Welding and Cutting Procedures. Crown Tonka

Transcription

1 Welding and Cutting Procedures Crown Tonka

2 Welding and Cutting Procedures Welding and Cutting Procedures Summary 2. Administrative Duties 3. Welding and Cutting Equipment 4. Training 5. Operating Procedures 6. Inspections 7. Signs and Labels 8. Recordkeeping Appendices a. A b. B 1

3 Welding and Cutting Procedures 1. Summary These written Welding & Cutting Procedures establish guidelines to be followed whenever any of our employees work with welding and cutting equipment at this company. The procedures here establish uniform requirements designed to ensure that welding and cutting safety training, operation, and maintenance practices are communicated to and understood by the affected employees. These requirements also are designed to ensure that procedures are in place to safeguard the health and safety of all employees. It is our intent to comply with the requirements of 29 CFR through.354. These regulations have requirements for welding and cutting operations. We also comply with applicable requirements of: Standard or Regulation: ANSI Z CGA Pamphlet P Name: Safety in Welding and Cutting Safe Handling of Compressed Gases 29 CFR 1926, Subpart D Occupational Health and Environmental Controls 29 CFR 1926, Subpart E Personal Protective And Life Saving Equipment 29 CFR (c) Electrical Specific Purpose Equipment and Installations 49 CFR 192 Transportation of Natural and Other Gas by Pipeline: Minimum Federal Safety Standards 49 CFR Hazardous Materials Regulations 2. Administrative Duties EMPLOYEE NAME/TITLE is responsible for developing and maintaining the written Welding & Cutting Procedures. These procedures are kept at the following location: LOCATION/WHERE 2

4 Welding and Cutting Procedures 3. Welding and Cutting Equipment Crown Tonka uses the following welding and cutting equipment: Make, model, and serial number: Type: Quantity: Purpose and location: 4. Training It is the policy of Crown Tonka to permit only trained and authorized personnel to operate welding and cutting equipment. EMPLOYEE NAME/TITLE will identify all new employees in the employee orientation program and make arrangements with department management to schedule training. The following person(s) will conduct initial training and evaluation: EMPLOYEE NAME/TITLE. This instructor(s) has the necessary knowledge, training, and experience to train new welding and cutting equipment operators. Initial Training All welders and cutters are trained and tested on the equipment they will be operating before they begin their job. During training, Crown Tonka covers the operational hazards of our welding and cutting operations, including: Hazards associated with the particular make and model of the welding and cutting equipment; Hazards of the workplace; and General hazards that apply to the operation of all or most welding and cutting equipment. See Appendix A for company-specific hazards of our welding and cutting equipment at our workplace. Each potential welder or cutter who has received training in any of the elements of our training program for the types of equipment which that employee will be authorized to operate and for the type of workplace in which the welding and cutting equipment will be operated need not be retrained in those elements before initial assignment in our workplace if Crown Tonka has written documentation of the training and if the employee is evaluated to be competent. 3

5 Welding and Cutting Procedures Training is done in-house. Training Certification After an employee has completed the training program, the instructor will determine whether the potential welder or cutter can safely perform the job. At this point, the trainee will take a performance test or practical exercise through which the instructor(s) will decide if the training has been adequate. All welding and cutting trainees are tested on the equipment they will be operating. EMPLOYEE NAME/TITLE is responsible for keeping records certifying that each employee who has successfully completed training and testing. Each certificate includes the name of the employee, the date(s) of the training, and the signature of the person who did the training and evaluation. Performance Evaluation Each certified welder or cutter is evaluated to verify that the welder or cutter has retained and uses the knowledge and skills needed to operate safely. If the evaluation shows that the welder or cutter is lacking the appropriate skills and knowledge, the welder or cutter is retrained by our instructor(s). When a welder or cutter has an accident or near miss or some unsafe operating procedure is identified, we do retraining. Current Welders and Cutters Under no circumstances may an employee operate welding or cutting equipment until he/she has successfully completed this company's welding and cutting training program. This includes all new welders and cutters regardless of claimed previous experience. The following table lists employees who are currently authorized welders and cutters at this company: Department or work area: Employee name/title: Equipment make and model: All employees have a general obligation to work safely with and around welding and cutting operations. 4

6 Welding and Cutting Procedures 5. Operating Procedures Welding and cutting can create certain hazards that only safe work practices can prevent. That s why we have created a set of operating procedures. Our operating procedures follow: Compressed Gas Cylinders Gas Welding and Cutting Arc Welding and Cutting Fire Prevention Fire Watchers Ventilation Personal Protective Equipment Confined Spaces Flammable, Toxic, or Hazardous Materials Electrical Equipment Fall Protection 6. Inspections A number of inspections are required under the welding and cutting regulations. To make inspections efficient, we have compiled a list of inspection items to be checked before welding or cutting: CHECKLIST 5

