ABSTRACT
Preface.................................................................................................................. xxiii Author ................................................................................................................... xxv
Chapter 1 Introduction to the Service Industry .................................................... 1
1.1 NAICS............................................................................................................ 2 1.2 Employment in the Service Industry ............................................................. 2 1.3 Safety ............................................................................................................. 3 1.4 Why Trauma Prevention? .............................................................................. 5 1.5 Accidents or Incidents ................................................................................... 5 1.6 Comprehensive Accident Prevention............................................................. 6 1.7 Fatality and Injury Profile for the Service Industry....................................... 7 1.8 Occupational Illnesses in the Service Industry............................................ 10 References ............................................................................................................... 11
Chapter 2 Transportation.................................................................................... 13
2.1 Transportation .............................................................................................. 14 2.1.1 Truck Transportation......................................................................... 14 2.1.2 Air Transportation............................................................................. 17 2.1.3 Rail Transportation ........................................................................... 18
2.2 Profile of Transportation Workers’ Deaths, Injuries, and Illnesses ............. 19 2.2.1 Deaths ............................................................................................... 19 2.2.2 Injuries .............................................................................................. 19 2.2.3 Illnesses............................................................................................. 19
2.3 Hazards Faced by the Transportation Sector ............................................... 19 2.4 Occupations.................................................................................................. 22
2.4.1 Truck Transportation......................................................................... 22 2.4.2 Air Transportation............................................................................. 23 2.4.3 Rail Transportation ........................................................................... 25
2.5 Applicable OSHA Regulations .................................................................... 25 References ............................................................................................................... 29
Chapter 3 Utilities Sector ................................................................................... 31
3.1 Electric Power Generation, Transmission, and Distribution ....................... 32 3.2 Natural Gas Distribution .............................................................................. 33 3.3 Water, Sewage, and Other Systems............................................................. 33
3.4 Profile of Utility Workers’ Deaths, Injuries, and Illnesses .......................... 35 3.4.1 Deaths ............................................................................................... 35 3.4.2 Injuries .............................................................................................. 35 3.4.3 Illnesses............................................................................................. 36
3.5 Hazards Faced by Utility Workers .............................................................. 36 3.6 Occupations.................................................................................................. 39 3.7 Applicable OSHA Regulations .................................................................... 41
Chapter 4 Administrative and Support and Waste Management and Remediation Services ................................................................. 45
4.1 ASWMR Services ........................................................................................ 46 4.2 Profile of Administrative and Support and Waste Management
and Remediation Services............................................................................ 47 4.2.1 Deaths ............................................................................................... 47 4.2.2 Injuries .............................................................................................. 47 4.2.3 Illnesses............................................................................................. 48
4.3 Hazards Faced by ASWMR Workers.......................................................... 48 4.4 Occupations.................................................................................................. 49 4.5 Applicable OSHA Regulations .................................................................... 51
Chapter 5 OSHA Regulations ............................................................................ 53
5.1 Federal Laws................................................................................................ 54 5.2 OSHACT ....................................................................................................... 54 5.3 Content of the OSHACT............................................................................... 54 5.4 Regulatory Process....................................................................................... 57 5.5 Federal Register ........................................................................................... 60 5.6 Code of Federal Regulations ....................................................................... 61 5.7 Regulation Paragraph Numbering System................................................... 62
Chapter 6 Occupational Safety and Health Programs........................................ 67
6.1 Development of a Safety and Health Program............................................ 68 6.1.1 Rules ................................................................................................. 68 6.1.2 Communications ............................................................................... 68 6.1.3 Training............................................................................................. 70 6.1.4 Accident Investigation ...................................................................... 72 6.1.5 Evaluation ......................................................................................... 74
6.2 Explaining the Requirements and Elements of OSHA Guidelines for a Safety and Health Program ................................................................. 74 6.2.1 Management Commitment and Leadership...................................... 75 6.2.2 Assignment of Responsibility ........................................................... 76 6.2.3 Identification and Control of Hazards .............................................. 77
6.2.4 Training and Education..................................................................... 78 6.2.5 Recordkeeping and Hazard Analysis................................................ 79 6.2.6 First Aid and Medical Assistance..................................................... 79 6.2.7 Emergency and Firefighting Procedures........................................... 80
6.3 Model Safety and Health Program .............................................................. 80 6.3.1 Management Safety and Health Policy Statements .......................... 80
6.3.1.1 Example of Statement for All Employees .......................... 80 6.3.1.2 Example of a Statement for a Large Company .................. 81 6.3.1.3 List of the Company Objectives and Safety
and Health Goals................................................................. 81 6.4 Other Required Written Programs ............................................................... 84
Chapter 7 Safety Hazards ................................................................................... 87
