Safety Manual - Dematic Corp.

Dematic Corp. Health and Safety Program 507 Plymouth Ave Rev.2 Grand Rapids, MI 49505 July 2011 1

Dematic Corp.

Health and Safety Program

Health and Safety Program Table of Contents

Rev. 2 July 2011 1

Contents

Section Subject 1 Statement of Management Support 2 Health and Safety Policy 3 Responsibility for Safety in the Organization 4 Employee Conduct and Safety Rules 5 Drug, Alcohol, and Contraband 6 New Project Start Up 7 Safety Requirements for Subcontractors 8 Safety Training 9 Safety Meetings 10 Job Hazard Analysis 11 Jobsite Inspection 12 Investigations 13 First-Aid Procedures 14 Bloodborne Pathogens Exposure Control Plan (Addendum Section) 15 Electrical Safety and Assured Grounding 16 Mobile Equipment 17 Cranes, Rigging and Tools 18 Fall Protection 19 Fire Prevention 20 Hazard Communication Program 21 Lock-Out/Tag-Out 22 Personal Protective Equipment 23 Stairways and Ladders 24 Oxy-Fuel, Cutting, Brazing, and Welding 25 Steel Erection 26 Forms

Health and Safety Program Statement of Management Support

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1 Statement of Management Support

The safety objective of Dematic Corp. is to ensure that no job is so important that we cannot perform it in a safe manner and that all injuries can be prevented. We are vitally concerned about the human suffering and financial losses resulting from on-the-job accidents, both for the individual and the company. All levels of management are responsible for implementation of legal requirements and standards for health, safety and emergency plans. Ensuring safe facilities, accident prevention, safety awareness and continuous improvement are integral parts of leadership responsibility. Employees should be trained, equipped and competent to carry out their responsibilities, avoid hazards and risks and take necessary precautions related to Health and Safety. Legal requirements will be translated into practical instructions and safe work procedures so that affected personnel can comply with the laws and standards. Employees must be supplied with the required safety equipment appropriate for their occupation and be obligated to use it. All employees are expected to contribute actively to Health and Safety and either eliminate hazards themselves or report them. Managers are required to immediately initiate corrective action. As stated in the Dematic Corp. Health and Safety Program, we are convinced that safety ranks equally with production, quality and cost. It is expected that a high level of safety performance will be maintained at all customer jobsite locations. We also expect our suppliers, contractors and other business partners to place an equally high priority on Health and Safety in their operations.

John Baysore ___________________________ President & CEO Dematic Corp.

Health and Safety Program Health and Safety Policy

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2 Health and Safety Policy

We, at Dematic Corp., are committed to achieving high standards of health and safety. We are also committed to providing a safe, healthy, and productive working environment for our employees as well as our customer and subcontractor’s employees. We are convinced that safety ranks equally with production, quality, cost, etc. It is expected that a high level of safety performance will be maintained at all company and site locations.

Our safety program has been developed to ensure compliance with federal, state, local, and customer rules and regulations. This is to protect the health and safety of ALL our employees.

It is the obligation of all employees to be knowledgeable of the company’s standards and regulations. As well as implement all rules, procedures, and regulations contained herein. Employees at all levels must work diligently to execute Dematic Corp. policies and procedures pertaining to occupational health and safety issues. We encourage our employees to seek creative and innovative solutions to continuously improve our health and safety performances.

2.1 Managing the Health and Safety Program It is not in the best interest of the company or it’s employees to consider safety as something apart from production, quality, and cost. Since these factors are managed on a day-to-day basis, the health and safety program should benefit from the same treatment by implementing the following principles at each job site.

� Safety must be planned into every job, and attention to problems and potential hazards of the work and the work place is a continuing obligation. Safety, job competence, and work efficiency go together for a successful and profitable job.

� Safety is a condition of employment, and all employees must exhibit a conscientious assumption of health and safety responsibility.

� People are the most essential element of the program because concerned, involved, and trained employees are Dematic Corp.’s greatest resources.

� Health and safety rules are a time saver and accident preventer because they set certain behavioral procedures to be followed. Developing, reinforcing, and updating these rules are a continuous activity and usually result from lessons learned and past experiences.

� An employee who has been properly instructed by the first line supervisor is more likely to do a job quickly, conscientiously, efficiently, safely, and

Health and Safety Program Health and Safety Policy

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correctly the first time it is done. Taking time to do a job right the first time prevents wasted time from having to do it over.

� For safe work practices to become work habits, daily safety tips should be given on new, different, unusual, or critical jobs or when variations occur. Safety tips are reminders that promote production, quality, efficiency, and safety requirements.

� Having group safety meetings allows health and safety information to be distributed to the workforce. Frequent reminders and opportunities to “tell why” are necessary to train, motivate, convince, and educate employees to perform their work in the most productive and safe manner.

� Ongoing operations that cause equipment to become defective because of normal wear and tear creates unsafe conditions and possible down time. Through inspections, the chance of accidents and down time because of “sudden” failures is reduced, and undesirable situations are corrected before losses occur.

� Investigating accidents leads to accident prevention. Learning from losses, establishing controls, and conducting follow-ups keeps similar accidents from happening. Sharing investigated findings from other areas to help all work areas makes the most of lessons learned.

� There are certain jobs, procedures and processes where the risk of serious injury, loss of production, and the loss of efficiency are critical. It is vital to have control over these jobs and the way they are performed by identifying the methods to be used to prevent loss, establishing written minimum procedures, training employees, and following up to assure compliance.

The jobsite supervisor, the foreman, and project management are ultimately responsible for implementing the Health and Safety Program and for preventing accidents and injuries. The lead must come by example rather than just rhetoric because the strength of these principles ties in their application. Knowledge isn’t enough – attitude and the execution make the difference.

Health and Safety Program Responsibility for Safety in the Organization

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3 Responsibility for Safety in the Organization

Purpose: The purpose of this procedure is to define the individual roles and responsibilities of management and employees for implementing the health and safety program.

3.1 Jobsite Management At each Dematic Corp. jobsite, the jobsite supervisor and other supervisory personnel are responsible for establishing, maintaining, disseminating, and enforcing the health and safety program. This program shall encompass and adhere to all company as well as customer policies, standard operating procedures, federal, state, and local regulations.

This Health and Safety Manual represents the requirements to be followed at all jobsites, but does not limit the scope of the program that can be developed at each jobsite. Additional regulations, procedures, and standards may be developed as dictated by the customer, the work involved, or the work location. Where customer safety procedures and regulations, encompass areas not formalized in Dematic Corp’s Health and Safety program, they may be incorporated into the program, as well as the Occupational Health and Safety Administration’s (OSHA’s) procedures and regulations.

Once the Health and Safety program is established at the jobsite, the jobsite supervisor is responsible for ensuring that the program is understood, maintained, practiced, and enforced. Any failure in the jobsite supervision to maintain these noted items could result in disciplinary action up to and including termination. Supervisors and foremen are responsible for the daily implementation and enforcement of the program. Each employee is expected to be aware of and understand that safety is a condition of employment. Each employee shall be knowledgeable of, and always adhere to, all Dematic Corp. rules and regulations.

3.2 Supervisors and Foremen While safety is the responsibility of all levels of management, the supervisors are primarily responsible for the safe conduct of operations because they can most effectively carry the Health and Safety Program directly to the employee.

The supervisors must provide the daily leadership, proper example, and administrative control for accident prevention efforts to be successful.


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Management helps assist the supervisor in the planning, education, and enforcement matters that make up this Health and Safety Program. Dematic Corp. provides safety and management programs educational materials in the form of posters, training films, and safety records to develop and maintain employee interest in the program.

The Corporate Construction Safety Engineer coordinates, assists, monitors, and evaluates the effectiveness of these programs and then makes appropriate recommendations. However, the supervisor and or other supervisory personnel at each jobsite are directly responsible for the establishment, implementation, distribution, and enforcement of the program.

3.3 Jobsite Safety Representatives The jobsite safety representative is responsible for the following:

� Establishing and distributing Dematic Corp. health and safety policies and procedures to all supervisory personnel and hands.

� Ensuring the company and customer Health and Safety Programs are merged and incorporated into one safety action plan for the jobsite and that the plan complies with federal regulations.

� Assisting in the development and implementation of the New Employee Orientation Program with documentation (the site specific jobsite and Dematic Corp. program should be incorporated into one).

� Assisting with the development and the distribution of the jobsite Hazard Communication Program, merging the customer’s and Dematic Corp. Hazard Communication Programs, and ensuring that each employee receives the required training and that copies of the training documentation is maintained on site.

� Establishing a periodic review with all employees of materials presented at the new employee orientation.

� Assisting in the evaluation of injured employees and ensuring that the appropriate medical attention is received.

� Assisting in the investigation and documentation of all accidents, injuries, property damage, and near-miss-incidents, analyzing circumstances for “root causes” that led up to and contributed to the incident. Assisting in the development of corrective procedures that will help to avoid future incidents, and distributing accident investigation information and corrective actions to all personnel (including customer personnel).

� Assisting in the development, maintenance, and evaluation of an up-to-date first aid log with tabulation, evaluation, and distribution of all incidents and trends.


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� Distributing any new or revised rules, regulations, procedures, or recommendations by federal, state, or local authorities as well as the customer or Dematic Corp. to all personnel.

� Coordinating with the customer and jobsite personnel to develop and implement required testing and inspection programs.

� Coordinating with the customer and jobsite personnel to implement compliance programs for OSHA regulations such as fall protection, assured grounding, and lock-out/tag-out, including monitoring, training, and documentation.

� Coordinating the development, implementation, and documentation of tools and equipment inspections when they are first put into service as well as at required periodic intervals.

� Coordinating all programs that designate specifically trained qualified employees, or competent persons, such as operators, to operate equipment, and ensure that only trained and qualified employees operate designated equipment.

� Performing daily safety audits.

� Assisting and monitoring the development and the use of documentation for special projects such as lift plans.

� Assisting in the development of an ongoing health and safety awareness training.

� Coordinating with supervisory personnel for special jobs and turnarounds (i.e., confined workspaces, jobs requiring respiratory protection, lock-out/tag-out, etc.).

� Assisting in the development of ongoing safety improvements and employee’s safety awareness training.

� Attending, assisting, monitoring, and evaluating safety meetings conducted by jobsite supervisory personnel for all employees, and monitoring and tabulating the attendance of the employees to ensure that they receive the safety training.

� Meeting with supervisory personnel to review current and past safety performance and accidents.

� Meeting with customer personnel to review and evaluate safety performance.

� Monitoring the documentation and record retention of the required orientations, training, and inspections.


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3.4 Employees New employees should be instructed in the general safety policies, rules, and procedures before being referred to their supervisor for job training or job assignment. The supervisor should then review safety measures of the particular job and work area before the employee starts to work.

:NOTE: Documentation of training should be kept in the employee’s personnel file.

New employees will learn about hazards that may be present and how to recognize, avoid, and react to these hazards in the event that they are encountered. Subsequently, employees should be monitored to make sure they understand and are adhering to the safety instructions applicable to their job.

The involvement and cooperation of the individual employee is vital to the success of the Health and Safety Program. Continuing education is required to make certain that management and employees alike do their part in protecting the safety of the individual at all times. Every available medium, such as safety booklets, posters, signs, newsletters, videos, and meetings may be used to further the objective of such a program.

Health and Safety Program Employee Conduct and Safety Rules

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4 Employee Conduct and Safety Rules

Purpose: The purpose of this procedure is to establish specific guidelines and rules to govern employee conduct and actions. These guidelines and rules are not intended to cover all aspects of every discipline; however, there are specifics in each section that provide detailed rules, procedures and company policies.

4.1 General Dematic Corp. has established policies and procedures regarding employee conduct and expectations in order to protect employees and the jobsite. All employees shall be informed of these policies and procedures as well as the consequences of unacceptable conduct. A copy of this policy will be available to each employee at the time of employment.

All employee actions contrary to this policy will lead to disciplinary action up to and including termination. In cases where rules have been broken the facts and merits of the case will be reviewed by management before disciplinary action is taken. The job supervisor will keep all pertinent persons advised of all disciplinary action taken.

It is not intended that the following cover all causes for disciplinary action. It is meant to address general types of infractions that are obviously contrary to the best interest of all concerned. Any one of these infractions may be cause for disciplinary action up to and including termination.

4.2 Harassment Policy All employees are expected to conduct themselves with respect for fellow employees and other people who may have contact with the Company. Harassment on the job is unacceptable, and all employees are required to cooperate in preventing conduct of this nature.

4.2.1 Harassment Harassment of other employees, customers, suppliers, or others will not be tolerated. This includes sexual harassment, as well as harassment based on a person’s race, ethnicity, religion, disability, or any other characteristic or activity that is protected by law. Violation of this policy will result in disciplinary action up to and including termination of employment.


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While this policy is not limited to harassment based on sex or any other particular characteristic, the following description of sexual harassment illustrates the types of conduct that will be considered to be harassment.

Sexual harassment includes:

Unwelcome sexual advances, requests for sexual favors, or other verbal or physical conduct of a sexual nature, where:

(1) Submitting to or rejecting the conduct becomes a condition of a person's continued employment with the Company, or becomes the basis for employment decisions affecting; or

(2) The conduct creates an intimidating, hostile or offensive working environment.

This policy applies to actual or attempted physical acts, conduct, statements, jokes, displays, gestures, or any other acts or communications that are harmful, offensive, derogatory, abusive, insulting, threatening, or intimidating. Each employee is responsible to ensure that his or her behavior complies with the standards expressed in this policy. Behavior that is harassing toward others will not be excused simply because the actor(s) did not intend any harm or offense. If you believe you have been subjected to or witnessed harassment, you should report it immediately to your supervisor, manager, or a member of the Human Resources staff. Each report will be given serious consideration and investigated promptly. The Human Resources Department will interview the individuals who are directly involved and other potential witnesses, and review personnel records as needed. Within 10 working days (except in unusual circumstances), Human Resources will complete its investigation and submit a report to management for review and decision. In any case in which harassment is found, appropriate corrective action will be taken. Reports and investigations will be handled with discretion.

4.3 Violation of Safety Procedures There will be Zero Tolerance for the repeated or intentional violation of safety rules and procedures, such as those established for lock-out/tag-out, fall protection, etc., shall be cause for disciplinary action up to and including termination. Intentional violation of safety procedures also includes the removal, circumvention, alteration, or bypassing of any guard, safety device, or indicator and the intentional misuse of equipment, materials, or tools.


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4.4 Violation of Personal Protective Equipment (PPE) Requirements

Employee requirements for Personal Protection Equipment (PPE) have been established through pre-job hazard assessment. PPE includes, but is not limited to, ANSI-approved hard hats, safety glasses with side shields, safety-toed footwear, work gloves, and specialized work clothing (i.e., fire retardant garments, hearing protection, respiratory protection, additional eye and/or face protection, and fall protection). The employee’s manager, job supervisor, foremen, and/or safety representative is responsible for advising employees of the specific PPE required for each job duty. Failure of the employee to use the required PPE shall be grounds for disciplinary action.

4.5 Unsafe Conduct Horseplay, practical jokes, fighting, or roughhouse activities of any sort are not permitted on jobsite property.

4.6 Contraband The use or possession of weapons, ammunition, explosives, intoxicants, illicit drugs, or narcotics on jobsite property, including parking lots, is strictly prohibited. Bringing “strike anywhere” matches to the jobsite or having any type of match, cigarette lighter, or flame producing device in restricted areas is also prohibited.

:NOTE: Smoking is permitted, but only in designated areas.

Any employee possessing contraband, smoking in unauthorized areas, or reporting to work under the influence of drugs or intoxicants may be subject to disciplinary action.

4.7 Failure to Report Incidents and Injuries All unsafe conditions must be reported. All injuries, no matter how slight, must be reported immediately to supervision. The supervisor will then direct the employee for treatment. Failure to report near-miss incidents, accidents, injuries, unsafe acts, or unsafe conditions immediately to supervision may result in disciplinary action.

Health and Safety Program Drug and Alcohol Policy

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5 Drug and Alcohol Policy

Purpose: The Dematic Corp. Drug and Alcohol Policy has been adopted in order to provide a safe and healthy working environment for all employees. The purpose of the policy is to ensure that all installation sites are free from the influence of alcohol, illegal drugs or other substances that may affect the ability of employees to perform their jobs safely. Violation of this policy will result in discipline up to and including termination of employment.

5.1 Policy Statement Prohibited Conduct—All Employees

1. The manufacture, use, possession, distribution, dispensation or sale of controlled substances1 (“Drugs”) or drug paraphernalia2 during Company time or on Company premises3, in Company vehicles, or at Company-sponsored events.

2. The manufacture, distribution, dispensation or sale of any medications whether available for purchase over-the-counter or requiring a physician’s prescription during Company time or on Company premises, in Company vehicles or at Company-sponsored events.

3. The unauthorized possession, use, distribution or sale of alcoholic beverages by any employee during his or her scheduled hours of work, in Company vehicles or while on Company premises.

4. Being under the influence4 of alcohol or Drugs during an employee’s scheduled hours of work, in Company vehicles or on Company premises.

Prohibited Conduct—Employees in Safety Sensitive Positions

1 The phrases “controlled substances” or “Drugs” as used in this policy include all substances listed in the Controlled Substances Act and its implementing regulations contained at 21 USC § 812; 21 CFR §§ 1308.11-1308.15 including, but not limited to, marijuana, cocaine, heroin, phencyclidine (PCP), LSD, mescaline and amphetamine. 2 The phrase “drug paraphernalia” as used in this policy refers to pipes, needles, clips and other devices and materials commonly used in handling or ingesting illicit drugs. 3 Company premises include all locations where Dematic Corp. is performing work as well as locations where an employee is performing work for or representing Dematic Corp., whether or not those locations are owned by Dematic Corp. Company premises include storage areas and parking lots. 4 The phrase “under the influence” as used in this policy means having a detectable level of drugs or their metabolites in one’s system; or having an alcohol concentration of .02 or greater (expressed in terms of grams of alcohol per 210 liters of breath as indicated by a breath test); or having a level of alcohol or drugs in one’s system sufficient to present a risk to the safety or well-being of the employee or others or to impair the employee’s job performance.


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Safety sensitive positions are those job positions at Dematic Corp. that have been specifically designated as posing a particular risk of injury or harm to employees and others present at the work site. Dematic Corp. has designated the following job positions as safety sensitive: electrical installers, mechanical installers, electrical supervisors/foreman, mechanical supervisors/foremen, site managers/superintendents and mechanical/electrical controls engineers.

It is prohibited for any employee holding a safety sensitive position to be under the influence of any medication (whether prescription or over-the-counter) which may impair the employee’s ability to safely perform his or her assigned duties. A safety sensitive employee who is taking medication that causes the employee to experience side effects which impair the employee’s ability to safely perform his or her job duties must inform his or her supervisor before commencing work. The employee should notify his or her supervisor if the medication causes the employee to experience symptoms such as drowsiness, dizziness, light headedness, weakness or slowed reflexes.

This policy does not require the employee to disclose the type of medication or the physical or mental condition for which medication is being taken.

Dematic Corp. reserves the right to require the employee to obtain a certification from a health care provider certifying that the employee can safely perform his or her job duties while taking the medication.

5.2 Drug Testing Dematic Corp. may use urine testing to determine the absence or presence of drugs or alcohol. These tests may be used in the following circumstances.

1. As part of the applicant screening process

2. When a supervisor has a reasonable suspicion that an employee who holds a position designated as safety sensitive is under the influence of drugs or alcohol

3. Following on-the-job accidents or injury

4. Random samplings

A manager/supervisor who has reason to believe, based on his or her own personal observations, that an employee may be under the influence of Drugs, alcohol or medication should notify Human Resources immediately.