7 Welding and Cutting Procedures Maintenance Any deficiencies found in our welding and cutting equipment are repaired, or defective parts replaced, before continued use. However, no modifications or additions that affect the capacity or safe operation of the equipment may be made without the manufacturer s written approval. If such modifications or changes are made, the capacity, operation, and maintenance instruction plates, tags, or decals, must be changed accordingly. In no case may the original safety factor of the equipment be reduced. While defective parts may be found, we prefer to invest time and effort into the proper upkeep of our equipment, which results in day-to-day reliability. Keeping up with the manufacturer s recommended maintenance schedules, and completing the proper records, will also increase our welding and cutting equipment s longevity. EMPLOYEE NAME/TITLE complete(s) a receiving or delivery inspection whenever our company purchases welding and cutting equipment. EMPLOYEE NAME/TITLE follow(s) the manufacturer s operator instruction manual for daily or weekly maintenance. See manufacturer s operator instruction manual(s). Periodic maintenance (those completed monthly or less frequently) is done by a factory-trained-expert, or a dealer. 7. Signs and Labels Our company posts signs as follows: DESCRIBE SIGNS, WHERE/LOCATION We use the following labels: DESCRIBE LABELS 8. Recordkeeping EMPLOYEE NAME/TITLE is responsible for maintaining the following records: LIST RECORDS 6

8 Welding and Cutting Procedures Appendix A Company-specific hazards of our welding and cutting equipment and our workplace include: Task and location: Equipment: Hazard: Appendix B We have attached the following documents to this written Welding and Cutting Procedures: Hot Work Safety Procedures, Reference: OSHA 29 CFR

9 Tool Hand and Power Program Crown Tonka

10 Tools Hand and Power Program Tool Hand and Power Hazard Recognition 2. Hand Tools 3. Power Tool Precautions 4. Guards 5. Safety Switches 6. Electric Tools 7. Powered Abrasive Wheel Tools 8. Pneumatic Tools 9. Explosive Actuated Tools 10. Fasteners 11. Hydraulic Power Tools 12. Jacks 13. General Safety Precautions 14. Compressed Air Used for Cleaning 1

11 Tools Hand and Power Program 1. Hazard Recognition Tools are such a common part of our lives that it is difficult to remember that they may pose hazards. All tools are manufactured with safety in mind but, tragically, a serious accident often occurs before steps are taken to search out and avoid or eliminate tool related hazards. In the process of removing or avoiding the hazards, workers must learn to recognize the hazards associated with the different types of tools and the safety precautions necessary to prevent those hazards. 2. Hand Tools Hand tools are non-powered. They include anything from axes to wrenches. The greatest hazards posed by hand tools result from misuse and improper maintenance. Some examples: Using a screwdriver as a chisel may cause the tip of the screwdriver to break and fly, hitting the user or other employees. If a wooden handle on a tool such as a hammer or an axe is loose, splintered, or cracked, the head of the tool may fly off and strike the user or another worker. A wrench must not be used if its jaws are sprung, because it might slip. Impact tools such as chisels, wedges, or drift pins are unsafe if they have mushroomed heads. The heads might shatter on impact, sending sharp fragments flying. «Company» is responsible for the safe condition of tools and equipment used by employees but the employees have the responsibility for properly using and maintaining tools. «Company» should caution employees that saw blades, knives, or other tools be directed away from aisle areas and other employees working in close proximity. Knives and scissors must be sharp. Dull tools can be more hazardous than sharp ones. 2

12 Tools Hand and Power Program Appropriate personal protective equipment, e.g., safety goggles, gloves, etc., should be worn due to hazards that may be encountered while using portable power tools and hand tools. Safety requires that floors be kept clean and dry as possible to prevent accidental slips with or around dangerous hand tools. Around flammable substances, sparks produced by iron and steel hand tools can be a dangerous ignition source. Where this hazard exists, spark-resistant tools made from brass, plastic, aluminum, or wood will provide for safety. 3. Power Tool Precautions Power tools can be hazardous when improperly used. There are several types of power tools, based on the power source they use: electric, pneumatic, liquid fuel, hydraulic, and powder-actuated. Employees should be trained in the use of all tools - not just power tools. They should understand the potential hazards as well as the safety precautions to prevent those hazards from occurring. The following general precautions should be observed by power tool users: Never carry a tool by the cord or hose. Never yank the cord or the hose to disconnect it from the receptacle. Keep cords and hoses away from heat, oil, and sharp edges. Disconnect tools when not in use, before servicing, and when changing accessories such as blades, bits and cutters. All observers should be kept at a safe distance away from the work area. Secure work with clamps or a vise, freeing both hands to operate the tool. Avoid accidental starting. The worker should no hold a finger on the switch button while carrying a plugged-in tool. Tools should be maintained with care. They should be kept sharp and clean for the best performance. Follow instructions in the user's manual for lubricating and changing accessories. Be sure to keep good footing and maintain good balance. 3

