing times:

1) Initially when the plan is developed.

2) Whenever the employee’s responsibilities ordesignated actions under the plan change.

3) Whenever the plan is changed.

c. The contractor/employer must review with eachemployee upon initial assignment those parts ofthe plan which the employee must know toprotect the employee in the event of anemergency.

d. The written plan must be kept at the workplaceand made available for employee review.

B. Fire Protection

1. Fire Protection Plan

Should include the following:

a. A list of the major workplace fire hazards and theirproper handling and storage procedures.

b. A list of potential ignition sources (such aswelding, smoking and others) and their controlprocedures.

c. The type of fire protection equipment or systemswhich can control a fire involving the potentialignition sources.


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d. Names or regular job titles of those personnelresponsible for maintenance of equipment andsystems installed to prevent or control ignitions orfires.

e. Names or regular job titles of those personnelresponsible for control of fuel source hazards.

f. Procedures to control accumulations of flammableand combustible waste materials and residues sothat they do not contribute to a fire emergency.

g. Training requirements

1) Communication to employees of the firehazards of the materials and processes to whichthey are exposed.

2) Review with each employee upon initialassignment those parts of the fire preventionplan which the employee must know to protectthe employee in the event of an emergency.The written plan must be kept in the work-place and made available for employee review.

h. Maintenance requirements

Regularly and properly maintain, according toestablished procedures, equipment and systemsinstalled on heat-producing equipment to preventaccidental ignition of combustible materials.

i. General requirements

1) Contractors/employers must become familiarwith the emergency response and evacuationplan.

2) Store materials to allow adequate accessthroughout the area and minimize the spreadof fire.

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3) Do not store anything within 18 inches (46centimeters) of ceiling fire sprinkler heads.

4) Collect and dispose of waste or scrap regularlyto prevent their accumulation. Follow properhousekeeping procedures at all times.

5) Tobacco smoking rules are to be establishedand followed.

6) Storage and use of flammable materials:

a) You must use approved (for example, UL)safety containers to transport gasoline orother flammable material. Such materialsshall not be stored in vehicle passengercompartments or automobile trunks. Onlyin an emergency may such materials betransported in automobile trunks. (SeeFigure 6-1 below.)

b) Store flammable and combustible liquidsonly in designated cabinets and areas.

c) Flammable liquids (for example, gasoline)shall not be used as cleaning agents.

Figure 6-1: Approved Safety Containers


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2. Fire Protection Measures

a. A smoke detector’s battery shall not be removedunless it is replaced immediately with a fresh/charged one.

b. Fire doors

1) Each factory building must have at least twomeans of escape remote from each other.

2) Must not be left open unless equipped withself-closing mechanisms.

3) Must not be locked or chained closed.

4) Must be kept free of obstructions that wouldprevent the door from closing.

5) Exit routes from buildings must be clear andfree of obstructions and properly marked withsigns designating exits from the building.

c. Fire alarm system(s) shall be periodically tested (atleast monthly).

3. Fire Brigades

The following requirements apply if the contractor/employer has established a fire brigade:

a. Contractors/employers must prepare and maintaina statement or written policy which establishes:

1) The existence of a fire brigade.

2) The basic organizational structure.

3) The type, amount, and frequency of training tobe provided to fire brigade members.

4) The expected number of members in the firebrigade.

5) The functions that the fire brigade is toperform at the workplace.

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b. The organizational statement must be available forinspection.

c. Contractors/employers must ensure thatemployees who are expected to do interiorstructural fire fighting are physically capable ofperforming duties that may be assigned to themduring emergencies. Contractors/employers mustnot permit employees with known heart disease,epilepsy, or emphysema to participate in firebrigade emergency activities unless a physician’scertificate of the employees’ fitness to participatein such activities is provided.

d. Training and education

1) Contractors/employers must provide trainingand education for all fire brigade memberscommensurate with those duties and functionsthat fire brigade members are expected toperform. Such training and education must beprovided to fire brigade members before theyperform fire brigade emergency activities. Firebrigade leaders and training instructors mustbe provided with training and education that ismore comprehensive than that provided to thegeneral membership of the fire brigade.

2) Contractors/employers must ensure thattraining and education is conducted frequentlyenough to ensure that each member of the firebrigade is able to perform the member’sassigned duties and functions satisfactorily andin a safe manner so as not to endanger firebrigade members or other employees. All firebrigade members must be provided withtraining at least annually. In addition, firebrigade members who are expected to performinterior structural fire fighting must be


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provided with an education session or trainingat least quarterly.

3) Contractors/employers must inform firebrigade members about special hazards—suchas storage and use of flammable liquids andgases, toxic chemicals, radioactive sources, andwater reactive substances—to which they maybe exposed during fire and other emergencies.The fire brigade members must also be advisedof any changes that occur in relation to thespecial hazards. The contractor/employer mustdevelop and make available for inspection byfire brigade members written procedures thatdescribe the actions to be taken in situationsinvolving the special hazards and must includethese in the training and education program.

e. Fire fighting equipment

1) Contractors/employers must maintain andinspect, at least annually, fire-fighting equip-ment to ensure the safe operational conditionof the equipment. Portable fire extinguishersand respirators must be inspected at leastmonthly.

2) Fire fighting equipment that is damaged or inunserviceable condition must be removed fromservice and replaced.

f. Protective clothing

The following requirements apply to thoseemployees who perform interior structural firefighting. The requirements do not apply toemployees who use fire extinguishers or standpipesystems to control or extinguish fires only in theincipient stage.

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1) Contractors/employers must provide protectiveclothing at no cost to the employee. As the newequipment is provided, the employer mustassure that all fire brigade members wear theequipment when performing interior structuralfire fighting.

2) Contractors/employers must ensure thatprotective clothing protects the head, body, andextremities, and consists of at least the follow-ing components: foot and leg protection, handprotection, body protection, eye, face, andhead protection.

4. Fire Extinguishers

a. Portable Fire Extinguishers

1) Each factory building must have a full comple-ment of the proper type of fire extinguisher forthe fire hazards present, except when thecontractor/employer has employees evacuateinstead of fighting small fires.

2) Employees expected or anticipated to use fireextinguishers must be instructed on the hazardsof fighting fire, how to properly operate the fireextinguishers available, and what procedures tofollow in alerting others to the fire emergency.

a) Contractors/employers must providetraining upon initial hire and at leastannually thereafter.

b) Contractors/employers must provideemployees who have been designated to usefire-fighting equipment as part of anemergency action plan with training in theuse of the appropriate equipment.

3) Where the contractor/employer wishes toevacuate employees instead of having them


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fight small fires there must be written emer-gency action plans and employee training forproper evacuation.

4) The contractor/employer must mount, locate,and identify extinguishers so they are readily

Figure 6-2: Wheeled Extinguisher

Figure 6-3: Hand-Held Portable Extinguisher(Dry Chemical Cartridge Type)

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accessible to employees without subjecting theemployees to possible injury.

5) Extinguishers must be conspicuously locatedand readily accessible for immediate use.

6) Extinguishers must be clearly visible. Inlocations where visual obstruction cannot becompletely avoided, directional arrows must beprovided to indicate the location of extinguish-ers and the arrows marked with the extin-guisher classification.

7) Extinguishers must be marked/labeled toensure that the proper class extinguisherselection is made at the time of a fire. Labelswill be placed on the front of the shell.

8) Operating instructions must always faceoutward and the extinguisher must be placedso that it can be removed easily.

9) Markings/labels must be of a size and form tobe legible from a distance of 3 feet (0.9meters).

10) Extinguishers having a gross weight notexceeding 40 pounds (15 kilograms) must beinstalled so that the top of the extinguisher isnot more than 5 feet (1.5 meters) above thefloor.

11) Extinguishers with a gross weight greater than40 pounds (15 kilograms), except wheeledtypes, must be installed so that the top of theextinguisher is not more than 3½ feet (1.3meters) above the floor.

12) In no case can the clearance between thebottom of the extinguisher and the floor be lessthan 4 inches (10 centimeters).


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13) Extinguishers must be maintained in a fullycharged and operable condition and kept intheir designated places at all time except duringuse.

14) Portable fire extinguishers or hose must bevisually inspected monthly.

15) Only approved fire extinguishers are permittedto be used in factories.

a) Contractors/employers must provideportable fire extinguishers based on theclasses of anticipated workplace fires and onthe size and degree of hazard that wouldaffect their use.

b) Contractors/employers must distributeportable fire extinguishers for use byemployees on Class A fires so that the traveldistance for employees to any extinguisher is75 feet (22.9 meters) or less.

c) Contractors/employers may use uniformlyspaced standpipe systems or hose stationsconnected to a sprinkler system installed foremergency use by employees instead ofClass A portable fire extinguishers, providedthat such systems have total coverage of thearea to be protected, and that employees aretrained at least annually in their use.

d) Contractors/employers must distributeportable fire extinguishers for use byemployees on Class B fires so that the traveldistance from the Class B hazard area to anyextinguisher is 50 feet (15.2 meters) or less.

e) Contractors/employers must distributeportable fire extinguishers used for Class C

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hazards on the basis of the appropriatepattern for the existing Class A or Class Bhazards.

f ) Contractors/employers must distributeportable fire extinguishers or other contain-ers of Class D extinguishing agent for useby employees so that the travel distancefrom the combustible metal working area toany extinguishing agent is 75 feet (22.9meters) or less. Portable fire extinguishersfor Class D hazards are required in thosecombustible metalworking areas wherecombustible metal powders, flakes, shav-ings, or similarly sized products are gener-ated at least once every two weeks.

g) Contractors/employers will not provide ormake available in the factory portable fireextinguishers using carbon tetrachloride orchlorobromomethane extinguishing agents.

16) Portable fire extinguishers must be givenmaintenance service at least once a year and awritten record kept showing the maintenanceor recharging date.

17) Contractor/employer must ensure that trainedpersons with suitable testing equipment andfacilities perform hydrostatic testing.

18) Contractors/employers must ensure thatportable fire extinguishers are hydrostaticallytested at the intervals listed in Table 6-1 nextpage.

19) Extinguishers with the following conditions arenot eligible for testing and recharging andshould be removed from service:


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a) When the unit has been repaired bysoldering, welding, brazing, or use ofpatching compounds.

b) When the cylinder or shell threads aredamaged.

c) When there is corrosion that has causedpitting, including corrosion under remov-able name plate assemblies.

d) When the extinguisher has been burned in afire.

e) When a calcium chloride extinguishingagent has been used in a stainless steel shell.

Table 6-1: Extinguisher Testing

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20) Contractors/employers must maintain andprovide upon request evidence that therequired hydrostatic testing of fire extinguishershas been performed at the time intervals shownin Table 6-1 previous page. Such evidence mustbe in the form of a certification record thatincludes the date of the test, the signature ofthe person who performed the test and theserial number, or other identifier, of the fireextinguisher that was tested. Such records shallbe kept until the extinguisher is hydrostaticallyretested at the time interval specified in Table6-1 or until the extinguisher is taken out ofservice, whichever comes first.

21) Portable fire extinguishers are to be used forextinguishing beginning-stage fires only.Beginning-stage fires are fires in early stages ofdevelopment that, in the judgment of theemployee, can be extinguished with portableequipment.

22) Extinguishers are to be located no more than30 feet (9 meters) from fire hazards such asflammable storage areas, cleaning tanks, etc.

23) Fire extinguishers are to be selected to ensurethat they are suited to the hazards in the areaand the type of fire that is likely to occur:

a) Class A—Firesinvolving ordinarycombustibles such aspaper, wood, rubber,and many plasticswhere the coolingeffects of watersolutions are mostefficient.


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b) Class B—Firesinvolving flammable orcombustible liquids,gases, and greaseswhere air exclusion byblanketing is mosteffective.

c) Class C—Firesinvolving energizedelectrical equipmentwhere the extinguishingmedia must be non-conductive (unless theequipment is de-energized; then Class Aor Class B extinguishersmust be used).

d) Class D—Firesinvolving combustiblemetals such as magne-sium, titanium,zirconium, sodium, andpotassium.

e) Some fire extinguisherscarry multiple classes.

b. Inspection and Maintenance of PortableEquipment

The ESH Committee must inspect fireextinguishers in their regular inspections.

c. Fixed Fire Extinguishers

Consult with your local Nike compliance managerfor fixed suppression equipment requirements.

d. Inspection and Maintenance of Fixed Systems

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Water spray, sprinkler, halon, CO2, dry chemical,

and foam systems shall be inspected and tested asrequired by the manufacturer.

C. Medical Services and First Aid

1. General Requirements

a. Contractors/employers must develop andimplement a medical and first aid programspecific to each factory. The program must includethe following elements:

1) An evaluation/assessment of the workplace formedical and first aid requirements. Among thefactors that must be considered are:

a) Location and availability of medical facilitiesand emergency services.

b) Availability of medical personnel forconsultation on occupational health issues.

c) Types of accidents that could reasonablyoccur at the workplace.

d) Response time for external emergencyservices.

e) Number of employees at the plant and thelocations of employees within the plant.

f ) Use of corrosive materials at any place in theworkplace.

g) Applicable industry specific requirements orcountry requirements.

h) What first aid supplies should be available.

i) What level(s) of training employees shouldreceive, and which employees should betrained.


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2) The availability of medical personnel forconsultation regarding occupational healthissues. Provide the names and telephonenumbers for professionals with whom thecontractor/employer has agreements.

3) At least one person, and preferably two ormore, trained in first aid must be available atthe worksite if either of these conditions exist:

a) If life-threatening injuries can reasonably beexpected, trained personnel must beavailable within 4 minutes. This generallymeans that community emergency medicalservices cannot be relied on since theirresponse time is usually greater than 4minutes.

b) If serious injuries other than life threateninginjuries can be expected, the response timefor trained personnel is extended to 15minutes.

c) Multiple individuals must be trained inorder to provide coverage when the primaryresponder is unavailable.

4) The trained first aid responder(s) must bedesignated and the other employees must knowwho they are and how to contact them so theycan respond within the required time.