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5.3 Zero Tolerance Human Resource Personnel will enforce, and require all Dematic Corp. supervisory employees to strictly enforce the Drug and Alcohol Policy. Any Dematic Corp. employee, whether or not he or she holds a safety sensitive position, is subject to immediate termination if he or she is found to be in violation of any of the “Prohibited Conduct” provisions of the Drug and Alcohol Policy applicable to all employees. A Dematic Corp. employee or subcontracted employee who holds a safety sensitive position and has been asked to submit to reasonable suspicion testing will be terminated immediately if:

• The employee tests positive for Drugs • The employee has a blood alcohol level above the legal limit to operate a motor vehicle • The employee refuses to submit to a drug /alcohol screening

Health and Safety Program New Project Start-Up

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6 New Project Start-Up

Purpose: The purpose of this procedure is to provide information and guidance to jobsite personnel regarding the correct way to set up a new job from a health and safety perspective.

6.1 Pre-Project Safety planning and Beginning a New Project

Before beginning any project, the jobsite supervisor will obtain and become thoroughly familiar with all procedures, rules, regulations, and requirements of the customer and the particular area where work is to be performed. This information is to be distributed to all supervisory personnel as a new project orientation before they begin work.

The supervisor is responsible for assembling all the appropriate hazard information. Hazard information required includes the following:

� Hazardous processes, materials, equipment, and accompanying Material Safety Data Sheets (MSDS)

� Medical surveillance and industrial hygiene monitoring requirements

� Emergency reporting and responses

� Safety and personal protective equipment requirements

� Fire suppression equipment and responsibilities

� Special tools or equipment requirements

� Lock-out/Tag-out requirements

� Reporting requirements

� Orientation requirements

� Exit procedures

� Record keeping requirements

� Establishment of a site specific Emergency Action Plan

Information regarding designated physicians, hospitals, ambulances, security, or fire units that are to be used in the event of an accident, injury, or other emergency shall be developed and distributed. Arrangements for making contact with and using these services shall be formalized before beginning a project. All supervisory personnel shall know all arrangements and locations.


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6.2 Human Resources and Safety-Related Material required at a Jobsite

The following is an outline of the human resources and safety related material that should be maintained onsite. Jobsites that are comprised of several smaller locations may need multiple postings.

� Federal and State Labor Law Postings

The following federally required material should be displayed where employees routinely gather:

� Employee Right To Know Notice (Hazard Communication)

� Harassment Policy

� OSHA Job Safety and Health Protection

� Employee Polygraph Protection Notice

� Equal Employment Opportunity

� Family Medical Leave Act

� Federal Minimum Wage

The following state required material should be displayed where employees routinely gather:

� Unemployment Insurance Benefits

� Labor Laws for Minors

� Worker’s Compensation Law

:NOTE: State and Federal “All-On-One” posters are available through Compliance Poster Co. (800-817-7678). They are also available online at - http://www.complianceposter.com. Any questions regarding these postings should be directed to the Human Resources Department.

� OSHA 1926 and 1910 Manuals

A current copy of the OSHA-1926 (Construction) and the OSHA-1910 (General Industry) manuals will be kept at the jobsite office.

� Dematic Corp. Health and Safety Program

An up-to-date copy of the Health and Safety Program will be available at the jobsite office. The jobsite supervisor shall ensure that all supervisory personnel are familiar with the Company’s Health and Safety Program and all procedures and regulations. If additional regulations are announced or incorporated from the customer, they shall be added to the Health and Safety Program.

� Employee Notice of Reporting Accidents


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A notice shall be kept posted where employees routinely gather that describes an employee’s obligation for reporting a job-related accident or injury.

6.3 OSHA 300 Log An up-to-date OSHA 300 Log is to be established and maintained at the jobsite. A signed copy of the previous years OSHA 300A Log Summary sheet is to be posted in a prominent location from February 1st to April 30th each year. The OSHA 300 Log Summary sheet can be obtained from Human Resources.

At the end of the calendar year or when a job ends, the signed and completed OSHA 300 Log is to be immediately forwarded to the Human Resource Department. If there are no OSHA recordable accidents, this should be reflected by zeros on the signed log. An Accident, Injury, or Illness Report must accompany each entry on the OSHA 300 Log.

6.4 Emergency Phone Numbers Emergency phone numbers (hospitals, ambulances, fire, doctor, etc.) are to be posted by each telephone. Ensure that all supervisory personnel are familiar with emergency procedures and that all employees understand procedures for reporting an accident or injury, for an emergency situation, and for a jobsite emergency.

6.5 Information Signs Supervisors and foremen shall ensure that, where required, adequate signs, signals, and/or barricades are in place to designate hazards and hazardous locations or operations. Areas requiring restrictive and/or informative signs are to be well designated. All personnel are to be educated as to the meaning and intent of signs and signals and must understand that they are to observe and obey all warning and information signs, signals, and barricades.

6.6 Emergency Signals and Evacuations Emergency signals, evacuation routes, and evacuation procedures are to be conspicuously posted. This information is to be explained to all employees before they begin work and periodically thereafter.

Assembly points and procedures for personnel accounting shall be developed and understood by all employees before beginning work. The lines and systems of communication shall be developed and understood by


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all supervisory personnel. There shall be periodic reviews of all procedures and responsibilities.

NOTE This should be addressed in the Emergency Action Plan

6.7 Hearing Conservation Standard A copy of the OSHA Standard 29 CFR 1910.95, Occupational Noise Exposure, shall be made available for employees should they request it.

Health and Safety Program Safety Requirements for Subcontractors

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7 Safety Requirements for Subcontractors

Purpose: The purpose of this procedure is to establish and maintain health and safety requirements for subcontractor work.

7.1 General No subcontractor shall be allowed on a job until the appropriate documents and contracts have been signed and returned.

The subcontractor is to provide a thorough orientation that includes hazards, potential hazards, and equipment in the area, emergency signals, evacuation routes, telephone communications, reporting, and emergency services. Documentation of such shall be established and maintained.

Before beginning work, the subcontractor shall furnish the Dematic Corp. Project Manager with documentation ensuring that all employees have received a new jobsite orientation that includes requirements covered by the Dematic Corp. Health and Safety Program, which may include but not limited to Job Hazard Analysis, Hazard Communication, Fall Protection, and Lockout/Tagout. It is the responsibility that each subcontractor has a written Fall Protection Program, Lockout/Tagout Program, PPE program and a Hazard Communication Program, associated material safety data sheets, and hazardous chemicals or products notification, which the subcontractor may introduce onto the jobsite.

Subcontractors shall inform Dematic Corp. Project Management immediately of all accidents, near-miss incidents, alleged injuries, and damage to equipment. The investigation and supporting documentation will be completed and submitted within 24 hours of the incident to the Dematic Corp. Project Management.

Subcontractors shall adhere to and abide by all aspects of the Dematic Corp. Health and Safety Program, including customer, federal, state, and local regulations. Subcontractors shall also comply with the Dematic Corp’s as well as the customers Drug, Alcohol, and Contraband Policy. Documentation of such shall be retained on file.

:NOTE: There may be other company-specific requirements for subcontractors. Subcontractors are required to comply with the Subcontractor Acknowledgement and Safety Compliance Terms.

Health and Safety Program Installation Safety Training

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8 Installation Safety Training

Purpose: The purpose of this procedure is to outline Occupational Safety and Health Administration (OSHA) and Dematic Corp. training requirements. The required information will be provided to all employees through an initial orientation and annually as needed.

8.1 General Training must be documented by completing a training roster. This is to include each employee’s name, last four digits of Social Security number, and the date. Dematic Corp. responsibilities regarding health and safety training includes, but are not limited to the following:

� Permitting only employees qualified by training and testing to operate equipment and machinery.

� Instructing employees in the recognition and avoidance of unsafe conditions and the regulations applicable to their work environment to control or eliminate any hazard or other exposures to illness or injury.

� Providing instructions to employees regarding the safe handling and use of certain materials. Making the employees aware of the potential hazards, personal hygiene, and personal protective measures required.

� Providing instruction for employees required to work around, handle, or use flammable liquids, gasses, or toxic materials regarding the safe handling and use of these materials and of any specific requirements.

� Ensuring that employees comply with any regulations and procedures that apply to working in dangerous or potentially dangerous areas or types of work.

8.2 Definitions New Hire – Employees hired to work at a facility that they have never worked in before or at a facility they have not worked in for the past six consecutive months.

Annually – Every 12 months after the time of hire.


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8.3 Employee Orientation A general Dematic Corp. orientation shall include hazard communication and will be conducted in a central location or, at the jobsite office at the time of initial hire.

Once new hire employees are assigned to a jobsite, but before beginning work, the supervisor shall ensure that they undergo a thorough and formal new employee orientation. This orientation shall include, but not be limited to, the following:

� Emergency signals and evacuation procedures

� Personal protective equipment and hazard assessment

� Fall protection

� Stairs and ladders

� Hazard communication and material safety data sheets (MSDS)

� Smoking policy

� Respiratory protection

� Operating and inspecting machinery, tools, and equipment

� Compressed gas cylinders

� Reporting near-miss incidents, property damage, accidents, injuries, and emergency situations

� Duties of a firewatch

� Fire extinguishers

� Electrical safety and assured grounding procedures

� Housekeeping

� Disciplinary action

� Entrance and exit procedures

� Drug, Alcohol, and Contraband Policy

� Job hazard analysis

� Mobile equipment training

� Forklift safety training

When employees are working in the vicinity of hazardous materials, chemicals, or operations, they shall receive formal education so that they can exercise hazard awareness and hazard avoidance.

All employees should understand that they are not to undertake any job or use any equipment unless they have been adequately instructed and trained.


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8.4 Annual Training Requirements The following is a sample of training topics required by OSHA:

� Bloodborne pathogens

� Emergency action plan

� Fall protection

� Fire prevention and protection

� Hazard communication

� Hearing conservation

� Industrial trucks (forklift, every 3 years)

� Lock-out and tag-out

� Personal protective equipment (PPE)

� Scaffold, ladders, and stairs

� Signs and tags

� Tools (powder actuated)

� Welding, cutting, and brazing

� Crane operator’s refresher training

There are additional subjects on which Dematic Corp. requires that employees receive training. Although there are no specific training requirements under OSHA for these topics, employees will be provided with the appropriate information.

In addition to the OSHA and Dematic Corp. required training topics listed, there are many other health and safety related topics that employees must be trained on, including the following:

� Manual material handling

� Material storage

� Floor and wall opening

� Mobile lifting equipment

� Housekeeping

� Slips, trips, and falls

� Hand signals and rigging

Health and Safety Program Safety Meetings

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9 Safety Meetings

Purpose: The purpose of this procedure is to establish a scheduled meeting process to keep all employees informed and trained on the pertinent safety information as required by Dematic Corp., the customer, state, and federal regulations. The management at each jobsite is responsible for this process.

9.1 General Safety information will be distributed to all employees during a mandatory weekly safety meeting. Information on known hazards, potential problems, employee education, and general safety awareness are some of the areas that will be covered. The meetings are for educational purposes, so keep them focused and positive.

:NOTE: Supervisors are also required to attend other meetings to help with the Information and training process.

Documentation will be kept for all meetings. As a general rule, employees’ names, signature, and pertinent subject matter will be recorded and maintained on file (Company Standardized meeting forms are available in the forms section of this book).

9.2 Corporate Safety Meetings All corporate safety personnel shall attend a Dematic Corp. safety meeting to update health and safety information once a year. HR Corporate safety shall then distribute this information to supervisors at their jobsites.

9.3 Safety Meetings for Employees Supervisors/foreman shall conduct weekly safety meetings for continued safety education and safety awareness. Near miss incidents, accident investigations, corrective actions, and safety procedures should be discussed at this time. Supervisors should also conduct a daily toolbox safety meeting to discuss the hazards involved with the work activities being performed that day.

Employees should be involved and should present ways to recognize and eliminate hazards or unsafe work practices. These meetings should be positive and should emphasize improving and expanding the employee’s safety knowledge, understanding, and awareness. Documentation, signed by all employees in attendance, will be maintained at the job site.

Health and Safety Program Safety Meetings

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:NOTE: Safety training may be held more frequently, depending on the nature of the work, hazards encountered, previous incidents and/or accidents, and information that may need to be distributed.

9.4 Personal Contact for Safety Supervisors/foreman shall establish a daily ongoing dialogue with employees to improve and expand their safety awareness and performance. This dialogue will include job efficiency, production, job competence, and an awareness of the employee’s mood, attitude, personal concerns, physical condition, and well being.

Project Safety Orientation is one way to have personal contact with each employee. At the beginning of each project, during orientation, any and all safety concerns should be mentioned at this time.

Health and Safety Program Job Hazard Analysis

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10 Job Hazard Analysis

Purpose: The purpose of this procedure is to provide guidance on implementing a Job Hazard Analysis (JHA) program that will allow employees to take an active approach in their own safety and health. This involves the completion of a JHA for every task undertaken.

10.1 General The Job Hazard Analysis (JHA) is one of the most effective tools that can be used to reduce incidents and accidents on the jobsite. Completing the JHA is mandatory for all jobs, with the exception of administrative work and non-field work, unless the jobsite is given a deviation by Dematic Corp. management.

10.2 Pre-Job Preparation The JHA must be filled out prior to starting a work activity. The supervisor/foremen will review the work to be performed in order to assess the entire scope of the work activity and any hazards that may be involved. The work sheet will be used to indicate any specific details related to that work activity (i.e., if ladders are to be used, indicate that they must be tied off). The supervisor/foremen must also indicate any additional information that may be necessary for the crew to complete their job assignments successfully. The completed JHA is then reviewed with all employees who will be involved with the job.

10.3 Potential Risks and Preventive Measures The next steps in the JHA process are to analyze the job procedure and to inspect the surrounding areas and other work groups in the area in order to identify any potential risks that may be involved in completing the job task.

After the work crew has identified the potential risks associated with the job, a plan of preventive measures designed to minimize or eliminate each of the hazards must be developed.

After all of these steps have been completed, each member of the work crew must abide by the preventive measures listed.

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10.4 Job Execution The supervisor/foremen will randomly review the work in progress to ensure that the crew is following the recommendations made during the JHA’s completion. If additional risks are identified, they must be documented on the form and discussed with the work crew.

10.5 Housekeeping The work area is to be left cleaner than it was found, and any deficiencies will be noted. Housekeeping is an integral part of proper job execution and is a continuous work activity.

Health and Safety Program Jobsite Inspections

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11 Jobsite Inspections

Purpose: The purpose of this procedure is to provide guidance on the types of inspections that are required on a jobsite and ways to perform them.

11.1 Jobsite Inspection Guidelines Jobsite inspections serve the following basic functions:

� They maintain a safe work environment and the control of unsafe actions of people.

� They maintain operation profitability. Management inspections can be a good tool to measure the supervisor’s performance in safety. This practice will assure that supervisor/foremen inspect their areas more often to ensure that conditions remain safe and to reduce the occurrence of unsafe acts.

The inspection process should cover the following areas:

� Supervisors should conduct daily inspections of their jobsites.

� The safety representative on a random schedule must also conduct daily inspections.

� Inspections must be documented in writing.

� The completed inspection report should be kept on file for one year.

11.2 Safety Audits and Performance Inspections

11.2.1 Jobsite Safety Audits and Performance Inspections Periodically, the Corporate Construction Safety Engineer shall conduct a jobsite safety audit and performance inspection. Safety inspection reports will address only those areas where corrective action is recommended or where deficiencies are believed to be occurring with respect to Dematic Corp., customer, federal, and state policies and procedures.

The safety inspection report will indicate the personnel who will receive the inspection. It will then be reviewed by the jobsite supervisor with indicated items corrected or explained in detail, signed by the jobsite supervisor, and returned to the Corporate Construction Safety Engineer and Installation Manager. All items are to be reviewed with supervisor/foremen personnel with appropriate corrective actions discussed and implemented.


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:NOTE: All safety performance inspections, along with corrective action documentation should be copied to the appropriate project/department manager for inclusion in the project file.

11.3 Supervisor Safety Performance Inspection The jobsite supervisor will make a daily safety performance observation of the work area. The supervisor should look for evidence of the program being implemented and for employee understanding, acceptance, cooperation, responsiveness, attitude, and knowledge of the program.

:NOTE: Documentation should be established when a Field Safety Representative is not available and reviewed with the foremen.

11.4 Field Safety Representative Safety Performance Inspections

At least one time daily, a documented safety performance inspection shall be conducted of a designated area to discover hazards, unsafe conditions, unsafe work habits, or employees with weak safety attitudes. This inspection should look at facilities, tools, equipment, work areas, surrounding areas and work, as well as employees working. A comparison of this inspection and the supervisor’s inspection shall be made as an educational tool in which supervisor/foremen can improve their inspection techniques.

:NOTE: Documentation should be submitted to the supervisor and maintained in a file on the jobsite.

11.4.1 OSHA Inspection at the Jobsite An employee complaint, a serious or fatal accident, a special-emphasis program, or a planned audit may initiate inspection of a jobsite by an OSHA compliance officer. If an OSHA compliance officer shows up at your jobsite, you are to contact your Dematic Corp. Manager immediately.

11.4.1.1 Inspection of Credentials

Upon arriving to the main gate or entrance, the compliance officer will present credentials and ask to see the individual in charge. You must verify the officer’s credentials. If they are not offered, ask to see them. If there is any doubt as to the individual’s authenticity, call OSHA’s area office for verification. The officer should then be escorted to the supervisor’s office.


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11.4.1.2 Opening Conference

The compliance officer should be asked again for credentials once in the supervisor’s office. The officer will then explain the purpose of the visit and outline the scope of the inspection. If a general inspection is being conducted, the officer may request that subcontractor representatives be present during the opening conference. If the visit is based on an employee complaint, a copy of the complaint will be provided. Once the officer has stated the purpose of the visit, advise the officer of jobsite safety requirements such as wearing safety glasses, hard hat, no smoking policy, etc.

:NOTE: If the customer has an established procedure, customer notification and participation during an inspection is expected, if applicable.

11.4.1.3 During the Inspection

The supervisor or safety representative should keep thorough notes during the walk-through with the compliance officer. The notes should list all employees or witnesses that the officer speaks with. If the officer takes photographs, a description of what was shot should be recorded. If the jobsite camera is available photos should be taken of the same items. If an industrial hygiene survey is made, note the type of instrument used, calibration procedures, areas and or personnel monitored, and preliminary results, if available.

11.4.1.4 Closing Conference

Once the inspection is completed, the compliance officer will hold a closing conference with the supervisor and any subcontractor inspected where the officer will review the initial findings. Keep written notes during the closing conference.

Health and Safety Program Investigations

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12 Investigations

Purpose: The purpose of this procedure is to provide information and guidance on investigating accidents, injuries, and near-miss incidents to determine root cause and to prevent them from recurrence.

12.1 General In the work place, roughly 90% to 96% of all accidents are the result of an individual’s action or inaction. In most instances, the unsafe act was committed numerous times before it resulted in an injury. The accident or near-miss incident is an indication that a situation has been allowed to occur repeatedly and no attention has been given to it. Safety and the prevention of accidents are management’s responsibility, and everyone in the management system must begin to accept this responsibility.

Management must be held accountable for the accidents occurring on their sites. Department/project managers, supervisors, and foremen should accept the responsibility for their occurrence and assist in development of new procedures that will prevent similar occurrences in the future.

One tool that is available is the thorough investigation of all accidents and near-miss incidents. Jobs suffering from poor safety performance are often those jobs where there is no in-depth investigation of accidents or near misses. The purpose of an investigation is to provide helpful, constructive, and specific information to prevent recurrence of unproductive behavior.

Front-line supervisors are responsible for thoroughly investigating accident causes for correction. The jobsite supervisor is responsible for involving all levels of supervision leading down to the employees involved.

The supervisor shall ensure that procedures for the timely and thorough investigations of all accidents, injuries, and near-miss incidents are in place. Any incident alleged to involve Dematic Corp. personnel, equipment, work, or that of any subcontractors or other contractors in the area shall be investigated and documented. The incident is to be investigated to determine the facts, the cause of the incident, and the people with knowledge of the incident. The emphasis of the investigation is not to place blame, but to develop means of prevention in future work. All investigations are to be coordinated with the customer where possible.

As part of the Dematic Corp. Drug, Alcohol, and Contraband Policy, a urine drug screen and alcohol screen are required as part of accident investigations relating to serious near-miss incidents, accidents, injury claims, or alleged claims.