13 Tools Hand and Power Program The proper apparel should be worn. Loose clothing, ties, or jewelry can become caught in moving parts. All portable electric tools that are damaged shall be removed from use and tagged "Do Not Use." 4. Guards Hazardous moving parts of a power tool need to be safeguarded. For example, belts, gears, shafts, pulleys, sprockets, spindles, drums, fly wheels, chains, or other reciprocating, rotating, or moving parts of equipment must be guarded if such parts are exposed to contact by employees. Guards, as necessary, should be provided to protect the operator and others from the following: point of operation in-running nip points rotating parts, and flying chips and sparks. Safety guards must never be removed when a tool is being used. For example, portable circular saws must be equipped with guards. An upper guard must cover the entire blade of the saw. A retractable lower guard must cover the teeth of the saw, except when it makes contact with the work material. The lower guard must automatically return to the covering position when the tool is withdrawn from the work. 5. Safety Switches (a)(2) The following hand-held powered tools must be equipped with a momentary contact "on-off" control switch: drills, tapers, fastener drivers, horizontal, vertical and angle grinders with wheels larger than 2 inches in diameter, disc and belt sanders, reciprocating saws, saber saws, and other similar tools. These tools also may be equipped with a lock-on control provided that turnoff can be accomplished by a single motion of the same finger or fingers that turn it on. 4

14 Tools Hand and Power Program The following hand-held powered tools may be equipped with only a positive "on-off" control switch: platen sanders, disc sanders with discs 2 inches or less in diameter; grinders with wheels 2 inches or less in diameter; routers, planers, laminate trimmers, nibblers, shears, scroll saws and jigsaws with blade shanks ¼-inch wide or less. Other hand-held powered tools such as circular saws having a blade diameter greater than 2 inches, chain saws, and percussion tools without positive accessory holding means must be equipped with a constant pressure switch that will shut off the power when the pressure is released. 6. Electric Tools Employees using electric tools must be aware of several dangers; the most serious is the possibility of electrocution. Among the chief hazards of electric-powered tools are burns and slight shocks which can lead to injuries or even heart failure. Under certain conditions, even a small amount of current can result in fibrillation of the heart and eventual death. A shock also can cause the user to fall off a ladder or other elevated work surface. To protect the user from shock, tools must either have a three-wire cord with ground and be grounded, be double insulated, or be powered by a low-voltage isolation transformer. Three-wire cords contain two current-carrying conductors and a grounding conductor. One end of the grounding conductor connects to the tool's metal housing. The other end is ground through a prong on the plug. Anytime an adapter is used to accommodate a two-hole receptacle, the adapter wire must be attached to a known ground. The third prong should never be removed from the plug. Double insulation is more convenient. The user and the tools are protected in two way: by normal insulation on the wires inside, and by a housing that cannot conduct electricity to the operator in the event of a malfunction. 5

15 Tools Hand and Power Program These general practices should be followed when using electric tools: Gloves and safety footwear are recommended during use of. When not in use, tools should be stored in a dry place. Electric tools should not be used in damp or wet locations. Work areas should be well lighted. 7. Powered Abrasive Wheel Tools (c) Powered abrasive grinding, cutting, polishing, and wire buffing wheels create special safety problems because they may throw off flying fragments. Before an abrasive wheel is mounted, it should be inspected closely and sound-or ring-tested to be sure that it is free from cracks or defects. To test, wheels should be tapped gently with a light non-metallic instrument. If they sound cracked or dead, they could fly apart in operation and so must not be used. A sound and undamaged wheel will give a clear metallic tone or "ring." To prevent the wheel from cracking, the user should be sure it fits freely on the spindle. The spindle nut must be tightened enough to hold the wheel in place, without distorting the flange. Follow the manufacturer's recommendations. Care must be taken to assure that the spindle wheel will not exceed the abrasive wheel specifications. Due to the possibility of a wheel disintegrating (exploding) during start-up, the employee should never stand directly in front of the wheel as it accelerates to full operating speed. Portable grinding tools need to be equipped with safety guards to protect workers not only from the moving wheel surface, but also from flying fragments in case of breakage. In addition, when using a powered grinder: Always use eye protection. Turn off the power when not in use. Never clamp a hand-held grinder in a vise 6

16 Tools Hand and Power Program 8. Pneumatic Tools (b) Pneumatic tools are powered by compressed air and include chippers, drills, hammers, and sanders. There are several dangers encountered in the use of pneumatic tools. The main one is the danger of getting hit by one of the tool's attachments or by some kind of fastener the worker is using with the tool. Eye protection is required and face protection is recommended for employees working with pneumatic tools. Noise is another hazard. Working with noisy tools such as jackhammers requires proper, effective use of hearing protection. When using pneumatic tools, employees must check to see that they are fastened securely to the hose to prevent them from becoming disconnected. A short wire or positive locking device attaching the air hose to the tool will serve as an added safeguard. A safety clip or retainer must be installed to prevent attachments, such as chisels on a chipping hammer, from being unintentionally shot from the barrel. Screens must be set up to protect nearby workers from being struck by flying fragments around chippers, riveting guns, staplers, or air drills. Compressed air guns should never be pointed toward anyone. Users should never "dead-end" it against themselves or anyone else. 9. Explosive Actuated Tools (d) Explosive- or powder-actuated tools operate like a loaded gun and should be treated with the same respect and precautions. In fact, they are so dangerous that they must be operated only by specially trained employees. 7