The trained responder must have a current firstaid certificate.

5) A first aid kit must be available at the worksite.The program must note the location of the firstaid kit(s). The contractor/employer is respon-sible for determining the need for additionalfirst-aid kits, quantities and the types ofsupplies at the factory.

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6) Emergency telephone numbers must beconspicuously located by each telephone.

7) Sufficient ambulance service must be availableto handle any emergency. This requiresadvance contact with ambulance services toensure they become familiar with plantlocation, access routes, and hospital locations.

8) If corrosive materials are used, eyewash andbody flush facilities must be provided.

9) Records of first aid and medical treatmentsmust be maintained.

b. Contractors/employers must ensure the readyavailability of medical personnel for advice andconsultation on matters of occupational health.

c. Contractors/employers must train an employee oremployees to render first aid when a medicalfacility/clinic/infirmary/hospital for treatment ofinjured employees is not available in proximity tothe workplace.

2. First Aid and Kits

First aid and CPR training is anintegral part of a safety program.Employees must be trained inthese skills.

a. The basic procedures tofollow in a serious or life threatening first aidincident are:

1) Protect yourself first. Do not put yourself atrisk.

2) Notify. Get help. Summon emergency medicalservices to the scene.


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3) Stabilize. While waiting for medical help, anemployee shall provide first aid and reassur-ance. Do not move the victim unless absolutelynecessary.

4) Transport. The person in charge of the facilitymust ensure appropriate measures are taken totransport the sick or injured person to asuitable medical facility.

b. Contractors/employers mustensure that adequate first aidsupplies are readily available.Additional items must beadded to the minimumrequirements listed below,based upon specificworkplace hazards. The selection of additionalsupplies must be made by consulting with a healthcare professional or a person competent in first aidwho is knowledgeable of the hazards found in thatspecific factory.

Figure 6-4: Proper and Improper Methods forMoving an Injured Person

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c. Basic Supplies:

1) Absorbent Compress, 32 square inches (206.5square centimeters) (No side smaller than 4inch (10 centimeters), Qty (1)

2) Adhesive bandages, 1 × 3 inch (2.54 × 7.62centimeter), Qty (16)

3) Adhesive tape, 5 yards (4.57 meters), Qty (1)

4) Antiseptic, 0.5 gram application, Qty (10)

5) Burn Treatment, 0.5 gram application, Qty (6)

6) Medical exam gloves, Qty (2 pair)

7) Sterile pad, 3 × 3 inch (7.62 × 7.62 centime-ter), Qty (4)

8) Triangular bandage, 40 × 40 × 56 inch (101.5× 101.5 × 142.24 centimeter), Qty (1)

d. Each complete first aid kit must have a label onthe back or outside of the kit listing its contents.

e. First aid kits must be inspected on a weekly basisto ensure that they are full, in good condition andhave not expired. The contents list for the first aidkits must be periodically reviewed to ensure that itmeets the needs of the workplace hazards at alltimes.

f. Over-the-counter medicine may be put in first aidkits if packaged in single dose, tamper-evidentpackaging and labeled. Over-the-counter drugproducts must not contain ingredients that areknown to cause drowsiness.

3. Eyewash and Shower/Drenching Equipment

a. Where the eyes or body of any person may beexposed to injurious corrosive materials, suitablefacilities for quick drenching or flushing of the


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eyes and body must beprovided within the workarea for immediateemergency use.

b. General requirements forstandard eyewash and bodyflushing stations:

1) The water in the eyewash station must bepotable (drinkable).

2) A controlled flow of water must be provided toboth eyes simultaneously at a velocity lowenough to not injure the user.

3) There must be no sharp projections anywherein the operating area of the unit.

4) Nozzles must be protected from airbornecontaminants. The removal of such protectionmust not require a separate motion by theoperator when activating the unit.

5) Eyewash equipment must be capable ofdelivering to the eyes a minimum of 0.4gallons (1.5 liters) per minute for 15 minutes.

Note: Medical and industrial experiences haveshown that the initial first aid treatment forchemical splash must be to flush the eyes for15 minutes prior to medical treatment. MostMaterial Safety Data Sheets recommend this,or state that eyes must be flushed with copiousamounts of water. Data sheets must beconsulted for additional recommendations.

6) There must be sufficient space around theeyewash equipment to allow eyelids to be heldopen with the hands while the eyes are beingflushed.

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7) The control valve must be:

a) Capable of being quickly located andoperated,

b) Capable of being fully activated in onesecond or less, and

c) Designed to remain on until intentionallyshut off.

8) The eyewash unit must be in an accessiblelocation as close to the hazard as possible, butwith a travel/distance no greater than 100 feet(30.5 meters) and must require no more than10 seconds to reach.

9) The eyewash unit mustbe identified with ahighly visible sign. Thearea around or behind,or both, must be painted a bright color, andmust be well lit.

10) Water nozzles must be positioned between 33inches (83.8 centimeters) and 45 inches (114.3centimeters) from the floor.

11) Plumbed eyewash units must be activatedweekly to flush the line and verify properoperation. Self-contained units must beinspected according to manufacturers'specification.

12) All employees who may be exposed to eyeinjury must be instructed in the proper use ofemergency eyewash units.

13) Self-contained units containing a reservoir offlushing fluid must be constructed of materialsthat will not corrode. The flushing fluid mustbe protected from airborne contaminants.


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14) Outdoor units must be freeze protected.

15) Water temperature in units must be main-tained at between 60 and 90 degrees Fahren-heit (15 and 35 degrees Celsius).

c. Selection and Installation

1) Showers (Plumbed and Self-Contained)

a) Plumbed Shower: An emergency showerpermanently connected to a source ofpotable water.

b) Self-Contained Shower: A shower thatcontains its own flushing fluid, and must berefilled or replaced after use.

2) Specifications (for plumbed showers)

a) Heads

• Positioned 82 inches to 96 inches (208centimeters to 244 centimeters) fromfloor.

• Spray pattern must have a minimumdiameter of 20 inches (51 centimeters) at60 inches (152 centimeters) above thefloor.

• Flow Rate=20 gallons (76 liters) perminute (GPM) at 30 pounds (11 kilo-grams) per square inch (PSI).

• The center of the spray pattern must belocated at least 16 inches (41 centimeters)from any obstruction.

b) Valves

• Activate in 1 second or less.

• Stay-open valve (no use of hands).

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• Valve remains on until the user shuts itoff.

3) Installation

a) Shower must be located in an area thatrequires no more than 10 seconds to reach.

Figure 6-5: Emergency Drenching andEyewash Shower


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Note: Consult a medical professional todetermine the appropriate distance for harshacids and caustics (high hazard=closerdistance).

b) Shower location must be in a well-lit areaand identified with a sign.

c) Shower must be located on the same level asthe hazard.

4) Maintenance and Training

a) Plumbed showers will be activated weekly toverify correct operation.

b) All employees who might be exposed to achemical splash must be trained in the useof the equipment.

c) All showers must be inspected annually.

5) Eyewashes (Plumbed and Gravity-Feed)

a) Plumbed Eye Wash: An eye wash unitpermanently connected to a source ofpotable water.

b) Gravity-Feed Eye Wash: An eye wash devicethat contains its own flushing fluid andmust be refilled or replaced after use.

6) Specifications

a) Heads

• Positioned 33 inches (83.8 centimeters) to45 inches (114.3 centimeters) from floor.

• Positioned 6 inches (15.24 centimeters)from wall or nearest obstruction.

• Plumbed units must provide 0.4 gallons(1.5 liters) per minute (GPM) for 15minutes flushing fluid at 30 PSI.

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• Gravity-feed units must provide 0.4gallons (1.5 liters) per minute (GPM) for15 minutes.

b) Valves

• Activate in 1 second or less.

• Stay-open valve (leaving hands free).

7) Installation

a) Eyewash equipment must be located in anarea that requires no more than 10 secondsto reach.

Note: Consult a medical professional todetermine the appropriate distance for harshacids and caustics (high hazard=closerdistance).

b) The location of the eye wash unit must bein a well-lit area and identified with a sign.

Figure 6-6: Pressurized and NonpressurizedSelf-Contained Eyewash Units


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c) Eyewash equipment must be on the samelevel as the hazard.


a) Plumbed eye wash units must be activatedweekly to verify proper operation.

b) Gravity-feed units must be maintainedaccording to the manufacturer’sinstructions.

c) All employees who might be exposed to achemical splash must be trained in the useof the equipment.

d) All eyewash equipment must be inspectedannually.

9) Eye/Face Wash

A device used to irrigate and flush both theface and the eyes.

10) Specifications

a) Heads

• Positioned 33 inches (83.8 centimeters) to45 inches (114.3 centimeters) from floor.

• Positioned 6 inches (15.24 centimeters)from wall or nearest obstruction.

• Large heads to cover both eyes and face orregular size eye wash heads plus a facespray ring.

• 3 gallons (11.4 liters) per minute (GPM)for 15 minutes.

b) Valve

Same as eye wash.

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11) Installation

Same as eye wash.


Same as eye wash

13) Drench Hoses (Hand Held)

A flexible hose connected to a water supply andused to irrigate and flush eyes, face and bodyareas.

14) Specifications

a) Heads

3 gallons (11.4 liters) per minute (GPM).

b) Valve

Activate in 1 second or less.

15) Installation

a) Assemble per the manufacturer’sinstructions.

b) The location of the drench hose must be ina well-lit area and identified with a sign.

Figure 6-7: Hand-Held Drench Hose


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a) Activate weekly to verify proper operation.

b) All employees who might be exposed to achemical splash must be trained in the useof the equipment.

c) All drench hose equipment must beinspected annually.

Note: Hand-held drench hoses supportshower and eyewash units but must notreplace them.

17) Personal Eyewash

A supplementary eyewash that supportsplumbed units, gravity-feed units, or both bydelivering immediate flushing fluid.

Note: Personal eyewash units canprovide immediate flushing whenthey are located near the worksta-tions. Personal eyewash equipmentdoes not meet the requirements ofplumbed or gravity-feed eyewashequipment. Personal eyewashunits can support plumbed orgravity-feed eyewash units, butcannot be a substitute.

7. Personal Protective EquipmentAppropriate clothing and personal protective equipment(PPE) must be worn by all employees and visitors wheredesignated or posted.

PPE must meet standards established by recognizedgovernmental and/or industry groups.

Employees are responsible for the maintenance and careof their PPE.

1. Job Attire

a. General Guidelines

1) Employees must be properly clothed at alltimes.

2) Loose clothing, neckties, and loose jewelrymust not be worn when working aroundmoving machinery.

3) Clothing that has been contaminated by apotentially hazardous (flammable or toxic)material must be removed as soon as possibleand not worn until the clothing has beencleaned.

Figure 7-1: Some Personal Protective Equipment

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4) Hair long enough to be potentially hazardouswhile working around moving machinery orrotating tools and equipment must be secured.

5) Facial hair that may present a potential hazardwhile working around moving or rotatingmachinery is not permitted.

2. Head Protection

a. Hard hats must be worn by employees, visitors,and contract employees in all designated areas.

b. Figure 7-2 below presents examples of hard hats.

c. Electricians and other employees who could beexposed to electrical hazards should wear hard hatswith dielectric properties. Nonmetallic accessories,such as liners and chinstraps, are also available fordielectric hard hats.

d. Hard hats must not be altered.

Figure 7-2: Hard Hats

Personal Protective Equipment 7–3

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3. Eye and Face Protection

a. General Guidelines

1) Eye protection must be worn by employeeswhose duties indicate the need for protection.Safety glasses must meet ANSI Z87.1 (orequal) standards.

2) When required, safety glasses (nonprescription)with side shields must be furnished by thecontractor/employer.

3) Contact lenses do not provide eye protection.On the contrary, they increase the need for eyeprotection since small foreign particles maybecome trapped under the lenses and damagethe cornea. Contact lens wearers must informtheir supervisor and co-workers of their use.

b. Requirements

1) Goggles

a) Impact-type goggles must be worn duringactivities involving flying or falling objectsor particles, such as, but not limited to,chipping, scraping, buffing, grinding, andhammering.

b) Splash-proof chemical goggles and faceshields must be worn when handlingpotentially hazardous chemical liquids andsolids or in any other operation where theeyes may be exposed to potentially hazard-ous chemicals in either liquid or solid form.

c) Goggles are also required in areas thatinclude, but are not limited to, the follow-ing hazards:

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d) Potential dust hazards.

e) The use of compressed air to clean or blowout debris.

f ) Cutting and tying of cable or wire rope.

g) Operations where there may be danger fromspraying of hot oils or chemicals.

2) Shaded Lenses

a) Arc welding requires the use of a weldinghelmet fitted with the proper shaded lenses.

b) Use Table 7-1 below to select the propershaded lens for welding.

Table 7-1: Recommended Lens Shading


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Figure 7-3: Eye Protection

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4. Hand Protection

a. Employees must wear hand protection appropriatefor the activity and conditions. Examples ofappropriate hand protection include but are notlimited to:

1) Chemical resistant gloves when handling acidsor caustic chemicals.

2) Insulated or heat-resistant gloves whenperforming duties requiring burn protection.

3) Hydrocarbon-resistant gloves when usinghydrocarbon-based solvents, cleaning agents,or chemicals.

4) Mesh steel gloves when using fabric cutters.

[See Glove Chart next pages.]

Figure 7-4: Protective Steel Mesh Glove


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Tab

le 7

-2: G

love

Ch

art—

Co

mp

are

Ch

emic

al C

om

pat

ibili

ty

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7

7–10 ESH Handbook

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5. Foot Protection

a. Employees mustwear footprotectionappropriate forthe activity andconditions.

b. Safety-toefootwear mustmeet ANSIZ41.1requirements (orequivalent) andmust befurnished bycontractor/employer.

6. Respiratory Protection

a. Employees must wear respiratory protectionappropriate for potential workplace atmospherichazards.

Figure 7-5: Examples of Respiratory Protection

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b. Prior to being approved for the use of respiratoryprotection equipment, employees must:

1) Have medical clearance.