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Any known or alleged accident, injury, and/or damaged property or equipment of a third party in which Dematic Corp. employees, equipment, or area of work is involved shall be immediately investigated. The facts shall be documented and promptly forwarded to the Dematic Corp. Human Resource Department.

An investigation that produces answers such as “employee should have used more care” or that the accident was caused by “carelessness” is unsatisfactory. Corrective actions along the lines of “told employee to pay more attention to their work” or “cautioned employee to be more careful” are meaningless.

The information developed through an investigation must be right. It must achieve an understanding of what is correct, and it must encourage the employee to want to do what is right, not to do what is wrong.

Investigation reports should name all employees involved in the accident and any other individuals who have any knowledge of the sequence of events relating to the accident. It is equally important to ascertain which employees or potential witnesses have no knowledge of the sequence of events involved in the accident.

The investigation should start as soon as possible after the accident and should start at the scene of the accident. The investigation should focus on determining the cause of the accident and not on placing blame.

:NOTE: The Corporate Construction Safety Engineer is available to assist in investigative procedures.

12.2 Accident Investigation Documentation It is extremely important that an investigation include all of the necessary information. Documentation in an investigation shall include the following:

� Exact date, time, condition, and location of the accident.

� Names and addresses of the owner of any property damaged and employer of personnel involved.

� Name and addresses of the owner of any vehicle, tools, equipment, etc. involved in the accident.

� Names and addresses of the operator/driver of the equipment or vehicles.

� An explanation of the job or work performed.

� A description of the accident, including a detailed description of bodily injuries and property damage.

� Details of any and all events or conditions that may have influenced the sequence of events of the accident.

� Names and addresses of all parties involved in the accident, including witnesses with and without knowledge of the accident.


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� Diagrams, drawings, and pictures of the accident results and the accident scene.

� An exact description of any tools, equipment, machinery, or vehicles involved in the accident, including brand name, make, model, identification number, year, color, ownership, origin, serial number, etc.

All near-miss incidents are to be investigated, documented, and reported with the same thoroughness as all other accidents and losses. Preventive measures are to be developed and distributed to all employees. Corrective action must be initiated and enforced if recurrence of the accident is to be prevented. Corrective action should be accomplished by the following:

� Engineering

� Management policy changes, implementation, or modification of policies or standard operating procedure

� Education that involves changing skills, knowledge, or attitudes, including styles of supervision.

Key elements in a program of corrective action are sincerity in investigation of accidents, perseverance with training, and recognition of individuals for results achieved. The findings of an investigation and the subsequent corrective action must be communicated to all individuals at all levels.

The jobsite supervisor is responsible for seeing that an Accident/Near-Miss Investigation Report is completed when an accident or near miss occurs. This report is to be thoughtfully completed and reviewed, and the information should be made available to all levels of supervision.

All employees in the work crew or those with direct knowledge of the accident should complete the Employee/Witness Statement. This form can be used to secure a statement from injured employees or as a means of the employee giving written notice of a reported accident. (Statements from employees indicating that they have “no knowledge” of an alleged accident are as important as employees who can provide information of the alleged accident).

In the case of an accident or near miss, the Accident/Near-Miss Investigation Report and the Accident Investigation Employee/Witness Statements are to be forwarded to the Human Resource Department. In the case of an accident First Report of Injury and Illness with the Employee/Witness Statements are to be attached to the Accident/Near-Miss Investigation Report.

The information in this report should be thoroughly discussed when the supervisor holds the weekly safety meeting with all employees. Corrective actions are to be formulated, communicated to all employees, promptly implemented, and enforced.

:NOTE: First-Aid Logs should be analyzed to indicate trends and areas of concern with respect to first-aid (near-miss) incidents.


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12.3 Procedure for Handling Accidents and Injuries To standardize the handling of accidents at our jobsites, the following standard operating procedure has been developed and will be used by all operations within Dematic Corp.

At this time (except emergencies), the injured employee shall supply all information requested and sign the Employee/Witness Statement. If additional descriptions or explanations are desired or requested, the additional information should be attached to the employee’s statement.

Prior to sending an injured employee to a physician’s office or emergency room for evaluation and medical treatment, telephone communications should be established with the facility to be used. After giving a brief description of the injury, you will ascertain the most convenient location and means for receiving prompt medical attention.

In the event of a serious injury, the injured employee should be transported to an emergency room at a local hospital. The emergency room should be appraised of the impending arrival and the situation. For injuries of a less serious nature, establish telephone communications with the medical facility and/or physician prior to transporting the injured/ill employee to that facility. The necessary phone numbers should be posted conspicuously by each phone at the jobsite.

A Dematic Corp. Representative at the foreman level or above will accompany the injured employee to the hospital and/or physicians office to facilitate communications and understanding between all parties involved (physician, employee, and employer).

The Dematic Corp. Representative will see that all necessary information has been provided. Permission to remain with the injured employee should be requested and consultation with the attending physician prior to the injured party being released. All pertinent information should be attached to the First Report of Injury and Illness Form.

Upon returning to the office, the representative will complete the First Report of Injury and Illness for prompt forwarding to the Human Resource Department within 24 hours after the injury occurs. In the event of a serious injury, communications with the Corporate Construction Safety Engineer should be established immediately.

Where applicable, the necessary forms for the customer describing the injury and treatment should be completed and promptly forwarded to the appropriate authority. This information should then be entered into the OSHA 300 Log.

When serious accidents, lost-time accidents, or a serious near-miss occurs, a written report is to be attached to the First Report if Injury and Illness with a copy forwarded to the Human Resource Department. This report should describe in detail the situation and events leading up to the accident or near miss and the


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sequence of events of the accident or near miss. Statements of witnesses and supervisory personnel should be included with reasoning as to why the incident occurred and means to preventing similar occurrences in the future. Additionally, diagrams of the physical setting and the accident should be supplied.

In the event of a lost-time injury or when an employee does not report for work following an accident, establish communications on a daily basis with the injured employee and, when necessary, with the attending physician. When an employee returns after lost time, the Human Resource Department is to be notified on the day the employee returns to work or has been released by the attending physician. If an employee with a lost-time accident leaves the job, for whatever reason, the Human Resource Department is to be notified immediately.

Receipts for prescriptions and office visits should be clearly marked “PAID” when paid by the employee. Prescription tickets must show date, prescription number, name of patient, and amount. Also, the job number, superintendent’s name, and employee’s Social Security number will help identify them and assure prompt reimbursement.

It is imperative that the Human Resource Department is notified immediately when the following occurs:

� A fatality

� A serious accident

� Three or more employees are involved in one accident or become ill

� A serious near-miss incident

� A lost-time accident

� An employee returns from a lost-time accident

� An injured employee leaves the job, for whatever reason

� Information contained in the original first injury report has been changed or was discovered to be incorrect

� Third party injuries, property, or equipment damage

Every attempt should be made to accommodate an injured employee’s restrictions by placing them in light duty. With implementation of a light duty program, there are several objective results that can be expected:

� Reduced employee time lost from work due to minor injuries or illness.

� Injured employee returned to regular work assignment sooner.

� Better control and monitoring of injured employee’s condition.

� Reduced worker’s compensation cost.


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The basis of such a procedure shall be to ensure that when an employee incurs a non-disabling occupational injury or illness, an attempt is made to see that the employee be given some form of productive work which the employee can adequately perform considering his/her injury.

12.4 Reporting Accidents All supervisory personnel shall be educated in the proper procedures for reporting an accident, injury, damaged property, and near-miss incidents and the proper follow-up procedures to be used. Accidents involving the following situations must be promptly reported to your immediate supervisor and the Human Resource Department:

� Bodily injury occurring to Dematic Corp. personnel or to personnel of other employers working in conjunction with or around Dematic Corp. employees

� Property damage to tools, vehicles, utilities, equipment, facilities, real estate, or rented or borrowed equipment of facilities, etc. that occur in areas where Dematic Corp. employees are working or have worked.

� Bodily injury and/or property damage resulting from accidents that occur in areas where Dematic Corp. personnel are, or have been, involved in the planning, construction, assembling, erection, dismantling, modification, demolition, maintenance, or operation of machinery or equipment,

� Bodily injury and/or property damage occurring with Dematic Corp. rented, maintained and operated, or loaned equipment (these accidents are also to be reported to the equipment rental company.)

� Bodily injury and/or property damage resulting from accidents in which Dematic Corp. vehicles or equipment are involved in any manner.

All reports must be completed within 24 hours of the accident or incident and then be promptly forwarded to the Human Resource Department. Promptness, accuracy, and thoroughness are essential.

To report an accident and/or injury, the following original forms must be competed and forwarded to the Human Resource Department (Attn; Bonnie Jangda):

a. First Report of Injury

b. Employee’s Statement

c. Witness Statement (for each employee in a crew or around the incident with or without any knowledge of the incident)

d. Supervisor’s Statement

Procedures for notifying the Human Resource Department and any customer coordinator are to be explained to all supervisory personnel.


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All employees must understand their responsibility for reporting any accident, injury, property damage, near miss, or any unusual incident, unsafe practices, or condition to supervision immediately to avoid potential accidents.

The jobsite supervisor is responsible for reporting the alleged accident, injury, or employee’s changed medical or work status to the Human Resources Department.

Every employee, under the law, has the right to file a claim for an injury or accident, and an employee informing the supervisor and/or foreman constitutes an employee having filed a claim.

Supervisors and supervisory personnel are not to determine the validity of an accident or injury claim. Supervision is to gather all the facts and notify the appropriate office so that an investigation can either dispute the claim or minimize the extent of any loss or alleged loss. All alleged claims must be immediately reported “for record purposes only.” In order to dispute a claim thought to be not job-related, facts must be substantiated and well documented.

Employees that request medical evaluation and/or treatment must be treated with consideration and understanding. Denying an employee’s request can lead to undesirable results and can make the claim unmanageable. Incidents and conditions found to be not job-related once documented would become the responsibility of the employee.

Supervisors shall ensure that all supervisory personnel are thoroughly educated with respect to their responsibility and the procedures in reporting all accidents, injuries, and alleged accidents and injuries.

Health and Safety Program First-Aid Procedures

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13 First-Aid Procedures

Purpose: The purpose of this procedure is to establish clear guidelines for incidents that cause injury at the jobsite. Prompt medical attention, first-aid services, or outside care should be used or given to treat any injury sustained on the job.

13.1 First-Aid Supplies If adequate first-aid facilities and care are not readily accessible, the superintendent should establish and maintain an approved first-aid kit at the jobsite office. This kit should be weather proofed with individually sealed packages of each type of item. Emergency first-aid kits shall be maintained at each site office with multiple or remote locations.

A First-Aid Log shall be maintained with each first-aid kit or room and kept up to date. The First-Aid log shall reflect the number of any incidents that requires any examination and/or treatment. All logs shall be periodically studied by supervision. First-Aid logs shall be submitted to the Human Resource Department on a monthly basis. Logs will be due on the first week of the month following the preceding month (i.e., September log due the first week of October).

The assigned first aid provider will ensure that adequate supplies are maintained. This will be accomplished by taking a weekly inventory and reordering needed supplies.

13.2 First-Aid Training The supervisor shall determine whom to designate as an onsite employee(s) as a first-aid provider for treatment. Anyone who is designated as a first-aid provider must have a valid first-aid card, as well as being certified in emergency response and first aid procedures. Any employee(s) who is designated as a first-aid provider by the supervisor will participate in the Dematic Corp. Bloodborne Pathogens Exposure Control Program and must be informed of and trained on the requirements of OSHA’s Bloodborne Pathogen Standards.

13.3 Medical Record Keeping Medical records are maintained by the Human Resources Department and are kept in strict confidence. Requests for information may be made by contacting the Human Resources Department. No information in violation of any federal,

Health and Safety Program First-Aid Procedures

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state, or local law will be released. Per HIPPA no personal medical information will be released with out the approved written consent of the employee.

13.4 Employee Transportation For minor injuries (i.e., lacerations, strains, minor sprains), the injured employee will be transported by the Site Safety Coordinator or Jobsite Supervisor/ Foreman in a personal vehicle (to be compensated by the current mileage reimbursement plan in effect) to a pre-determined medical service facility capable of evaluating, and treating the injury. For injuries and medical conditions that are beyond the standard capabilities of routine first aid or are considered life threatening, an ambulance will be used. All emergency services required to handle such emergencies will be pre-determined and listed on the emergency phone number form that is posted near each phone used at the facility.

13.5 Emergency Eyewash Each jobsite will have eyewash areas located in or near the established first-aid facility. In situations where the potential for eye injuries is high or where the work location is not near the first-aid facility, the supervisor will make sure that temporary eyewash areas are in strategic locations in the work area.

Health and Safety Program Bloodborne Pathogen Exposure Control Plan

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14 Bloodborne Pathogen Exposure Control Plan

14.1 Policy It is the policy of Dematic Corp. to protect the health and safety of its employees from all possible hazards that may be encountered in the workplace. As the Dematic Corp. Hazard Communication Program addresses the employee’s exposure to hazardous chemicals and substances, the Bloodborne Pathogens Exposure Control Plan addresses the employee’s exposure to biological hazards.

Bloodborne Pathogens are microorganisms present in the blood that can cause disease.

In December 1991, the Occupational Safety and Health Administration (OSHA) published (29 CFR 1910.1030) the “Occupational Exposure To Bloodborne Pathogens” standard. (Addendum A) The purpose of this regulation is to “eliminate or minimize occupational exposure to Hepatitis B Virus (HBV), Human Immunodeficiency Virus (HIV) and other “bloodborne pathogens.”

In order to fulfill its responsibilities towards its employees and comply with all applicable Federal/State/Local regulations concerning possible employee exposure to hazards of infectious diseases, all employees who may be considered first aid responders will be informed and trained as to the potential exposure to bloodborne pathogens and other potentially infectious materials.

It is the responsibility of management and supervision at each jobsite location to ensure that all affected employees are aware of the Bloodborne Pathogens Exposure Control Plan and are properly trained. It is the responsibility of the employee to follow the appropriate health and safety practices in accordance with the training received.

14.2 Exposure Determination � In review of the job requirements and frequency of incidents on a typical

Dematic Corp. Material handling equipment installation job site, there is no job classification that would require or expect an employee to have an occupational exposure to bloodborne pathogens as a part of their normal duties.


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� In as much as specific employees have been given first aid training to be able to react properly under personal accident emergencies, Dematic Corp. has chosen to initiate a procedure to reduce the risk of hazardous exposure to bloodborne pathogens and other potentially infectious materials.

� No other employee other that a first aid responder is required or expected to assist, should an accident occur. Any action on the part of other employees would be at their own discretion and considered a “GOOD SAMARITAN ACT.”

14.3 Compliance Methods � Universal precautions will be observed at all times on the job site, such as,

all blood or Other Potentially Infectious Materials (OPIM) will be considered hazardous regardless of the perceived status of the source individual.

� For any first aid incident there will be no items used other than standard first aid kit and biohazard kit. Therefore, work practice controls will be limited to having a proper biohazard bag for disposal of any contaminated items. The disposal bag will be found in the biohazard kit.

� Being a construction site, immediate hand washing facilities may not be readily available. Should this condition occur, the antiseptic towelettes provided in the biohazard kit will be used.

� If a first aid incident occurs involving the presence of blood or OPIM, the field superintendent/foreman will be responsible for insuring that employees remove contaminated items and wash or flush any potentially contaminated skin area as soon as feasible following the incident.

14.4 Jobsite Guidelines

14.4.1 Personal Protective Equipment � The field superintendent/foreman/supervisor will be responsible for insuring

the first aid and biohazard kit is available and complete. If items are used they will be replaced with new items to maintain the kits readiness.

� All contaminated items of personal protective equipment will be disposed of following an exposure incident. There will be no attempt to clean or launder.

14.4.2 Contaminated Equipment � The field superintendent/foreman will be responsible for ensuring that all

equipment and items that may have become contaminated from a first aid incident involving blood or OPIM are properly decontaminated prior to reuse or shipment using a solutions of 50% bleach and 50% water.


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14.4.3 Work Area Restrictions – Housekeeping � As there is no specific area designated as a first aid area, the need for work

area restriction does not apply.

� Housekeeping is applicable only in the respect that if an incident occurs any contaminated area will be cleaned with a bleach solution (50% bleach – 50% water).

14.4.4 Regulated Waste – Labels and Signs � Any contaminated items resulting from an exposure incident will be placed

in proper RED biohazard bags and disposed of in accordance with applicable local regulations.

� The field supervisor/foreman will be responsible for insuring the proper RED biohazard bags contained in the kits are used. (This is an acceptable alternative to labels.)

14.4.5 Needles – Containers for Sharps � There will be no required use of needles or other sharps on the jobsite by

any employee.

� No containers for sharps will be needed.

� Employees using needles or sharps for personal medical reasons are responsible for the proper disposal of such items.

14.5 Training Information and Records In as much as there is no normal job exposure to bloodborne pathogens, the training for all employees who qualify as first aid responders will consist of:

� A copy of the OSHA Bloodborne Pathogen Standard and an explanation of it contents.

� A discussion of the epidemiology and symptoms of bloodborne diseases.

� An explanation of the modes of transmission of bloodborne pathogens.

� An explanation of the Dematic Corp. Bloodborne Pathogens Exposure Control Plan and how to obtain a copy.

� Types of conditions that could pose a risk.

� Type of personal protective equipment available at jobsite.

� How to properly decontaminate an area.

� Where to properly decontaminate an area.

� Information on how to recognize colored coded biohazard bags.


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� Information on how the Hepatitis B vaccination will be offered within 24 hours of an exposure.

� Information on the appropriate actions to take and who to contact should an exposure to blood or other potentially infectious material occurs.

� Information on the reporting procedures and the medical follow-up.

� Information on the evaluation and follow-up required after an exposure incident.

Training records shall be maintained for three years of the date of training and become part of the employee’s personnel file. Such records shall contain the following information: (Addendum B: Bloodborne Pathogen Training Record)

� The names, last four digits of employee’s Social Security Number, employee clock number and signature of the employee’s attending the training session.

� The dates of the training session.

� An outline describing the material presented.

� The names and qualifications of persons conducting the training.

14.6 Biological Hazard Incident Procedure Based on the specific job requirement and infrequent exposure, Dematic Corp. will offer the Hepatitis B vaccine and vaccination to a first aid responder within 24 hours following a first aid incident where blood or OPIM was present. The field supervisor/foreman will be responsible for insuring that the employee has been offered and received, if desired the Hepatitis B vaccine and vaccination at no cost to the employee.

All employees that decline the Hepatitis B vaccination offer shall sign the required waiver indicating their refusal. (Addendum C: Hepatitis B Vaccine/Vaccination Waiver)

If the first aid incident involved the presence of blood or OPIM, the field supervisor/foreman must complete a report, with the following information, before the end if the shift during which the incident occurred. (Addendum D: Exposure Incident Investigation Form)

� Names of all first aid providers who rendered assistance.

� A description of the incident time and date.

� A determination whether or not, in addition to the presence of blood or OPIM, an “exposure incident” as defined by OSHA standard occurred.

� If an actual exposure incident occurred, the proper post-exposure evaluation, prophylaxis and follow-up procedures will be made available


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immediately to the employee. (Contact Dematic Corp. Human Resources Department.)

Exposure incident is defined as specific eye, mouth, or other mucous membrane, non-intact skin or parenteral contact with blood or OPIM. Parenteral means piercing mucous membranes or the skin barrier through such events as needle sticks, human bites, cuts, and abrasions.

14.7 Post Exposure Follow Up All exposure incidents shall be reported, investigated, and documented. The Dematic Corp. Human Resources Dept. will be responsible for ensuring that the exposed employee is immediately given a confidential medical evaluation as well as the following: (Addendum E: Exposure Evaluation and Follow up Checklist)

� Documenting the route of exposure and the circumstances under which the exposure occurred.

� Identifying the source individual, unless identification is not feasible or prohibited by state or local law.

� Obtaining the consent of the source individual to have his blood tested, as soon as feasible after the incident. If consent cannot be legally obtained it must be documented as to who made the request and that it was denied. If consent is not required by the source individual the blood available shall be tested and the results documented. However, if the source individual is already known to be infected with HBV or HIV, testing need not be repeated.