17 Tools Hand and Power Program Safety precautions to remember include the following: These tools should not be used in an explosive or flammable atmosphere. Before using the tool, the worker should inspect it to determine that it is clean, that all moving parts operate freely, and that the barrel is free from obstructions. The tool should never be pointed at anybody. The tool should not be loaded unless it its to be used immediately. A loaded tool should not be left unattended, especially where it would be available to unauthorized persons. Hands should be kept clear of the barrel end. To prevent the tool from firing accidentally, two separate motions are required for firing: one to bring the tool into position, and another to pull the trigger. The tools must not be able to operate until they are pressed against the work surface with a force of at least 5 pounds greater than the total weight of the tool. If a powder-actuated tool misfires, the employee should wait at least 30 seconds, then try firing it again. If it still will not fire, the user should wait another 30 seconds so that the faulty cartridge is less likely to explode, than carefully remove the load. The bad cartridge should be put in water. Suitable eye and face protection are essential when using a powder-actuated tool. The muzzle end of the tool must have a protective shield or guard centered perpendicularly on the barrel to confine any flying fragments or particles that might otherwise create a hazard when the tool if fired. The tool must be designed so that it will not fire unless it has this kind of safety device. All powder-actuated tools must be designed for varying powder charges so that the user can select a powder level necessary to do the work without excessive force. If the tool develops a defect during use it should be tagged and taken out of service immediately until it is properly repaired. 8

18 Tools Hand and Power Program 10. Fasteners (d)(3) When using powder-actuated tools to apply fasteners, there are some precautions to consider. Fasteners must not be fired into material that would let them pass through to the other side. The fastener must not be driven into materials like brick or concrete any closer than 3 inches to an edge or corner. In steel, the fastener must not come any closer than one-half inch from a corner or edge. Fasteners must not be driven into very hard or brittle materials which might chip or splatter, or make the fastener ricochet. An alignment guide must be used when shooting a fastener into an existing hole. A fastener must not be driven into a spalled area caused by an unsatisfactory fastening. 11. Hydraulic Power Tools The fluid used in hydraulic power tools must be an approved fire-resistant fluid and must retain its operating characteristics at the most extreme temperatures to which it will be exposed. The manufacturer's recommended safe operating pressure for hoses, valves, pipes, filters, and other fittings must not be exceeded. 12. Jacks (a) All jacks - lever and rachet jacks, screw jacks, and hydraulic jacks - must have a device that stops them from jacking up too high. Also, the manufacturer's load limit must be permanently marked in a prominent place on the jack and should not be exceeded. A jack should never be used to support a lifted load. Once the load has been lifted, it must be immediately be blocked up. Use wooden blocking under the base if necessary to make the jack level and secure. If the lift surface is metal, place a 1 inch-thick hardwood block or equivalent between it and the metal jack head to reduce the danger of slippage. 9

19 Tools Hand and Power Program To set up a jack, make certain of the following: the base rests on a firm level surface, the jack is correctly centered, the jack head bears against a level surface, and the lift force is applied evenly. Proper maintenance of jacks is essential for safety. All jacks must be inspected before each use and lubricated regularly. If a jack is subjected to an abnormal load or shock, it should be thoroughly examined to make sure it has not been damaged. Hydraulic jacks exposed to freezing temperatures must be filled with an adequate antifreeze liquid. 13. General Safety Precautions (a) Employees who use hand and power tools and who are exposed to the hazards of falling, flying, abrasive and splashing objects, or exposed to harmful dusts, fumes mists, vapors, or gases must be provided with the particular personal equipment necessary to protect them from the hazard. All hazards involved in the use of power tools can be prevented by following five basic safety rules: Keep all tools in good condition with regular maintenance. Use the right tool for the job. Examine each tool for damage before use. Operate according to the manufacturer's instructions. Provide and use the proper protective equipment. Employees and employers have a responsibility to work together to establish safe working procedures. If a hazardous situation is encountered, it should be brought to the attention of the proper individual immediately. 10

20 Tools Hand and Power Program 14. Compressed Air Used For Cleaning (b) Using compressed air for cleaning tasks can be a risky proposition. According to OSHA, compressed air cannot be used for cleaning purposes (work surfaces) unless the pressure is reduced to less than 30 p.s.i, and then only when effective chip guarding and personal protective equipment is used. The regulation, however, does not give details as to how the pressure is to be reduced. Some of the methods OSHA suggests for pressure reduction include the following. Reducing the pressure level of the air compressor. Fitting the air source with a relief device which will release the air when the nozzle is dead-ended. Installing an air nozzle with holes which will reduce the air pressure to less than 30 p.s.i. when the nozzle is dead-ended. You can purchase commercially-made nozzles which are designed to reduce the p.s.i. to less than 30 or drill holes in existing nozzles, in which case you must be sure to test the nozzle's air release with a pressure gauge. For worker safety, OSHA recommends that a brush be used to remove dust and debris from clothing. 11

21 Stairways and Ladders Crown Tonka

22 Stairways and Ladders Stairways and Ladders Introduction 2. General Requirements 3. Stairways 4. Stairs in Temporary Service During Construction 5. Stair-rails and Handrails 6. Ladders 7. Portable Ladders 8. Fixed Ladders 9. Cages for Fixed Ladders 10. Wells for Fixed Ladders 11. Safety Devices 12. Mounting Ladder Safety Devices 13. Use of All Ladders 14. Structural Defects 15. Training Requirements 16. Glossary 1