2) Receive required training in the selection, use,care, and limitations of the specific respiratormodel.

3) Be seal or fit-tested, as appropriate for theequipment.

Figure 7-6: Dust Filters No Substitutefor Respirators


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c. If an employee has previous successful experiencewearing contact lenses, the employee may wearsoft or gas permeable lenses.

d. Specially designed eyeglass adapters must beobtained and used if an employee requiresprescription glasses when using a full-facepiecerespirator.

e. Nothing must pass between the wearer’s face andthe facepiece, including but not limited to thefollowing:

1) Glasses with temple pieces.

2) Facial hair such as stubble, mustaches, side-burns, and beards.

3) Bangs.

f. Respirators must be examined prior to each use.

g. Employees must clean, disinfect, and properlystore respirators after each day’s use, unless thisresponsibility is assigned to others.

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7

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7

Figure 7-7: Examples of Hearing Protection

7. Hearing Protection

a. Hearing protection must be worn in high-noiseareas. This may require wearing a combination ofhearing protection devices (for example, earplugsand earmuffs).

b. Employees included in a hearing conservationprogram must comply with its requirements.

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Figure 7-6: Examples of Anchor Systems

8. Fall Protection

a. Fall protection should be used when fall hazardsequal or exceed 6 feet (1.83 meters).

b. Fall protection devices include, but are not limitedto, safety belts/harnesses, lanyards, lifelines, ladderclimbing devices, and safety nets.

1) Personal Fall Arrest Systems:

a) The system must withstand a minimumforce of 5,000 pounds (1,866 kilograms).

b) Free-fall distance generally ranges between4–6 feet (1.22–1.83 meters).

2) Anchor Systems:

a) Must withstand a minimum force (breakingstrength) of 5,000 pounds (1,866 kilo-grams).

b) Many manufacturers require 5,400 pounds(2,015 kilograms) minimum anchoragestrength for their equipment.

c) No knots shall be tied in anchorageconnectors.

3) Snap-hooks and Carabiners:

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Table 7-3: Visual Indications ofEquipment Damage

a) Minimum strength 5,000 pounds(1,866 kilograms); must be self-locking type.

b) Must withstand a side loadingforce of 350 pounds (130kilograms); the gate mustwithstand a force of 220 pounds(82 kilograms).

4) Lanyards:

a) Strength of 5,000 pounds (1,866kilograms).

b) Length variesfrom 2–6 feet(0.6–1.83meters).


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c) Synthetic rope lanyard minimum diameteris 0.5 inch (1.25 centimeters).

b. Fall protection devices must be examined beforeeach use for excessive wear or damage. Worn ordamaged equipment must be immediatelyremoved from service and destroyed.

NOTE:

It is important that the belt/harness is properly worn, andthat the wearer allows nomore slack in the securedsafety line than is necessary.Tie-off points should beabove waist height.Consider the potential for a“swing fall” whenever youuse a self-retracting lifeline.You increase the risk of a“swing fall” by moving awayfrom the anchorage point andincreasing the lifeline length.You will swing back under theanchorage during a fall. A“swing fall” increases your riskof striking an object or lowerlevel during the pendulummotion.

c. Calculating Total Fall Distances

To calculate total fall distance for worker exposedto a fall, determine the location where the tie-offpoint is, including lanyard length, decelerationdistance, which is not more than 42 inches (107centimeters), height of the worker, and clearancedistance from foot of the worker to the groundbelow. If the tie-off point location is below the D-

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Figure 7-8: Calculating Total Fall Distance

ring of the harness, this will increase the total falldistance.

d. Elevated Working Surfaces

1) Fall protection must be used in certainsituations. These include but are not limitedto:

a) Open-sided floors, floor openings, catwalks,or platforms elevated 4 feet (1.22 meters) orhigher where handrails or barricades are notprovided;

b) Working above potential hazards.

e. Fixed Ladders

1) Employees must use fall protection deviceswhere they are installed.


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2) Where cage protection is not provided onladders over 20 feet (6.1 meters) in unbrokenlength, employees must use appropriate fallprotection devices.

8. Machine and Equipment Safety

A. Motor Vehicle Operation and Forklifts

1. Safe driving policy

a. Employees operating vehicles must:

1) Have in their possession a valid driver’s licenseappropriate for the vehicle and its use.

2) Operate vehicles in a proper manner andobserve traffic regulations.

3) Use vehicles only for authorized purposes.

4) Wear seat belts in all vehicles. The vehicleoperator is responsible to see that passengersfasten their seat belts.

b. Operating a vehicle while under the influence ofintoxicating beverages or drugs is prohibited.

2. General guidelines

a. Vehicle operators must practice defensive drivingat all times. Defensive driving means being alertfor potential accident-producing situations andbeing prepared to take evasive action.

b. Vehicles must be maintained in proper operatingcondition. A vehicle operator who detects amechanical defect or a potential safety hazard in avehicle must make arrangements for promptrepairs or report the mechanical defect orpotential safety hazard to his/her supervisor or thedesignated person responsible for vehiclemaintenance.

c. Speed must be consistent with road and weatherconditions and posted limits.

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d. Vehicles must be parked so as not to roll out ofcontrol.

e. When practical, vehicles must be parked so theycan be driven forward when next moved.

f. The vehicle operator must check for potentialhazards behind the vehicle before backing. Thismay require the operator to walk around thevehicle.

g. When operators are out of their vehicles, theengine must be shut off and the parking brake set.

h. Gasoline or other flammable material must betransported only in approved (for example, UL)safety containers. Such materials must not bestored in vehicle passenger compartments orautomobile trunks.

i. Portable safety containers must be removed fromvehicles while being filled with flammable liquids.

j. Employees must not ride in the rear area (truckbed) of trucks or pickups.

k. Cargo or heavy tools must not be transported inthe passenger compartment of vehicles at the sametime as passengers.

l. Loose objects must not be stored in the rearwindow tray or the front dashboard of vehicles.

m. Operators of the contractor-/employer-owned orrented/leased vehicles, and operators of personalvehicles on an allowance basis in contractor/employer service must report accidents in whichthey are involved to their supervisor as soon aspossible. The supervisor must coordinate a reviewto determine the facts and complete the requiredreports.

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3. Forklift Safety

a. These procedures are setforth to insure operatorsafety and the safety andhealth of allemployees, and toreduce equipment“down time.”

b. Required training

1) Before operating powered equipment, youmust complete the forklift safety trainingprogram.

2) Never attempt to operate a piece of equipmentunless you are trained and authorized tooperate it.

c. Inspection and repairs

1) Inspect equipment daily before use.

2) Report any “unsafe condition” immediately.

3) Do not make repairs to equipment withoutprior authorization. Your supervisor mustapprove any repairs, alterations, or modifica-tions to equipment.

4) Never drive a lift with a DO NOT OPERATEtag on it.

5) Battery chargers must be used only by autho-rized personnel.

d. Operating powered equipment

1) All operators are expected to conduct theirdaily functions in an orderly and business-likemanner. All operators are responsible formaintaining a safe and clean work area.

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2) All machines must be operated from thedesignated operating position. Never havearms, legs, fingers, etc., protruding from theoperator compartment.

3) All operators must pay particular attention tosprinkler heads when operating with the liftmechanism raised.

4) Any damage to equipment and/or buildingmust be reported immediately to your supervi-sor. Abuse of equipment will not be tolerated.

5) Always yield right of way to pedestrians. UseEXTREME CAUTION when travelingthrough highly traveled pedestrian areas,especially during breaks and lunch hour.

6) Do not allow anyone to stand or pass under liftequipment.

7) Start, stop, change direction, travel, and brakesmoothly. Slow down for turns or when onuneven or slippery surfaces that could causetruck to slide or tip.

8) Before any powered equipment is driven in orout of a trailer, the lift operator must make surethe trailer wheels are chocked.

9) You must use mirrors and slow down at allintersections, particularly when entering amain aisle from a secondary aisle.

10) Use the horn when:

a) Starting the machine from a stoppedposition.

b) At all intersections.

c) Changing directions, i.e., turning orchanging from forward to reverse.


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d) Approaching a pedestrian from behind.

11) During a fire drill or evacuation, stop yourmachine immediately and exit building vianearest fire exit.

12) Do not eat or drink while on equipment.

13) No horseplay on equipment.

Figure 8-1: The Stability Triangle

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e. Battery charging

DANGER! RISK OF BATTERY EXPLOSION FROMHYDROGEN GAS. MAY RESULT IN BLINDNESS,SERIOUS INJURY, PERMANENT DISFIGUREMENTAND SCARRING.

1) Safety

a) Batteries generate explosive hydrogen gas,even during normal operation. People havebeen injured by battery parts flying in anexplosion. They can explode under normaloperating conditions, such as starting yourcar. They can explode under abnormalconditions, such as jump starting, or ifshort-circuited by a tool. They can explodein a parked car or sitting on a table.

b) To help reduce the risk of these dangers andinjury, it is of the utmost importance thateach time before using your charger, you

Figure 8-2: Wear Safety Goggles!


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read and understand this manual and anywarnings and instructions by the batterymanufacturer. Follow these instructionsexactly.

c) Wear personal protective equipment.

Always wear complete eye protection (thatprotects eyes from all angles).

d) Avoid flames or sparks near battery andfuel.

• Always keep flames, matches, lighters,cigarettes, or other ignition sources awayfrom battery.

• Do not put flammable material on orunder charger. Do not use near gasolinevapors.

• Make sure charger clips make goodcontact by twisting or rocking them backand forth several times. The second clipconnection must always be made awayfrom the battery. Always plug the chargerinto an electrical outlet after all connec-tions have been made. See operatinginstructions.

• If necessary to remove battery from vehicleto charge, always turn off all accessories inthe vehicle. Then always remove groundedterminal (connected to vehicle frame)from battery first.

• A tool touching both battery posts orbattery post and vehicle metal parts is ashort circuit and will spark. Be carefulwhen using metal tools on or near battery.Do not drop a tool on battery.

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e) Reduce explosive gas (hydrogen)

• Before connecting charger, always addwater to each cell until battery acid coversplates to help purge extra gas from cells.Do not overfill. Battery acid expandsduring charge. After charging, fill to levelspecified by battery manufacturer. For abattery without removable caps (i.e.,maintenance-free battery), carefully followmanufacturer’s instructions on charging.

• Some sealed maintenance-free batterieshave a battery-condition indicator. A lightor bright colored dot indicates low water.Such a battery needs to be replaced, notcharged or jump started.

• Charge battery with caps in place. MostUS batteries are made with flame-arrestingcaps. Do not pry caps off sealed batteries.Place wet cloth on batteries with non-flame arresting caps.

• Be sure area around battery is wellventilated before and during chargingprocess. Never charge in a closed orrestricted area.

f ) Stay away from battery when possible.

• Never put face near battery.

• Always locate charger as far from batteryas DC cables permit.

• Always have plenty of fresh water and soapnearby in case battery acid contacts eyes,skin, or clothing. If battery acid contactsskin or clothing, wash immediately withsoap and water. If acid enters eye, immedi-


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ately flood eye with cold running water forat least 15 minutes and get medical helpimmediately.

f. Battery charger instructions

Connecting the charger to the battery

1) If charger has switch with off position, it mustbe set to off.

2) AC power cord must be unplugged.

3) Charging battery in vehicle:

a) If vehicle has negative ground (most vehiclesdo; if you are not sure, have it checked),connect positive (red) charger clip topositive post of battery. Some newer vehicleshave a remote positive terminal locatedaway from the battery. Use this remoteterminal for charging connections. See yourvehicle owner’s manual.

b) Connect negative (black) charger clip to carframe or engine block away from battery.

CAUTION: DO NOT CONNECT CLIP TOCARBURETOR, FUEL LINES, OR SHEET METALBODY PARTS. CONNECT TO HEAVY GAUGE

Figure 8-3: Charging Typical Negative-GroundBattery Inside Vehicle

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METAL PART OF THE FRAME OR ENGINE BLOCK.DO NOT FACE BATTERY WHEN MAKING FINALCONNECTION.

c) If vehicle has positive ground (most vehiclesdo not; be sure to check), connect thenegative (black) charger clip to the negativeungrounded post of battery.

d) Connect positive (red) charger clip tovehicle frame or engine block away frombattery.

B. Energy Control (Lockout/Tagout)

1. General

a. Energy control is required while employees areservicing and/or maintaining machines andequipment if an unexpectedstart-up or release of energyor substances could causeinjury.

b. Only an authorizedemployee (one who has beentrained and is authorized toboth lock out the equipmentand to work on it) shallimplement lockout/tagout.

c. The supervisor or authorizedemployee must notifyaffected employees in thework area of the type andduration of the work to beperformed, and of theapplication and/or removalof lockout and/or tagoutdevices. Notification must be


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given before the controls are applied and after theyare removed from the machine or equipment.

d. A tag, identifying who placed the lock, the date,and the area/lease, must be attached to each lock.(See Figure 8-4 below.)

e. Locks and tags must remain in place until thework is completed. Employees must follow theprocedures outlined in the facility’s lockout/tagoutto remove locks and tags other than their own.

f. Employees must use only lockout/tagout devicesspecified by the facility and issued by the facility.

g. Locks used for lockout must not be used for otherpurposes.

h. Employees must position themselves outside thepath of potential energy releases when equipmentis being opened or returned to service. Thesereleases can include pressurized gases and liquids,falling objects, electrical energy.

Figure 8-4: Lockout/Tagout Tags

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i. All isolation and lockout/tagout operations mustbe performed according to the requirements of thefacility’s Lockout/Tagout programs/policy.

2. Procedures

a. Energy-control procedures must clearly identifythe sources of energy and describe how workerswill:

1) Secure energy-isolating devices

2) Use and remove locks and tags

3) Test the effectiveness of energy-isolating devices

b. Energy-control procedures will vary depending onequipment design and types of energy involved.However, the procedures do need to meet certainminimum requirements and the procedures mustbe done in the proper sequence. Here is a checklistthat covers the minimum requirements.