� Making results of the source individuals testing available to the exposed employee, and making the employee aware of the applicable laws and regulations concerning disclosure of the identity and infectious status of the source individual.

� Obtaining the exposed employee’s consent and ensuring that the exposed employee’s blood is collected and tested, as soon as feasible following the incident.

� Ensuring that the employee is offered the option of having their blood collected for testing of HIV/HBV serological status at a later date. The blood sample will be preserved for up to 90 days to allow the employee to decide.

The Dematic Corp. Human Resource Dept. will be responsible for ensuing that all medical evaluations, the Hepatitis B vaccine and vaccination series and post exposure follow up procedures including prophylaxis are:

� Made available at no cost to the employee.

� Made available at a reasonable time and place.


Rev. 2 July 2011 14-6

� Performed by or under the supervision of a licensed physician or healthcare professional.

� Provided according to the recommendations of the U.S Public Health Service.

14.8 Information Provided to Healthcare Professional Dematic Corp. Human Resources Dept. will be responsible for ensuring the healthcare professional responsible for the exposed employee’s Hepatitis B vaccination is provided with the following:

� A copy of 29 CPR 1910.1030.

� A written description of the exposed employee’s duties as they relate to the exposure incident.

� Written documentation of the route of exposure and the circumstances under which the exposure occurred.

� Results of the sources individual’s testing, if available.

� All medical records relevant to the appropriate treatment of the exposed employee, including vaccination status.

14.9 Healthcare Professional’s Written Opinion Dematic Corp. Human Resource Dept. will be responsible for ensuring a copy of the healthcare professional’s written opinion is obtained and provided to the exposed employee within 15 days of the completion of the evaluation.

The healthcare professional’s written opinion for post exposure follow up shall be limited to the following:

� A statement that the employee has been informed of the results of the evaluation.

� A statement that the employee has been told about any medical conditions resulting from exposure to blood or OPIM which require further evaluation or treatment.

14.10 Medical Records Dematic Corp. Human Resources Dept. will be responsible for maintaining all medical records associated with an exposure incident. Such records will be maintained at our Corporate Offices located at 507 Plymouth Ave. N.E., Grand Rapids, Michigan 49505.

Medical records shall be maintained for the duration of employment plus 30 years and shall be kept confidential. The records shall include:


Rev. 2 July 2011 14-7

� The name and Social Security Number of the employee.

� A copy of the employee’s HBV vaccination status, including dates of vaccination.

� A copy of the results of examinations, medical tests and follow-up procedures.

� A copy of the information provided to the healthcare professional, including a description of the employee’s duties as they relate to the exposure incident and documentation of the routes of exposure and circumstances of the exposure.

14.10.1 Transfer of Medical Records If Dematic Corp. is closed or there is no successor to receive and retain records of the prescribes period of time, the area Director for Occupational Health shall be contacted for disposition.

14.10.2 Medical Record Availability � All employee records shall be made available to the employee in

accordance with 29 CFR 1910.20.

� All employee records shall be made available to the area Director of Labor or the Director of Occupational Health upon request.

14.11 Evaluation and Review The Human Resources Dept. shall be responsible for annually reviewing the Bloodborne Pathogen Program, its effectiveness and for updating the program as needed.

As required, all affected employees of the Bloodborne Pathogen Exposure Control Plan will be retrained annually.


Rev. 2 July 2011 14-8

Addendum A

OSHA OCCUPATIONAL EXPOSURE TO

BLOODBORNE PATHOGENS STANDARD

(See 29 CFR 1910.1030 OSHA Standards for General Industry)


Rev. 2 July 2011 14-9

Addendum B

BLOODBORNE PATHOGENS

TRAINING RECORD


Rev. 2 July 2011 14-10

DEMATIC CORP. INSTALLATION BLOODBORNE PATHOGENS TRAINING RECORD

Date of Training Session: __________________________________ Outline of Presented Attached: __________________________________ INSTRUCTORS QUALIFICATIONS ____________________________________________________________________________ ____________________________________________________________________________

ATTENDING EMPLOYEES

NAME SIGNATURE LAST FOUR (4) DIGITS OF SSN EMPLOYEE CLOCK #

1. ______________________________________________________________ 2. ______________________________________________________________ 3. ______________________________________________________________ 4. ______________________________________________________________ 5. ______________________________________________________________ 6. ______________________________________________________________ 7. ______________________________________________________________ 8. ______________________________________________________________ 9. _____________________________________________________________ 10. ______________________________________________________________


Rev. 2 July 2011 11

Addendum C

HEPATITIS B VACCINE/VACCINATION

WAIVER


Rev. 2 July 2011 12

DEMATIC CORP. HEPATITIS B VACCINE/VACCINATION WAIVER

Date: __________________________ Name: __________________________ Employee Clock #: __________________________ Last four (4) digits of SSN: __________________________ I understand that due to my collateral duty as a possible first aid responder I may be exposed to blood or other potential infectious materials that may put me at risk or acquiring hepatitis B virus (HBV) infection. I have been given the opportunity to be vaccinated with hepatitis B virus, at no charge to myself. However, I decline the hepatitis B vaccination at this time. I understand that by declining this vaccine, I continue to be at risk of acquiring hepatitis B, a serious disease. If in the future I continue to have exposure to blood or other potentially infectious materials and I want to be vaccinated with Hepatitis B vaccine, I can receive the vaccination at no charge to me. ______________________________ __________________________ Signature Date

______________________________ __________________________ Dematic Corp. Representative Signature Date


Rev. 2 July 2011 13

Addendum D

EXPOSURE INCIDENT INVESTIGATION

FORM


Rev. 2 July 2011 14

DEMATIC CORP. EXPOSURE INCIDENT INVESTIGATION FORM

Date of Incident: _______________ Time of Incident: ______________ Location: _____________________________________________________ Potentially Infectious Materials Involved: Type: ___________________________ Source: _________________________ ___________________________ _________________________ Circumstances (work being performed, etc.): ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________ How incident was caused (accident, equipment malfunction, etc.): ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Personal Protective Equipment Being Used: ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Actions Taken (decontamination, clean-up report, etc.): ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________ Recommendations for Avoiding Repetition: ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Rev. 2 July 2011 15

Addendum E

POST EXPOSURE EVALUATION

AND

FOLLOW-UP CHECKLIST

Health and Safety Program

Rev. 2 July 2011 16

DEMATIC CORP. POST-EXPOSURE EVALUATION AND

FOLLOW-UP CHECKLIST The following steps must be taken and information transmitted in the case of an employee’s exposure to Bloodborne Pathogens: ACTIVITY COMPLETION DATE

• Employee furnished with documentation regarding exposure incident ____________ • Source individual Identified ____________

(____________________) Source individual

• Source individual’s blood tested and results given to exposed employee ____________

_______ Consent has not been able to be obtained. • Exposed employee’s blood collected and tested ____________ • Appointment arranged for employee with healthcare professional. ____________

(______________________________) Professional’s Name

• Documentation forwarded to healthcare professional. ____________

_______ Bloodborne Pathogens Standard _______ Description of exposed employee’s duties. _______ Description of exposure incident including routes of exposure _______ Result of source individual’s blood testing _______ Employee’s medical records

Health and Safety Program Electrical Safety and Assured Grounding

Rev. 2 July 2011 15-1

15 Electrical Safety and Assured Grounding

Purpose: The purpose of this procedure is to prevent injury from electrical shock by defining basic requirements to be followed by Dematic Corp. employees when working with or around electrical energy sources.

15.1 General All electrical work, installation, and wire capacities shall be in accordance with the provisions of the National Electrical Code, NFPA 70-1984, unless a special provision of an OSHA standard is provided for specific equipment.

Only qualified personnel that are familiar with the construction and operation of the equipment and the hazards involved shall be allowed to perform electrical work. Verification of such qualification is required before an employee is allowed to begin such work.

15.2 Safety Related Work Practices

15.2.1 Unqualified Persons Unqualified personnel working around electrical power sources will adhere to the following work practices.

� Work shall not be permitted around an electrical power circuit where contact is possible unless de-energizing, grounding, or guarding by insulation provides protection against electrical shock.

� All employees shall be trained on Dematic Corp. Hazardous Energy Control Procedure – Lock-out/Tag-out.

� An unqualified person working on the ground near overhead lines may not bring a conductive object closer to unguarded, energized overhead lines than the following distances:

Table 1 Unqualified Personnel Distances

Voltage Range (phase to phase) Minimum Approach Distance

300V and less Avoid Contact

301V to 750V 1 ft.


Rev. 2 July 2011 15-2


Voltage Range (phase to phase) Minimum Approach Distance

751V to 2kV 1ft. - 6 in.

3kV to 15kV 2 ft.

16kV to 37kV 3 ft.

38kV to 87.5kV 3 ft. - 6 in.

87.6 kV to 121 kV 4 ft.

122 kV to 140 kV 4 ft. - 6 in.

� In work areas where the exact location of underground power lines is unknown, ground probing will be conducted. If ground probing is not possible, employees using hand tools (jackhammers, bars, etc.) that may contact a power line are given insulated protective gloves.

� The supervisor is responsible for knowing if any part of an energized electrical circuit exposed or concealed, is so located that the performance of the work may bring any person, tool, or machine into physical or electrical contact with the electrical power circuit.

� Warning signs shall be posted where these circuits exist, and all employees shall be advised of the location of such lines, hazard involved, and the protective measures to be taken.

� Barriers or other means of guarding shall ensure that workspaces for electrical equipment will not be used as passageways when energized parts are exposed.

� Workspaces, walkways, and similar locations shall be kept clear of cords to prevent hazardous conditions.

� Spaces that contain exposed energized parts shall be illuminated prior to employees entering the space.

� Protective shields, protective barriers, or insulating material shall protect against inadvertent contact with exposed energized parts prior to entering a confined space.

� Employees shall use only portable ladders constructed of nonconductive material.

� When employees are working in locations where there is the potential of contacting exposed energized parts, they may not wear conductive articles such as watchbands, bracelets, rings, key chains, or necklaces.

� The user will visually inspect all electrically powered tools each day.

� Worn of frayed electric cords or cables shall not be used.

� Extension cords shall not be fastened with staples, hung from nails, or suspended by wire.

� Only double insulated extension cords are to be used.


Rev. 2 July 2011 15-3

� When an unqualified person is working in an elevated position near overhead lines, the location shall be such that the person and the longest conductive object being carried cannot come closer to any unguarded, energized overhead line than the following distances:


Minimum Nominal Voltage (kV) Minimum Required Clearance (feet)

0 to 50 10

51 to 75 11

76 to 100 12

101 to 125 13

126 to 200 15

201 to 300 19

301 to 400 22

401 to 500 25

501 to 700 32

701 to 1000 34

15.2.2 Qualified Employee Qualified employee means an employee who has the training, experience, and technical knowledge necessary to install wiring and equipment in accordance with the standard rules and regulations governing such work.

15.2.3 Working on Energized Electrical Equipment: The site Superintendent/Project Manager shall assure that an employee does not engage in work on energized electrical equipment unless the employee is a licensed electrician, or the employee is working with, or under the supervision of a licensed electrician. Qualified employees are not required to be licensed when working on utility installation or maintenance such as but not limited to substations, switch yards, and street or highway lighting.

The site Superintendent/Project Manager shall insure that all live parts of electrical equipment operating at 50 volts or more are properly guarded against accidental contact.

The site Superintendent/Project Manager shall do all of the following: (a) Limit access to energized electrical equipment such as, but not limited to, switch gear, transformers, and service panels, to qualified employees. (b) Provide, and insure the proper use of, an accident prevention sign on electric apparatus, equipment, and enclosures. The voltage shall be indicated. (c) Provide a conductor of an ampacity of not less than the rating of the circuit breaker or fuses protecting that circuit.


Rev. 2 July 2011 15-4

(d) Insure that a bare conductor or earth return is not used for any temporary circuit. (e) Insure that all electrical wiring is protected from physical damage. Electrical installations: (1) Electrical apparatus and equipment used for construction operations shall bear an approved label or marking. (2) Before work begins, a competent person shall ascertain by inquiry, observation, or instruments whether any part of an electric power circuit, exposed or concealed, is so located that, in performance of the work, contact by an employee, tool, or equipment can be made with the circuit. (3) Any employee shall not be permitted to be in proximity to any part of an electric power circuit that he may contact unless the employee is protected against electric shock by de-energizing the circuit and locking out and tagging it, or unless the employee working on an energized circuit is guarded by insulation, insulated tools, or insulating matting or blankets sufficient to protect against the voltage involved. (4) Where an electrical power circuit exists that can be contacted by an employee, the Site superintendent/Supervisor shall do both of the following: (a) Post and maintain accident prevention signs. (b) Advise the employee of the location of the lines, hazards involved, and protective measures taken or to be taken. (5) When an employee is using a jack hammer, bar, or other tool which could come in contact with an underground line, the energy source shall be de-energized. (6) A work space of not less than 3 feet wide and 6 1/2 feet high, in addition to space necessary to open equipment doors not less than 90 degrees, shall be provided and maintained in the area of electrical equipment. (7) Barriers or other means shall be provided to ensure that the work space for electrical equipment is not used as a passageway during periods when energized parts of electrical equipment are exposed. (8) Where the work requires exposure to, or handling of, energized conductors or switch gear of 440 volts or more between phases, 2 or more qualified employees shall work together.

Work on energized equipment is not permitted. It is recognized that tests must be performed frequently on energized equipment in order to diagnose a problem. In such cases where work on energized equipment is necessary, the following procedure shall be observed.

:NOTE: Low voltage means up to 120 volts; Medium voltage means between 121 and 599 volts; High voltage means 600 volts and above

If work is required on or near equipment that may come in contact with medium or high voltage that cannot be de-energized and made safe, the site supervisor, Dematic Corp. safety representative, along with the customer/manager, shall review the job to determine if the equipment cannot be de-energized. As well as making sure appropriate safety precautions have taken place.

Work on energized electrical equipment shall proceed only if Dematic Corp. and customer manager agree that the work must proceed at that time, that the equipment cannot be de-energized, and that the safety procedure includes the requirements under NFPA 70E 2004.


Rev. 2 July 2011 15-5

PPE Requirements for qualified employee’s working on or near live parts: General PPE for working on or near live parts:

• Hard Hat – Type 1 Class E (20,000 volts) • Safety Glasses with Side shields • Safety Toe footwear/over the ankle/Leather construction • Under garments – T-shirt/underwear have to be of 100% natural fibers.

o No jewelry, watches, necklaces or other metallic items should be worn by employees working near live parts.

When qualified employees are working on or near live parts, employees shall wear the following garments listed below depending on the hazard category. General PPE must still be worn. Hazard/Risk Category 0, 240 V and below - Circuit Breaker or fused switch operation with covers on: Circuit Breaker or fused switch operation with covers off. Work on energized parts including voltage testing. Opening hinged covers to expose bare, energized parts. (Notes 1 and 3.)

• Shirt – Long Sleeve, 100% cotton. • Pants – Long, 100% cotton. • Voltage rated gloves.

Hazard/Risk Category 1, 240v-600v Circuit Breaker or fused switch operation with covers off: Work on energized parts including voltage testing. CB or fused switch operation with covers off: (With covers on is reduced to hazard category 0) Removal/installation of CBs or fused switches: Notes 1 and 3.

• Pants – Fire resistant (FR) or untreated denim cotton blue jeans are acceptable. • Shirt – Long sleeve, FR. • Coveralls – Fire resistant can also be worn instead of fire resistant pants/shirt • Voltage rated gloves.

Hazard/Risk Category 2, 240v-600v Work on energized parts including voltage testing: 600 V Class motor control centers (MCC’s), 600 V Class Switch gear. Notes 1 and 3.

• Voltage rated gloves and leather protectors. • Voltage rated tools • T-Shirt – 100% cotton • FR Long Sleeve shirt • FR Pants or coveralls • Arc rated face shield (minimum rating 8) • Hearing protection • Heavy Duty Leather Work Boots • Double-layer switching hood. (Required for 2* hazard category)

(Note 1 – 25 ka short circuit current available. 0.03 second (2cycle) fault clearing time.) (Note 3 – For < 10 ka short circuit current available, the hazard/risk category may be reduced by one number.)


Rev. 2 July 2011 15-6

15.3 Temporary Wiring Requirements The following standards shall be adhered to regarding temporary wiring requirements.

� Temporary wiring shall be guarded or isolated by elevation to prevent accidental contact with workers or equipment.

� Vertical clearance above walkways shall be greater than 7 ft. for circuits carrying 600V or less.

� For temporary wiring over 600V, fencing, barriers, or other effective means shall be provided to prevent access of unauthorized and unqualified personnel.

� Wires shall be insulated from their supports.

� Electrical cords shall not suspend temporary lights unless cords and lights are designated for this means of suspension.

� All lamps for general illumination shall be protected from accidental contact or breakage, and metal-case sockets shall be grounded.

� Temporary lighting strings shall be made up with cords having lamp sockets and connections protected by insulating coverings.

� Flexible cords and cables shall be protected from damage, sharp corners, and projections shall be avoided.

� Flexible cords and cables may pass through doorways or other pinch points If protection is provided.

� Extension cord sets used with portable electric tools and appliances shall be three-wire type and shall be designed for heavy industrial usage. Receptacles shall be of the grounding type.

� Portable electric lighting used in wet and/or other conductive locations (i.e., drums, tanks, and vessels) shall be operated at 12V or less. However, 120V lights may be used if protected by a ground fault circuit interrupter. (GFCI)

15.4 Ground Fault Protection Either ground fault circuit interrupters (GFCI) and/or an Assured Equipment Grounding Conductor Program shall provide employee protection on construction sites. Some customers may require the use of both GFCI and the program. Additionally, each project shall designate a competent person who is responsible for implementing the program.


Rev. 2 July 2011 15-7

15.5 Installations All 120V, single phase, 15 and 20-ampere receptacles shall be grounded by connection to the equipment-grounding conductor of the circuit supplying the receptacles in accordance with the requirements of the National Electric Code.

All 120V flexible cord sets (extension cords) shall have an equipment-grounding conductor that shall be connected to the grounding contact of the connector on each end of the cord.

The exposed non-current-carrying metal parts of the 120V cord and plug-connected tools and equipment that are likely to become energized shall be grounded in accordance with the requirements of the National Electric Code.

15.6 Visual Inspection and the Testing and Assured Grounding Program

All employees shall be instructed that each cord set and any equipment connected by cord and plug, except cord sets and receptacles that are not exposed to damage, shall be visually inspected daily for defects by the user.

Damaged equipment shall be removed from service and “tagged out” with a “DANGER – DO NOT USE” tag.

All 120V, single phase, 15 and 20-ampere receptacles, 120V flexible cord sets, and 120V equipment connected by cord and plug that are not part of the permanent wiring of the building or structure shall be tested to assure that electrical continuity is maintained. These tests shall be conducted as follows:

� All equipment-grounding conductors shall be electrically continuous and shall be tested for continuity.

� Each receptacle, attachment cap, and plug and receptacle of cord sets shall be tested for correct attachment of the equipment-grounding conductor. The equipment-grounding conductor shall be connected to its proper terminal.

15.7 Testing Intervals Tests shall be performed at the following intervals:

� Before the first use

� Before equipment is returned to service following any repairs

� Before equipment is used after an incident that can be reasonably suspected to have caused damage (i.e., cord set is run over)


Rev. 2 July 2011 15-8

� Every three months – except cord sets and receptacles that are fixed and not exposed to damage shall be tested at intervals not to exceed six months.

Equipment shall not be used if it has not passed the required tests.

15.8 Test Verification Color coding with electrical color tape is the recommended method of verifying that testing is current and that all receptacles, portable cords, and tools have been inspected and tested as required.

Table 3 Color Code Scheme

Quarterly

First Quarter (Jan to Mar) Red

Second Quarter (April to June) Blue

Third Quarter (July to Sept) Green

Fourth Quarter (Oct to Dec) Yellow

Six month Interval

First Half (Jan to June) White

Second Half (July to Dec) Orange Records shall be kept that identify each receptacle. Cord sets, and cord and plug connected equipment inspected. As well as indicate the latest date or the interval for which it was tested. (Refer to the Assured Equipment Grounding record sheet.)