23 Stairways and Ladders 1. Introduction Ladders are a common sight during a construction operation. Though they are frequently used, it doesn t mean they are always safely used. OSHA has developed a set of regulations covering stairways and ladders, found in 29 CFR , Subpart X. Following these regulations, along with common sense, should reduce accidents. The following is a summary of the OSHA requirements. 2. General Requirements Stairways or ladders are required at all worker points of access where there is a break in elevation of 19 inches or more and no ramp, runway, embankment, or personnel hoist exists. If there is one point of access between levels, it must be kept clear to permit free passage. If free passage becomes restricted, a second access point must be used. All stairway and ladder fall protection systems must be installed and standard requirements met before employees begin work requiring use of stairways or ladders and fall protection systems. 3. Stairways Stairways not a permanent part of the structure must have landings at least 30 inches deep and 22 inches wide every 12 feet or less of vertical rise. Stairways must be installed between 30 degrees, and 50 degrees, from horizontal. Variations in riser height or stair tread depth may not exceed 1 / 4 inch, including any foundation structure used as one or more treads. Where doors or gates open directly onto a stairway, a platform is required at least 20 inches in width beyond door swing. Metal pan landings and metal pan treads must be secured in place before filling. All stairway parts must be free of dangerous projections such as protruding nails. Slippery conditions on stairways must be corrected. Spiral stairways that will not be a permanent part of the structure may not be used by workers. 2

24 Stairways and Ladders 4. Stairs in Temporary Service During Construction Stairways with metal pan landings and treads may not be used where treads and/or landings have not been filled in with concrete or other material, unless temporarily filled in with wood or other material. All treads and landings must be replaced when worn below top edge of pan. Skeleton metal frame structures and steps must not be used (where treads and/or landings are to be installed later) unless stairs are fitted with secured temporary treads and landings. Temporary treads must be wood or other solid material installed full width and depth of stair. 5. Stair-rails and Handrails Stairways with four or more risers, or rising more than 30 inches in height, whichever is less, must have at least one handrail. A stair-rail must also be installed along all unprotected sides or edges. Winding or spiral stairways require a handrail to prevent using areas where tread width is less than 6 inches. Mid-rails, screens, mesh, intermediate vertical members, or equivalent intermediate structural members must be provided between top rail and stairway steps of stairrail system. Mid-rails, when used are located midway between top of stair-rail system and stairway steps. Screens or mesh, when used, must extend from top rail to stairway step, and along the opening between top rail supports. Intermediate vertical members, such as balusters, must not be more than 19 inches apart. Other intermediate structural members, when used, must be installed so there are no openings of more than 19 inches wide. Handrails and top rails of stair-rail systems must be capable of withstanding at least 200 pounds of weight applied within 2 inches of top edge in any downward or outward direction, at any point along top edge. Height of handrails must not be more than 37 inches nor less than 30 inches from upper surface of handrail to surface of the tread. Height of the top edge of a stair-rail system used as a handrail must not be more than 37 inches nor less than 36 inches from upper surface of stair-rail system to the surface of the tread. Stair-rail systems and handrails must be surfaced to prevent injuries such as punctures or lacerations and to keep clothing from snagging. Handrails must provide an adequate handhold to grasp to prevent falls. Ends of stair-rail systems and handrails must be constructed to prevent dangerous projections such as rails protruding beyond system end posts. Temporary handrails must have a minimum clearance of 3 inches between handrail and walls, stair-rails systems and other objects. Unprotected sides and edges of stairway landings must be provided with standard 42 inch guardrail systems. 3

25 Stairways and Ladders 6. Ladders A double cleated ladder or two or more ladders are required when ladders are the only way to enter or exit a work area having 25 or more employees, or when a ladder serves simultaneous two way traffic. Ladder rungs, cleats, and steps must be parallel, level, and uniformly spaced. Rungs, cleats, and steps of portable and fixed ladders (except as provided below) must not be spaced less than 10 inches apart, nor more than 14 inches apart, along the ladder s side rails. Rungs, cleats, and steps of step stools must not be less than 8 inches apart, nor more than 12 inches apart, between center lines of rungs, cleats, and steps. Rungs, cleats, and steps at the base section of extension trestle ladders must not be less than 8 inches nor more than 18 inches apart, between center lines. Rung spacing on the extension section must not be less than 6 inches nor more than 12 inches. Ladders must not be tied or fastened together to create longer sections unless specifically designed for such use. Metal spreader or locking devices are required on stepladders to hold front and back sections in an open position when the ladder is in use. When splicing side rails, the resulting side rail must be equivalent in strength to a one piece side rail made of the same material. Two or more separate ladders used to reach an elevated work area must be offset with a platform or landing between ladders, except when portable ladders are used to gain access to fixed ladders. Ladder components must be surfaced to prevent injury from punctures or lacerations, and prevent snagging of clothing. Wood ladders must not be coated with opaque covering, except for identification or warning labels placed on one face of a side rail. 7. Portable Ladders Non self supporting and self supporting portable ladders must support at least four times maximum intended load; extra heavy duty type 1A metal or plastic ladders must sustain 3.3 times maximum intended load. Ability of a self supporting ladder to sustain loads must be determined by applying load to ladder in a downward vertical direction. Ability of a non self supporting ladder to sustain loads must be determined by applying the load in a downward vertical direction when ladder is placed at a horizontal angle of 75.5 degrees. The minimum clear distance between side rails for all portable ladders is 11.5 inches. 4