1) Prepare to shut down the equipment

a) Each authorized employee who shuts downequipment must know the type andmagnitude of the energy, its hazards, andhow to control the energy.

b) All affected employees must know that theequipment is being serviced or maintainedand that it will be shut down and lockedout for the duration of the service ormaintenance work.

2) Shut down the equipment

a) If the equipment is operating, shut it downby the normal stopping procedures.

b) Shutdown may be as simple as pressing thestop switch.


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3) Isolate the equipment from the energy source

a) Locate every energy-isolating device thatcontrols energy to the equipment.

b) Position the energy-isolating device(s) sothat the equipment is isolated from theenergy source(s).

c) Keep in mind that when two or moreauthorized employees are working together,each must apply his or her own lock.

4) Lock out or tag out the energy-isolating device

a) Locks: Lock out the energy-isolating deviceswith designated locks. The person who doesthe service or maintenance work must placethe locks and a personal identification tag.Secured locks must hold the energy-isolatingdevices in a “safe” or “off” position.

b) Tags: The authorized employee who will bedoing the service or maintenance work mustplace tags on the energy-isolating devices.Tags must clearly state that changing theenergy-isolating devices from the “safe” or“off” position is prohibited. Because tagsdon’t eliminate the hazard, you must useadditional methods such as blocking acontrol switch or opening an extra discon-nect. If you can’t place a tag on the energy-isolating device, you must place it as close aspossible to the device.

5) Eliminate potentially hazardous stored energy

a) Capacitors, coiled springs, elevated machinemembers, rotating flywheels, air, gas, steam,chemical, and water systems are sources ofstored energy.

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b) If stored energy can return to a hazardouslevel, you must make sure that the energyremains isolated from the equipment untilall service or maintenance work is com-pleted.

6) Remove the lockout or tagout device

a) The person who applied the device alsomust remove it.

b) If the person who applied the device is notavailable to remove it, the employer mayauthorize another employee to remove thedevice. However:

• The employer must be trained and followthe appropriate procedures.

• The employer must verify that the personwho applied the device is not available toremove it.

• The employer must attempt to contactand inform the person that the lockout/tagout device has been removed.

• The employer must make sure the personknows about the removal before he or shereturns to work.

c) Be sure to have a documented procedure forremoving another person’s lock.

7) Documentation

a) You need to document procedures for eachparticular machine or piece of equipment.

b) You can use a single procedure for morethan one piece of equipment if the energysources and control methods are identical.


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3. Blinding Piping and Equipment

a. Purpose

1) A blind is a metal plate inserted on the end of apipe or between gasketed pipe flanges toprevent the flow of gas or liquid in eitherdirection.

2) A blind must be of sufficient strength towithstand the pressure it could reasonably beexpected to encounter.

b. Blinding Procedure

1) The decision to install and/or remove a blindmust be made by or at the direction of facilitysupervision or a designated representative.

2) Blinds must be installed on or in all pipingconnected to tanks or vessels or equipmentscheduled for maintenance, entry, or hot work.Blinds must be near the tank or vessel,preferably on the first flange from the tank orvessel shell.

3) In some instances a valve, spool piece, or otherdevice must be removed from the line and ablind flange installed on the line and the tankor vessel.

4) A blind must be installed with three majorconsiderations in mind:

Figure 8-5: Blinds and Spacers

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a) Will the blind effectively accomplish itspurpose in the location selected?

b) Can the blind be safely removed?

c) Is there access to the selected location?

5) A list must be maintained of the blinds used ina specific job. This list includes the size,location, and date of installation and removalof any blind.

C. Machine Guarding

1. Guarding

a. Power transmission points must be guarded. Thisincludes, but is not limited to, counterweights onpumping units, flywheels, rotating shafts, in-running pinch points, V-belt drives, gears, movingparts, etc. The guarding can take many forms butmust be effective in preventing employee contactwith the hazard. Forms of guarding include, butare not limited to, enclosures, barriers, fences, andinterlock systems.

b. Machinery guards must be in place before startingand during operation of the equipment.

c. Damaged machine guards must be repaired beforereturning the equipment to service.

d. Follow lockout/tagout procedures when removingmachine guards. Guards removed during repairoperations must be replaced upon completion ofthe repairs.

2. Machinery in Motion

Whenever feasible, equipment must be shut downwhen servicing. When operations must be performedaround engines or equipment while they are running,proper precautions must be taken.


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3. Rotating Machinery

a. General

Rotating machinery is dangerous because of thehigh speeds and pressures used in its operation.Repairs must not be initiated until the fuel supplyis shut off and the starting circuits disconnected,locked out, and tagged.

Figure 8-6: Examples of Guard Construction

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b. Pumps

1) Prior to initiating repairs or maintenance, thepump must be shut down, isolated, and theinternal pressure bled down.

2) Main electrical disconnects and valves must belocked out and tagged prior to initiating work.

4. General Rules

To prevent accidents, the following guidelines must befollowed:

a. Read and comply with the instruction suppliedwith the machine.

b. Check whether safety devices are workingproperly.

c. Immediately report any trouble to the appropriateperson and warn any person likely to work withthe machine of the trouble.

d. Refuse to work with the machine when any safetydevice is not working properly.

e. Make sure the work area around the machine andthe machine itself is kept clean and neat.

Figure 8-7: Guard Location Guide


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f. Do not clean the machine while it is running.

5. Machine Guarding and Safety Devices

Wear and tear of the machine’s parts may have animpact on the proper function of safety devices andguards. For this reason, a qualified and specificallydesignated person must regularly check the safetydevices and guards with regard to the machinemanufacturer documentation.

6. Safety Guards

On every safety guard, the following must be checked:

a. The guards must be complete and in goodcondition.

b. The guards and their electrical contacts must bekept clean.

c. All machine components must STOP as soon as asingle interlock is open.

7. Push-button for Emergency Stops

Check the following items on every mushroom-shaped emergency stop push-button:

a. Press each emergency stop push-button and makesure that all machine components stopimmediately.

b. Make sure that each emergency stop push-buttonremains in its pushed in and locked position byitself and that in this position, the machine cannotbe restarted.

c. Button must be red color.

(See Figures 8-8 through 8-10 next pages forexamples of machine guards.)

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Figure 8-8: Types of Machine Guards


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Figure 8-11: Methods of Guarding Actions andMotions: Enclosure Guards

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Figure 8-12: Methods of Guarding Actions andMotions: Interlocking Guards


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Figure 8-13: Methods of Guarding Actions andMotions: Automatic Guards

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Figure 8-14: Methods of Guarding Actions andMotions: Remote, Placement, Feeding, Ejecting


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D. Mills and Calenders

1. Mill Roll Heights

a. All new mill installations must be installed so thatthe top of the operating rolls is not less than 50inches (127 centimeters) above the level on whichthe operator stands, irrespective of the size of themill.

b. This distance must apply to the actual workinglevel, whether it be at the general floor level, in apit, or on a platform.

2. Mill Safety Controls

A safety trip control must be provided in front and inback of each mill. It must be accessible and mustoperate readily on contact. The safety trip controlmust be one of the following types or a combinationthereof:

a. Pressure-sensitive body bars. Installed at frontand back of each mill having a 46-inch (117-centimeter) roll height or over. These bars mustoperate readily by pressure of the mill operator’sbody.

b. Safety triprod. Installed in the front and in theback of each mill and located within 2 inches (5centimeters) of a vertical plane tangent to thefront and rear rolls. The top rods must be notmore than 72 inches (183 centimeters) above thelevel on which the operator stands. The triprodsmust be accessible and must operate readily,whether the rods are pushed or pulled.

c. Safety tripwire cable or wire center cord. Installedin the front and in the back of each mill andlocated within 2 inches (5 centimers) of a verticalplane tangent to the front and rear rolls. The

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cables must not be more than 72 inches (183centimeters) above the level on which the operatorstands. The tripwire cable or wire center cordmust operate readily, whether cable or cord ispushed or pulled.

d. Auxiliary equipment. All auxiliary equipmentsuch as mill divider, support bars, spray pipes, feedconveyors, strip knives, etc., must be located insuch a manner as to avoid interference with accessto and operation of safety devices.

3. Calender Safety Controls

a. Safety trip, face. A safety triprod, cable, or wirecord must be provided across each pair of in-running rolls extending the length of the face ofthe rolls. It must be readily accessible and operate

Figure 8-15: Pressure-Sensitive Body Bar


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whether pushed or pulled. The safety trippingdevices must be located within reach of theoperator and the bite.

b. Safety trip, side. On both sides of the calenderand near each end of the face of the roll, theremust be a cable or wire center cord connected tothe safety trip. They must operate readily whenpushed or pulled.

4. Trip and Emergency Switches

All trip and emergency switches must not be of theautomatically resetting type, but must require manualresetting.

5. Stopping Limits

a. Determination of distance of travel. Allmeasurements on mills and calenders must betaken with the rolls running empty at maximumoperating speed. Stopping distances must beexpressed in inches of surface travel of the rollfrom the instant the emergency stopping device isactuated.

b. Stopping limits for mills. All mills, irrespective ofsize of the rolls or their arrangement (individuallyor group-driven) must be stopped within adistance, as measured in inches of surface travel,not greater than 1.5 percent of the peripheral no-load surface speeds of the respective rolls asdetermined in feet per minute.

c. Example: Using 100 feet (30.5 meters) perminute, we would calculate stopping distances asfollows:

100 FPM × 1.5% = 1.5 = 18 inches stopping distance

d. The stopping distance is obtained by multiplyingthe running speed in feet by the 1.5% constant

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permitted for stopping. This results in a figureshowing feet which must be multiplied by 12 toobtain inches for permissible stopping distance.

6. Stopping Limits for Calenders

a. All calenders, irrespective of size of the rolls ortheir configuration, must be stopped within adistance as measured in inches of surface travel,not greater than 1.75 percent of the peripheral no-load surface speeds of the respective calender rollsas determined in feet per minute.

Table 8-1: Mill and Calender Safety StoppingEquipment Inspection Form


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b. Where speeds above 250 feet (76 meters) perminute as measured on the surface of the drive rollare used, stopping distances of more than 1.75percent are permissible. Such stopping distancesmust be subject to engineering determination.

E. Electrical Safety

1. General

a. Only authorized personnel, licensed for electricalwork, are permitted to repair, adjust, test, orservice electrical equipment. Follow federal, state,and local codes and regulations at all times.

b. Live electrical equipment or electrical componentparts must be grounded, isolated or provided withsome other means of protection to preventpotential exposure to employees.

c. Wiring must be fully closed in metal conduits.

2. Using Electrical Equipment

a. All electrical equipment must be in safe conditionbefore using. If you have questions regarding thesafety and health impacts of equipment, notify asupervisor immediately. Remove defectiveequipment from service until it is repaired orreplaced.

Figure 8-16: 120 Volt Branch Circuit Wiring

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Figure 8-17: Correctly Wired 110-Volt Circuit

Figure 8-18: Duplex Receptacle Correctly Wiredto Designated Terminals


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b. Personal portable electrical equipment, such asheaters, etc., must be approved prior to use.

c. All electrical office equipment and appliancesmust be certified by Underwriters Laboratory(UL). Avoid using electrical equipment/appliancesin wet or moist locations.

d. Do not overload electrical equipment or electricaloutlets. Only use approved extension cords andoutlets.

e. Only use extension cords that are intended for theequipment and conditions associated with theoperation. Cords must be grounded and inspectedprior to use to assure proper grounding.

f. Power strips must be used, whenever possible,instead of extension cords.

3. Inspecting Equipment

Inspect electrical equipment prior to its use, including:

a. Check for evidence of loose or visibly damagedparts, switches, shielding devices, nuts, bolts, etc.

b. Examine the electrical cord outer insulation forcuts and abrasions.

c. Examine the plug for loose or missing prongs.

d. Inspect the outlet receptacle for burn marks,cracks, broken insulation, missing cover plates, orother noticeable defects.

e. If the receptacle is discovered to be loose whenyou insert the plug, immediately disconnect theplug.

f. Immediately report the above defects. Do not useany electrical equipment or outlets with identifieddefects.

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4. Ground-Fault Circuit Interrupters

a. General

1) Insulation and grounding are used to preventinjury from electrical-wiring systems orequipment.However, there areinstances whenthese recognizedmethods do notprovide the degreeof protectionrequired.

2) A few instanceswhere ground-faultcircuit interrupterswould provideadditional protec-tion:

a) Many portable hand tools, such as electricdrills, are now manufactured with non-metallic cases, sometimes referred to as“double-insulated.” Although this designmethod assists in reducing the risk fromgrounding deficiencies, a shock hazard canstill exist. In many cases, employees mustuse such electrical equipment where there isconsiderable moisture or wetness. Althoughthe employee is insulated from the electricalwiring and components, there is still thepossibility that water can enter the toolhousing. Ordinary water is a conductor ofelectricity. Therefore, if the water contactsenergized parts, a path will be providedfrom inside the housing to the outside,bypassing the double insulation. When an


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employee holding a hand tool under theseconditions touches another conductivesurface in their work environment, anelectric shock will result.

b) Double-insulated equipment or equipmentwith non-metallic housings that does notrequire grounding under the NationalElectrical Code (NEC) is frequently usedaround sinks or in situations where theequipment could be dropped into water.Frequently, the initial human response is tograb for the equipment. If an employee’shand is placed in the water and anotherportion of his or her body is in contact witha conductive surface, a serious or deadlyelectric shock can occur.

c) In construction work and regular factory-maintenance work, if is frequently necessaryto use extension-cord sets with portableequipment. These cords are regularlyexposed to physical damage. Although safework procedures require adequate protec-tion, it is not possible to prevent all damage.Frequently, the damage is only to theinsulation, exposing energized conductors.It is not unusual for an employee to handlethe cord often with the possibility ofcontacting the exposed wires while holdinga metal case tool or while in contact withother conductive surfaces.

3) Since neither double insulation nor groundingcan provide protection under these conditions,it is necessary to use other protective measures.One acceptable method is a ground-faultcircuit interrupter, commonly referred to as aGFCI.