7.1 Hazard Prevention and Controls .................................................................. 87 7.2 Engineering Controls ................................................................................... 88 7.3 Awareness Devices ...................................................................................... 88 7.4 Work Practices ............................................................................................. 89 7.5 Administrative Controls ............................................................................... 89
7.5.1 Management Controls ....................................................................... 89 7.6 Personal Protective Equipment .................................................................... 90
7.6.1 Hazard Assessment ........................................................................... 90 7.6.2 Establishing a PPE Program ............................................................. 91
7.7 Ranking Hazard Controls............................................................................. 92 7.8 Other Tools That Can Be Used for Hazard Control.................................... 92
7.8.1 Accident=Incident Reporting............................................................. 92 7.8.2 Hazard Audits ................................................................................... 94 7.8.3 Safe Operating Procedure ................................................................. 94 7.8.4 Job Safety Assessment...................................................................... 95
7.9 Hazard Control Summary ............................................................................ 95
Chapter 8 Health Hazards................................................................................... 97
8.1 Health Hazards............................................................................................. 97 8.2 Cold Stress ................................................................................................... 98
8.2.1 Health Effects.................................................................................... 99 8.2.2 Cold and the Workplace ................................................................. 101 8.2.3 Protective Steps............................................................................... 102 8.2.4 Symptoms of Cold Stress ............................................................... 103
8.3 Heat Stress ................................................................................................. 104 8.3.1 Heat Transfer .................................................................................. 104 8.3.2 Health-Related Disorders ................................................................ 104 8.3.3 Working in Hot Environments ....................................................... 106 8.3.4 Heat Index....................................................................................... 106 8.3.5 Controlling Exposure ...................................................................... 108
8.4 Noise-Induced Hearing Loss.................................................................... 110 8.4.1 Noise Exposure ............................................................................. 110 8.4.2 Controlling Noise Levels .............................................................. 111 8.4.3 Hearing Conservation ................................................................... 112
8.5 Vibration .................................................................................................. 116 8.6 Workplace Stress...................................................................................... 117
Chapter 9 Hazardous Chemicals and Waste Management .............................. 119
9.1 Hazardous Chemicals............................................................................... 119 9.2 Hazardous Waste ..................................................................................... 121 9.3 Hazardous Waste Operations (1926.65 or 1910.120) ............................. 122
9.3.1 Hazardous Waste Site Requirements ............................................ 122 9.3.2 Written Safety and Health Program.............................................. 123 9.3.3 Site Safety and Health Plan .......................................................... 124 9.3.4 Site Evaluation .............................................................................. 125 9.3.5 Site Control ................................................................................... 126
9.4 Training.................................................................................................... 128 9.5 Medical Surveillance................................................................................ 130 9.6 Hazard Controls ....................................................................................... 132
9.6.1 Personal Protective Equipment ..................................................... 132 9.6.2 Monitoring .................................................................................... 133
9.7 Handling and Transporting Hazardous Materials .................................... 134 9.7.1 Handling Drums and Containers .................................................. 134 9.7.2 Drum or Container Staging........................................................... 136 9.7.3 Lab Packs...................................................................................... 136 9.7.4 Decontamination ........................................................................... 136
9.8 Emergency Response Plan....................................................................... 137 9.9 Sanitation ................................................................................................. 138 9.10 New Technologies ................................................................................... 138 9.11 RCRA....................................................................................................... 138 9.12 Emergency Response ............................................................................... 138
9.12.1 Emergency Response Training ................................................... 142 9.13 Summary .................................................................................................. 143
Chapter 10 Confined Spaces ............................................................................ 145
10.1 Confined Spaces....................................................................................... 145 10.2 Confined Space Identification .................................................................. 146 10.3 PRCS Identification ................................................................................. 146 10.4 PRCS Entry Program............................................................................... 148 10.5 Confined Space Entry Permit System...................................................... 149
10.5.1 Confined Space Entry Permit ..................................................... 150 10.6 Common Confined Space Hazards .......................................................... 150
10.6.1 Hazardous Atmospheres ............................................................. 150 10.6.2 Oxygen-Deficient Atmospheres .................................................. 150 10.6.3 Oxygen-Enriched Atmospheres .................................................. 151
10.6.4 Flammable Atmospheres......................................................... 151 10.6.5 Toxic Atmospheres ................................................................. 152
10.7 Confined Space Atmospheric Testing.................................................... 152 10.7.1 Pre-Entry Testing .................................................................... 152
10.7.1.1 Oxygen Level Test .................................................. 153 10.7.1.2 Flammability Test ................................................... 153 10.7.1.3 Toxicity Test ........................................................... 154
10.7.2 Periodic=Continuous Testing .................................................. 154 10.8 Controlling Atmospheric Hazards ......................................................... 154
10.8.1 Ventilation............................................................................... 154 10.8.2 Cleaning .................................................................................. 155
10.9 Physical Hazards .................................................................................... 156 10.9.1 General=Physical Hazards....................................................... 156 10.9.2 Controlling General=Physical Hazards ................................... 157