26 Stairways and Ladders Rungs and steps of portable metal ladders must be corrugated, knurled, dimpled, coated with skid resistant material, or treated to minimize slipping. 8. Fixed Ladders A fixed ladder must be capable of supporting at least two loads of 250 pounds each, concentrated between any two consecutive attachments. Fixed ladders also must support added anticipated loads caused by ice buildup, winds, rigging, and impact loads resulting from use of ladder safety devices. Individual rung/step ladders must extend at least 42 inches above access level or landing platform either by continuation of rung spacings as horizontal grab bars or by providing vertical grab bars that must have the same lateral spacing as vertical legs of the ladder rails. Each step or rung of a fixed ladder must be capable of supporting a load of at least 250 pounds applied in the middle of step or rung. The minimum clear distance between the sides of individual rung/step ladders and between the side rails of other fixed ladders must be 16 inches. The rungs of individual rung/step ladders must be shaped to prevent slipping off end of rungs. Rungs and steps of fixed metal ladders manufactured after January 14, 1991, must be corrugated, knurled, dimpled, coated with skid resistant material, or treated to minimize slipping. Minimum perpendicular clearance between fixed ladder rungs, cleats, and steps, and any obstruction behind ladder must be 7 inches, except clearance for an elevator pit ladder must be 4.5 inches. Minimum perpendicular clearance between the centerline of fixed ladder rungs, cleats, and steps, and any obstruction on climbing side of ladder must be 30 inches. If obstructions are unavoidable, clearance may be reduced to 24 inches, provided deflection device is installed to guide workers around obstruction. Step across distance between center of steps or rungs of fixed ladders and nearest edge of a landing area must be no less than 7 inches and no more than 12 inches. A landing platform must be provided if step across distance exceeds 12 inches. 5

27 Stairways and Ladders Fixed ladders without cages or wells must have at least a 15 inch clear width to nearest permanent object on each side of ladder centerline. Fixed ladders must be provided with cages, wells, ladder safety devices, or self retracting lifelines where length of climb is less than 24 feet but top of ladder is at a distance greater than 24 feet above lower levels. If total length of climb on fixed ladder equals or exceeds 24 feet, the following requirements must be met: fixed ladders must be equipped with either (a) ladder safety devices: (b) self retracting lifelines, and rest platforms at intervals not to exceed 150 feet; or (c) cage or well, and multiple ladder sections, each ladder section not to exceed 50 feet in length. These ladder sections must be offset from adjacent sections, and landing platforms provided at maximum intervals of 50 feet. Side rails of through or side step fixed ladders must extend 42 inches above top level or landing platform served by the ladder. For a parapet ladder, access level must be at the roof if parapet is cut to permit passage through it; if parapet is continuous, access level is at top of parapet. Steps or rungs for through fixed ladder extensions must be omitted from the extension; and extension of side rails must be flared to provide between 24 inches and 30 inches clearance between side rails. When safety devices are provided, maximum clearance between side rail extensions must not exceed 36 inches. 9. Cages for Fixed Ladders Horizontal bands must be fastened to the side rails of rail ladders, or directly to the structure, building, or equipment for individual rung ladders. Vertical bars must be on the inside of horizontal bands and must be fastened to them. Cages must not extend less than 27 inches, or more than 30 inches from the centerline of step or rung, and must not be less than 27 inches wide. The inside of the cage must be clear of projections. Horizontal bands must be spaced at intervals not more than 4 feet apart measured from centerline to centerline. Vertical bars must be spaced at intervals not more than 9.5 inches apart measured from centerline to centerline. The bottom of the cage must be between 7 feet and 8 feet above point of access to bottom of ladder. Bottom of the cage must be flared not less than 4 inches between bottom horizontal band and next higher band. Top of the cage must be a minimum of 42 inches above top of the platform, or point of access at top of ladder. Provisions must be made for access to platform or other point of access. 6