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b. How a Ground-Fault Circuit Interrupter Works

1) A ground-fault circuit interrupter is not anovercurrent device like a fuse or circuit breaker.GFCIs are designed to sense an imbalance incurrent flow over the normal path.

2) The GFCI contains a special sensor thatmonitors the strength of the magnetic fieldaround each wire in the circuit when current isflowing. The magnetic field around a wire isdirectly proportional to the amount of currentflow. Thus, the circuitry can accuratelytranslate the magnetic information into currentflow.

3) If the current flowing in the black (un-grounded) wire is within 5 (plus or minus 1)milliamperes (mA) of the current flowing inthe white (grounded) wire at any given instant,the circuitry considers that situation normal.All the current is flowing in the normal path.

Figure 8-19: How the GFCI Protects


8

4) If, however, the current flow in the two wiresdiffers by more than 5mA, the GFCI willquickly open the circuit. (See Figure 8-19previous page.)

5) Note that the GFCI will open the circuit if5mA or more of current returns to the serviceentrance by any path other than the intendedwhite (grounded) conductor. If the equipmentgrounding conductor is properly installed andmaintained, this will happen as soon as thefaulty tool is plugged in. If by chance thisgrounding conductor is not intact and of low-impedance, the GFCI may not trip out until anemployee provides a path. In this case, theemployee will receive a shock, but the GFCIshould trip out so quickly that the shock willnot be harmful.

c. Types of Ground-Fault Circuit Interrupters

There are several types of GFCIs available, withsome variations within each type. Although alltypes will provide ground-fault protection, thespecific application may dictate one type overanother.

1) Circuit-Breaker Type—The circuit-breakertype includes the functions of a standard circuitbreaker with the additional functions of aGFCI. It is installed in a panelboard and canprotect an entire branch circuit with multipleoutlets. It is a direct replacement for a standardcircuit breaker of the same rating.

2) Receptacle Type—The receptacle style GFCIincorporates within one device one or morereceptacle outlets, protected by the GFCI. Suchdevices are becoming very popular because oftheir low cost. Most are of the duplex-recep-

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tacle configuration and can provide GFCIprotection for additional non-GFCI typereceptacles connected “downstream” from theGFCI unit.

3) Permanently Mounted Type—The perma-nently mounted types are mounted in anenclosure and designed to be permanentlywired to the supply. Frequently, they are usedaround large commercial swimming pools orsimilar wet locations.

4) Portable Type—Several styles of portableGFCIs are available that are designed to beeasily transported from one location toanother. They usually contain one or moreintegral receptacle outlets protected by theGFCI module. Some models are designed toplug into existing non-GFCI protected outletsor, in some cases, are connected with a cordand plug arrangement. The portable type alsoincorporates a no-voltage release device whichwill disconnect power to the outlets if anysupply conductor is open. Units approved foruse outdoors will be in enclosures suitable forthe environment. If exposed to rain, they mustbe listed as rainproof.

5) Cord Connected Type—The power supplycord type GFCI consists of an attachment plugthat incorporates the GFCI module. It providesprotection for the cord and any equipmentattached to the cord. The attachment plug hasa non-standard appearance and is equippedwith test and reset buttons. Like the portabletype, it incorporates a no-voltage release devicewhich will disconnect power to the load if anysupply conductor is open.


8

d. Classes of Ground-Fault Circuit Interrupters

Ground-Fault Circuit Interrupters are divided intotwo classes:

1) Class A devices are designed to trip whencurrent flow, in other than the normal path, is6 milliamperes or greater. The specification is5mA plus or minus 1mA.

2) Class B devices will trip when current flow, inother than the normal path, is 20mA orgreater. Class B devices are approved for use onunderwater swimming pool lighting installedprior to the adoption of the 1965 NationalElectrical Code.

e. Testing Ground-Fault Circuit Interrupters

1) Due to the complexity of a GFCI, it isnecessary to test the device on a regular basis.

2) For permanently wired devices, a monthly testis recommended.

3) Portable type GFCIs must be tested each timebefore use.

4) GFCIs have a built-in test circuit whichimposes an artificial ground fault on the loadcircuit to assure that the ground fault protec-tion is still functioning.

5) Test and reset buttons are provided for testing.

5. Circuit Breakers and Electrical Panels

a. Electrical panels, switch boxes, and other electricalcontrol devices must;

1) Have an access clearance of three feet in front.

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2) Be provided with a lock or other means torestrict access at the housing box whennecessary.

3) Be labeled to indicate the circuits or equipmentthey affect.

b. All openings in switch boxes, circuit breakerpanels, etc., are to be covered.

c. Damaged or missing electrical fixtures must bereplaced.

d. Adapters which increase the number of outlets arenot allowed.

6. Cabinets, Boxes and Fittings

1) Conductors Entering Boxes, Cabinets, or Fittings

a) Conductors can be damaged if they rub againstthe sharp edges of cabinets, boxes, or fittings;they must be protected from damage wherethey enter. To protect the conductors, sometype of clamp or rubber grommet must beused. The device used must close the holethrough which the conductor passes as well asprovide protection from abrasion. If theconductor is in a conduit and the conduit fitstightly in the opening, additional sealing is notrequired.

b) The knockouts in cabinets, boxes, and fittingsshould be removed only if conductors are to berun through them. However, if a knockout ismissing or if there is another hole in the box,the hole or opening must be closed.

2) Covers and Canopies

a) All pull boxes, junction boxes, and fittingsmust be provided with covers approved for the


8

purpose. If metal covers are used, they must begrounded.

b) In completed installations, each outlet boxmust have a cover, faceplate, or fixture canopy.

c) Covers of outlet boxes having holes throughwhich flexible cord pendants pass must beprovided with bushings designed for thepurpose or must have smooth, well-roundedsurfaces on which the cords may bear.

7. Flexible Cords and Cables

a) There is a definite need and place for cords, butthere is also a temptation to misuse them becausethey seem to offer a quick and easy way to carryelectricity to where it is needed. The basicproblem is that flexible cords in general are morevulnerable than the fixed wiring of the building.Therefore, cords must not be used if one of therecognized wiring methods can be used instead.

b) Use of Flexible Cords and Cables

1) Flexible cords and cables must be approved andsuitable for conditions of use and location. Thestandard lists specific situations in whichflexible cords may be used. Flexible cords andcables must be used only for:

a) Pendants (a lampholder or cord-connectorbody suspended by a length of cordproperly secured and terminated directlyabove the suspended device).

b) Wiring of fixtures.

c) Connection of portable lamps or appli-ances.

d) Elevator cables.

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e) Wiring of cranes and hoists (where flexibil-ity is necessary).

f ) Connection of stationary equipment tofacilitate their frequent interchange(equipment which is not normally movedfrom place to place, but might be onoccasion).

g) Prevention of the transmission of noise orvibration. (In some cases vibration mightfatigue fixed wiring and result in a situationmore hazardous than flexible cord.)

h) Appliances where the fastening means andmechanical connections are designed topermit removal for maintenance and repair(e.g. water coolers, exhaust fans).

i) Data processing cables approved as a part ofa data processing system.

2) Note that all of the above situations involveconditions where flexibility is necessary. Unlessspecifically permitted by one of these situa-tions, flexible cords and cables may not beused:

a) As a substitute for the fixed wiring of thestructure.

b) Where run through holes in walls, ceilings,or floors.

c) Where run through doorways, windows, orsimilar openings.

d) Where attached to building surfaces.

e) Where concealed behind building walls,ceilings, or floors.


8

3) There is usually not much question about useof the short length of cord which is furnishedas part of an approved appliance or tool; thereis usually no question about an extension cordused temporarily to permit use of the applianceor tool in its intended manner at some distancefrom a fixed outlet; but there are questionswhen the usage is not obviously temporary, andwhen the cord is extended to some distantoutlet in order to avoid providing a fixed outletwhere needed.

8. Identification, Splices and Terminations

a. Flexible cords must be used only in continuouslengths without splice or tap. Hard service flexiblecords, No. 12 or larger, may be repaired if splicedso that the splice retains the insulation, outersheath properties, and usage characteristics of thecord being spliced.

b. Flexible cords must be connected to devices andfittings so that strain relief is provided which willprevent pull from being directly transmitted tojoints or terminal screws.

F. Cranes, Hoists, Chains & Slings

1. General Safety Rules

a. All crane and hoist hooks must have safety latches.

b. Hooks must not be painted (or re-painted) if thepaint previously applied by the manufacturer isworn.

c. Crane pendants must have an electrical disconnectswitch or button to open the main-line controlcircuit.

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d. Cranes and hoists must have a main electricaldisconnect switch. This switch must be in aseparate box that is labeled with lockoutcapability.

e. Crane bridges and hoist monorails must belabeled on both sides with the maximum capacity.

f. Each hoist-hook block must be labeled with themaximum hook capacity.

g. All newly installed cranes and hoists, or those thathave been extensively repaired or rebuiltstructurally, must be load tested at 125% capacityprior to being placed into service.

h. If an overload device is installed, a load test to theadjusted setting is required.

i. Do not engage in any practice that will divert yourattention while operating the crane.

Figure 8-20: Gantry Crane


8

j. Respond to signals only from the person who isdirecting the lift, or any appointed signal person.Obey a stop signal at all times, no matter whogives it.

k. Do not move a load over people. People must notbe placed in jeopardy by being under a suspendedload. Also, do not work under a suspended loadunless the load is supported by blocks, jacks, or asolid footing that will safely support the entireweight. Have a crane or hoist operator remain atthe controls or lock open and tag the mainelectrical disconnect switch.

l. Ensure that the rated load capacity of a crane’sbridge, individual hoist, or any sling or fitting isnot exceeded. Know the weight of the object beinglifted or use a dynamometer or load cell todetermine the weight.

m. Check that all controls are in the OFF positionbefore closing the main-line disconnect switch.

n. If spring-loaded reels are provided to lift pendantsclear off the work area, ease the pendant up intothe stop to prevent damaging the wire.

Figure 8-21: Overhead Traveling Crane

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o. Avoid side pulls. These can cause the hoist rope toslip out of the drum groove, damaging the rope ordestabilizing the crane or hoist.

p. To prevent shock loading, avoid sudden stops orstarts. Shock loading can occur when a suspendedload is accelerated or decelerated, and canoverload the crane or hoist. When completing anupward or downward motion, ease the load slowlyto a stop.

2. Rigging

a. General Rigging Safety Requirements

1) Use only rigging equipment that is in goodcondition. All rigging equipment must beinspected annually; defective equipment is tobe removed from service and destroyed toprevent inadvertent re-use. The load capacitylimits must be stamped or affixed to all riggingcomponents.

2) Facility policy requires a minimum safety factorof 5 to be maintained for wire rope slings. Thefollowing types of slings must be rejected ordestroyed:

a) Nylon slings with:

• Abnormal wear.

• Torn stitching.

• Broken or cut fibers.

• Discoloration or deterioration.

b) Wire-rope slings with:

• Kinking, crushing, bird-caging, or otherdistortions.

• Evidence of heat damage.


8

• Cracks, deformation, or worn endattachments.

• Six randomly broken wires in a single ropelay.

• Three broken wires in one strand of rope.

• Hooks opened more than 15% at thethroat.

• Hooks twisted sideways more than 10degrees from the plane of the unbenthook.

c) Alloy steel chain slings with:

• Cracked, bent, or elongated links orcomponents.

• Cracked hooks.

d) Shackles, eye bolts, turnbuckles, or othercomponents that are damaged or deformed.

b. Rigging a Load

Do the following when rigging a load:

1) Determine the weight of the load. Do notguess.

2) Determine the proper size for slings andcomponents.

3) Do not use manila rope for rigging.

4) Make sure that shackle pins and shouldered eyebolts are installed in accordance with themanufacturer's recommendations.

5) Make sure that ordinary (shoulderless) eyebolts are threaded in at least 1.5 times the boltdiameter.

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6) Use safety hoist rings (swivel eyes) as apreferred substitute for eye bolts whereverpossible.

7) Pad sharp edges to protect slings. Rememberthat machinery foundations or angle-iron edgesmay not feel sharp to the touch but could cutinto rigging when under several tons of load.Wood, tire rubber, or other pliable materialsmay be suitable for padding.

8) Do not use slings, eye bolts, shackles, or hooksthat have been cut, welded, or brazed.

9) Install wire-rope clips with the base only on thelive end and the U-bolt only on the dead end.Follow the manufacturer's recommendationsfor the spacing for each specific wire size.

10) Determine the center of gravity and balancethe load before moving it.

11) Initially lift the load only a few inches to testthe rigging and balance.

3. Hand Signals

Signals to the operator must be in accordance with thestandard hand signals unless voice communicationsequipment (telephone, radio, or equivalent) is used.Signals must be discernible or audible at all times.Some special operations may require addition to ormodification of the basic signals. For all such cases,these special signals must be agreed upon andthoroughly understood by both the person giving thesignals and the operator, and must not be in conflictwith the standard signals. (See Figure 8-22 nextpages.)


8

Figure 8-22: Hand Signals

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8

4. Inspection, Maintenance, and Testing

All tests and inspections must be conducted inaccordance with the manufacturers recommendations.

a. Monthly Tests and Inspections

1) All in-service cranes and hoists must beinspected monthly and the results documented.

2) Defective cranes and hoists must be locked andtagged “out of service” until all defects arecorrected. The inspector must initiate correc-tive action by notifying the manager.

b. Annual Inspections

A qualified contractor (Crane MaintenanceContractor and/or Manufacturer) must scheduleand supervise annual preventive maintenance(PM) and annual inspections of all cranes andhoists. The annual PM and inspection must cover:

1) Hoisting and lowering mechanisms.

2) Trolley travel or monorail travel.

3) Bridge travel.

4) Limit switches and locking and safety devices.

5) Structural members.

6) Bolts or rivets.

7) Sheaves and drums.

8) Parts such as pins, bearings, shafts, gears,rollers, locking devices, and clamping devices.

