Essentials of Safety Construction Training & Reference Guide Volume 2 by MANCOMM

UPC

88550 00075

315 West Fourth Street Davenport, Iowa 52801 (563) 323-6245 1-800-MANCOMM (626-2666) Fax: (563) 323-0804 Website: http://www.mancomm.com E-mail: safetyinfo@mancomm.com All rights reserved. Printed in the U.S.A. This publication is intended for instructional and educational use only. This book is meant to provide a formatted and easy to understand tool for the reader to train and be trained pursuant to OSHA requirements for 10 and 30 hour Construction safety training. While these volumes meet and exceed the OSHA guidelines, please note that they are not an exhaustive overview of every OSHA topic or regulation. It does not alter or determine compliance responsibilities in Title 29, Code of Federal Regulations Parts 1903, 1904, 1910 and 1926 or the Occupational Safety and Health Act of 1970. Except as permitted under applicable law, no part of this publication may, by the person to whom it is first provided or by any other person(s), be reproduced or distributed in any form or by any means, or stored in any database or other retrieval system, without the prior written permission of the publisher. This publication is provided as training information in connection with a training course. Although the Federal Regulations published as promulgated are in the public domain, their formatting and sequencing, and other materials contained herein, are subject to copyright law. While best efforts have been made in order to ensure that the information contained herein is as accurate and as complete as possible at the time of printing, the frequency of changes to the regulations makes it impossible to guarantee the completeness and accuracy of the following information. Therefore MANCOMM and its subsidiaries shall under no circumstances be liable for any damages resulting from the use of or reliance upon this publication. In no event does MANCOMM or its subsidiaries express or imply any warranties or assume any liabilities whatsoever arising out of the use or inability to use this material. Furthermore, the mention or appearance of any products, services, companies, organizations, or individuals in no way implies endorsement or denouncement of same by MANCOMM or any of its subsidiaries. This publication is constructed in order to provide accurate information in regard to the material included. It is made with the understanding that the publisher is not involved in providing any accounting, legal, or other professional service(s). If legal consultation or other expert advice is required, the services of a professional person should be engaged.

Library of Congress Control Number: 2011934633 ISBN: 1-59959-284-3

Table of Contents Module Twenty - Steel Erection

Controlling Contractor....................................................................................................... 2 Site Layout........................................................................................................................ 2 Hoisting and Rigging......................................................................................................... 3 Structural Steel Assembly................................................................................................. 3 Column Anchorage........................................................................................................... 4 Beams and Columns......................................................................................................... 4 Systems-Engineered Metal Buildings............................................................................... 5 Falling Object Protection................................................................................................... 5 Fall Protection................................................................................................................... 6 Training............................................................................................................................. 8

Module Twenty-One - Welding and Cutting

Gas Welding and Cutting................................................................................................ 10 Arc Welding..................................................................................................................... 12 Fire Prevention................................................................................................................ 13 Welding Accident............................................................................................................. 14 Preservative Coatings..................................................................................................... 14 Ventilation....................................................................................................................... 15 Personal Protective Equipment....................................................................................... 16

Module Twenty-Two - Motor Vehicles

Equipment....................................................................................................................... 18 Motor Vehicles on the Worksite....................................................................................... 18 Roadside Construction Safety........................................................................................ 20 Flaggers.......................................................................................................................... 24

Module Twenty-Three - Powered Industrial Trucks

Powered Industrial Trucks............................................................................................... 26 Fueling and Recharging Operations............................................................................... 27 Trucks and Railroad Cars............................................................................................... 28 Operator Training............................................................................................................ 29

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TOC

Operating Forklifts Safely................................................................................................ 30 Powered Industrial Truck Maintenance........................................................................... 31

Module Twenty-Four - DOT Placarding

DOT Markings, Placards, and Labels............................................................................. 34

Module Twenty-Five - Electrical

How Does Electricity Work?............................................................................................ 36 General Requirements.................................................................................................... 36 Wiring Design and Protection......................................................................................... 38 Grounding connections................................................................................................... 39 Wiring Methods, Components, and Equipment.............................................................. 40 Temporary Lighting......................................................................................................... 43 GFCI Outlets................................................................................................................... 44 Hazardous (Classified) Locations................................................................................... 44 Safety-Related Work Practices....................................................................................... 45 Arc Flash......................................................................................................................... 47 Use of Flexible Cords and Cables.................................................................................. 49