28 Stairways and Ladders 10. Wells for Fixed Ladders Wells must completely encircle the ladder and be free of projections. Inside face of the well on climbing side of ladder must extend between 27 inches and 30 inches from centerline of step or rung. Inside width of well must be at least 30 inches. Bottom of the well above point of access to bottom of the ladder must be between 7 feet and 8 feet. 11. Safety Devices Safety devices must be capable of withstanding, without failure, a drop test consisting of a 500 pound weight dropping 18 inches. Safety devices must permit workers to ascend or descend without continually having to hold, push, or pull any part of the device, leaving both hands free for climbing. All safety devices must be activated within 2 feet after a fall occurs, and limit the descending velocity of an employee to 7 ft/sec. or less. Connection between carrier or lifeline and point of attachment to body belt or harness must not exceed 9 inches in length. 12. Mounting Ladder Safety Devices Mountings for rigid carriers must be attached at each end of the carrier, with intermediate mountings, spaced along entire length of carrier, to provide necessary strength to stop falls. Mountings for flexible carriers must be attached at each end of the carrier. Cable guides for flexible carriers must be installed with a spacing between 25 feet and 40 feet along the entire length of the carrier, to prevent wind damage to the system. Design and installation of mountings and cable guides must not reduce strength of the ladder. Side rails, and steps or rungs for side step fixed ladders must be continuous in extension. 13. Use of All Ladders When portable ladders are used for access to an upper landing surface, side rails must extend at least 3 feet above upper landing surface. When such an extension is not possible, the ladder must be secured, and a grasping device such as a grab rail provided to assist workers in mounting and dismounting the ladder. A ladder extension must not deflect under a load that would cause ladder to slip off its support. 7

29 Stairways and Ladders Ladders must be maintained free of oil, grease, and other slipping hazards. Ladders may not be loaded beyond maximum intended load for which they were built nor beyond manufacturer s rated capacity. Ladders must be used only for purpose for which they were designed. Non self supporting ladders must be used at an angle where horizontal distance from top support to foot of ladder is approximately 1 / 4 of working length of ladder. Wood job made ladders with spliced side rails must be used at an angle where horizontal distance is 1 / 8 working length of ladder. Fixed ladders must be used at a pitch no greater than 90 degrees from horizontal, measured from the back side of ladder. Ladders must be used only on stable and level surfaces unless secured to prevent accidental movement. Ladders must not be used on slippery surfaces unless secured or provided with slip resistant feet. Slip resistant feet are not a substitute for care in placing, lashing, or holding ladders on slippery surfaces. Ladders placed in areas such as passageways, doorways, or driveways, or where they can be displaced by workplace activities or traffic must be secured to prevent accidental movement, or a barricade must be used to keep traffic or activities away from the ladder. Areas around top and bottom of ladders must be kept clear. Top of a non self supporting ladder is placed with two rails supported equally unless equipped with single support attachment. Ladders must not be moved, shifted, or extended while in use. Ladders must have nonconductive side-rails if used where workers or the ladders could contact exposed electricity. The top or top step of a stepladder must not be used as a step. Cross bracing on the rear section of stepladders must not be used for climbing unless the ladders are designed and provided with steps for climbing on both front and rear sections. Ladders must be inspected by a competent person for visible defects on a periodic basis and after any incident that could affect their safe use. 8

30 Stairways and Ladders Single rail ladders must not be used. When ascending or descending a ladder, workers face the ladder. Each worker uses at least one hand to grasp the ladder when moving up or down. Workers on ladders cannot carry objects or loads that could cause worker to lose balance and fall. 14. Structural Defects Portable ladders with structural defects such as broken or missing rungs, cleats, or steps, broken or split rails, corroded components, or other defective components must immediately be marked defective or tagged and withdrawn from service. Fixed ladders with structural defects such as broken or missing rungs, cleats, or steps, broken or split rails, or corroded components must be withdrawn from service until repaired. Defective fixed ladders are considered withdrawn from use when they are (a) immediately tagged with Do Not Use or similar language; (b) marked in a manner that identifies them as defective; or (c) blocked (such as with a plywood attachment that spans several rungs). Ladder repairs must restore ladder to a condition meeting its original design criteria, before returned to use. 15. Training Requirements Employers must provide a training and retraining program. Employers must ensure each employee is trained by a competent person in nature of fall hazards in work areas; correct procedures for erecting, maintaining, and disassembling fall protection systems; proper construction, use, placement, and care in handling of all stairways and ladders; and in understanding and knowledge acquired through compliance with the standard. 16. Glossary CLEAT Ladder crosspiece of rectangular cross section placed on edge upon which a person steps while using a ladder. DOUBLE CLEAT LADDER A ladder with a center rail to allow simultaneous two way traffic. FAILURE Load refusal, breakage, or separation of components. FIXED LADDER Ladder that cannot be readily moved or carried because it is an integral part of a building or structure. 9

31 Stairways and Ladders HANDRAIL Rail used to provide employees with a handhold for support. JOB MADE LADDER Ladder fabricated, typically at the construction site; not commercially manufactured. LOAD REFUSAL Point where structural members lose their ability to carry the load. POINT OF ACCESS All areas used by employees for work related passage from one area or level to another. PORTABLE LADDER Ladder that can be readily moved or carried. RISER HEIGHT Vertical distance from top of a tread or platform/landing to top of the next higher tread or platform/landing. SIDE STEP FIXED LADDER Fixed ladder that requires a person getting off at the top to step to side of ladder side rails to reach landing. SINGLE CLEAT LADDER Ladder consisting of a pair of side rails connected together by cleats, rungs, or steps. STAIRRAIL SYSTEM Vertical barrier erected along unprotected sides and edges of a stairway to prevent employees from falling. TEMPORARY SERVICE STAIRWAY Stairway where permanent treads and/or landings are to be filled in at a later date. THROUGH FIXED LADDER Fixed ladder that requires a person getting off at the top to step between side rails to reach landing. TREAD DEPTH Horizontal distance from front to back of a tread, excluding any nosing. 10