9) Brake system parts, linings, pawls, and ratchets.

10) Load, wind, and other indicators over their fullrange.

11) Gasoline, diesel, electric, or other power plants.

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12) Chain-drive sprockets.

13) Crane and hoist hooks.

14) Electrical apparatus such as controller contrac-tors, limit switches, and push button stations.

15) Wire rope.

16) Hoist chains.

c. Load Testing

1) Newly installed cranes and hoists must be loadtested at 125% of the rated capacity bydesignated personnel.

2) Slings must have appropriate test data whenpurchased. It is the responsibility of thepurchaser to ensure that the appropriate testdata are obtained and maintained.

3) Re-rated cranes and hoists must be load testedto 125% of the new capacity if the new ratingis greater than the previous rated capacity.

4) Fixed cranes or hoists that have had majormodifications or repair must be load tested to125% of the rated capacity.

5) Cranes and hoists that have been overloadedmust be inspected prior to being returned toservice.

6) Personnel platforms, baskets, and riggingsuspended from a crane or hoist hook must beload tested initially, then re-tested annuallythereafter or at each new job site.

7) All cranes and hoists with a capacity greaterthan 3 tons (2722 kilograms) must be loadtested every four years to 125% of the ratedcapacity. Cranes and hoists with a lesser


8

capacity must be load tested every eight yearsto 125% of the rated capacity.

8) All mobile hoists must be load tested atintervals to be determined by the manufac-turer.

d. Records

The Facility must maintain records for all cranes,hoist and rigging equipment.

5. Alloy Chain Slings

Alloy chain slings are made by bending, electricwelding, and heat treating alloy steel rods into chainlinks. Alloy chain slings are more rugged and flexible,but less shock resistant than wire rope, manila rope, orbraided slings. The size is measured by the diameter ofthe link stock.

6. Safe Practices

a. Alloy chainslings must beprotectedagainstchemicals, rustand corrosion.Extremely low temperatures (below zero) maycause brittle fractures, and it is advisable to reducesafe load ratingunder thoseconditions byabout 50%.

b. Knots weakenalloy chainslings and maycause chainlinks to bend or

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otherwise fail. Knotsmust not be used.

c. Alloy chain slings maybe shortened byhooking back into thechain, into the masterlink, or with grabhooks. A chain mustnever be shortened bytwisting, knotting, or byuse of bolts.

d. Alloy chain slings must beprotected from sharpcorners which might bendthe links. Lagging, cornerirons, etc., should be usedfor this purpose.

e. When making chokerhitches with alloy chainslings, always face thehook opening out andaway from the pull of thesling so the hooks will notslip out when slack istaken out of the sling.

f. Alloy chain slings must bechecked for:

1) Nicks, cracks, gouges,and wear.

2) Bent links, lifted weldfins, opened hooks,and stretch.

3) Rust and corrosion.


8

4) Uneven lengths when sling legs are handingfree.

g. If all the legs ofan alloy steelchain sling arehooked back intothe master link,the safe loadcapacity of thewhole sling maybe increased 50percent.

h. Finished surfacesmay be protectedfrom alloy chainslings by bagging,lagging, etc.

i. Sling hooks mustnot be point loadedunless designatedand rated for thatuse.

j. The larger end of pear-shaped links must be usedon the crane hook so as to prevent the masterlinks from binding. The smaller end is used forthe alloy sling chain.

k. Interlink wear, not accompanied by stretch inexcess of 5 percent, must be noted and the chainremoved from service when maximum allowablewear at any point of link, as indicated in tablebelow, has been reached.

l. Chain slings must be removed from service when,due to stretch, the increase in length of ameasured section exceeds 5 percent; when a link is

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bent, twisted or otherwise damaged, or whenraised scarfs or defective welds appear.

m. All sling chains, including end fastenings, must begiven a visual inspection before being used on thejob. A thorough inspection of all chains in usemust be made every three months. Each chainmust bear an indication of the month in which itis thoroughly inspected. The thorough inspectionmust include inspection for wear, defective welds,deformation and increase in length or stretch.

n. All repairs to chains must be made under qualifiedsupervision. Links or portions of the chain foundto be defective as described in subparagraph l ofthis section must be replaced by links havingproper dimensions and made of material similar tothat of the chain. Before repaired chains arereturned for service, they must be proof tested tothe proof-test load recommended by themanufacturer.

Figure 8-23: Maximum Allowable Wearat Any Point of Link


8The right way to clip wire rope The wrong way to clip wire rope

Figure 8-24: Wire Rope Clips

7. Applying Wire Rope Clips

a. A correct method of attaching U-bolt wire ropeclips to rope ends is shown in Figure 8-24 below.The base of the clip bears against the live end ofthe rope, while the “U” of the bolt presses againstthe dead end.

b. The clips are usually spaced about six ropediameters apart, to give adequate holding power.

c. Before ropes are placed under tension, the nuts onthe clips must be tightened. It is advisable totighten them again after the load is on the rope totake care of any reduction in the rope’s diametercaused by the weight or tension of the load.

d. A wire-rope thimble must be used in the loop eyeto prevent kinking when wire-rope clips are used.

e. The correct number of clips for safe application,and spacing distances, are shown in Table 8-2 nextpage.

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Table 8-2: Number of Clips and Spacingfor Safe Application

9. General Health

A. Dormitories

1. Housing

a. Housing must be structurally sound, in goodrepair, in a sanitary condition, and must provideprotection to the occupants against the elements.

b. Housing must have flooring constructed of rigidmaterials, smooth finished, and readily cleaned.

c. In dormitory accommodations using double bunkbeds only, not less than 40 square feet (12.2square meters) per occupant must be provided.

d. Separate sleeping accommodations must beprovided for each gender.

e. Adequate and separate arrangements for hangingclothing and storing personal effects for eachperson must be provided.

f. Each habitable room (not including partitionedareas) must have at least one window or skylightopening directly to the out-of-doors.

g. All outside openings must be protected withscreening of not less than 16 mesh.

h. All screen doors must be tight fitting, in goodrepair, and equipped with self-closing devices.

i. Sleeping facilities must be provided for eachperson, and must consist of comfortable beds,cots, or bunks.

j. Any bedding that is provided by the housingoperator must be clean and sanitary.

k. Triple-deck bunks are prohibited.

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l. Beds used for double occupancy may be providedonly in family accommodations.

2. Toilets

a. Toilets must be constructed, located, andmaintained so as to prevent any nuisance or publichealth hazard.

b. Toilets or privy seats for each gender must be inthe ratio of not less than one such unit for each 15occupants, with a minimum of one unit for eachgender in common-use facilities.

c. Urinals, constructed of nonabsorbent materials,may be substituted for men’s toilet on the basis ofone urinal or 24 inches (61 centimeters) oftrough-type urinal for one toilet.

d. Except in individual family units, separate toiletaccommodations for men and women must beprovided.

e. If toilet facilities for men and women are in thesame building, they must be separated by a solidwall from floor to ceiling.

f. Toilets must be distinctly marked “men” and“women” in the native language of the personsexpected to occupy the housing.

g. Common-use toilets must be well lighted andventilated and must be clean and sanitary.

h. Toilet facilities must be located within 200 feet(61 meters) of each living unit.

i. All toilet facilities must be cleaned at least dailywith anti-bacterial soap and water.

3. Bathing

a. Bathing and hand-washing facilities, supplied withhot and cold water under pressure, must be

General Health 9–3

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provided for the use of all occupants. Thesefacilities must be clean and sanitary and locatedwithin 200 feet (61 meters) of each living unit.

b. There must be a minimum of 1 showerhead per15 persons.

c. Showerheads must be spaced at least 3 feet (0.914meters) apart.

d. Shower floors must be constructed ofnonabsorbent, nonskid materials and sloped toproperly constructed floor drains.

e. Separate shower facilities must be provided foreach gender, and must be plainly designated“men” or “women” in the native language of thepersons expected to occupy the housing.

f. When common-use shower facilities for bothgenders are in the same building, a solid,nonabsorbent wall extending from the floor toceiling must separate them.

g. Adequate, dry dressing space must be provided incommon-use facilities.

4. Safety

a. Any stoves or other sources of heat utilizingcombustible fuel must be installed and vented insuch a manner as to prevent fire hazards and adangerous concentration of gases.

b. Any wall or ceiling within 18 inches (46centimeters) of a solid- or liquid-fuel stove or astovepipe must be of fireproof material. A ventedmetal collar must be installed around a stovepipe,or vent passing through a wall, ceiling, floor orroof.

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c. All buildings, in which people sleep or eat, mustbe constructed and maintained in accordance withapplicable state or local fire and safety laws.

d. In family housing and housing units for less than10 persons, of one story construction, two meansof escape must be provided.

e. All sleeping quarters intended for use by 10 ormore persons, central dining facilities, andcommon assembly rooms must have at least twodoors remotely separated so as to provide alternatemeans of escape to the outside or to an interiorhall.

f. Sleeping quarters and common areas on thesecond story and above must have a stairway, anda permanent, affixed exterior ladder or a secondstairway.

g. Fire-extinguishing equipment must be provided ina readily accessible place located not more than100 feet (30 meters) from each housing unit.

h. There must be at least 2 clearly marked exits oneach floor, and emergency lighting installed inhalls, stairwells, and above each exit.

i. Halls and exits must be kept clear of obstructionsto allow for a safe and rapid evacuation in case offire or other emergencies.

j. Directions for evacuation in case of fire or otheremergencies must be posted in all sleepingquarters.

k. Fire drills must be conducted at least quarterly.

l. No flammable or volatile liquids or materials mustbe stored in or adjacent to rooms used for livingpurposes, except for those needed for currenthousehold use.


9

m. Agricultural pesticides and toxic chemicals mustnot be stored in the housing area.

n. First-aid kits must be provided and readilyaccessible for use at all times, in a ratio of 1 perevery 50 persons.

5. Electrical

a. All dormitories must be provided with electricservice.

b. Each habitable room, all common-use rooms, andareas such as halls and stairways must containadequate ceiling or wall-type light fixtures.

c. At least one wall-type electrical outlet must beprovided in each individual living room.

d. All wiring and lighting fixtures must be installedand maintained in a safe condition.

e. Adequate lighting must be provided for the yardarea, and pathways to common-use facilities.

6. Sanitation

a. Housing and facilities must be free of insects,rodents, and other vermin.

b. Durable, fly-tight, clean containers in goodcondition must be provided adjacent to eachhousing unit for the storage of garbage and otherrefuse.

c. Provisions must be made for collection of refuse atleast twice a week, or more often if necessary.

d. The disposal of refuse must be in accordance withstate and local law.

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B. Clinics and Occupational Health Programs

1. Clinics

a. All health care staff must be trained in the practiceof Occupational and Emergency Medicine.

b. All health care staff should be licensed andregistered for the level of care that they areproviding.

c. Guidelines should be established for triage ofpatients to allow for better access to the health-care system.

d. Guidelines should be established for theadmission, treatment, transport and discharge ofpatients.

e. Infection control procedures should beimplemented, and appropriate equipment on-hand (e.g., sterile gloves, CPR barrier mask,autoclave, disposable needles, and suture kits).

Figure 9-1: Clinic


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f. Protocols for the use, testing, maintenance andcalibration of medical and surveillanceinstruments should be developed andimplemented.

g. All health-care facilities should have equipmentavailable to provide an advanced level of traumalife support (e.g., Ambu-bag, EKG, AED, oxygentanks, airways, IV capability).

h. Protocols should be established for the return towork of employees who have been absent fromwork as a result of infectious or contagiousdiseases.

i. The contractor should establish procedures toensure that all employees have access to healthsurveillance that is appropriate to the health andsafety risks they incur at work.

j. The contractor/employer should provide aminimum of 1 private bed for every 1,000employees.

k. The contractor/employer should equip the clinicfacility with a mechanical ventilation system thatis capable of maintaining the temperature between70 and 80 degrees Fahrenheit (21– 27 degreesCelsius) at all times.

l. The contractor/employer should establish clinicalguidelines for the treatment of all infectiousdiseases and have them available in the health carefacility at all times.

m. Strict adherence to sanitation standards should bein place at all times.

2. Health Risk Assessment

a. The contractor/employer should measure existingexposure levels to include: noise, temperature, UV

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rays, VOC vapor, dust, exhaust ventilation, andrepetitive trauma.

b. The contractor/employer should review all on-hand Material Safety Data Sheets for the purposeof establishing or verifying PPE requirements.

c. The contractor/employer should establish aprocedure to insure compliance with PPErequirements.

d. The contractor/employer should periodicallyreview the PPE program for effectiveness.

e. The contractor/employer should implementstandards to control the exposure to identifiedrisks (e.g., Hearing Conservation Program, HeatStress Reduction, VOC reduction, Eye Protection,Foot Protection, Bloodborne Pathogens program,Hazard Communication, Infectious Diseases,etc.).

3. Health Surveillance

a. The contractor/employer should establish astructured health-surveillance program based onthe results of the Risk Assessment.

b. A system should be established to analyze theresults of the surveillance programs, and provideguidance for corrective action and medicaltreatment.

c. A procedure should be developed to insure thatconfidentiality of medical information ismaintained.

d. A procedure should be established to evaluate thegeneral health of employees at all stages of theemployment continuum (pre-employment,baseline testing, pre-assignment, post sickness).


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4. First Aid and Emergency Medical Response

a. The contractor/employer should develop, post,implement and test a Medical EmergencyResponse Plan.

b. The contractor/employer should develop thecapability of handling a medical emergencythrough training of the workforce in basic firstaid, CPR, and First Response.

c. The number of employees trained should besufficient to insure that there is adequate coverageavailable at all times. Names of these employeesshould be posted in each work area.

Figure 9-2: First Aid Station

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d. The contractor/employer should insure that allemployees who provide first aid or otheremergency care are trained in and adhere to theBloodborne Pathogens standard.

e. Protocols should be established for the transportof injured workers via ambulance to off-sitemedical treatment centers.

f. All transport vehicles should be equipped withAdvanced Life Support apparatus (oxygen tanks,emergency air ways, back boards, cervical collars,EKG, AED, etc.).

g. The contractor/employer should hold mockemergency drills on a regular basis to insure thatthe process is effective.