Module Twenty-Six - Lockout/Tagout

Lockout/Tagout General Information............................................................................... 54 Training........................................................................................................................... 57 General Lockout/Tagout Suggested Procedures............................................................ 58 Special Requirements..................................................................................................... 62 Outside Personnel (Contractors).................................................................................... 63

Module Twenty-Seven - Signs / Tags

Classification of Signs..................................................................................................... 66 Accident Prevention Tags................................................................................................ 67

Module Twenty-Eight - HazCom 2

Hazard Communications................................................................................................. 70 HazCom Program........................................................................................................... 71 Identify Responsible Staff............................................................................................... 71 Develop a List of Hazardous Chemicals......................................................................... 72 List of Hazardous Chemicals Workshop......................................................................... 72 Material Safety Data Sheets Procedures ....................................................................... 72 Identify Chemical Hazards Workshop............................................................................. 73 Labeling Procedures....................................................................................................... 74 Container Labeling Workshop......................................................................................... 74 Employee Training Requirements................................................................................... 75

TOC

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Module Twenty-Nine - Hazardous Waste Operations and Emergency Response (HAZWOPER) HAZWOPER................................................................................................................... 78 Emergency Response..................................................................................................... 78

Module Thirty - Ergonomics

Ergonomics and the General Duty Clause...................................................................... 81 Musculoskeletal Disorders (MSDs)................................................................................. 83 Conclusion...................................................................................................................... 84

Module Thirty-One - Safety and Health Programs

General Guidelines......................................................................................................... 85 Design Standards........................................................................................................... 86 Performance Standards.................................................................................................. 86 Major Elements............................................................................................................... 87 Recommended Actions................................................................................................... 88 Safety & Health Program Checklist................................................................................. 90

Module Thirty-Two - Assesing Safety and Health Programs

Introduction..................................................................................................................... 91 Conclusion.................................................................................................................... 100

Module Thirty-Three - Industrial Hygiene

Industrial Hygiene......................................................................................................... 101 Worksite Analysis.......................................................................................................... 102

Module Thirty-Four - Recordkeeping

Reporting...................................................................................................................... 108 Recordkeeping.............................................................................................................. 108 Step 1: Are You Required to Maintain a 300 Log?........................................................ 109 Step 2: Is This Person Recordable?..............................................................................110 Step 3: Is This Case Work-Related?..............................................................................110 Step 4: Is This a New Case?..........................................................................................112 Step 5: Is This Case Recordable?.................................................................................112 Step 7: How to Update This Case (When Required).....................................................118 Step 8: How to Complete, Display, and Retain Records................................................118 Employee Involvement...................................................................................................119

Module Thirty-Five - Medical Records

Medical and Exposure Records ................................................................................... 122 Preservation of Records............................................................................................... 124 Access to Records........................................................................................................ 125

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iii

Module Thirty-Six - Inspections, Citations, and Penalties

Reasons for Inspections............................................................................................... 128 Employer Rights............................................................................................................ 128 Inspection Preparation.................................................................................................. 128 The Inspection ............................................................................................................. 130 If Citations Are Issued................................................................................................... 132 Appeal Process............................................................................................................. 132 Compliance Duties Owed to Each Worker.................................................................... 133

Module Thirty-Seven - Bloodborne Pathogens

Bloodborne Pathogens................................................................................................. 136 Exposure Control Plan.................................................................................................. 137 Engineering and Work Practice Controls...................................................................... 137 Personal Protective Equipment..................................................................................... 138 Housekeeping............................................................................................................... 138 Hepatitis B Vaccination................................................................................................. 139 Exposure Incident......................................................................................................... 139 Communicate Hazards to Employees........................................................................... 140 Records......................................................................................................................... 141

Module Thirty-Eight - Open Forum................................................................................... 143 Photography Credits.......................................................................................................... 145 Index.................................................................................................................................. 147

TOC

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Steel Erection

Module Twenty

Steel Erection Subpart R

Steel Erection

Scope

§1926.750

Management Controls

.752(a); .755(b)(2); .759(b); .760(e)

Alerts (postings, signs, markings)

§1926.754(e)(3)(iii); .760(c)(3)

Records and Procedures

§1926.752(a), (b), (d); .755(b)(2); Subpart R Appendix G (c)(4)(ii)