32 Scaffolding and Aerial Lifts Safety Procedures Crown Tonka

33 Scaffolding and Aerial Lifts Safety Procedures Scaffolding and Aerial Lifts Safety Procedures Purpose 2. Application 3. General Procedures 4. Capacity 5. Platform Construction 6. Gaining Access to Scaffolds 7. Fall Protection Plan 8. Falling Object Protection 9. Using Scaffolds 10. Specific Procedures 11. Prohibited Practices 12. Aerial Lifts 13. Ladder Trucks and Tower Trucks 14. Extensible and Articulating Boom Platforms 15. Duties of Competent and Qualified Persons 16. Training 1

34 Scaffolding and Aerial Lifts Safety Procedures 1. Purpose It is Crown Tonka's purpose in issuing these procedures to further ensure a safe workplace based on the following formal, written procedures for scaffold work. These procedures will be reviewed and updated as needed to comply with new OSHA regulations, new best practices in scaffolding, and as business practices demand. EMPLOYEE NAME/TITLE is the plan coordinator/manager and is responsible for its implementation. 2. Application This general scaffold plan applies to all employees of Crown Tonka. 3. General Procedures The following general procedures apply to all scaffold and aerial lift operations for Crown Tonka. 4. Capacity Taking into account the OSHA rules we must apply and the engineering/manufacturing requirements of our scaffolds, the following rules apply. Note: We have also included in the appendix, the manufacturer's safety requirements for particular scaffold assemblies. Each scaffold and scaffold component we use will support, without failure, its own weight and at least four times the maximum intended load applied or transmitted to it. When we use non-adjustable suspension scaffolds, each suspension rope, including connecting hardware, will support, without failure, at least six times the maximum intended load applied or transmitted to that rope. 5. Platform Construction This section documents the procedures and safety requirements we use to construct our scaffold platforms. Type of Scaffold: Type of Planking: Fall protection used: 2

35 Scaffolding and Aerial Lifts Safety Procedures The following safety rules apply for this scaffold platform construction: Each scaffold plank will be installed so that the space between adjacent planks and the space between the platform and uprights is no more than one inch wide. If, in certain situations, we need to make this space wider, we will attach our demonstration in the appendix to this plan. Except for outrigger scaffolds (3 inches) and plastering and lathing operations (18 inches), the front edge of all platforms will not be more than 14 inches from the face of the work, unless we have a guardrail or personal fall arrest system in place that meets regulations. The following additional construction and safety information is included depending on the type of scaffold being erected. Supported Scaffolds Supported scaffolds with a height to base width ratio of more than four to one (4:1) must be restrained from tipping by guying, tying, bracing, or equivalent means. Supported scaffold poles, legs, posts, frames, and uprights will always bear on base plates and mud sills or other adequate firm foundations. Suspension Scaffolds Before a scaffold is used, all direct connections will be evaluated by our competent person. Our competent person will confirm, based on the evaluation, that the supporting surfaces are capable of supporting the loads that will be imposed. When winding drum hoists are used on a suspension scaffold, they will never contain less than four wraps of the suspension rope at the lowest point of scaffold travel. 6. Gaining Access to Scaffolds We know that getting to the working platform is critical to the safety of our employees. This section outlines the mechanical requirements for gaining access to scaffold platforms such as: (1) ladders, (2) ramps and walkways, (3) stair rails, and (4) direct access from another scaffold. This section is divided into two parts. The first part is for workers gaining access to scaffold platforms to do work; the second part is access for employees erecting and dismantling scaffolds. 3

36 Scaffolding and Aerial Lifts Safety Procedures Working Employees: Portable, hook-on, and attachable ladders will be positioned so as not to tip the scaffold. All stair rail systems and handrails will be surfaced to prevent injury to our employees from punctures or lacerations, and to prevent snagging of their clothes. Erectors and Dismantlers: Crown Tonka shall provide safe means of access for each employee erecting or dismantling a scaffold where the provision of safe access is feasible and does not create a greater hazard. We shall have a competent person determine whether it is feasible or would pose a greater hazard to provide, and have employees use a safe means of access. This determination shall be based on site conditions and the type of scaffold being erected or dismantled. Hook-on or attachable ladders shall be installed as soon as scaffold erection has progressed to a point that permits safe installation and use. When erecting or dismantling tubular welded frame scaffolds, (end) frames, with horizontal members that are parallel, level and are not more than 22 inches apart vertically may be used as climbing devices for access, provided they are erected in a manner that creates a usable ladder and provides good hand hold and foot space. Cross braces on tubular welded frame scaffolds shall not be used as a means of access or egress. 7. Fall Protection Plan Fall protection planning is critical to the safety and well being of our employees. Our fall protection plan follows the OSHA requirements that are different depending on the type of scaffold we are using. In this plan we address fall protection for our scaffold erectors and dismantlers separately. One fact never changes. We know we must provide fall protection for any employee on a scaffold more than 10 feet above a lower level. 4