5. Recordkeeping

a. The contractor/employer should establish aprocedure to insure that the confidentiality of allmedical records is maintained at all times.

b. Occupational health records should be maintainedfor a period of 30 years.

c. Health Assessment and Surveillance data shouldbe included as part of the medical record, andmaintained as such.

d. The contractor/employer should establish acomputerized system for the tracking ofoccupational health records and data.

e. Summary surveillance data should be forwardedto supervisors for corrective action, in aconfidential manner.

f. Occupational health data should be analyzedregularly for the purposes of trend identification,corrective action, and health promotion activityplanning.


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6. Health Promotion

a. The contractor/employer should utilize health riskassessment data to target high-risk occupational,environmental and lifestyle diseases for thedevelopment of health promotion activities.

b. Heath-promotion activities should be multi-mediaand culturally relevant whenever possible.

c. Preventative measures should be instituted as ameans of reducing the overall health risk of theworkforce (e.g., smoking cessation, AIDS training,family planning, tetanus vaccinations, Hepatitis Bvaccinations, etc.).

d. The contractor/employer should establish aprocess to monitor and measure the effectivenessof health promotion activities.

e. All health promotion activities should bedocumented.

C. Canteens


a. When central food service facilities are provided,the kitchen and dining hall must be in properproportion to the capacity of the housing, and beseparate from the sleeping quarters.

b. All food service facilities must be maintainedclean, clear of refuse and garbage, and free ofrodent and insect infestations.

c. All floors, walls, ceilings, studs, joints, rafters, andpipes must be constructed to provide easy accessfor cleaning.

d. Adequate light must be provided to all surfacesand equipment in food service spaces.

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e. All rooms must be adequately ventilated and air-intake ducts and interiors of ventilation ductingcleaned at least quarterly to prevent accumulationof dirt and grease.

f. Ventilation hoods and grease filters must becleaned weekly to prevent fires.

g. Garbage and refuse must be kept in leak-proof,nonabsorbent containers.

h. Sufficient numbers of garbage and refusecontainers are required to prevent overfilling.They must be provided with tight-fitting coversand emptied as necessary during operation hoursand at a minimum of each working day.

i. Garbage and refuse on the premises must bestored in a location inaccessible to insects androdents. When garbage or refuse rooms are used,they should not be located within 100 feet of thefood-service facility.

j. Garbage containers must be cleaned inside andout after they are emptied at the end of the day.

k. Effective measures to eliminate or control thepresence of rodents, flies, cockroaches, and otherpests must be maintained.

l. The food-service facility and its adjacent groundsmust be kept free of litter and debris.

m. Floors must be of nonabsorbent, easily cleanedmaterials.

n. Floors must be cleaned and disinfected daily.

o. All floor drains must be cleaned and disinfecteddaily.

p. Wall surface adjacent to all food preparation andcooking areas must be of nonabsorbent, easily


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cleaned material. In addition, the wall surfaceadjacent to cooking areas must be of fire-resistantmaterial.

q. Tables and chairs or equivalent seating must beprovided, and must be adequate in number toaccommodate the workers that will be served.

2. Food Preparation/Handling

a. All food-service workers must undergo medicalexaminations at a minimum of twice annually,and certified as being free from communicablediseases.

b. Certification must be posted in the service area.

c. Food-service workers must wear hairnets, gloves,and aprons while preparing and serving food.

d. Food-service workers must thoroughly wash anddisinfect hands after using toilet facilities orengaging in any other activities that couldcontaminate the hands. Signs must be posted inthe toilet areas clearly stating this requirement.

e. Food-service workers must thoroughly wash anddisinfect hands when switching between workingwith raw food and food that is ready to eat.

f. Food-service workers who contract a disease thatis transmissible through food must be removedfrom all food-handling activities until they arecertified as being disease free by a medical doctor.

g. Mechanical refrigeration that is capable ofmaintaining a temperature of not more than 41°Fahrenheit (5° Celcius) must be provided for thestorage of potentially hazardous food.

h. Sinks with hot and cold water under pressuremust be provided.

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i. All cooking, serving, and eating utensils must beconstructed of stainless steel, and must bethoroughly washed and disinfected after every use.

j. All tabletops and counters must be thoroughlywashed and disinfected after each use.

k. Countertops that are used for food preparationmust be constructed of stainless steel.

l. All food must be cooked and served or discardedwithin 4 hours after being removed fromrefrigeration.

Figure 9-3: Proper Hand Washing


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m. All potentially hazardous food must be cooked toa temperature of 140° Fahrenheit (60° Celcius), orabove.

n. Food must be stored off of the floor, and covered.

o. All food-service facilities should be maintainedclean, clear of refuse and garbage, and free ofrodent and insect infestations.

p. All food-service facilities must be provided withadequate food-storage shelves.

D. Sanitation

1. General

a. The floor of every workroom must be maintainedin a dry condition to the extent that is possibleconsidering the work being performed.

b. Where wet processes are used, drainage must bemaintained and platforms, mats or other drystanding places must be provided. If that is notpossible, appropriate waterproof footwear must beprovided at no cost to the employee.

c. To facilitate cleaning, every floor, working placeand passageway must be kept free of protrudingnails, splinters, loose boards, and unnecessaryholes or floor openings.

2. Waste Disposal (Non-Hazardous)

a. Any receptacle used for solid or liquid waste orrefuse with the potential to decay must beconstructed so that it does not leak and may bethoroughly cleaned and maintained in a sanitarycondition. These receptacles should also beequipped with a solid, tight fitting cover.

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b. All solid or liquid wastes, garbage or refuse mustbe removed as often as necessary to maintain thesanitary condition of the work place.

3. Vermin/Pest Control

a. Every enclosed workplace must be constructed,equipped and maintained in such a way as toprevent the entrance or harborage of rodents,insects or other vermin to the extent possible.

b. Where the presence of pests is detected, acontinuous and effective extermination programmust be instituted.

4. Toilet Facilities

a. Toilet rooms must be provided that are separatedby gender, and clearly marked as such. Wherephysical space does not allow for separate toiletrooms, gender signs must be posted outside ofeach individual toilet facility/compartment.

b. The number of toilet facilities that are necessarymust be determined by the number of employees

Figure 9-4: Lavatory


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of each gender that will utilize the facilities, basedon the following chart:

Number of Employees ....................................Min. No. Toilets1

1–15 ....................................................................................... 116–35 ...................................................................................... 236–55 ...................................................................................... 356–80 ...................................................................................... 4

81–110 ..................................................................................... 5111–150 .................................................................................... 6Over 150 ..................................................................................... 2

1Where toilet facilities will not be used by women, urinalsmay be provided instead of toilets, except that the numberof toilets in such cases must not be reduced to less than two-thirds of the minimum specified.2Additional fixture for each additional 40 employees.

c. Each toilet must occupy a separate compartmentwith a door and walls, or partitions betweenfixtures that are sufficiently high to assure privacy.

d. Covered trash receptacles must be provided ineach compartment.

e. Trash receptacles must be emptied and disinfectedat least daily.

f. All toilet facilities must be maintained in asanitary condition, with floors and fixturescleaned using soap and disinfectant at least daily.

g. All toilet facilities must be adequately ventilatedand have enclosed pipes and drains.

h. Deodorant tablets must be used in all urinals.

i. No chemicals other than cleaning products maybe stored in a toilet room.

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5. Washing Facilities

a. Lavatories (washing basins or sinks) must be madeavailable in all work places.

b. Each lavatory must be provided with hot and coldrunning water, to the extent possible. Where hotwater is not available, cold or tepid running watermust be available.

c. Hand soap or similar cleansing agent must beprovided.

d. Individual paper hand towels, warm air blowers,clean individual sections, or continuous clothtoweling must be provided convenient to thelavatories.

e. All washing facilities must be maintained in asanitary condition, with floors and fixturescleaned using soap and disinfectant at least daily.

6. Eating and Drinking Areas

a. No employee must be allowed to consume food orbeverages in a toilet facility, or in any other areathat is exposed to toxic material.

b. Receptacles with a tight-fitting cover must beprovided for the disposal of waste food, and mustbe emptied and disinfected at least daily.

c. No food or beverages must be stored in a toiletroom or in any other area that is exposed to toxicmaterial.

E. Drinking Water


a. Potable water must be provided in all work areas.


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b. Drinking water dispensers must be designed,constructed, and serviced in such a way thatsanitary conditions are maintained.

c. Drinking water dispensers must be capable ofbeing closed to the work environment.

Figure 9-5: Methods of Providing Drinking Water

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d. Individual drinking cups or other containers mustbe available for each employee’s use. Commondrinking cups or utensils are prohibited.

e. Outlets for non-potable water, such as that usedfor firefighting or other industrial purposes mustbe marked in a manner that clearly indicates thatthe water is not fit for human consumption.

f. All non-potable water systems must beconstructed in such a way that back flow orsiphonage into a potable water system isprevented.

g. Non-potable water must be boiled or otherwisedecontaminated prior to being used for foodpreparation or cooking.

h. Non-potable water may be used to clean thegeneral work premises, provided that it does notcontain chemicals or other substances that couldbe harmful to employees or the environment.

i. Contractors/employers must establish a watersampling program. Sampling frequency for awater system is based on user population.

Population Served .......................... Minimum Samples/Month

25–1,000 .............................................................................. 18,501–12,900 ......................................................................... 10

17,201–21,500 ........................................................................ 2041,001–50,000 ........................................................................ 50

j. A water system is considered to be in complianceif the following bacteria and disinfection levels aremet:

1) Fecal coliforms = 0; however, if the samples permonth are less than 40, then 1 failure permonth is acceptable.


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2) 99.9 percent inactivation of Giardia lambliacysts, 99.99 percent inactivation of viruses;however, 1 failure per month is acceptable.

3) Residual disinfectant concentration in thewater entering the system cannot be less than0.2 milligrams/liter.

4) The residual disinfectant concentration in thedistribution system measured as total chlorine,combined chlorine or chlorine dioxide must bedetectable in 95 percent of the samples eachmonth.

F. Childcare Facility Management


a. Each childcare center must have a programdirector that is employed full time.

b. When mobile classroom units are used, they mustbe securely anchored to the ground and must meetall requirements for permanent structures.

c. All stairs that have more than two steps must beprovided with sturdy handrails. When balustersare more than 4 inches (10 centimeters) apart,provisions must be made to prevent a child’s heador body from falling through.

d. Landings or gates must be provided beyond eachexterior door, and any door opening onto a full-length stairway.

e. Each window and glass door must be screened orguarded.

f. Floors must be smooth and not slippery, free fromcracks, clean and in good condition. A floorcovering is required over concrete.

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g. Walls must be clean and free of cracks.

h. All surfaces must be free of toxic materials.

i. Electrical outlets within the reach of children mustbe provided with receptacle covers when not inuse.

j. Extension cords must not be used.

k. Each room occupied by children must haveadequate lighting in all parts of the room.

l. The premises must be maintained in goodcondition and must be clean at all times, free fromaccumulated dirt and trash, and any evidence ofvermin or rodent infestation. Each outdoor trashand garbage container must be covered, and thecontents must be removed at least weekly.

m. Each room occupied by the children must beheated, ventilated and cooled. The temperature ineach room must be not be less than 65°Fahrenheit (18° Celcius) nor more than 90°Fahrenheit (32° Celcius).

n. Each electric fan, if used, must be mounted highon the wall or must be guarded.

o. When a gas heater is used, it must be approved bya fire inspector before use. Open-faced heaters areprohibited.

p. All heating elements, including hot water pipes,must be insulated or installed in such a way thatchildren cannot come in contact with them.Asbestos insulation must not be used. Fireplacesmust not be used when children are present.

q. Medicines, poisons, and other dangeroussubstances and instruments must be in lockedstorage.


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r. Storage of firearms in any area used for children’sactivities is prohibited. Firearms stored in anyother area of the premises must be in lockedstorage, or must be equipped with trigger locks.

s. Carpeting must be clean and in good repair.Newly installed carpeting must meet fire safetyrequirements of the local fire authorities.

2. Fire Safety

a. The building must meet the legal requirements ofthe community as to fire protection, water supply,and sewage disposal.

b. The building must have two exits approved by afire inspector. One exit must lead directly to theoutside.

c. Second floors approved by a fire inspector may beused for children 2½ years or over. Second-floorwindows must be guarded.

d. Fire evacuation drills must be conducted at leastonce a month for all children and adults presentusing at least 2 means of exit.

e. Drills must be conducted according to procedureswhich are posted in each room utilized bychildren.

f. A record of drills must be available for inspectionby the local authorities.

3. Play Area

a. A fenced outdoor play area must be provided forchildren 6 weeks to kindergarten age.

b. The outdoor play area must be able toaccommodate at least 25 percent of the capacity atone time.

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c. The fence for the outdoor play area must be atleast 3 feet (1 meter) high, free from sharp,hazardous edges, and of sufficient construction tokeep animals and intruders out.

d. There must be no farm animals or fowl in the playarea. Pets, if present, must be physically controlledor restrained.

e. The grounds must be kept neat and clean andsafe, and must be properly sloped or drained toprevent stagnant water collection.

f. Hazards, such as flammable materials, deep pools,or farm equipment, must be inaccessible; potentialhazards, such as uncovered wells, broken glass,boards containing nails, and other debris must beeliminated.

4. Water Supply

a. The water supply must be from a source approvedby a local health authority.

b. Sanitary drinking facilities must be available tochildren while indoors or outdoors. One of thefollowing methods must be used:

1) Individual disposable cups and a waterdispenser.

2) Individually-marked glasses or cups whichmust be washed daily.

3) A fountain designed so that a child can get adrink of water without assistance.

c. Drinking fountains must not be plumbed to sinks.

d. Cold water and hot water not exceeding 110°Fahrenheit (43° Celcius) must be supplied tolavatory fixtures accessible to children.