15.9 Training Electrical safety awareness training shall be conducted annually to the general jobsite population.

Health and Safety Program Mobile Equipment

Rev. 2 July 2011 1

16 Mobile Equipment

Purpose: The purpose of this procedure is to provide guidelines that only authorized employees shall operate fork lift trucks, aerial platform lifts, or other mobile equipment.

“Authorized Employees” are those who have received operator’s training for the respective mobile equipment.

16.1 Safety Guideline Material handling mobile equipment is built for safe and economical operation but such equipment is only as safe as the operator.

No load shall be lifted in excess of the rated capacity of any crane, sling or choker, fork truck, aerial platform or any other mobile equipment and related lifting device

16.2 Pre-Start Inspection Prior to use of any mobile equipment each day, or at the beginning of each shift, the operator shall visually inspect and/or perform a functional test of the following (please refer to the forms section for the appropriate required inspection form for the type of equipment being used/inspected):

� Operating and emergency controls

� Safety and warning devices

� Personal Protective Equipment

� Hydraulic and fuel systems leaks

� Cable and wiring harnesses

� Loose or missing parts

� Wire rope, cable, and sheaves

� Tires and wheels

� Placards on rated load capacity, operating speeds, hazard warnings and other essential information

� Outrigger and stabilizers

� Fuel, water, oil levers, battery charge, etc.


Rev. 2 July 2011 2

� Gauges, horns, and lights

� Vehicle damage – deformation or structural cracks or fracture

16.3 Problems and Malfunctions The operator shall promptly report any and all problems or malfunctions on any piece of mobile equipment to the jobsite supervisor/foreman.

The jobsite supervisor/foreman will determine the effect(s) of any mobile equipment problem or malfunction on the safety of operations of such equipment and the level of experience needed for repair.

If correction or repair of an unsafe item cannot be made immediately, the unit shall be tagged “Danger – Do Not Operate” and removed from service until the corrective action has been taken.

16.4 Workplace Inspections Prior to and during the use of any mobile equipment, the operator shall check the workplace area in which the unit is to be used for hazards such as:

� Drop offs, holes, bumps and floor obstructions

� Materials, equipment, and debris

� Overhead obstructions and high voltage conductors

� Hazardous material locations

� Inadequate surface and support to withstand all load forces imposed by the mobile equipment in all operating configurations

� Wind and weather conditions

� Presence of unauthorized persons

In the event that any of the above work area hazards exist, the operator shall take the appropriate safeguards when operating mobile equipment in such areas.

16.5 General Safe Practices � Routine maintenance, fueling or repairs must not be performed while the

equipment is in use, engine running or power on � When handling or recharging batteries or using jumper cables, a face shield

must be worn � A fire extinguisher rated at least 5 BC shall be located on all mobile

equipment


Rev. 2 July 2011 3

� Stunt driving or horseplay on any mobile equipment is strictly prohibited. � The use of planks, ladders or any other device on any aerial platform lift for

the purpose of achieving additional height or reach is strictly prohibited. � The use of safety belts with lanyard attached to the anchor rings on aerial

platform boom lift equipment is mandatory.

It is unlawful to operate forklift trucks, aerial platform lifts or any other mobile equipment within ten (10) feet of high voltage lines of 50,000 volts or less.

Operators of LPG fueled mobile equipment shall adhere to the following procedures for changing fuel cylinders:

� Close container valve by turning to the right (clockwise) � Operate engine until it stops. All gas vapors should now be burned. Turn

key switch off � Disconnect fuel line at quick-disconnect coupling. Tools should not be

required to connect or disconnect coupling � Loosen container fastener; swing and lift up container mounting; remove

cylinder � Replace with recharge cylinder by reversing the above procedure. Make

sure that tank locating hole is secured over the positioning pin in the tank cover

� Open tank valve slowly to insure that the automatic safety check valve does not cut off fuel supply.

� Replace empty LPG cylinder in a rack or in a designated storage area to protect against possible damage

Operators of Fork lift trucks must have completed a written test and trained for the specific type and model before bring authorized to operate the equipment.

16.6 Mobile Equipment Inspections A qualified person this is to ensure that all mobile equipment is maintained in safe and proper working order in accordance with the manufacturers operating maintenance specifications shall perform frequent inspections of all mobile equipment.

16.7 Operator’s Training and Authorization Only properly trained employees shall be authorized to operate material handling mobile equipment. Training for each specific type of mobile equipment is


Rev. 2 July 2011 4

mandatory prior to authorization being given to the employee to operate that specific type of equipment.

Training for all material handling mobile equipment shall include the following:

� Review of the Safety and Operations Manual for specific type of mobile equipment.

� Viewing of a training video on safety and proper operation of the specific type of mobile equipment.

� A written examination demonstrating the employee’s understanding of safety and proper operation of the specific type of mobile equipment.

� An operator’s performance examination to demonstrate the employee’s ability to

� Actually operate the specific type of mobile equipment in accordance with all safety and functional guidelines. The trainer shall give the exam.

Upon successful completion of the training course for each specific type of mobile equipment, the employee will sign an acknowledgement stating that they have received training and that they understands all safety and functional procedures required to operate that specific type of mobile equipment.

The supervisor and/or the trainer will also sign an acknowledgement stating that the employee has successfully completed a training course for the specific type of mobile equipment and is therefore authorized to operate such equipment of the job site, and will issue an operator’s card with the equipment noted.

A record of each employees training and authorization shall maintained by Dematic Corp. for three (3) years after which time the employee shall be retrained unless equipment specific annual training is required.

(Ref: Mobile Equipment Authorization Form)

Health and Safety Program Cranes, Rigging, and Tools

Rev. 2 July 2011 17-1

17 Cranes, Rigging, and Tools

Purpose: The purpose of this procedure is to define the individual roles and responsibilities and to establish safe work practices and safety requirements to be followed by all employees when handling Dematic Corp. cranes, tools, and rigging.

17.1 Crane Operations Employees shall not operate any motorized crane until they have demonstrated the written and practical skills necessary to operate such equipment in a safe and professional manner.

The qualification process consists of testing potential equipment operators by a designated person or company qualified to perform this task. This person or company will administer the program through the Human Resource Department. All written tests and operator evaluations will be maintained in their personnel file.

Operator qualifications will be valid for one year only, wherefore the operator must re-qualify. A qualification card issued by the designated person shall state the date the operator was tested and the equipment that the operator is qualified to operate.

No one, other than the qualified/authorized personnel, shall operate mobile cranes, with the exception of the following persons:

� Supervisors whose duties require them to do so

� Learners under the direct supervision of a qualified operator after they have completed a written and practical skills test

� Maintenance and testing personnel, when it becomes necessary in their duties

� Inspectors

17.2 Physical Requirements Crane operators must be physically and mentally fit and must not engage in any practices that would divert their attention while operating equipment. Certain physical requirements must be met for all equipment operators in order to provide for the safety of personnel, equipment, and the general public during any lifting operation. Operators shall meet the following physical qualifications prior to operating any mobile lifting equipment:


Rev. 2 July 2011 17-2

� Have vision of at least 20/30 in one eye and 20/50 in the other, with or without glasses

� Be able to distinguish red, green, and yellow regardless of the position of the colors

� Hearing, with or without a hearing aid, must be adequate for the specific operation

� A history of epilepsy, diabetes or of a disabling heart condition shall be sufficient reason for disqualification. A statement must be obtained from a physician stating that this condition is controlled and will not effect job performance.

:NOTE: A valid driver’s license may be used as proof of these conditions.

17.3 Training and Testing Requirements Once operators have met the physical requirements, they must then be trained on the type of equipment being used in accordance with ASME B30.5-2000. After the training has been completed, the employee must pass both a written and practical skills test.

17.4 Safety Operating Procedures � All cranes shall be equipped with a functioning “Anti Two Block” device.

� It is the operator’s responsibility to keep the load under control at all times. This can be accomplished by starting and stopping smoothly and by avoiding swinging the load too fast. Never allow the load or any object to strike the boom. The operator must, at all times, operate the equipment within the guidelines set forth by the manufacturer.

� A tag line shall be used on all suspended loads.

� Always place the boom directly above the load when lifting. Never side-load a boom or use the crane to push or pull a load.

� The equipment operator is ultimately responsible for all operations. If there are any questions, doubts, or uncertainties about the equipment, rigging, equipment set up area, load chart interpretation, or the load; it is the operator’s responsibility to halt proceedings until the appropriate authority source has been consulted.

� At no time shall any mobile industrial equipment (crane) be engaged in operation unless appropriate load chart, operator’s manual, and necessary decals are in place.

� To safely perform a lift, it is imperative that the weight of the load be known. The operator shall ensure that no lift exceeds the manufacturer’s rated capacity for a given radius, angle, or configuration.


Rev. 2 July 2011 17-3

17.5 Communication Communication is the key to any safe job. Prior to making a lift, communication should be established to discuss the job with all parties involved. The operator shall respond to signals only from the appointed signal person or by radio contact. The operator shall obey an emergency stop signal when given at any time, regardless of who gives the signal.

17.6 Working Around High-Voltage Electricity Power distribution lines are major cause in the electrocution of equipment operators. At no time shall any part of the load or the crane be closer to 10 ft. for lines rated less the 50kV. For lines rated over 50kV, an additional 0.4 inches should be added for each 1kV. During transit with no load and boom lowered, the equipment clearance shall be a minimum of 4 ft. for voltage less the 50kV, 10 ft. for voltages between 50kV and 345kV, and 16 ft. for voltages up to and including 750kV.

Table 1 Required Clearances from Live Electrical Lines

Minimum Nominal Voltage (kV) Minimum Required Clearance (feet)

0 to 50 10

51 to 75 11

76 to 100 12

101 to 125 13

126 to 200 15

201 to 300 19

301 to 400 22

401 to 500 25

501 to 700 32

701 to 1000 34

17.7 Matting Requirement The crane operator is responsible for the use and selection of crane outrigger mats. Since the maximum outrigger loading on a single outrigger pad can exceed 28,000 lb./ft. squared, a thorough investigation of ground conditions must be made prior to positioning the crane. By contrast, ground-bearing pressures on our largest lift rarely exceed 3,000 lb./ft. squared. To ensure the safest working conditions, observe the following minimal guidelines when positioning for a lift:

� Thoroughly check surface conditions to ensure they will support the intended loading.��


Rev. 2 July 2011 17-4

� Make inquiries regarding the presence of voids beneath the surface, such as loose fill, piping, conduit, drainage channels, etc.��

� Use outrigger mats at least 2 ft. wider that the outrigger plate to distribute loads over a greater area in order to reduce the possibility of surface failure.��

� Level and center mats beneath the outrigger pads. Mats should be strong enough to prevent crushing, free from defects, and of sufficient width and length to prevent shifting or toppling under a load.��

� Recheck mat positioning and integrity after each lift.��

17.8 Crane Inspections At the beginning of each shift, the authorized operator shall conduct a visual and functional inspection prior to using the crane. The inspections shall be documented on the Daily Equipment Inspection Form and shall be maintained onsite for one year.

All cranes shall undergo a thorough annual inspection by a qualified person or company recognized by the U. S. Department of Labor. The jobsite supervisor is responsible for ensuring that annual inspection reports are available for all cranes being used, whether borrowed, rented, owned, or assigned. Dematic Corp. shall maintain a record of the dates and results of inspections for each crane until it is time for renewal of the annual inspection.

Deficiencies that are discovered through operational use or inspection should be reported immediately to the jobsite supervisor, and the defective crane should be placed out of service. No crane shall be placed back in service until deficiencies are evaluated and corrected by a qualified person.

Crane headache balls and blocks shall be inspected on an annual basis.

Employees must not modify, redesign, or repair tools or equipment without specific instructions from the jobsite supervisor. Tools and equipment are to be used only for the purposes for which they are designed and in accordance with the manufacturer’s recommendations, unless specific consent is obtained from the jobsite supervisor.

17.9 Critical Lifts A critical lift is any lift with a mobile crane that meets the following criteria:

� The lift exceeds 70% of the rated capacity of the equipment as determined by the load chart�

� The lift equipment setup uses more than 75% of the maximum boom length used�


Rev. 2 July 2011 17-5

� The lift is made over an operating unit or product lines (consideration must be given to adjacent operating units within the boom length)�

� All multi-crane lifts (excluding tailing rigs)

� Any other lift that may not be completely routine, such as the following:�

� All lifts where the boom or load is over live conveyor or other critical equipment

� All lifts of special value

� Lifts requiring modifications or special configurations of lifting equipment

� Lifts requiring design and/or fabrication of special rigging equipment

� Any other lift deemed critical by any single or combination of factors

A pre-lift meeting shall be held for all critical lifts. At a minimum, meeting attendance shall include the supervisor, foreman, equipment operators, and all other employees directly associated with the lift.

While the lifting is in progress, the representative in charge of the lift shall assure all nonessential personnel leave the lift area.

17.10 Lift Plans A lift plan must be completed for all critical lifts and must be available for presentation to any requesting party. The following points must be completed when preparing a lift plan:

� Once a formal lift plan has been developed, if any of the variables in the equipment, load, or lift change, then a new plan must be developed.�

� ALL lifts must be planned with equipment capabilities, weights of load, radius of lifts, etc. determined before any lift is made.�

� The signed and dated documentation of the formal lifting plan is to be retained in the jobsite files for one year.�

� If there are any questions, doubts, or uncertainties about the equipment, rigging, equipment setup, load chart interpretation, or the load, the appropriate authority source should be consulted prior to completing a formal lifting plan.�

� These guidelines do not limit the documentation of any lift. Many variables may dictate that other lifts are defined, as “critical” or that documentation may be desired for other lifts.�


Rev. 2 July 2011 17-6

17.11 General Rigging Safety

17.11.1 Lifting with Hoisting Equipment Dos and Don’ts � Do give safety first consideration in the handling of materials.�

� Do familiarize yourself with the types of slings available for easiest and safest lifting.�

� Do inspect the lifting equipment before and after it is used to make certain it is in good condition.�

� Do report any lifting equipment that appears to be unsafe before someone else uses it.�

� Do remove damaged lifting equipment.�

� Do report all accidents causing damage to lifting equipment, operating equipment, and products even if you feel there is no danger.�

� Do refuse to move a load if you are not satisfied with the way the load is attached.�

� Do not lift a piece without knowing its weight.�

� Do not make a lift without knowing the lifting equipment’s capacity and the method to be used.�

� Do not use lifting equipment that is damaged to lift loads lower in capacity than the original rate capacity of the equipment.�

� Do not leave equipment where it can be accidentally damaged by bending, cutting, or crushing.�

� Do not let anyone overrule the judgement of the operator. Higher authority should be considered.�

17.11.2 Proper Use of Chain and Wire Rope Sling Dos and Don’ts � Do protect the sling from the cutting action in making a lift by using padding,

blocks, or corner protectors.�

� Do choose a sling one size larger where conditions will subject the sling to severe wear, abrasion, impact, or corrosive conditions.�

� Do select the proper style hook or attachment.�

� Do stand clear while a sling is being drawn from beneath a load. Hooks and slings may catch and suddenly fly-free or tip the load.�

� Do face the hook opening out and away from the sling pull when making choker hitches.�

� Do not point load (tip load) standard sling hooks.�


Rev. 2 July 2011 17-7

� Do not subject hooks or attachments to bending actions.�

� Do not let the load lay directly on a sling wrapped around a load (lower the load on proper blocking).�

� Do not assume in a choker hitch that the hook is going to stay in place when the slack is being taken out of the sling.�

17.11.3 Shackle Dos and Don’ts � Do make certain that the bolt in a screw pin shackle turns easily, and then

tighten it (use oil on the threads).�

� Do use safety shackles wherever possible (they are safer).�

� Do use the largest bearing surface possible on the shackle pin. This will reduce the bending movement on the pin.

� Do not use a shackle unless you know it’s rated load capacity.�

� Do not use any screw pin shackle where the bolt is very difficult to turn (the pin is either bent due to overload or the threads have been damaged).�

� Do not use round pin shackles. Instead use safety shackles or screw pin shackles.�

17.11.4 Proper Use of Nylon Webbing Slings Dos and Don’ts � Do inspect the surface and stitching of the sling for cuts and abrasions.

� Do use softeners, pads, sheaths, etc. to protect nylon and synthetic slings from cuts and abrasions.

� Do not attempt to inspect the inside nylon fibers of webbing (this is not necessary because these fibers are protected by the outside fibers, and it may damage the sling).

� Do not use nylon slings on hoist hooks that are gouged or nicked (there could be sharp edges that could cut the sling).

� Do not use nylon slings to lift structural steel.

� Do not use any sling if its rated capacity is not clearly identified.

17.12 Tools and Equipment Tools and equipment are not to be modified, interchanged, or put to uses other than those described by the manufacturer. Tools and equipment are to be repaired only by designated persons and are not to be left running, energized, or under pressure when unattended. Defective tools and equipment are to be reported immediately and removed from service until the defect can be corrected. Any defect shall be indicated on a “DANGEROUS-DO NOT USE”


Rev. 2 July 2011 17-8

label if the tool and equipment is left unattended. Only qualified persons or the manufacturer will repair tools and equipment.

All guards are to be left in place and are to be properly used. Do not modify or tamper with the guards. Tools and equipment with defective, broken, modified, or missing guards are to be tagged “DANGEROUS-DO NOT USE” and removed from service. Any employee found modifying or deactivating a safety guard or mechanism will be subject to disciplinary action up to and including termination.

Only employees qualified by training or experience shall use tools or equipment. Supervisory personnel must determine an employee’s skills and abilities prior to assigning work. Employees are obligated to ask for training when a tool or piece of equipment is to be used that the employee is not thoroughly familiar with.

17.13 Tools and Equipment Inspections At least quarterly, all tools, equipment, slings, chokers, ladders, and hand-operated lifting equipment will be inspected. Defective tools and equipment will be immediately repaired by competent personnel or tagged and removed from service. Appropriate documentation of inspections and/or repairs will be developed and maintained at the jobsite. All employees are responsible for inspecting tools, equipment, slings, chokers, and mechanical lifting devices prior to use. Employees must not use defective or broken tools or equipment. All deficiencies are to be reported and corrected immediately, or the tool or equipment is to be tagged and removed from service.

Employees must not modify, redesign, or repair tools and equipment without specific instructions from the jobsite supervisor. Tools and equipment are to be used only for the purposes for which they were designed and in accordance with the manufacturer’s recommendations.

17.13.1 Inspection of Manual Lifting Equipment

17.13.1.1 Daily Inspections

The user is required to inspect all rigging materials prior to each use and at intervals during each use if conditions warrant. The following points should be checked:

17.13.1.2 Wire Rope Slings

� Six randomly distributed broken wires in one rope lay or three broken wires in one strand in one rope lay (snagged, nicked, or severely bent wires count as broken wires)

� Abrasion, scrubbing, or peening causing loss of more than one-third the original diameter of outside individual wires


Rev. 2 July 2011 17-9

� Evidence of rope deterioration from corrosion

� Kinking, crushing, or other damage that results in detrimental distortion of the rope structure

� Any evidence of heat damage, including bare electrical conductor, ground, or welding arc

� Any marked reduction in diameter either along the entire main length or in one section

� Unlaying or opening up of a tucked splice

� Core protrusion along the main length

� End attachments that are cracked, deformed, worn, or loosened

� Any indication of strand or wire slippage in the end attachments

� More than one broken wire in the vicinity of the zinced-on or swaged fitting

17.13.1.3 Synthetic Web Slings

� Melting, charring, or weld splatter on any part of the sling

� Holes, cuts, tears, snags, or imbedded particles

� Broken or worn stitching in load bearing splices

� Excessive abrasion

� Knots in any part of the sling

� Distortion, corrosion, or pitting of metal fittings, hooks, or master links

� Visible indicator core yarn

� Any other defect that might affect the strength and reliability of the sling

17.13.1.4 Chain Falls and Come-A-Longs

� Kinks, nicks, twists, or any bad spots in the chain

� Wear deformities

� Safety latches are in place and work properly

� Hooks for spread , bends, or any deformities

� Free gearing system

17.13.1.5 All Rigging Materials

� Capacity tags to ensure the material will handle the lifted load�


Rev. 2 July 2011 17-10

17.14 Basic Crane Hand Signals

HOIST. With forearm vertical, and forefinger pointing up, move hand in small horizontal circle.�

LOWER. With arm extended downward, forefinger pointing down, move hand in a small horizontal circle.�

BRIDGE TRAVEL. Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel.�

TROLLEY TRAVEL. Palm up, fingers closed, thumb pointing in direction of motion, jerk hand horizontally.�

STOP. Arm extended, palm down, hold position rigidly.�

EMERGENCY STOP. Arm extended, palm down, move hand rapidly right and left.��

��

MULTIPLE TROLLEYS. Hold up one finger for block marked "1" and two fingers for block marked "2". Regular signals follow.�

MOVE SLOWLY. Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist slowly shown as example)�

�

�


Rev. 2 July 2011 17-11

Types of Rigging Equipment Slings

�

Chain Wire Rope Metal Mesh Synthetic

Examples of Defects and Cause for Removal from Service

The grooves must be smooth and free from surface defects which

could cause rope damage.