10.10 Confined Space Entry Team .................................................................. 158 10.10.1 Entrant Duties ......................................................................... 159 10.10.2 Attendant Duties ..................................................................... 159 10.10.3 Entry Supervisor Duties.......................................................... 160
10.11 Emergency and Rescue Procedures ....................................................... 160 10.11.1 Rescue Training ...................................................................... 161
10.12 Summary ................................................................................................ 161
Chapter 11 Electrical Hazards .......................................................................... 163
11.1 Electricity ............................................................................................... 163 11.2 Electrocutions......................................................................................... 164 11.3 Shock versus Electrocution.................................................................... 164 11.4 Shock Burns........................................................................................... 166 11.5 Freeze on from Shock............................................................................ 167
11.5.1 Static Electricity Shock............................................................. 167 11.6 Controlling Electrical Hazards............................................................... 167
11.6.1 Insulation................................................................................... 168 11.6.2 Guarding ................................................................................... 168 11.6.3 Circuit Protection Devices ........................................................ 170 11.6.4 Safe Work Practices.................................................................. 170 11.6.5 Worker-Initiated Safety............................................................. 171 11.6.6 Lockout=Tagout ........................................................................ 172 11.6.7 Overhead Power Lines.............................................................. 172 11.6.8 Electrical Personal Protective Equipment................................. 173 11.6.9 Tool Maintenance ..................................................................... 173
11.7 Training.................................................................................................. 174 11.8 Safety and Health Program.................................................................... 175 11.9 Applicable Regulations .......................................................................... 175 11.10 Summary ................................................................................................ 175
11.10.1 Electrical Precautions.............................................................. 176 11.10.2 Electrical Safety Tips .............................................................. 177
Chapter 12 Ergonomics=Lifting ....................................................................... 179
12.1 CTDs ...................................................................................................... 180 12.1.1 Preventing CTDs....................................................................... 184
12.2 Infrastructure Tasks and Ergonomic Risks............................................ 185 12.3 Tools and Their Design ......................................................................... 186
12.3.1 Hand Tool Design to Reduce CTDs......................................... 186 12.4 Conducting Ergonomics Assessments ................................................... 189 12.5 Ergonomics Regulations ........................................................................ 189 12.6 Ergonomics Programs ............................................................................ 189 12.7 Manual Material Handling..................................................................... 190 12.8 Back Injury Prevention .......................................................................... 191
12.8.1 Preventive Actions .................................................................... 194 12.8.2 Good Health and a Healthy Back............................................. 196 12.8.3 Back Injury Management.......................................................... 197 12.8.4 Training..................................................................................... 198
12.9 Lifting and Material-Handling Aids ...................................................... 199 12.10 Planning Manual Material Handling...................................................... 200 12.11 Summary ................................................................................................ 200
Chapter 13 Excavations=Trenches.................................................................... 201
13.1 Excavations=Trenches ............................................................................ 201 13.2 Proper Planning...................................................................................... 203
13.2.1 Underground Utilities ............................................................... 203 13.3 Informing Workers................................................................................. 204 13.4 Making Excavations Safe ...................................................................... 204
13.4.1 Selection of Protective Systems................................................ 204 13.4.2 Other Precautions...................................................................... 206 13.4.3 Installing or Removing Protective Systems.............................. 206 13.4.4 Safe Materials and Equipment for Protective Systems ............ 207
13.5 Additional Hazards and Protections ...................................................... 207 13.5.1 Water-Related Hazards ............................................................. 208 13.5.2 Hazardous Atmospheres ........................................................... 208 13.5.3 Means of Access and Egress .................................................... 208
13.6 Special Purpose PPE.............................................................................. 209 13.7 Conducting Inspections.......................................................................... 209 13.8 Summary ................................................................................................ 210
13.8.1 General Trenching and Excavation Rules ................................ 211
Chapter 14 Falls................................................................................................ 213
14.1 Fall Protection ........................................................................................ 214 14.2 Responsibility to Have Fall Protection .................................................. 214 14.3 Fall Protection Systems.......................................................................... 216
14.3.1 Guardrail Systems ..................................................................... 217 14.3.2 Safety Nets ................................................................................ 218
14.3.3 Personal Fall Arresting System................................................... 220 14.3.4 Warning Lines............................................................................. 223 14.3.5 Safety Monitoring System .......................................................... 225
14.4 Fall Protection Plan.................................................................................. 225 14.5 Training.................................................................................................... 226 14.6 Other Elevated Fall Hazards .................................................................... 227
14.6.1 Falls from Buckets ...................................................................... 227 14.6.2 Aerial Lifts and Falls .................................................................. 227 14.6.3 Scissor Lifts and Elevated Work Platforms................................ 227 14.6.4 Fall from Trucks or Other Equipment ........................................ 228
14.7 Summary .................................................................................................. 229
Chapter 15 Flammable and Combustible Liquids............................................ 233
15.1 Combustible Liquids ................................................................................ 233 15.2 Flammable Liquids .................................................................................. 234 15.3 Containers and Storage ............................................................................ 234