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5. Sanitation

a. All plumbing fixtures and building sewers must beconnected to public sewers where available.

b. When a public sewer is not available, a privatesewage disposal system meeting requirements ofthe local health and environmental authoritiesmust be installed and connected to all plumbingfixtures.

6. Bathroom Facilities

a. Plumbing must be installed and maintainedaccording to local plumbing codes.

b. Bathroom facilities must be readily accessible tothe children, and must be placed low or beprovided with safety steps.

c. There must be 1 toilet and 1washbasin for each15 children.

d. Bathroom facilities must be planned to assureprivacy for staff.

e. Soap, individual cloth towels or paper towels, andtoilet paper must be provided. The use ofcommon towels and wash cloths is prohibited.

f. When cloth towels and wash cloths are used, theymust be labeled with the child’s name andlaundered at least weekly.

7. Sleeping Accommodations

a. Individual cribs, cots, or mats (suitable to thechild’s age and level of development) and a covermust be provided for each child.

b. For evening care, each child must be providedwith a cot with a firm, waterproof mattress.

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c. At least 3 feet (0.914 meters) of space mustseparate the cribs, cots, and mats.

d. Cots, cribs, and mats must be disinfected daily ormarked for individual use and disinfected weeklyor more often when needed.

e. Stacked cribs must not be used for infant sleeping/napping.

f. Smoking is prohibited in the center or preschool.

g. Alcohol or non-prescribed controlled substances(drugs) must not be consumed on the premisesduring hours of operation, nor while children arepresent.

h. Each child’s hands must be washed with soap andwater before and after eating and after toileting.

i. Children must be allowed to go to the bathroomindividually as needed.

8. Illness

a. When a child is absent due to a communicabledisease, staff must inform other parents of thenature of the illness.

b. Communicable diseases (anthrax, influenza,Hepatitis A, B, or C, etc.) must be reported to therelevant local authorities.

c. Symptoms of illness must be reported immediatelyto parents.

d. A quiet area must be provided for sick children,who must be supervised by an adult.

e. Non-prescription medications must not beadministered to any child except on written orderof the parent or guardian.

f. Orders must be renewed yearly.


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g. A designated staff member must administermedication.

h. One designated staff member, per session, per unitmust administer prescription medication from apharmacy container labeled with the child’s name,the name of the medication, dosage, dosageintervals, the name of the physician, and the datethe prescription was filled. The label must beconsidered the order from the physician.

i. A record must be kept in the child’s file as to whogave the medication and of the date and time itwas given.

10. Sampling Equipment/DeviceGuidelines

A. 3M Organic Vapor Monitors (OVM)

These diffusion monitors are a sampling device designed tomeasure average concentrations over a measured timeinterval. Sampling times will vary according to contaminantconcentrations and environmental conditions such ashumidity. For complete details on sampling times refer tothe last page of this document. This monitor can be used aseither a personal or area monitor. As a personal monitor, it isworn near the breathing zone of individuals exposed topotentially hazardous environments. When used as an areamonitor, hang it away from walls, corners, table tops, orother regions where the air movement in the room may belimited.

Diagram 1 Diagram 2 Diagram 3

Diagram 4 Diagram 5

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1. Preparation of Blanks

Good industrial hygiene practice indicates that ablank monitor be included with each set of samples tocheck for any contamination of the samples. Theblank is a monitor which has been handled in thesame manner as the sample monitors, but has notbeen exposed to the atmosphere in the area beingmonitored. For every ten samples submit at least oneblank.

2. Sampling Instructions

a. Remove monitor from its container and record thetime on both the monitor back section and on thecorresponding data sheet. Keep the container.

b. Before monitoring, record the followinginformation in your data sheet: 1) monitor serialnumber (each monitor has a four digit numberand letter), 2) sampling date, 3) employee or areaI.D., 4) temperature and relative humidity (ifknown), and 5) compounds to be analyzed.

c. Record the date, employee or area I.D. andsampling start time on the monitor label(Diagram 1). DO NOT REMOVE WHITEFILM AND PLASTIC RING.

d. Monitor can be used as an area or personalmonitor. For personal sampler attach the monitornear employee breathing zone (Diagram 2). Placethe monitor on the worker by affixing the alligatorclip to the shirt collar with the white membraneside exposed (on the outside). When used as anarea monitor, hang it away from walls, corners,table tops, or other regions where the airmovement in the room may be limited.

e. When removing the monitor record the end timeon both the monitor and data sheet. Calculate the

Sampling Equipment/Device Guidelines 10–3

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total time of sampling on the data sheet. If thesampling period spans the lunch hour, subtractthe lunchtime from the total time betweenmonitor placement and removal.

f. After sampling period is ended, remove plasticring and white film from the monitor (Diagram3). Snap the elution cap (with plugs) onto the topof the primary body. Separate the primary bodyand secondary body sections (Diagram 4). Snapthe bottom cup (no plugs) into the bottom of theprimary section (Diagram 5). Snap elution cap onthe secondary body. You may wish to secure themwith scotch tape before placing them back in cans.Monitor is now ready for shipment. Note: Theprimary and secondary sections should have thesame identification numbers.

g. Return monitor to can and close with plastic lidprovided. Pack monitors securely into a box and,where possible, with a cool pack to further ensuresample preservation.

h. Send samples “Next Day Air” to an accreditedlaboratory for analysis.

Note: Certain compounds (e.g., acetone, MEK, vinylacetate, etc.) may show a decreased recovery when sampledin high relative humidity. Refrigerate and/or expedite foranalysis to help ensure accurate results.

The placement of any sampling material or equipment onworkers should be voluntary. Workers should be instructedto go about their normal duties and not alter their routinesin any way. Monitors can be kept on during lunch if thesampling period requires it.

It is important to periodically check the monitors during thesampling period to make sure they are still properly placedand not damaged or covered with material or clothing.

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For many situations passive sampling, Organic VaporMonitors (OVM), is preferred over comparable activemethods. This section is based upon guidelines for the 3Morganic vapor monitors.

Desorbing Solvents are listed for each compound in thefollowing table. The desorbing solvent allows an individualto determine what other compounds if any may be sampledon the same organic vapor monitor at the same time. Two ormore compounds with the same desorbing solvent can besampled concurrently on the same OVM. It is essential thatthe minimum and maximum exposure times be adhered tofor the compounds being sampled. The following tablespecifies this information.

*Shading denotes the most typical chemicals sampled infootwear, apparel, and equipment factories.

Table 10-1: Desorbing Solvents


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B. Sound Level Meter Guidelines

1. Monitoring Equipment

a. The Quest™ 2400 Type 2 sound-level meter willprimarily be used to quantify continuous orintermittent noise exposure surveys. The operatormust record the measured sound level. The soundlevel meter kit will include a calibrator, calibrationtool, wind guard, wrist strap and two 9-voltalkaline batteries. Calibration must occur prior tosampling and after sampling each day. Do notsubstitute with another type of calibrator. TheQuest™ 2400 and calibrator must be sent back toan authorized maintenance and calibration vendoreach year. It is recommended that the user readthe Quest instructions and this guide and becomesfamiliar with the equipment prior to use.

b. The Quest™ 2400 sound level meter must not beused in flammable atmospheres or near opencontainers of flammable materials.

c. Calibrating the Quest™ 2400 sound level meter:

1) Slide the frequency weightings switch to “A.”

2) Slide the range switch to high (70–140 dBA).

3) Slide the response switch to “Slow.”

4) Slide the display mode to “Run.”

5) Tun on the power to the meter. The LCD(liquid crystal display) should indicate thestatus of the batteries and the current soundlevel.

6) If low battery status is indicated, turn off thepower. Open the batteries door and discard theold batteries. Slide two new 9-volt alkalinebatteries into the space as shown by the label in

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the battery door. New batteries should provideapproximately 25 hours of continuous use.Recording the date on each battery is recom-mended.

7) Turn on the power. The display should indicatesufficient battery power for the planned surveyand the current sound levels.

8) Slide the calibrator onto the silver microphoneuntil fully inserted. The current sound levelreading should be lower. (The calibration dateby the authorized vendor must be on thecalibrator and be current within one year.)

9) Turn on the calibrator. The sound level shouldrise to the calibrator source level. Note on thecalibrator label the appropriate sound level.

10) If the sound level meter reads the same as thecalibrator source level label, the meter isproperly calibrated.

11) If the sound level meter is not calibrated, usethe calibrator tool to adjust the calibrationscrew on the sound level meter until it matchesthe calibrator source level label. If the soundlevel meter will not calibrate, install a newbattery in the calibrator. Start at Step 8) tocomplete the calibration. If the sound levelmeter will not calibrate, return it to anauthorized maintenance and calibrationvendor.

12) Turn off the calibrator and remove it from themicrophone. The sound level meter is cali-brated. Record in your notes that calibrationwas conducted including, date, time and name.

13) After monitoring is complete for the day,follow calibration Steps 7) through 12).


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d. Using the Quest™ 2400 sound level meter:

1) Assure that proper calibration was conductedbefore use.

2) Attach the wrist strap to the meter and yourwrist to prevent damage if dropped.

3) Do not talk or create noises while monitoring.All sound levels measured should be from thetypical work environment.

4) Wind or high air velocities can create whistlesor distortions around the microphone that cancause sampling data errors. Where high air-velocities are present during sampling, thewind guard should be installed over themicrophone. Note in the documentation if thewind guard was used.

5) The meter should be held with your armextended away from your body approximatelyat the employee’s ear level. Areas with seatedemployees should be sampled at seatedemployee ear level and standing employee earlevel. If no employee is present, hold the meterapproximately 5 feet (1.5 meters) above thefloor. Similar to the employee’s ear, themicrophone should point sideways approxi-mately perpendicular to the direction theemployee is standing. Record the samplingheight and location.

6) Monitor and record the sound levels fromdifferent task specific areas around a noisesource. (Example, for a product grinder,monitor near the loading area, control paneland discharge area.)

7) Each different employee task that involves anoise source should be monitored and re-

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corded. (For example, for a product grinder,the product loader, operator and maintenanceperson may have different noise exposures.)

8) Some sound level fluctuations are common.After 10 seconds, record the estimated averageor center tendency sound level for eachposition. If the fluctuation is greater than 3dBA, record the minimum, maximum andestimated average levels.

9) Maximum levels can also be determined bysliding the display switch to “Max Hold”mode. Reset to “Run” mode before continuingthe sample.

10) Record the time, date, exact location, equip-ment in operation and rate. Record operation,name of task or operation, sine of room orarea, number of employees present, duration ofthe task or exposure to the noise source,identity of sound level meter, sound levelsmeasured, name of person conducting thesurvey and other applicable information.

11) Noise dosimeters may be worn by an employeeto document the various noise exposuresthroughout a work period. The dosimeterrecords and calculates the daily noise dose forthe workday. Dosimeters must be calibratedand all settings set for A weighting, slowresponse, threshold at 80 dBA, exchange rateof 5 dBA and criterion at 90 dBA. Themicrophone should be attached to the collarapproximately 6 inches (15.2 centimeters)from the ear and pointing up toward the ear.

e. Exposure Monitoring

All facilities should be systematically assessed forhigh noise sources and work areas. All areas


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believed or known to be higher than 85 dBAshould be identified and monitored. Any workarea that requires the employees to shout to beheard or understood from a distance ofapproximately 1 meter should be evaluated. Thesound level meter can survey specific operations,machines or work areas. Adjacent equipment canbe turned off to determine the noise caused by asingle machine. A simple plan should include thefollowing issues:

1) A person experienced with the facility shouldconduct an initial walk through of all work andmaintenance areas identifying potential highnoise locations. Develop a detailed listing anddiagram of noise sources and areas of highnoise. Different shift operations and scheduledmaintenance activities should be listed.

2) Locate employee work areas near all of thenoise sources. Record how long they work withspecific equipment and the duration of work ina high noise area.

3) Conduct sound level measurements for eachidentified work area or noise source. Recordthe sound levels and status (on or off, full orhalf speed, production rate) of each adjacentpiece of equipment.

4) All equipment with employee exposure tosound levels above a time weighted average of90 dBA should be evaluated for engineeringcontrols, enclosures, adding sound absorbingmaterials, replacement with quieter equipment,etc.

5) If available, a dosimeter can be worn by anemployee to record the duration of exposureand exposure levels. Compare the dosimeter

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record with the measured sound levels andestimated time of exposures. All significantdifferences (>3 dBA) should be monitoredagain.

6) Summarize all noise source areas greater than85 dBA and all employee work areas. Writingthe sound levels on a floor plan, blue print,photo or a simple sketch of the work area maybe helpful.

7) All employees with an 8-hour time weightedaverage of 85 dBA will be included in thehearing conservation program. See Calcula-tions section.

f. Calculations

A maximum time weighted average of 90 dBA or1.0 (100%) for noise exposures are based on the8-hour workday. Employees exposed above thislevel will be included in the hearing conservationprogram. The dBA scale is logarithmic and cannot be simply added or subtracted. A worker whoworks a full 8 hours in one location withcontinuous noise exposure will average thatexposure. Maximum exposures are listed in theTable 10-2 next page.


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Duration Per Day ......................................... Sound Level dBA

8 ........................................................................ 906 ........................................................................ 924 ........................................................................ 953 ........................................................................ 972 ...................................................................... 1001.5 ................................................................... 1021 ...................................................................... 1050.5 ................................................................... 1100.25 ................................................................. 115

Shorter duration or mixtures of exposures must be calcu-lated.

C1

C2

Cn

D = ---- + ---- + ----

T1

T2

Tn

With:

D = the total noise dose

C = employee’s duration of exposure at a specificnoise level

T = total duration of exposure allowed at that noiselevel

A dose of 1.0 (100%) is the same as an 8-hour timeweighted average of 90 dBA.

TWA = 16.61 times log10 (D) + 90 dBA

Table 10-2: Maximum Exposure Levels

11. General Information, Weights and Measures

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General Information, Weights & Measures 11–3

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ESH Handbook 2002

Documents

Transcript of ESH Handbook 2002