Training

§1926.753(d)(1)(iv); .760(b)(2); .760(c)(4); .761

Controlling Contractor The Controlling Contractor is a prime contractor, general contractor, construction manager, or any other legal entity which has the overall responsibility for the construction of the project —its planning, quality, and completion. §1926.751

§1926.752(c)

Site Layout The Controlling Contractor must make sure that the following are provided and maintained: ›› Adequate access roads into and through the site for the safe delivery and movement of derricks, cranes, trucks, other necessary equipment, and the material to be erected and means and methods for pedestrian and vehicular control. Exception: This requirement does not apply to roads outside of the construction site. ›› A firm, properly graded, drained area, readily accessible to the work with adequate space for the safe storage of materials and the safe operation of the erector's equipment.

§1926.752(a)

Before steel erection may begin, the Controlling Contractor must provide the steel erector with written notification that: ›› The concrete in the footings, piers, and walls has sufficient strength to support the loads imposed during steel erection. ›› The mortar in the masonry piers has sufficient strength to support the loads imposed during steel erection. ›› Any repairs or modifications to anchor bolts were properly conducted.

Steel Erection

Hoisting and Rigging Cranes All safety precautions regarding cranes, such as inspections and operations, must be followed when using cranes in steel erection.

Multiple Lifts (aka Christmas Treeing) Multiple lifts are only allowed: ›› According to manufacturer’s instructions. ›› If a multiple lift rigging assembly is used. ›› A maximum of five members per lift. ›› To lift beams and other structural members. ›› If all employees involved in the lift have been trained to do so.

§1926.753(c), (e)

§1926.754(a)

Structural Steel Assembly Structural stability must be maintained at all times.

§1926.754(c)(1)-(2)

Shear connectors Shear connectors must not be attached so that they stick up from the top flanges of beams, joists, or beam attachments until after the metal decking (or other walking/working surface) has been installed. Shear connectors may not be installed from within a controlled decking zone. © MCMXCVII - MMXI by www.mancomm.com

Column Anchorage All columns must be anchored by a minimum of four anchor rods/bolts.

§1926.755

Anchorage must be designed to resist a minimum eccentric gravity load on the column of 300 pounds. Columns must be evaluated by a competent person to determine whether they need to be guyed or braced.

§1926.756(a)

Repair, replacement, or field modification to anchor rods: ›› Must not happen without the approval of the project structural engineer. ›› The Controlling Contractor must provide written notification to the steel erector of adequacy of anchor bolts modified/repaired in the field.

Beams and Columns

§1926.756(c)(1)

During the final placing of solid web structural members, the load must not be released from the hoisting line until the members are secured with at least two bolts, per connection, of the same size and strength as shown in the construction documents. The bolts must be drawn up wrench-tight or secured by an equivalent connection as specified by the project structural engineer of record.

Double Connections When making a double connection at or near a column, the first member must remain connected to a supporting member by at least one connection bolt at all times unless a connection seat or equivalent connection device is supplied with the members to secure the first member.

Steel Erection

Open Web Steel Joists Minimize the risk of collapse of lightweight steel joists by: ›› Specifying erection bridging and method of attachment. ›› Requiring erection bridging to be anchored to terminus point. ›› Specifying method of placing loads on steel joists.

§1926.757

Systems-Engineered Metal Buildings Each structural column shall be anchored by at least four anchor rods/ anchor bolts. Rigid frames shall have 50 percent of their bolts or the number of bolts specified by the manufacturer (whichever is greater) installed and tightened on both sides of the web adjacent to each flange before the hoisting equipment is released. Construction loads must not be placed on any structural steel framework unless such framework is safely bolted, welded, or otherwise adequately secured.

§1926.758

§1926.759

Falling Object Protection Struck-by Hazard All materials, equipment, and tools that are not in use while aloft shall be secured against accidental displacement. The Controlling Contractor shall bar other construction processes below steel erection unless overhead protection for the employees below is provided.