15.3.1 Container and Portable Tank Storage......................................... 234 15.3.2 Design, Construction, and Capacity of Containers .................... 236 15.3.3 Design, Construction, and Capacity of Storage Cabinets .......... 236 15.3.4 Design and Construction of Inside Storage Rooms ................... 236 15.3.5 Rating and Capacity.................................................................... 237 15.3.6 Wiring ......................................................................................... 237 15.3.7 Ventilation................................................................................... 237 15.3.8 Storage ........................................................................................ 237
15.4 Storage Inside Buildings .......................................................................... 238 15.4.1 Egress .......................................................................................... 238 15.4.2 Office Occupancies ..................................................................... 238 15.4.3 General Purpose Public Warehouses .......................................... 238 15.4.4 Warehouses or Storage Buildings............................................... 238
15.5 Storage Outside Buildings ....................................................................... 238 15.5.1 Fire Control................................................................................. 239 15.5.2 Industrial Plants .......................................................................... 239 15.5.3 Incidental Storage or Use of Flammable
or Combustible Liquids .............................................................. 239 15.5.4 Containers ................................................................................... 240 15.5.5 Handling Liquids at the Point of Final Use................................ 240
15.6 Flammable and Combustible Liquids in the Service Industry ................ 241 15.6.1 Flammable and Combustible Liquids Checklist......................... 241
15.7 Summary of OSHA Regulations for Flammable and Combustible Liquids ......................................................................... 242 15.7.1 Flammable and Combustible Liquids
(29 CFR 1910.106) ..................................................................... 242
Chapter 16 Lockout=Tagout ............................................................................. 245
16.1 Lockout=Tagout ..................................................................................... 245 16.2 Energy Control Program........................................................................ 247 16.3 Lockout=Tagout Devices ....................................................................... 248 16.4 Periodic Inspections ............................................................................... 248 16.5 Training and Communications............................................................... 250 16.6 Energy Isolation ..................................................................................... 251
16.6.1 Established Procedure ............................................................... 251 16.6.2 Lockout or Tagout Device Application .................................... 252 16.6.3 Stored Energy ........................................................................... 252
16.7 Release from Lockout or Tagout ........................................................... 252 16.8 Testing or Positioning............................................................................ 253 16.9 Personnel-Related Issues........................................................................ 253
16.9.1 Outside Personnel ..................................................................... 253 16.9.2 Group Lockout or Tagout ......................................................... 253 16.9.3 Shift or Personnel Changes....................................................... 254
16.10 Applicable Regulations .......................................................................... 254 16.11 Lockout=Tagout Safety Checklist .......................................................... 255 16.12 Summary ................................................................................................ 258
Chapter 17 Machine Guarding ......................................................................... 259
17.1 Machine Guarding ................................................................................. 259 17.1.1 Types of Mechanical Components ........................................... 261 17.1.2 Types of Mechanical Motions .................................................. 261 17.1.3 Times When Hazards Are Most Frequent ................................ 262
17.2 Machine Guarding Assessment.............................................................. 262 17.3 Safeguarding Machines and Equipment ................................................ 265 17.4 Guards .................................................................................................... 265
17.4.1 Basic Safeguarding Methods .................................................... 266 17.4.2 Definition of a Guard................................................................ 266 17.4.3 Types of Guards........................................................................ 266
17.5 Safeguarding Devices ............................................................................ 267 17.6 Other Potential Safeguards .................................................................... 270
17.6.1 Foot Controls ............................................................................ 271 17.6.2 Control Machines with Clutches .............................................. 271 17.6.3 Do I Need to Safeguard Machinery?........................................ 272 17.6.4 Administrative Issues and Safeguarding................................... 272
17.7 Amputations ........................................................................................... 273 17.7.1 Machinery Associated with Amputations................................. 273
17.8 Summary ................................................................................................ 274
Chapter 18 Personal Protective Equipment and Controls ................................ 277
18.1 Controlling Hazards ............................................................................... 277 18.2 Engineering Controls ............................................................................. 278 18.3 Administrative Controls ......................................................................... 278 18.4 Personal Protective Equipment .............................................................. 279 18.5 Establishing a PPE Program .................................................................. 279 18.6 Hazard Assessment ................................................................................ 280 18.7 Eye and Face Protection ........................................................................ 280
18.7.1 Face Shields .......................................................................... 281 18.7.2 Eyewear Maintenance ........................................................... 282
18.8 Head Protection...................................................................................... 283 18.8.1 Protective Head Wear ........................................................... 284 18.8.2 Care of Hardhats ................................................................... 284
18.9 Foot and Leg Protection ........................................................................ 285 18.9.1 Electrical Foot Protection ..................................................... 286
18.10 Hand and Arm Protection ...................................................................... 287 18.10.1 Metal Mesh, Leather, or Canvas Gloves .............................. 288 18.10.2 Fabric and Coated Fabric Gloves ......................................... 289 18.10.3 Chemical-and Liquid-Resistant Gloves ............................... 289
18.11 Body Protection ..................................................................................... 290 18.12 Hearing Protection ................................................................................. 291
18.12.1 Noise Exposure Levels ......................................................... 291 18.12.2 Ear Protection........................................................................ 293