Damaged Wire Rope

Broken Strands

Sheaves

Damaged wire rope shall be removed from service

immediately.

Damaged Wire Rope

Crushed Rope

Health and Safety Program Fall Protection

Rev. 2 July 2011 18-1

18 Fall Protection

Purpose: The purpose of this procedure is to identify specific requirements for work that may include potential fall hazards. There will be ZERO TOLERANCE for not abiding by these requirements set forth for jobsite management, supervisors, employees and sub-contractors on jobsites which may include disciplinary action up to and including termination.

18.1 Definitions Competent Person – An individual who exhibits the following:

� Knowledge of fall protection equipment, including the manufacturer’s recommendations and instructions for proper use, inspection, and maintenance

� Able to identify existing and potential fall hazards � Authority to take corrective actions to eliminate hazards � Knowledge of the rules contained in this section regarding the erection, use,

inspection, and maintenance of fall protection equipment and systems

Drop Line – An independent lifeline secured to an upper anchorage for attaching a lanyard or a fall protection device. This line must be at least a ¾ in. maila rope or ½ in. nylon rope.

Fall-Restraint System – An approved device and other necessary components that function together to prevent an employee from falling to a lower level. When standard guardrails are selected, compliance with applicable sections governing their construction and use shall constitute approval.

Fall Distance – The actual distance from the worker’s support to the level where a fall would stop.

Hardware – Snap hooks, D-rings, buckles carabiners, adjusters, and C-rings that are used to attach the components of a fall protection system together.

Lanyard – A flexible line of webbing, rope, or cable used to secure a harness to a lifeline or an anchorage point, usually 2, 4, or 6-ft. long.

Lifeline – A line from a fixed anchorage or between two anchorages’s so that an employee is secured to prevent the worker from falling to a lower level.

Rope Grab – A fall arrester that is designed to move up or down a lifeline that is suspended from a fixed overhead or horizontal anchorage point or a lifeline which the belt or harness is attached. In the event of a fall, the rope grab locks


Rev. 2 July 2011 18-2

onto the live line rope through compression to arrest the fall. The use of a grab device is restricted for fall restraint applications.

Safety Line – See lifeline above

18.2 Fall Hazards The key factor in the protection against falls is hazard recognition. Falls are generally a result of poor work practices, poor conditions, or a combination of both. Standard protection against falls is achieved when adequate guardrails (handrail, mid-rail, toe plate) are installed on work platforms, scaffolds, or stairways (with four or more risers). Fall prevention begins in the planning stage of the project or task. Such planning includes the following:

� Layout and arrangement of tools and equipment

� Layout of aisles, passageways, floors, entrances, exits, and a clear access way

� Illumination and weather hazard recognition (rain, sleet, snow, mud, and ice)

� Use of personnel hoisting equipment (aerial platforms, boom lifts, etc.)

18.3 Same Level and Lower Level Fall Protection Good housekeeping is the key to the prevention of the same level falls. Usable and waste material shall be stored out of pathways and shall not congest a work area. Surfaces shall be kept free of slipping hazards (grease, oil, chemicals, metal shavings, etc.)

Floor holes and openings shall be covered and labeled with “HOLE” or “COVER” to provide warning of the hazard. Covers located in roadways and vehicular aisles have to be capable of supporting, without failure, at least twice the minimum axle load of the largest vehicle expected to cross over the cover. All other covers shall be capable of supporting, without failure, at least twice the weight of employees, equipment, and materials that may be imposed on the covers. Covers shall be secured so that accidental displacement by wind, equipment, or employees does not occur.

Attempts shall be made to maintain even floor surfaces. Material shall not be allowed to collect around worktables, desks, make up/fab areas, etc. that may cause a hazard to the worker.

Welding leads, extension cords, air hoses, etc. shall be elevated or positioned in such a way as to prevent tripping hazards.


Rev. 2 July 2011 18-3

18.4 Fall Protection Systems When employees are exposed to un-protected sides and edges 6 ft. or more above a lower level, they shall be protected from falling by use of guardrails, safety nets, or personal fall arrest systems. In the event that scaffolds, ladders, work platforms, or mechanical personnel lifts are used, they shall be in accordance with manufacturer’s specifications and Dematic Corp. policy.

18.5 Guardrail Systems A guardrail system is a barrier erected to prevent employees from falling to lower levels. All guardrail systems must comply with the following:

� A guardrail system must have a top edge height that is 42-in. (plus or minus 3 in.) above the walking/working level. When conditions warrant, the height of the top edge may exceed the 45-in. height as long as the systems meets all other applicable criteria.

� Mid-rails, screens, mesh, intermediate vertical members, or equivalent intermediate structural members must be installed between the top edge of the guardrail system and the walking/working surface when there is no wall or parapet wall at least 21-in. high.

� Mid-rails must be installed at a height midway between the top edge of the guardrail system and the walking/working level.

� Screens and mesh shall extend from the top rail to the walking/working level and along the entire opening between top rail supports.

� Intermediate members, when used between posts, shall be less than 19-in. apart.

� Other structural members must be installed so that there are no openings in the guardrail system that’s are less than 19-in. wide.

� Top rails and mid-rails must be at least ¼ in. diameter or thickness to prevent cuts and lacerations. If wire, nylon, manila rope is used for top rails, it shall be flagged at 6- ft. Intervals with high visibility material. Steel and plastic banding may not be used as top rails or mid-rails.

� Manila, plastic or synthetic rope being used for top rails or mid-rails shall be inspected as frequently as necessary to ensure that it continues to meet strength requirements. The ends of top rails and mid-rails may not hang over the terminal posts, except where the overhang will not constitute a projection hazard. The rails must be surfaced to prevent puncture, laceration, or snagging hazards.

� When guardrail systems are used in hoisting areas, a chain, gate, cable, rope or removable guardrail section is to be placed across the access opening between the guardrail sections when hoisting operations are not taking place.


Rev. 2 July 2011 18-4

� Guardrail systems used around holes for passing materials will not have more than two sides that are removable. When guardrails are used at holes or ramps, they will be erected on all unprotected sides or edges.

� Mid-rails, screens, mesh, intermediate vertical members, solid panes, and equivalent structural members will withstand, without failure, a force of at lease 150 lb. Applied in any downward or outward direction at any point along the mid-rail or other member.

� Guardrail systems will withstand, without failure, a force of at least 200 lb. applied within 2-in. of the top edge in any outward or downward direction at any point along the top edge. The test load applied in the downward direction cannot deflect the top edge of the guardrail to a height less than 39-in.

18.6 Personal Fall Arrest Systems A personal fall arrest system is used to stop an employee in a fall from a working level. It consists of an anchorage and connectors, or body harness, and may include a lanyard, deceleration device, lifeline, or a combination of these. When stopping a fall, a personal fall arrest system shall be designed to perform the following:

� Limit the maximum arresting force on an employee to 1,800 lb. when used with a body harness (the attachment point should be located in the center of their wearer’s back or above the head)

� Be rigged such that the employee cannot free fall more than 6-ft. or contact a lower level

� Bring an employee to a complete stop and limit maximum deceleration distance an employee travels to 3½ ft.

� Have the strength to withstand twice the potential impact energy of an employee free falling a distance of 6 ft. or the free fall distance permitted by the system, whichever is less.

18.7 Connectors All connectors, which may be independent components such as carabiners or integral components like buckles or D-rings, must be made from drop-forged, pressed, or formed steel or equivalent materials. They should have a corrosion resistant finish and all surfaces and edges should be smooth to prevent damage to the system’s interfacing parts.

D-rings and snaphooks shall have a minimum tensile strength of 5,000 lb. and will be proof tested to a minimum tensile load of 3,600lb. Without cranking, breaking, or taking permanent deformation.


Rev. 2 July 2011 18-5

When using a snaphook, it must be compatible with the member to which it is connected to prevent unintentional disengagement (“roll-out”), or use a locking type snaphook that is designed to prevent roll-out. A snaphook will not be engaged unless it is a locking type and designed for the following connections:

� To webbing, rope, or wire rope

� To each other

� To a D-ring where another snaphook or connector is attached

� To a horizontal lifeline

� To any object that is incompatibly shaped in relation to the snaphook such that rollout could occur by the connected object being able to depress the snaphook keeper and release it self.

When working on platforms or scaffolding with horizontal lifelines that may become vertical lifelines, a connector attached to the horizontal lifeline will lock in both directions.

18.8 Lanyards and Lifelines Horizontal lifelines shall be designed, installed, and used, under supervision of a qualified person, as part of a complete personal fall arrest system. Lanyards and vertical lifelines will have a minimum breaking strength of 5,000 lb., and each employee must be attached to a separate vertical lifeline, unless otherwise approved.

Self-retracting lanyards and lifelines that automatically limit free fall distance to 2 ft. or less shall sustain a minimum tensile load of 3,000 lb. when fully extended.

Self-retracting lanyards and lifelines that do not limit free fall distance to 2 ft. or less (ripstitch lanyards) shall sustain a minimum tensile load of 5,000 lb. Ropes and straps (webbing) used in lanyards, lifelines, and strength components of body harness will be made from synthetic fibers.

Lifelines, lanyards, and safety harnesses shall be protected from cutting, pinching, or burning and must not be placed over a sharp edge. In hot work operations or those involving the use of acids, solvents, or caustics, lifelines and lanyards shall be kept clear to avoid burning or damage. A two lanyard systems (one lanyard on side D-rings) may be needed in climbing from walls, in working pipe racks, etc.

18.9 Anchorage Employees must be secured to an object of substantial capacity that is capable of supporting 5,000lb. per employee (pipe, structure, cable, rope, lifeline, etc.) and will be designed, installed, and used as part of a complete personal fall


Rev. 2 July 2011 18-6

arrest system that maintains a safety factor of at least two, and it will be used under the supervision of a qualified person.

The anchorage used to support a personal fall arrest system has to be independent of any anchorage being used to support or suspend platforms.

18.10 Storage and General Use All equipment must be stored in a clean, dry place that is free from abrasive or cutting materials and excessive heat. Personal fall arrest systems and components subjected to impact loading will be immediately removed from service. The system will not be used again until it is inspected and determined by a competent person to be undamaged and suitable for reuse.

18.11 Inspection Prior issuance, a qualified person shall inspect all safety harnesses, lanyards, and lifelines. In addition, the personal fall arrest system shall be inspected on a quarterly basis following the initial inspection and prior to each use by the wearer and marked with the appropriate color code (see table). Both the initial and quarterly inspections must be documented. If the wearer feels the safety harness, lanyard, or lifeline is not in perfect condition, it shall be reported immediately for inspection. A visual inspection shall consist of the following:

� Harness

� Stitching

� Rivets

� Buckles and buckle tabs

� “D” rings

� Rust and abrasion

� Burns

� General appearance

� Lanyards and Lifelines

� Frayed strands

� Broken strands

� Rot

� Burns

� Corrosion

� General appearance


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Table 1 Color Code Scheme

Quarter Color

First Quarter Jan to Mar Red Second Quarter Apr to June Blue Third Quarter July to Sept Green Fourth Quarter Oct to Dec Yellow

18.12 Training Employees who may be exposed to fall hazards will be provided training on recognizing and minimizing the hazards. A competent person who is qualified in the following will train employees on:

� The nature of fall hazards in the work area

� Any Site specific or Customer specific fall protection requirements.

� The correct procedures for erecting, maintaining, disassembling, and inspecting the fall protection system to be used

� The use and operation of guardrail systems, personal fall arrest systems, warning line systems, safety monitoring systems, controlled access zones, and other protection to be used

� The role of each employee in the safety monitoring system

� The correct procedures for handling and storage of equipment and material and the erection of overhead protection

� The role of employees in fall protection plans

A written certification record containing the employee’s name, the training dates, and the signature of the person who conducted the training should be completed to document employee training. Employees will be retrained if it is evident that they do not understand the material presented.

Retraining is also required when the following occurs:

� Changes in the workplace make previous training obsolete

� Changes in types of fall protection systems or equipment to be used make previous training obsolete

� Inadequacies in an employee’s knowledge or use of fall protection systems or equipment indicate that the employee has not achieved the required level of understanding or skill.

Health and Safety Program Fire Prevention

Rev. 2 July 2011 19-1

19 Fire Prevention

Purpose: The purpose of this procedure is to establish a consistent method of fire prevention and to define placement and maintenance of portable fire extinguishers.

19.1 General The following guidelines shall be adhered to when dealing with fires and fire prevention:

� All fires must be reported.

� The prevention of fires is of utmost importance. Good housekeeping and equipment maintenance must be followed to keep fire hazards at a minimum.

� Matches and cigarette lighters may not be carried into any area where explosive atmosphere may be present.

� Smoking must be confined to specifically designated areas.

� Smoking is not permitted in any area suspected to contain flammable vapors. Any area subject to contamination by flammable liquids or gas should be designated as “NO SMOKING” area. A sign to that effect should be displayed.

� Cans of oil, kerosene, oily rags, waste, etc. are not allowed near stoves or welding/cutting operations.

� Oily waste or oil-soaked clothing can result in spontaneous combustion, can cause a fire, and must not be left lying around. To prevent such fires, covered metal containers for disposal of oily rags, waste, and other flammable rubbish must be provided. These must be emptied often enough to keep premises safe and sanitary.

� The use of gasoline as a cleaning agent is strictly forbidden.

� Oil or gasoline from leaks should be cleaned up and disposed of in a prescribed manner.

� All leaks should be reported and repaired immediately, if possible. If immediate repair is not possible, adequate warning signs must be posted and extra precautions taken against fires instituted.

� In the event of a gas leak, all fires and engines should be shut down without delay.


Rev. 2 July 2011 19-2

� When testing for gas leaks, use soapsuds or an approved leak detector fluid. Never use an open flame.

� Gasoline, kerosene, or other flammable liquids must not be stored in glass containers.

� Since paint, insect sprays, and most paint removers are usually flammable, their use near open flames or other sources of ignition must be avoided. Read the labels on the containers.

� A competent inspector will perform inspection and maintenance of all fire equipment. Records of inspection and maintenance must be maintained. The following general guidelines will be observed:

� Portable fire extinguishers shall be inspected at least monthly. At regular intervals, not more than a year apart, extinguishers shall be thoroughly examined, recharged or repaired to ensure operability or replaced as needed. Each extinguisher shall have a durable tag securely attached to show the maintenance or recharge date and the initial or signature of the person performing the service.

� Fire-fighting equipment is for fire use only and must be kept in its designated place at all times when not in use.

� All fire protection equipment must be in designated areas that are clearly identified with appropriate markings. This equipment should be located near likely fire hazards, and it must be accessible to operating personnel. The number, type, and location of extinguishers must meet all applicable standards.

� All employees should be instructed in the proper use of available fire-fighting equipment.

� A fire extinguisher that is empty, defective, or has been discharged should never be re-hung until it has been serviced or repaired. It is necessary that extinguishers operate at top efficiency the instant they are used. Manufacturer’s instructions for refilling and maintaining extinguishers must be followed.

19.2 Classes of Fires Class A - Those fires that occur in ordinary materials such as wood, paper, rags, and rubbish. The quenching and cooling effects of water, or of solutions containing large percentages of water, are of prime importance in extinguishing these fires.

Class B – Those fires that occur in the vapor-air mixture over the surface of flammable liquids such as gasoline, oil, grease, paints, and thinners. The limiting of air is of primary importance. Regular dry chemical, multi-purpose dry chemical, carbon dioxide, and foam may be used, depending on the circumstances of the fire. Solid streams of water are likely to spread the fire, but on large fires of this class, water fog nozzles prove effective.


Rev. 2 July 2011 19-3

Class C – Those fires that occur in or near electrical equipment when non-conducting extinguishing agents must be used. Dry chemical, carbon dioxide, compressed gas, or vaporizing liquid may be used. Foam or solid stream of water should not be used because both are good conductors and can expose the operator to a severe shock hazard.

Class D – Those fires that occur in combustible metals such as magnesium, titanium, zirconium, lithium, and sodium. Specialized techniques, extinguishing agents, and extinguishing equipment are needed to control and extinguish fires of this type. Normal extinguishing agents should not be used, as there is a danger of increasing the intensity of the fire by chemical reaction between some extinguishing agents and the burning metal.

19.3 Flammable Liquids (Flash Point of 100 Degrees Fahrenheit or less)

The following guidelines should be adhered to when dealing with flammable liquids:

� Flammable liquids such as gasoline, naphtha, and lacquer thinner must not be used for cleaning purposes.

� Do not store flammable liquids in open containers.

� Spills or overflow of flammable liquids should be avoided. However, in the event of spillage, immediate steps should be taken to clean up and minimize the danger of fire.

� All solvents should be kept in approved and properly labeled containers. Gasoline and other highly flammable liquids should be handled, transported, and dispensed only in properly labeled, red safety cans.

� With the exception of gasoline and oil, the mixing of two or more flammable liquids is prohibited.

� When pumping highly flammable liquids from one container to another, metallic contact should always be maintained between the two other containers.

19.4 Good Housekeeping to Prevent Fires Good housekeeping should be maintained at all work locations, tool/office trailers and in all vehicles. Combustible materials such as oil-soaked rags, waste, and shavings should be kept in approved metal containers with self-closing lids. Containers should be emptied daily. Paper and other combustible materials should not be allowed to accumulate.


Rev. 2 July 2011 19-4

19.5 Safe Handling and Storage of Flammable & Combustible Materials

The following guidelines should be adhered to when handling and storing flammable and combustible materials:

� Small quantities of flammable liquids should be stored in approved safety cans with self-closing lids, flame arresters, and pressure relief vent. The contents must be marked.

� Dispensing drums should be equipped with a special self-closing faucet and pressure vacuum relief vents and should be attached to a ground wire.

� No more than 25 gallons of flammable liquids may be stored outside an approved storage cabinet.

� Storage cabinets, rooms, or particular areas should be designated to store flammable liquids. Cabinets should be labeled “FLAMMABLE – KEEP FIRE AWAY.”

� No more than 60 gallons of flammable or 120 gallons of combustible liquid may be stored in any open storage cabinet or container.

� Large quantities of flammable liquids should be stored well away from the immediate work area.

� Never handle a flammable substance near a heat source or bring a heat source near a flammable substance.

� Safe transfers of flammable liquids must be made in an open and well-ventilated area where the vapors will be diluted and dissipated by large quantities of fresh air. There must be a bond between the containers to eliminate static electricity.

� Outside portable tank storage shall be located no closer than 25 feet from any building.

� Using funnels and spouted cans makes for quick transfer and helps prevent dangerous spills.

� Rags saturated with flammable and combustible liquids are highly susceptible to spontaneous combustion and must be disposed of in appropriate containers. Never pile them on the ground.

� When refueling or lubricating machinery, make certain that it is shutdown first. Pieces of machinery like exhaust pipes and bearings radiate heat and electrical systems generate sparks that can ignite in an accidental spill. If fuel is dispensed from a fuel truck, the truck should be grounded to the equipment being filled.

� Be certain that an engine is supplied with the proper type of fuel and the fuel supply is shut-off by a valve when the engine is not in use.