Index A

Arc Flash 47 Arc Welding Grounding 12 Training 12 Assessing Safety and Health Programs 91 Documentation 92 Employee Interviews 92 Site Conditions and Root Causes of Hazards 93

B Beams and Columns 4 Bloodborne Pathogens 135 Communicate Hazards to Employees 140 Definition 136 Engineering and Work Practice Controls 137 Exposure Control Plan 137 Exposure Incident 139 Hepatitis B 136 Housekeeping 138 Personal Protective Equipment 138 Records 141

D DOT Placarding 33

E Electrical 35 Approach Distances 46 Arc Flash 47 Extension Cords 50 Flexible Cords and Cables 49

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General Requirements 36 GFCI Outlets 44 Hazardous (Classified) Locations 44 Power Strips 51 Switchboards and panelboards 41 Switches 41 Temporary Lighting 43 Wiring Design and Protection 38 Employer Rights 128 Ergonomics 81 General Duty Clause 81 Musculoskeletal Disorders (MSD) 83 Solutions 84 Extension Cords 50

F Flexible Cords and Cables 49 Splices 50

G GFCI Outlets 44

H Hazard Communications (HazCom) 69 Employee Training Requirements 75 Labeling Procedures 74 List of Hazardous Chemicals Workshop 72 Material Safety Data Sheets Procedures 72 Program 71 "Right to Know" 70 Hazardous Waste Operations and Emergency Response (HAZWOPER) 77 Emergency Response 78 Documentation 79 Emergency Responders 78 Plan 78 Refresher Training 79

Index

147

Industrial Hygiene 101 Worksite Analysis 102 Air Contaminants 103 Biological Hazards 103 Chemical Hazards 103 Ergonomic Hazards 104 Physical Hazards 104 Inspections, Citations, and Penalties 127 Appeal Process 132 Citation appeal procedures 133 Notice of Contest 132 Review Commission 133 Complaints/referrals 128 Employer Rights 128 Fatality/catastrophe 128 If Citations are Issued 132 post citation 132 Imminent danger 128 Inspection Procedures 129 Programmed inspections 128 The Inspection 130 Closing Conference 131 Opening Conference 130 Walkthrough Inspection 131 Violations and Penalties 133

Powered Industrial Trucks 25 Fueling and Recharging Operations 27 Changing and charging storage batteries 27 Eye/Face Wash and Shower Units 28 Fuel handling and storage 27 Maintenance 31 Modifications and Attachments 26 Operating Forklifts Safely 30 Traveling with Trucks 30 Truck operations 30 Operator Training 29 Certification 29 Refresher training 29 Training 29 Safety guards 27 Trucks and Railroad Cars 28

L Lockout/Tagout 53 Electrical written program 55 General Requirements 54 Special Requirements 63 Stored Energy 60 Training 57

M Medical Records 121 Access to Records 125 Definitions 123 Preservation of Records 124 Purpose 122 Scope 122 Motor Vehicles 17 Equipment 18 General Requirements 18 Brakes 18 Lights 18 Roadside Construction Safety 20

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Index

R Recordkeeping 108 Recordkeeping and Reporting 107 Employee Involvement 119 Quick Start Guide STEP 1: Are you Required to Maintain a 300 Log? 109 Step 2: Is this Person Recordable? 110 Step 3: Is this Case Work-Related? 110 Step 4: Is this a New Case? 112 Step 5: Is this Case Recordable? 112 Step 7: How to Update this Case (When Required) 118 Step 8: How to Complete, Display, and Retain Records 118 Recordkeeping 108 Reporting 108 Reporting 108 Roadside Construction Safety 20

S Safety and Health Program 85 Design Standards 86 General Guidelines 85 Major Elements 87 Employee involvement 87 Hazard prevention and control 87 Management commitment 87 Safety and health training 87 Worksite analysis 87 Performance Standards 86 Recommended Actions 88 Safety & Health Program Checklist 90

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Signs / Tags 65 Accident Prevention Tags 67 Classification of Signs 66 Steel Erection 1 Beams and Columns 4 Column Anchorage 4 Controlling Contractor 2 Hoisting and Rigging 3 Open Web Steel Joists 5 Site Layout 2 Structural Steel Assembly 3 Systems-Engineered Metal Buildings 5 Stored Energy 60

V Violations and Penalties 133

W Welding and Cutting 9 Arc Welding Grounding 12 Training 12 Gas Welding and Cutting 10 Cylinders 10 Personal Protective Equipment 16 Preservative Coatings 14 Ventilation 15 Working Clearances 37

Training Arc Welding 12 Lockout/Tagout 57

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Index

149