18.13 Respiratory Protection............................................................................ 293 18.13.1 Respirator Training ............................................................... 294 18.13.2 Basic Respiratory Protection Safety Procedures .................. 295 18.13.3 Respirator User Policies........................................................ 297 18.13.4 Selection of Respirators ........................................................ 297 18.13.5 Identification of Filters and Cartridges ................................. 298 18.13.6 Respirator Filter and Canister Replacement ......................... 298 18.13.7 Filter and Cartridge Change Schedule.................................. 298 18.13.8 Respiratory Protection Schedule........................................... 299 18.13.9 Physical and Medical Qualifications..................................... 300 18.13.10 Additional Medical Evaluations ........................................... 301 18.13.11 Respirator Fit Testing ........................................................... 301
18.13.11.1 Types of Fit Tests ............................................. 302 18.13.12 Respirator Operation and Use............................................... 302 18.13.13 Continuing Effectiveness of Respirators .............................. 303 18.13.14 Procedures for IDLH Atmospheres ...................................... 303 18.13.15 Cleaning and Disinfecting .................................................... 304 18.13.16 Respirator Inspection ............................................................ 304 18.13.17 Respirator Storage................................................................. 305 18.13.18 Respirator Repairs................................................................. 305
18.14 Summary ................................................................................................ 306
Chapter 19 Power Tools ................................................................................... 307
19.1 Preventing Power Tool Accidents ........................................................... 309 19.1.1 Steps Used to Control Power Tool Accidents.......................... 309 19.1.2 Carrying Tools .......................................................................... 310 19.1.3 Use of Personal Protective Equipment ..................................... 310 19.1.4 Guards ....................................................................................... 310 19.1.5 Safety Switches ......................................................................... 311 19.1.6 Ergonomics and Power Tools................................................... 311 19.1.7 Old Tools .................................................................................. 313
19.2 Power Tools and Their Energy Source.................................................... 314 19.2.1 Electric Tools ............................................................................ 314 19.2.2 Hydraulic Power Tools ............................................................. 314 19.2.3 Liquid Fuel Tools ..................................................................... 314 19.2.4 Pneumatic Tools........................................................................ 315 19.2.5 Powder-Actuated Tools............................................................. 316
19.3 Specific Power Tool Safety ..................................................................... 318 19.3.1 Abrasive Wheel Tools .............................................................. 319 19.3.2 Drill Press Safety ...................................................................... 320 19.3.3 Forging Machines ..................................................................... 320 19.3.4 Grinder Safety ........................................................................... 321 19.3.5 Hydraulic Jacks......................................................................... 321 19.3.6 Jointer and Shaper Safety ......................................................... 322 19.3.7 Lathe Safety .............................................................................. 322 19.3.8 Nail=Air Gun Safety (Pneumatic Fastening Tools) .................. 323 19.3.9 Planer Safety ............................................................................. 323 19.3.10 Portable Grinders ...................................................................... 324 19.3.11 Sander Safety ............................................................................ 324 19.3.12 Saw Safety ................................................................................ 324 19.3.13 Woodworking Machinery ......................................................... 325
19.4 Use of Power Tools by the Service Industry........................................... 326 19.5 Summary of OSHA Applicable Regulations........................................... 326
19.5.1 Abrasive Wheel Equipment Grinders (29 CFR 1910.212, .215, and .243).......................................... 326
19.5.2 Belt Sanding Machines (29 CFR 1910.213) ............................ 327 19.5.3 Hydraulic Power Tools (29 CFR 1910.217) ............................ 327 19.5.4 Pneumatic Tools (29 CFR 1910.243)....................................... 327 19.5.5 Portable (Power-Operated) Tools and Equipment
(29 CFR 1910.243) ................................................................... 328 19.5.6 Powder-Actuated Tools (29 CFR 1910.243)............................ 328 19.5.7 Saws, Portable Circular (29 CFR 1910.243) ............................ 329 19.5.8 Woodworking Machinery (29 CFR 1910.213) ........................ 329
19.6 Power Tool Checklist............................................................................... 331 19.7 Summary .................................................................................................. 332
Chapter 20 Pressure Vessels............................................................................. 335
20.1 Preventing Accidents or Incidents ........................................................... 336 20.2 Safety Assessment.................................................................................... 339
20.2.1 Design and Construction............................................................. 339 20.2.2 Vessel Identification and Documentation ................................... 340 20.2.3 Pressure Testing and Labeling.................................................... 341 20.2.4 Service History............................................................................ 341 20.2.5 In-Service Inspections................................................................. 341 20.2.6 Specific Applications .................................................................. 341
20.3 Evaluation of Information........................................................................ 342 20.4 Nondestructive Examination Methods..................................................... 342
20.4.1 Visual Examination..................................................................... 342 20.4.2 Liquid Penetrant Test.................................................................. 343 20.4.3 Magnetic Particle Test ................................................................ 343 20.4.4 Radiography................................................................................ 343 20.4.5 Ultrasonic Testing ....................................................................... 344 20.4.6 Detection Probabilities and Flaw Sizing..................................... 344
20.5 Recent Cracking Experience in Pressure Vessels.................................... 345 20.5.1 Deaerator Service........................................................................ 345 20.5.2 Amine Service............................................................................. 346 20.5.3 Wet Hydrogen Sulfide ................................................................ 347 20.5.4 Ammonia Service........................................................................ 347 20.5.5 Pulp Digester Service.................................................................. 347 20.5.6 Summary of Service Cracking Experience................................. 348
20.6 General Operational Issues ...................................................................... 349 20.6.1 Pressure Equipment Operation ................................................... 349 20.6.2 Maintenance ................................................................................ 349 20.6.3 Storage and Disposition .............................................................. 349 20.6.4 Basic Rules for Operation........................................................... 349 20.6.5 Inspection and Retesting............................................................. 350