Rev. 2 July 2011 19-5

� Never use gasoline as a solvent – it produces dangerous amounts of vapor. Always use a high flash point solvent or thinner for cleaning off paint, grease, or oil around equipment.

� Because of their convenient size, aerosol cans are often stored or set down in unsafe places. Keep in mind that all aerosol cans are pressurized and that this pressure increases when exposed to heat. If the can is overheated, it will explode like a hand grenade.

19.6 Fire Extinguisher Requirements

19.6.1 General Requirements Portable fire extinguishers shall be maintained in a fully charged and operable condition and kept in their designated place at all times when they are not being used. Extinguishers shall be conspicuously located where they will be readily accessible and immediately available for use. They shall be located along normal paths of travel. In areas where visual obstructions cannot be completely avoided, the location and intended use of the extinguishers will conspicuously indicated.

Extinguishers having a gross weight less than 40 lb. should be installed so that the top of the extinguisher is less tan 5 ft. above the floor. Extinguishers having a gross weight greater than 40 lb. should be installed so that the top of the extinguisher is less than 3½ ft. above the floor.

The selection of fire extinguishers for a given situation will depend upon the characters of the fires anticipated, the construction and occupancy of the individual property, the vehicle or hazard to be protected, ambient temperature conditions, and other factors.

19.6.2 Fire Extinguisher Layout Criteria During the construction phase of facilities, the support buildings, or permanent plant buildings or facilities, of the construction area shall be provided with one portable, multi-purpose, cartridge-operated, minimum-rated, 2A-hand fire extinguisher. One extinguisher will be available for each 3,000-sq. ft. of area around the building construction site with a maximum travel distance to an extinguisher of 100 ft.

A 10-B fire extinguisher shall be provided within 50 ft. when more than 5 gallons of flammable or combustible liquids or 5 lb. of flammable gases are being used.

19.6.3 Proper Use of Fire-Fighting Equipment When fighting a fire with standard portable fire extinguisher, use the following procedures to extinguish the fire:


Rev. 2 July 2011 19-6

1. Always use the handle to carry a standard portable fire extinguisher. Walk at a rapid pace – do not run to a fire.

2. Proceed to the upwind side of a fire, and stay clear of the flames. When you are approximately 10 ft. upwind of the near edge, stop and ready your extinguisher for discharge.

3. Once you extinguisher is set for discharge, position yourself within 8 ft. if the near edge upwind of the fire. From this position, the air currents help carry the agent into the fire, assure maximum visibility, and provide protection from the heat.

4. When discharging the extinguishing agent, aim your stream just short of the near edge.

5. Apply the agent in a side-to-side sweeping action across the full width of the fire. Make sure each sweep of the agent is slightly wider than the near or leading edge of the fire.

6. Advance forward only as fast as the extinguishing action of your agent will permit. Do not outrun your protection. Do not raise your stream to chase the flame. Keep it down in front of the flame edge.

7. Stop short of the already extinguished fuel area. Do not become involved in the fire. Above all, maintain your side-to-side sweeping action until the fire is extinguished. Once the fire is out, stand by for a few minutes. Make sure there is no danger of a reflash. Do not ever turn your back on an apparently extinguished fire.

19.6.4 Maintenance At regular intervals, not more than one year apart or when specifically indicated by an inspection, extinguishers shall be thoroughly examined and/or recharged or repaired to ensure operability or replaced as needed.

Extinguishers removed from their locations to be recharged must be replaced by spare extinguishers during the period they are gone. Each extinguisher shall have a durable tag securely attached to show the maintenance or recharge date and the initial or signature of the person who performed this service.

19.6.5 Training Information Each employee will be given information in procedure requirements prior to their assignment. Training in the proper selection, use, and maintenance or portable fire extinguishers will be completed during this training session. As the procedure is updated or where job responsibilities change, especially regarding emergency plans, employees will be retrained prior to implementing the changes.


Rev. 2 July 2011 19-7

19.7 Fire Extinguisher Supporting Information

19.7.1 Using a Fire Extinguisher

There is a simple acronym to remember to operate most fire extinguishers - PASS. PASS stands for Pull, Aim, Squeeze and Sweep.

Pull the pin at the top of the cylinder. Some units require the releasing of a lock latch or pressing a puncture lever.

Aim the nozzle at the base of the fire.

Squeeze or press the handle.

Sweep the contents from side to side at the base of the fire until it goes out.

Shut off the extinguisher and then watch carefully for a rekindling of the fire

19.7.2 Ratings Symbols

Multi-Class Ratings

Class A Extinguishers will put out fires in ordinary combustibles, such as wood and paper. The numerical rating for this class of fire extinguisher refers to the amount of water the fire extinguisher holds and the amount of fire it will extinguish.

Class B Extinguishers should be used on fires involving flammable liquids, such as grease, gasoline, oil, etc. The numerical rating for this class of fire extinguisher states the approximate number of square feet of a flammable liquid fire that a non-expert person can expect to extinguish.

Class C Extinguishers are suitable for use on electrically energized fires. This class of fire extinguishers does not have a numerical rating. The presence of the letter “C” indicates that the extinguishing agent is non-conductive.

Class D Extinguishers are designed for use on flammable metals and are often specific for the type of metal in question. There is no picture designator for Class D extinguishers. These extinguishers generally have no rating nor are they given a multi-purpose rating for use on other types of fires.


Rev. 2 July 2011 19-8

Many extinguishers available today can be used on different types of fires and will be labeled with more than one designator, e.g. A-B, B-C, or A-B-C. Make sure that if you have a multi-purpose extinguisher it is properly labeled.

This is the old style of labeling indicating suitability for use on Class A, B, and C fires.

This is the new style of labeling that shows this extinguisher may be used on Ordinary Combustibles, Flammable Liquids, or Electrical Equipment fires. This is the new labeling style with a diagonal red line drawn through the picture to indicate what type of fire this extinguisher is NOT suitable for. In this example, the fire extinguisher could be used on Ordinary Combustibles and Flammable Liquids fires, but not for Electrical Equipment fires.

19.7.2 Number Rating

Fire extinguishers also have a number rating.

For Type A fires, a 1 would stand for 1 1/4 gallons of water, a 2 would represent 2 1/2 gallons, 3 would be 3 3/4 gallons of water, etc.

For Type B and Type C fire, the number represents square feet. For example, 2 would be two square feet, 5 is five square feet, etc.

Fire extinguishers can also be made to extinguish more than one type of fire.

For example, you might have an extinguisher with a label that reads 2A5B. This would mean this extinguisher is good for Type A fires with a 2 1/2 gallon equivalence and it is also good for Type B fires with a 5 square feet equivalency.

Health and Safety Program Hazard Communications Program

Rev. 2 July 2011 20-1

20 Hazard Communications Program

Purpose: The purpose of this procedure is to provide guidelines for the proper way to communicate hazards when working on jobsites. This program is to remain in a convenient location (for example, jobsite office) so employees may easily access it as needed.

20.1 Container Labeling The site supervisor will verify that all containers received for use will be clearly labeled with the following:

� The contents

� Appropriate hazard warnings

� The name and address of the manufacturer, importer, or responsible party

It is the policy of Dematic Corp. that no container will be released for use until this data is verified.

The area supervisor will ensure that all secondary containers are labeled with either a copy of the original manufacturer’s label or with the generic labels that have blocks for identity and for hazard warnings.

:NOTE: For help with labeling, please see the Safety Representative or Site Supervisor.

20.2 Material Safety Data Sheets (MSDS) � Copies of MSDS for all hazardous chemicals that employees may be

exposed to will be kept in the jobsite office

� MSDS will be available for employees to review during each work shift. If MSDS are not available for new chemical(s) in use and/or do not have MSDS, contact the site supervisor immediately

� The site supervisor will obtain and maintain MSDS for all chemicals that will be used onsite. MSDS are to be kept in a binder at the jobsite.


Rev. 2 July 2011 20-2

20.3 Employee Training Information Prior to starting work, each new employee will attend a health and safety orientation, conducted by the designated site safety coordinator/supervisor, and will receive information and training on the following:

� The requirements contained in the Hazard Communication Program

� Chemicals present in their workplace operations

� Locations and availability of the written Hazard Communication Program

� Physical and health effects of the hazardous chemicals

� Methods used to determine the presence or release of hazardous chemicals in the work area

� How to lessen or prevent exposure to these hazardous chemicals through usage of controlled work practices and personal protective equipment

� Advancements that the Company has taken to lessen or prevent exposure to these chemicals

� Emergency safety procedures to follow if exposed to these chemicals

� How to read labels and review MSDS to obtain appropriate hazard information

The format used to train employees is audiovisual, lecture/instructions, and handouts. After attending the training class, employees will sign a form to verify that they attended the training, received written materials, and understood Dematic Corp. policies on hazard communication.

Prior to a hazardous chemical being introduced into any work area, each employee of that work area will be given information as previously outlined. The site superintendent is responsible for ensuring that MSDS on the new chemicals are available.

:NOTE: The Hazard Communication Program only requires a list of all hazardous chemicals; however, it is felt that identifying the location and the processes will aid in carrying out the full program.

20.4 List of Hazardous Chemicals The following is a list of all known hazardous chemicals used by Dematic Corp. employees. Further information on each noted chemical can be obtained by reviewing the MSDS located in the jobsite office. Additional MSDS will be added to individual sites as needed.


Rev. 2 July 2011 20-3

20.4.1 Hazardous Chemicals • 10w30 Motor Oil

• Acetylene

• Alvin Lab Metal Putty

• Antifreeze

• Atom Arc Weld Rod 7018

• Carbon Steel electrode USW201M/L50

• CRC STA LUB Super White Grease

• CRC Wht Lithium Grease

• Diesel Fuel #2

• Dry Chemical Fire Extinguishers

• Glass Cleaner

• Kester - “44” Rosin Flux Cored Solder/“331” Flux Cored Solder

• Kilz Aerosol

• Kilz General Purpose Interior – Gallon

• Loctite – 262/271/242

• MAPP

• Mineral Spirits

• Mobile Gear 630/636/Vectra Oil No. 3/SHC 634/Mobilux EP2

• Oxygen/Propane

• Red Head Adhesive A7

• Rubber Belts

• Scotch Grip – 4693 H Plastic adhesive/1300-L Gasket adhesive/ 1357 Contact adhesive

• Shipping mate contact adhesive

• Simple Green

• Summa Recip – Reducer Oil

• Super 77 Spray adhesive

• Touch-up Paint Aerosol – Lakeshore/Michigan Coatings

• Unleaded gasoline

• WD40 Aerosol

• GOJO Orange Pumice Hand Cleaner

Health and Safety Program Lockout/Tagout

Rev. 2 July 2011 21-1

21 Lockout/Tagout

Purpose: The purpose of this procedure is to define requirements for the application and uses of energy control processes that enables employees to safely perform work on equipment that contains or has the potential to contain hazardous energy.

:NOTE: This procedure shall be followed unless superceded by an equal or more stringent procedure by the customer.

21.1 Definitions Affected Employee – an employee who is required to operate or use a machine or equipment on which servicing or maintenance is being performed under lock-out/tag-out or who is required to work in such an area where maintenance is being performed.

Authorized Employee – a person who locks-out/tags-out machines or equipment in order to perform servicing or maintenance on that machine or equipment. An affected employee becomes an authorized employee when that employee’s duties include performing servicing or maintenance.

Capable of Being Locked-Out – An energy-isolating device is capable of being locked-out if it has a hasp or other means of attachment of which, or through which, a lock-out can be affixed or if it has a locking mechanism built into it. Other energy-isolating devices are capable of being lock out if lock-out can be achieved without the need to dismantle, rebuild, or replace the energy-isolating device or permanently alter its energy control capability.

Energized – Connected to an energy source or containing residual or stored energy.

Energy-Isolating Device – Mechanical device that physically prevents the transmission or release of energy, including, but not limited to the following:

� Manually-operated electrical circuit breakers

� Disconnected switches

� Manually operated switches by which the conductors of a circuit can be disconnected from all ungrounded supply conductors and no pole can be operated independently

� Line valves

� Blocks and an similar device used to block or isolate energy


Rev. 2 July 2011 21-2

:NOTE: Push buttons, selector switches, and other control circuit type devices are not energy-isolating devices

Energy Source – Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy.

Lock-Out – The placement of a lock-out device on an energy-isolating device, in accordance with an established procedure, to ensure that the energy-isolating device and the equipment being controlled cannot be operate until the lock-out device is removed.

Lock-Out Device – A device that uses a positive means (i.e., a lock, either key or combination type) to hold an energy-isolating device in a safe position and prevent the energizing of a machine or equipment, including blank flanges and bolted slip lines.

Normal Production Operations – The use of a machine or equipment to perform its intended production function.

Servicing and/or Maintenance – Work place activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities include lubrication, cleaning or UN-jamming the machines or equipment, and making adjustments or tool changes where the employee may be exposed to the unexpected energization or start-up of the equipment or the release of hazardous energy.

Setting Up – Preparing a machine or equipment to perform its normal production operation.

Tag-Out – The placement of a tag-out device on an energy-isolating device, in accordance with an established procedure, to indicate that the energy-isolating device and the equipment being controlled cannot be operated until the tag-out device is removed.

Tag-Out Device – A prominent warning device, such as a tag and a means of attachment, that can be securely fastened to an energy-isolating device, to indicate that the device and the equipment being controlled cannot be operated until the tag-out device is removed.

21.2 Responsibilities The site supervisor is responsible for assuring that this procedure is implemented consistently throughout the job site. The supervisor will also assure that each affected employee is properly trained and efficient in applying these procedures, will ensure that periodic reviews are made to evaluate the energy-isolation programs, and will communicate any deficiencies in the application to the customer and safety personnel.


Rev. 2 July 2011 21-3

The supervisor/foreman is responsible for assuring proper field implementation of this procedure and for the consistent compliance of employees that perform tasks under the protection of energy controls. The supervisor/foreman will interface with appropriate operations personnel to ensure specific sequences are defined and documentation of the energy control procedures is completed. The supervisor/foreman will also ensure that communication and continued protection is provided in case of shift or personnel changes.

Employees who work under energy-isolation controls are responsible for ensuring that all required energy-isolation devices are properly applied and maintained throughout the task being performed. They are also responsible for the removal of the device and for communicating the removal of the device to their supervisor/foreman.

Employees that are members of a work crew that perform work under group lock out are responsible for reviewing and understanding the energy-isolation process. When the energy sources have been identified to be de-energized by work crews, they will place their locks on the lock box and sign the log in sheet. Once their portion of the task is complete, the work crewmembers will sign off the log and remove their locks from the lock box.

:NOTE: All individual locks or tags used by a company will contain the company name and the employees name that applies the lock.

21.3 Lock Removal A lock that has been applied by a specific person will be removed by that person only unless the project supervisor authorizes removal. In cases where a lock is left on as an energy control device and the employee is not available to remove the lock, the following procedure must be initiated:

� Ensure the equipment is in a safe condition (work completed)

� Attempt to contact the employee that applied the lock

� If the employee is contacted, notify the employee that the lock is to be removed

� If the employee cannot be reached, the time and method of the attempt should be documented

� The employee, upon returning to the site and prior to beginning work, will be informed that the lock was removed. The employee will sign the document verifying understanding.

21.4 Procedures Prior to applying an energy-isolation device on a piece of equipment, the responsible supervisor/foreman will contact the appropriate operations representative and conduct a survey, preferably with the representative, of the


Rev. 2 July 2011 21-4

potential energy sources of that equipment. The supervisor/foreman will rely heavily on the specific isolation procedures for that equipment and of the operation representative’s knowledge of the equipment.

Once the equipment has been surveyed and potential energy sources have been identified, the supervisor/foreman will ascertain information from the operations representative and from the job scope and make a decision based on the information whether or not individual lockouts or group lockouts are needed.

21.5 Individual Lock-Out/Tag-Out The supervisor/foreman will assign the work to be performed to qualified work members and will identify the locations where individual energy-isolations are to be applied. After verifying each location, the work crewmembers will sign on to the log and apply their energy-isolation devices. The work crewmembers will them identify that the equipment is de-energized by pushing start buttons, open bleeder valves, etc.

:NOTE: All start buttons must be returned to the neutral position, valves must be verified open, etc.

When the work task is complete, the work crewmembers will sign off of the log and notify the operations representative and their supervisor/foreman that they are removing their energy-isolation devices. Once the equipment is determined to be in a safe condition to be put into service, the operations representative will place the equipment in service.

21.6 Group Lock-Out/Tag-Out Where the use of a group lock-out/tag-out is determined, the following eight steps should be performed.

1. A company authorized person will work with the appropriate customer representative to verify each potential energy source to be, or that has been, isolated. At this time, all potential energy sources will be verified as de-energized.

2. Once the energy sources have been isolated, the key for the initial locks placed on the equipment will be put in a lock box. The operations representative and the authorized employee will then place their locks on the box to ensure the primary operation device keys are secured.

3. Each affected employee will be instructed in the purpose and application sequence as well as isolation locations. They are also responsible for verifying the application of energy-isolation devices prior to beginning work.

4. After verifying de-energization, each affected employee will sign the log and place their lock on the lock box. In case where shifts are used, the on coming shift will be required to follow the same verification sequence.


Rev. 2 July 2011 21-5

5. At the end of each shift, the off going shift will sign off of the log and remove their lock. The only lock that will remain in place during the shift change is that lock belonging to the authorized employee.

6. This sequence will be used until work is complete. At that time, each affected employees lock will be removed.

7. Authorized employees will then ensure that the equipment is in a safe condition for start-up and will inform the appropriate operations representative that they are signing off of the log and removing their lock.

8. The superintendent, upon verifying the safe condition for start-up can return the equipment to an energized state.

21.7 Periodic Inspections Periodic inspections of energy control procedures are to be conducted at the beginning of each shift and must include the following requirements:

� An authorized person, other than those using the isolation equipment, must perform periodic inspection.

� Periodic inspections should identify and correct any deviations from established procedures or energy-isolation inadequacies.

� Periodic inspections must include a review of the employee’s responsibilities between the inspector and the employee who applied the lock-out/tag-out devices.

:NOTE: If tag-out devices are used, the limitation of tags must be discussed with each employee who may be affected by the energy source isolated by the tag-out device.

Certification of periodic inspections are required and must include the following:

� Identity of the equipment or machine involved

� Date of inspection

� Employees included in the inspection and lock-out

� Person performing the inspection

21.8 Making Adjustments to Equipment If a piece of equipment must be energized in order to make adjustments, to perform hot alignment, or to take measurements, the authorized employee that applied the energy-isolation devices is allowed to remove those devices in accordance with this procedure. The steps to be taken in the case will be inclusive of the de-energization of isolation devices.

If, after the adjustments are made, there is a need to perform additional work on the equipment; it must be re-isolated in accordance with this procedure. The


Rev. 2 July 2011 21-6

isolation sequence will remain the same as when the equipment was originally isolated before adjustments were required.

21.9 Employee Training All employees that are required to work under the protection of energy-isolation controls will be trained in the following areas. All training will be documented and refresher training will be provided whenever a change in the policy is made, or at least annually, whichever comes first.

� The purpose and use of energy control procedures

� Recognition of potential energy sources

� Methods and means necessary to control and isolate potential energy sources

� Requirements of this procedure

� Essential components of energy-isolation devices

Health and Safety Program Personal Protective Equipment (PPE)

Rev. 2 July 2011 22-1

22 Personal Protective Equipment (PPE)

Purpose: The purpose of this procedure is to assist all jobsites in complying with federal regulations mandating that employers perform a hazard assessment. As well as to assist in selecting the type of personal protective equipment that will be necessary to minimize the risks associated with a particular hazard, and to train the affected employees in the use and care of the personal protective equipment (PPE).

22.1 General Personal protective equipment (PPE) should not be relied upon solely to provide protection against hazards. The equipment should be used in conjunction with safe work practices, guards, and engineering controls.

PPE issued to employees will be based upon the completion of a site-specific hazard assessment. All equipment must be maintained in a sanitary and reliable condition, disposable equipment will not be reused, and PPE that has been damaged or is defective will be discarded.