20.7 Pressure Vessels in the Service Industry ................................................. 350 20.8 Summary of Regulations ......................................................................... 350
20.8.1 Structure and Scope of Section VIII........................................... 351 20.8.2 Failure Modes for Pressure Vessels............................................ 352 20.8.3 Requirements .............................................................................. 352 20.8.4 Test and Inspection ..................................................................... 353
20.9 Checklist for Pressure Vessels ................................................................. 354 20.10 Summary .................................................................................................. 355
Chapter 21 Truck Safety .................................................................................. 357
21.1 Truckers ................................................................................................... 357 21.1.1 Trucker Illnesses and Injuries ..................................................... 357 21.1.2 Common Trucker Injuries........................................................... 358 21.1.3 Events or Exposures Leading to Trucker Injury ........................ 358
21.2 Trucking Regulations............................................................................. 358 21.2.1 Other Agency Overview ......................................................... 358 21.2.2 Federal Highway Administration............................................ 359 21.2.3 Federal Motor Carrier Safety Administration......................... 359
21.3 Fleet Safety Program.............................................................................. 359 21.4 Written Fleet Safety Program ................................................................ 360 21.5 Vehicle=Equipment Maintenance........................................................... 361 21.6 Truck Drivers ......................................................................................... 362
21.6.1 Records to Maintain................................................................ 362 21.6.2 Operator Recruitment and Selection....................................... 363 21.6.3 Operator Training.................................................................... 364
21.7 Operator Safety ...................................................................................... 365 21.7.1 Company’s Driver Manual...................................................... 365 21.7.2 Pre-Operation Inspection ........................................................ 365
21.8 Safe Driving Guidance........................................................................... 366 21.8.1 Common Driving Mistakes..................................................... 366 21.8.2 Recognizing Safe Driving....................................................... 367 21.8.3 Planning Schedules, Loads, and Routes ................................. 367
21.9 Preventing Accidents ............................................................................. 367 21.10 Preventive Maintenance Programs......................................................... 368 21.11 Components of PMP.............................................................................. 368
21.11.1 Preventive Maintenance.......................................................... 370 21.11.2 Management’s Role ................................................................ 370 21.11.3 PMP Program.......................................................................... 370 21.11.4 Drivers’ Inspections ................................................................ 371 21.11.5 Maintenance ............................................................................ 372 21.11.6 Management Responsibility.................................................... 372
21.12 Applicable Regulations .......................................................................... 372 21.12.1 Regulatory Guidance for Federal Motor Carrier Safety
Regulations ............................................................................. 373 21.13 Summary ................................................................................................ 374
Chapter 22 Scaffolds ........................................................................................ 377
22.1 Scaffolds................................................................................................. 377 22.2 General Requirements............................................................................ 377
22.2.1 Platforms ................................................................................. 378 22.2.2 Scaffold Components.............................................................. 379 22.2.3 Supporting Scaffolds............................................................... 379
22.3 Suspension Scaffolds ............................................................................. 380 22.4 Accessing Scaffolds ............................................................................... 383
22.4.1 Stairrails .................................................................................. 384 22.4.2 Stairways and Ramps.............................................................. 384 22.4.3 Integrated Scaffold Access ..................................................... 384 22.4.4 Access during Erecting or Dismantling.................................. 385
22.5 Other Scaffold Rules.............................................................................. 385
22.6 Fall Protection ........................................................................................ 387 22.6.1 Personal Fall Arrest System...................................................... 388 22.6.2 Guardrail Systems ..................................................................... 389
22.7 Falling Object Protection ....................................................................... 390 22.8 Training Requirements........................................................................... 391 22.9 Commonly Used Types of Scaffolds..................................................... 392
22.9.1 Tubular and Coupler Scaffolds ................................................. 392 22.9.2 Fabricated Frame Scaffolds ...................................................... 392 22.9.3 Mobile Scaffolds ....................................................................... 393 22.9.4 Pump Jack Scaffolds................................................................. 394 22.9.5 Ladder Jack Scaffolds ............................................................... 395 22.9.6 Boatswains’ Chair ..................................................................... 395 22.9.7 Two-Point Adjustable Suspension Scaffolds
(Swing Stages) .......................................................................... 396 22.9.8 Specific Types of Scaffolds ...................................................... 397
Chapter 23 Walking-Working Surfaces........................................................... 399
23.1 Walking-Working Surfaces ................................................................... 399 23.2 General Requirements............................................................................ 399
23.2.1 Housekeeping............................................................................ 399 23.2.2 Aisles and Passageways............................................................ 400 23.2.3 Covers and Guardrails .............................................................. 400 23.2.4 Floor Loading Protection .......................................................... 400
23.3 Guarding Floor and Wall Openings and Holes ..................................... 401 23.3.1 Protection for Floor Openings .................................................. 402 23.3.2 Protection of Open-Sided Floors, Platforms, and Runways..... 402 23.3.3 Stairway Railings and Guards .................................................. 402
23.4 Fixed Industrial Stairs ............................................................................ 404 23.4.1 Handrails and Stair Rails .......................................................... 405 23.4.2 Treads........................................................................................ 405 23.4.3 Safety Precautions..................................................................... 405
23.5 Portable Ladders .................................................................................... 405 23.6 Fixed Ladders......................................................................................... 407 23.7 Safety Requirements for Scaffolding..................................................... 408 23.8 Manually Propelled Mobile Ladder Stands
and Scaffolds (Towers) .......................................................................... 409 23.9 Other Working Surfaces ........................................................................ 410 23.10 Applicable OSHA Regulations .............................................................. 410 23.11 Summary ................................................................................................ 411
Chapter 24 Welding and Cutting ..................................................................... 413
24.1 Welding.................................................................................................. 413 24.1.1 Arc Welding.............................................................................. 413 24.1.2 Gas Welding ............................................................................. 414
24.2 Gas Cylinders........................................................................................... 415 24.2.1 Identification ............................................................................... 417 24.2.2 Securing Gas Cylinders .............................................................. 417 24.2.3 Gas Cylinder Precautions............................................................ 417 24.2.4 Use of Gas Cylinders.................................................................. 419 24.2.5 Leaking Cylinders....................................................................... 419 24.2.6 Disposing of Cylinders ............................................................... 420 24.2.7 Welding Gases ............................................................................ 420 24.2.8 Storing Fuel Gases ...................................................................... 421
24.2.8.1 Use of Fuel Gases for Welding and Cutting .............. 421 24.2.8.2 Acetylene Storage ....................................................... 422 24.2.8.3 Oxygen Storage........................................................... 422 24.2.8.4 Fuel Gas Storage ......................................................... 422 24.2.8.5 Usage of Oxygen ........................................................ 423 24.2.8.6 Usage of Acetylene ..................................................... 423
24.3 Welding Hazards...................................................................................... 423 24.3.1 Fumes.......................................................................................... 423 24.3.2 Eye Injuries ................................................................................. 425 24.3.3 Burns ........................................................................................... 427 24.3.4 Fire .............................................................................................. 427 24.3.5 Noise ........................................................................................... 428
24.4 Prevention and Control of Welding Hazards........................................... 428 24.4.1 General or Dilution Ventilation .................................................. 428 24.4.2 Local Exhaust Ventilation .......................................................... 428 24.4.3 Confined Spaces.......................................................................... 428 24.4.4 Electricity .................................................................................... 430 24.4.5 Fumes.......................................................................................... 430 24.4.6 Personal Protective Equipment ................................................... 431 24.4.7 Training....................................................................................... 432
24.5 OSHA Welding Regulations.................................................................... 433 24.6 Welding Checklist.................................................................................... 435 24.7 Summary .................................................................................................. 436
Chapter 25 Other Hazards ................................................................................ 441
25.1 Aerial Lifts (1926.556) ............................................................................ 441 25.2 Air Receivers (29 CFR 1910.169)........................................................... 442 25.3 Compressors and Compressed Air (29 CFR 1910.242) .......................... 443 25.4 Fire Protection and Prevention (1926.150).............................................. 443
25.4.1 Fire Prevention-Storage (CFR 1926.151) ................................ 446 25.5 Loading Docks......................................................................................... 447 25.6 Power Transmission and Distribution (1926.950)................................... 448
25.6.1 Tools and Protective Equipment (1926.951) .............................. 448 25.6.2 Mechanical Equipment (1926.952)............................................. 449 25.6.3 Material Handling (1926.953) .................................................... 449 25.6.4 Grounding for Protection of Employees (1926.954) .................. 450
25.6.5 Overhead Lines (1926.955) ...................................................... 450 25.6.5.1 Metal Tower Construction ........................................ 450 25.6.5.2 Stringing and Removing
De-Energized Conductors ......................................... 452 25.6.5.3 Stringing Adjacent to Energized Lines ..................... 452 25.6.5.4 Live-Line Barehand Work ........................................ 452
25.6.6 Underground Lines (1926.956) ................................................ 453 25.6.7 Construction in Energized Substations (1926.957) .................. 454 25.6.8 External Load Helicopters (1926.958)...................................... 454 25.6.9 Lineman’s Body Belts, Safety Straps,
and Lanyards (1926.959) .......................................................... 454 25.7 Radiation, Ionizing (1926.53) ................................................................ 454 25.8 Rigging (1926.251) ................................................................................ 455
25.8.1 Rigging Equipment for Material Handling (1926.251) ............ 455 25.8.2 Welded Alloy Steel Chains (1926.251).................................... 456 25.8.3 Wire Ropes (1926.251)............................................................. 457 25.8.4 Synthetic Rope (1926.251) ....................................................... 458 25.8.5 Web Slings (1926.251) ............................................................. 459 25.8.6 Shackles and Hooks (1926.251) ............................................... 460
25.9 Signs, Signals, and Barricades............................................................... 460 25.9.1 Accident Prevention Signs=Tags .............................................. 460
25.10 Tire Inflation .......................................................................................... 461
Chapter 26 Summary........................................................................................ 463
26.1 Chemicals............................................................................................... 463 26.2 Confined Spaces..................................................................................... 464 26.3 Driver and Vehicle Safety...................................................................... 465 26.4 Electrical ................................................................................................ 466 26.5 Emergency Response and Planning....................................................... 468 26.6 Ergonomics ............................................................................................ 469
26.6.1 Manual Material Handling........................................................ 469 26.6.2 Physical Energy Demands ........................................................ 469 26.6.3 Other Musculoskeletal Demands .............................................. 470 26.6.4 Computer Workstation.............................................................. 470 26.6.5 Environment.............................................................................. 470 26.6.6 General Workplace ................................................................... 470 26.6.7 Tools ......................................................................................... 471 26.6.8 Gloves ....................................................................................... 471 26.6.9 Administration .......................................................................... 471
26.7 Excavations=Trenches ............................................................................ 471 26.8 Fall Protection ........................................................................................ 472 26.9 Fire Protection and Prevention .............................................................. 474 26.10 Flammable and Combustible Materials ................................................. 476
26.11 Hand and Portable Powered Tools ........................................................ 477 26.11.1 Hand Tools and Equipment .................................................... 477 26.11.2 Portable (Power-Operated) Tools and Equipment.................. 478 26.11.3 Powder-Actuated Tools........................................................... 478 26.11.4 Walk-Behind and Power Mowers........................................... 479 26.11.5 Jacks........................................................................................ 479
26.12 Hazardous Chemical Exposure .............................................................. 479 26.13 Hazard Communication ......................................................................... 481 26.14 Hazardous Waste Operations and Emergency Response (Hazwoper) ...... 482 26.15 Health Hazards....................................................................................... 483 26.16 Lifting Safety ......................................................................................... 483 26.17 Lockout=Tagout Procedures................................................................... 484 26.18 Machine Guarding and Safety ............................................................... 485 26.19 Means of Exit......................................................................................... 486 26.20 Medical Services and First Aid ............................................................. 487 26.21 Personal Protective Equipment .............................................................. 487 26.22 Pressure Vessels ..................................................................................... 488 26.23 Scaffolding ............................................................................................. 489
26.23.1 Suspended Scaffolds ............................................................... 490 26.23.2 Aerial Lifts .............................................................................. 490
26.24 Walking-Working Surfaces ................................................................... 490 26.24.1 Walkways................................................................................ 491 26.24.2 Floor and Wall Openings........................................................ 491 26.24.3 Stairs and Stairways................................................................ 492 26.24.4 Elevated Surfaces.................................................................... 492
26.25 Welding and Cutting.............................................................................. 493 26.25.1 Gas Welding and Cutting ....................................................... 493 26.25.2 Arc Welding............................................................................ 494 26.25.3 Fire Prevention........................................................................ 494 26.25.4 Ventilation and Protection in Welding, Cutting,
and Heating ............................................................................. 494
Appendix A Common Exposures or Accident Types ...................................... 495
A.1 Accident Types ...................................................................................... 495 A.1.1 Struck-Against Types of Accidents ........................................ 495 A.1.2 Struck-By Types of Accidents................................................ 495 A.1.3 Contact-By and Contact-With Types of Accidents ................ 496 A.1.4 Caught-In and Caught-On Types of Accidents ...................... 496 A.1.5 Caught-Between Types-Of Accidents .................................... 496 A.1.6 Fall-to-Same-Level and Fall-to-Below Types of Accidents... 496 A.1.7 Overexertion and Exposure Types of Accidents .................... 497
Appendix B The 50 Most Common Chemicals Found on Hazardous Waste Sites by Frequency of Occurrence .................................... 499
Appendix C Sample Confined Space Entry Permit .......................................... 501
Appendix D Welding Fumes and Gases and Their Hazards ............................ 503
D.1 Chemical Agents ....................................................................................... 503 D.1.1 Acetylene..................................................................................... 503 D.1.2 Aluminum.................................................................................... 503 D.1.3 Antimony..................................................................................... 503 D.1.4 Arsenic ........................................................................................ 503 D.1.5 Asbestos ...................................................................................... 503 D.1.6 Beryllium..................................................................................... 504 D.1.7 Cadmium ..................................................................................... 504 D.1.8 Carbon Monoxide ....................................................................... 504 D.1.9 Chromium.................................................................................... 504 D.1.10 Chlorinated Hydrocarbon Solvents ............................................. 504 D.1.11 Cobalt .......................................................................................... 504 D.1.12 Fluorides...................................................................................... 505 D.1.13 Iron Oxide ................................................................................... 505 D.1.14 Lead............................................................................................. 505 D.1.15 Magnesium .................................................................................. 505 D.1.16 Manganese................................................................................... 505 D.1.17 Mercury ....................................................................................... 505 D.1.18 Molybdenum ............................................................................... 506 D.1.19 Nickel .......................................................................................... 506 D.1.20 Nitrogen Oxides .......................................................................... 506 D.1.21 Ozone .......................................................................................... 506 D.1.22 Phosgene...................................................................................... 506 D.1.23 Phosphine .................................................................................... 506 D.1.24 Vanadium .................................................................................... 506 D.1.25 Zinc.............................................................................................. 506
Appendix E Checklists for Use in Addressing Ergonomic, Material Handling, and Lifting Tasks .......................................... 507
Design Principles for Carrying Tasks................................................................... 507 Design Principles for Pushing and Pulling Tasks ................................................ 507 Design Principles for Lifting and Lowering Tasks .............................................. 508 General Workstation Design Principles................................................................ 509 Design Principles for Repetitive Hand and Wrist Tasks...................................... 509 Materials-Handling Checklist ............................................................................... 510
Bibliography ........................................................................................................ 513
Index ..................................................................................................................... 517