Where employees furnish their own PPE, the supervisor is responsible for assuring its adequacy to protect against the hazard for which it is applied (for example, hard hats, safety glasses, protective footwear).

The jobsite supervisor, with the assistance from safety representatives, is responsible for monitoring the selection, use, and condition of PPE used by the employees.

22.2 Hazard Assessment The work place must be assessed for hazards present, or likely to be present, to be determined what type of PPE is required to safely perform each job. This is accomplished by completing the written Job Hazard Analysis Form. The analysis must be dated, must include the area or job task being evaluated, and must be signed by a designated Dematic Corp. Representative (for example, supervisor, or safety coordinator who has attended Hazard Assessment Training). The Job Hazard Analysis must be used to provide the most effective hazard control possible.


Rev. 2 July 2011 22-2

22.3 Employee Training Employees who are required to wear PPE will receive training on the following:

� When PPE is necessary

� What PPE is appropriate for the hazard

� How to properly put on, take off, adjust, and wear PPE

� Proper care, maintenance, useful life, and disposal of PPE

Employees must demonstrate their understanding of this training prior to performing work that requires the use of any PPE. Refer to the Installation Safety Manual for guidelines and documentation requirements.

Employees will be retrained whenever changes in the work place or in the types of PPE render the previous training obsolete. Employees will also be retrained should observation indicate inadequacies in an affected employee’s knowledge or use of assigned PPE.

22.4 Required PPE The following PPE is mandatory for all Dematic Corp. employees and subcontractors during construction/installation until the customer signs off the project for completion:

All employees shall wear hard hats that meet requirements on ANSI Z89.1. This includes all equipment operators and project management/engineering/controls engineering staff and installers that are on site. Hard hats shall be worn in the proper manner with bills facing forward however, to accommodate welders hard hats may be worn backwards only during welding operations.

Safety glasses with side shields that meet current ANSI standards shall be worn by all personnel at all times while on site. Using approved safety glasses over prescription eyeglasses will be acceptable.

Safety Toed, over the ankle work boots that meet ANSI requirements shall be worn at all times.

Anytime powered actuated tools, electric or air-operated grinding tools, power or chop saws are operated, double eye and face protection (i.e., safety glasses/goggle and a face shield) shall be worn.

Suitable clothing for the construction site shall be worn. Shirts with sleeves at least T-shirt length and full-length pants shall be required (no tank tops). When doing run-in make sure employees are not wearing loose clothing or jewelry or gloves.


Rev. 2 July 2011 22-3

22.5 Respiratory Protection - Voluntary Use of Dust Masks

OSHA refers to disposable paper respirators (or dust masks) as “filtering facepieces.” This type of respirator is defined in OSHA’s Respiratory Protection standard as a “negative pressure particulate respirator with a filter that is an integral part of the facepiece or with the entire facepiece composed of the filter medium.”

When employees use dust masks on a voluntary basis, you are obligated to determine that the respirator use will not itself create a hazard. That is, to ensure that the dust masks are not dirty or contaminated, and that their use does not interfere with the employee’s ability to work safely.

Prior to use, the supervisor must provide a copy of the respiratory protection standard’s Appendix D to each voluntary wearer. This appendix provides basic information on the proper use of respirators for employees who are voluntary users of the equipment and thus are not required to undergo formal training.

Appendix D is a mandatory appendix, but you have the option to develop material that is equivalent in content to this appendix. The information may be transmitted either in written form or verbally.

Employees who use filtering facepiece respirators on a voluntary basis are not required to have medical evaluations.

Respirators worn when not required by OSHA or the employer do not require a fit test. Voluntary users are not prohibited from wearing a beard, even though good industrial hygiene practice recommends that facial hair that interferes with the face-to-facepiece seal should be avoided.

Health and Safety Program Stairways and Ladders

Rev. 2 July 2011 23-1

23 Stairways and Ladders

Purpose: The purpose of this procedure is to provide the necessary safety guidelines for the construction, set-up, use, and inspection of stairways and portable ladders.

23.1 General Requirements A stairway or ladder must be provided at all points of access where there is a break in elevation 19” (48 cm) or more and where no ramp, runway, embankment, or personnel hoist is provided.

When there is only one point of access between levels, it must be kept clear to permit free passage by workers. If free passage becomes restricted, a second point of access must be provided. Where there are more than two points of access between levels, at least one point of access should be kept clear.

23.2 Stairways � Stairways that will not be a permanent part of the structure of which work is

performed must have landings at least 30” deep and 22” wide at every 12’ or less of vertical rise.

� Stairways must be installed at between 30 degrees and 50 degrees from the horizontal.

� Variations and riser height or stair-tread depth must not exceed ¼” in any stairway system, including any foundation structure used as one or more treads of the stairs.

� When doors or gates open directly onto a stairway, a platform must be provided that extends at least 20” beyond the swing of the door.

� All stairway parts must be free of dangerous projection such as protruding nails.

� Slippery conditions on stairways must be corrected.

23.3 Stair Rails and Handrails � Stairways having four or more risers or rising more than 30” in height,

whichever is less, must have at least one handrail. A stair rail must also be installed along each unprotected side or edge. When the top edge of s stair rail system also serves as a handrail, the height of the top edge must be


Rev. 2 July 2011 23-2

between 36” and 37” from the upper surface of the stair rail to the surface of the tread.

� Stair rails installed after March 15, 1991 must be greater than 36”in height.

� Mid-rails, screens, mesh, intermediate vertical members, or equivalent intermediate structural members must be provided between the top rail and stairway steps to the stair rail system.

� Mid-rails, when used, must be located mid-way between the top of the stair rail system and the stair way steps.

� Screens or mesh, when used, must extend from the top rail to the stair way step and along the opening between top rail supports.

� Intermediate vertical members such as balusters, must be no more than 19” apart.

� Other intermediate structural members, when used, must be installed so that there are no openings of more than 19” wide.

� Handrails and the top rails of the stair rail systems must be able to withstand, without failure, at least 200 lb. of weight applied within 2” of the top edge in any downward or outward direction at any point along the top edge. Mid-rails must be able to withstand, without failure, at least 150 lb. of weight in any downward and outward direction.

� The height of handrails must be between 30” and 37” from the upper surface of the handrail to the surface of the tread.

� Stair rail systems and handrails must be surfaced to prevent injuries, such as punctures or lacerations, and to keep clothes from snagging.

� Handrails must provide and adequate handhold for employees to grasp to prevent falls.

� The ends of stair rail systems and handrails must be built to prevent dangerous projections, such as rails protruding beyond the end posts of the system.

� Temporary handrails must have a minimum clearance of 3” between the handrails and walls, stair rail systems, and other objects.

� Unprotected sides and edges of stairway landings must be provided with a standard 42” guardrail system.

23.4 Ladders � A double-cleated ladder or two or more ladders must be provided when

ladders are the only way to enter or exit a work area having more than 25 employees or when a ladder serves simultaneous two-way traffic.

� Ladder rungs, cleats, and steps must be parallel, level, and uniformly spaced when the ladder is in position for use.


Rev. 2 July 2011 23-3

� Rungs, cleats, and steps of portable and fixed ladders (except as provided below) must not be spaced between 10”and 14” apart, along the ladders side rails.

� Rungs, cleats, and steps of step stools must be between 8”and 12” apart between centerlines of the rungs, cleats, and steps.

� Rungs, cleats, and steps at the base section of extension trestle ladders must be between 8” and 18” apart between centerlines of the rungs, cleats, and steps. The rung spacing on the extension section must be between 6”and 12”.

� Ladders must not be tied or fastened together to create longer sections unless they are specifically designed for such use.

� A metal spreader or locking device must be provided on each stepladder to hold the front and back sections in an opening position when the ladder is being used.

� Two or more separate ladders used to reach an elevated work area must be offset with a platform or landing between the ladders, except when portable ladders are used to gain access to fixed ladders.

� Ladder components must be surfaced to prevent injury from punctures or lacerations and to prevent snagging of clothing.

23.5 Portable Ladders � Non-self-supporting and self-supporting portable ladders must support at

least four times the maximum intended load; extra heavy-duty type 1A metal or plastic ladders must sustain three and one third times the maximum intended load. The ability of the self-supporting ladder to sustain loads must be determined by applying the load to the ladder in a vertical direction. The ability of a non-self-supporting ladder to sustain loads must be determined by applying the load in a vertical direction when the ladder is placed at a horizontal angle of 75.5 degrees.

� The minimum clear distance between side rails for all portable ladders must be 11.5”.

� The rungs/steps of portable metal ladders must be corrugated, knurled, dimpled, coated with skid-resistant material, or treated to minimize slipping.

23.6 Use of all Ladders � When portable ladders are used for accessing an upper landing surface, the

side rails must extend at least 3 ft. above the upper landing surface. When such an extension is not possible, the ladder must be secured and a grasping device, such as a grab rail, must be provided to assist workers in mounting and dismounting the ladder. A ladder extension must not deflect under a load that would cause the ladder to slip off its supports.


Rev. 2 July 2011 23-4

� Ladders must be free of oil, grease, and other slipping hazards.

� Ladders must not be loaded beyond the maximum intended load for which they were built, or beyond their manufacturer’s rated capacity.

� Non-self-supporting ladders must be used at an angle where the horizontal distance from the top support to the foot of the ladder is approximately one quarter of the working length of the ladder. Wood job-made ladders with spliced side rails must be used at an angle where the horizontal distance is one-eighth the working length of the ladder.

� Fixed ladders must be used at a pitch no greater than 90 degrees from the horizontal, measured from the backside of the ladder.

� Ladders must be used only on stable and level surfaces unless secured to prevent accidental movement.

� Ladders must not be used on slippery surfaces unless secured or provided with slip-resistant feet to prevent accidental movement. Slip-resistant feet must not be used as a substitute for the care in placing, lashing, or holding a ladder on slippery surfaces.

� Ladders placed in areas such as passageways, doorways, driveways, or where they can be displaced by workplace activities or traffic must be secured to prevent accidental movement or a barricade must be used to keep traffic or activities away from the ladder.

� The area around the top and bottom of the ladder must be kept clear.

� The top of a non-self-supporting ladder must be places with two rails supported equally unless it is equipped with a single-support attachment.

� Ladders must not be moved, shifted, or extended while in use.

� Ladders must have nonconductive side rails if they are used where the worker or the ladder could contact exposed energized electrical equipment.

� The top or top step of a stepladder must not be used as a step.

� Cross-bracing on the rear section of stepladders must not be used for climbing unless the ladders are designed and provided with steps for climbing both on front and rear section.

� Single-rail ladders must not be used.

� When ascending or descending a ladder, the worker must face the ladder.

� Each worker must use at least one hand to grasp the ladder when climbing.

� Workers must not carry any object or load on a ladder that could cause them to lose their balance and fall.


Rev. 2 July 2011 23-5

23.7 Ladder Inspections � Ladders must be inspected by a competent person for visible defects on a

quarterly basis and after any incident that could affect their safe use. These quarterly inspections must be documented using the Portable Ladder Inspection Form. Ladders passing inspection must be marked with the appropriate color code.

Table 1 Color-Code Scheme

Quarter Color

First Quarter (Jan to March) Red Second Quarter (April to June) Blue Third Quarter (July to Sept) Green Fourth Quarter (Oct to Dec) Yellow

� Portable ladders with structural defects, such as broken or missing rungs, cleats, or steps, broken or split rails, corroded components, or other faulty or defective components, must immediately be marked defective or tagged with “DO NOT USE,” or similar language and withdrawn from service until repaired.

� Fixed ladders with structural defects such as broken or missing rungs, cleats, or steps, broken or split rails, or corroded components, must be withdrawn from use when they exhibit the following:

� Tagged with “DO NOT USE” or similar language

� Marked in a manner that identifies them as defective

� Blocked with a plywood attachment, or something similar, that spans several rungs.

� Ladder repairs must restore the ladder to a condition meeting its original design criteria before the ladder is returned to use.

Health and Safety Program Oxy-Fuel, Cutting, Brazing and Welding

Rev. 2 July 2011 24-1

24 Oxy-Fuel, Cutting, Brazing and Welding

Purpose: The purpose of this procedure is to establish minimum guidelines for performing tasks involving oxy-fuel cutting, brazing, and welding.

24.1 General There are numerous inherent hazards in the use of oxy-fuel cutting apparatus, and it is necessary that proper safety procedures be understood prior to use of such equipment. A thorough understanding of he following safety procedures will serve to minimize the hazards involved.

� In all cases of hot work, the material to be welded on and the surrounding work area shall be free of combustible materials. When combustible materials cannot be readily moved or otherwise guarded against, the supervisor will ensure that one of the following is achieved.

� The equipment shall be moved from the area that contains the hazardous environment.

� Fire containment may be used to protect combustible materials.

� If neither of the preceding can be achieved, the hot work must be terminated and appropriate steps must be taken to eliminate the hazardous condition prior to resuming work.

24.2 Storage and Handling of Compressed Gas Cylinders

� Cylinders must be secured and stored in assigned places where they will not be knocked over by passing or falling objects.

� Cylinders should be kept away from stoves, radiators, furnaces, or other hot places. They should be stored well away from highly combustible materials such as oil, grease, or excelsior.

� Oxygen cylinders should not be stored in the same compartment with acetylene or other fuel gas cylinders unless they are separated; there should be a fire-resistant partition between the oxygen cylinders and the acetylene and fuel gas cylinders.

� When cylinders are stored in the open, they should be protected from ice and snow accumulations and from the direct rays of the sun in localities


Rev. 2 July 2011 24-2

where extreme temperatures prevail. Oxygen cylinders should be placed at least 20 ft. from cylinders containing combustible gases or separated by a 5-ft. fire-resistant partition.

� Regulators should be removed and valve protection caps should be put in place when cylinders are not in use or when they are being transported.

� Cylinders must be secured in a vertical position.

� Gas cylinders shall not be hoisted using chokers or electric magnet, nor shall the valve protection cap lift them.

� Never use cylinders as rollers or supports.

� Never allow cylinders to come in contact with live wires, third rails, or ground wires from electrical equipment.

� Always close cylinder valves when work is finished, and always close the valves of empty cylinders while in storage prior to returning to the supplier.

� Keep oxygen cylinders and fittings away from oil or grease because they may ignite violently in the presence of oxygen under pressure. Oily or greasy substances must be kept away from cylinders, cylinder valves, couplings, regulators, hoses, and other apparatus. Do not handle oxygen cylinders or apparatus with oily hands or gloves. Oxygen cylinders should not be handled on the same platform with oil or be placed in a position where oil and grease from overhead cranes or belts are likely to fall upon them.

� A jet of oxygen should never strike an oily surface, greasy clothes, or enter a fuel oil or storage tank that has contained flammable substances.

� Do not drop cylinders or handle them roughly.

� Do not use a hammer or wrench to open oxygen cylinder valves.

� When a pressure-reducing regulator is attached, open the oxygen cylinder valve slightly at first to dislodge any trash that may be in the valve, and then attach the gauges and open the valve slowly. If the pressure is suddenly released, it may damage the regulator and its pressure gauges. Stand to one side of the regulator front and gauge faces when opening the cylinder valve. When the oxygen cylinder is in use, the valve should be opened fully.

� Never tamper with or attempt to repair oxygen cylinder valves. If trouble is experienced, notify the supplier.

� Acetylene cylinders should not be allowed to lie on their sides when in storage or while being used; always stand acetylene cylinders with valve-end up.

� The fusible safety plugs that all acetylene cylinders are provided with act as safety releases when the cylinder is exposed to excessive temperatures. Never tamper with these plugs. They melt at about the temperature of boiling water and release acetylene from the cylinder.


Rev. 2 July 2011 24-3

� Do not place cylinders below work where sparks or slag could fall on top of them.

� Do not use the top of any acetylene cylinder as a place for storing tools or clothing. This might interfere with quick closing the valve, and it might damage the fusible safety plugs. Never let the recessed top become filled with water when using the cylinder.

� Serious injury may result if oxygen is used as a substitute for compressed air. NEVER use oxygen in the following circumstances:

� In pneumatic tools

� In oil pre-heating burners

� To start internal combustion engines

� To blow-out pipelines

� To dust-off clothing or the work area

� To create pressure

� For ventilation

� To supply breathing air equipment

24.3 Reverse Flow Check Valves Reverse-flow check valves should always be used with all oxy-fuel gas welding, heating, cutting, and allied processes. Reverse-flow check valves are to be placed in the gas system between the outlet of the hose and the in let of the oxy-fuel gas torch and between the outlet of the regulator and the in let of the hose leading to the torch.

Note: Some of the new regulators have built in anti-flashback/reverse flow check valves. Check with the owner’s manual to make sure your protected.

All oxy-fuel gas torches are to be checked to make certain that they are properly equipped with reverse-flow check valves. The superintendent on each job will make certain that company personnel only use oxy-fuel equipment that is equipped with properly functioning reverse-flow check valves. In addition, superintendents will develop a schedule for the periodic Inspection of all oxy-fuel gas equipment on their jobs to test the performance of the reverse-flow check valves.

The superintendent shall ensure that only personnel trained and experienced in the proper use of oxy-fuel gas equipment will use this equipment.

:NOTE: Experience has shown oxy-fuel gas torches to be reliable and safe pieces of equipment when operated in accordance with manufacturer’s instructions. Under certain circumstances, the user’s failure to follow these


Rev. 2 July 2011 24-4

instructions can cause the back-flow of unwanted gas and/or a flashback in the up-stream gas system.

Check valves should be inspected at least once every six months. Careless usage, dirt, or abuse can shorten the service life of check valves, thus requiring more frequent checking. Be sure to inspect check valves in a well-ventilated area because the escaping gases create conditions for fire and explosions.

To check torch-type check valves, perform the following steps:

1. Adjust both regulator knobs so that no pressure will be delivered.

2. Disconnect hoses from regulators and torch check valves.

3. Remove the check valves from the torch.

4. Connect the check valves to the outlets of the regulators.

5. Adjust each regulator until a 2 to 5 PSI reading is obtained on the low pressure gauges.

6. Using a cup of water put the end of each check valve under water for 15 seconds; or cover the end with an approved leak-detector solution (or Ivory soap and water solution). If bubbles develop, a check valve is leaking.

7. If a check valve is leaking, turn off the pressure to check valve. Remove the check valve and reinstall it in the normal position on the end of the hose. Flush for 3 to 5 seconds with either 10 PSIG fuel gas or 30 PSIG oxygen, depending on the type of check valve. Remove and retest.

8. If the check valve is still leaking, it must be replaced with a new one.

9. Remove valves and place in the normal position on the torch.

To check regulator-type check valves, perform the following steps:

1. Adjust both regulator knobs so that no pressure will be delivered.

2. Disconnect the hoses from the regulator and torch check valves.

3. Remove the check valves from the regulators.

4. Connect the hoses to the outlets of the regulators.

5. Connect the torch end of the hosed to the regulator check valves.

6. Adjust each regulator until a 2 to 5 PSI reading is obtained on the low-pressure gauge.

7. Using a cup of water put the end of each check valve under water for 15 seconds; or cover the end with an approved leak-detector solution (or Ivory soap and water solution). If bubbles develop, a check valve is leaking.

8. If a check valve is leaking, turn off the pressure to check valve. Remove the check valve and reinstall it in a normal position on the end of the hose. Flush for 3 to 5 seconds with either 10PSIGfuel gas or 30PSIG oxygen, depending on the type of check valve. Remove and retest.


Rev. 2 July 2011 24-5

9. If the check valve is still leaking, it must be replaced with a new one.

10. Remove the check valve from the hoses, reconnect the hoses to the torch, and reinstall the regulator check valves on the regulator outlets.

24.4 Hose Maintenance � Flashback arrestors must be connected between both hose connections at

the torch.

� Heat-sensitive flashback arrestors that cutoff the flow of gas should be attached to the outlet of both regulators.

� Examine hoses carefully daily for leaks, worn places, and loose connections.

� Leaks in the hose at the nipple connection should be repaired immediately by cutting off the hose a few inches from the end and remaking the connection. Cutting of the bad section and inserting a hose coupling as a splice should repair leaks at other locations.

� Never repair a hose with tape. When hoses are taped together for convenience and to prevent tangling, do not cover more than 4” out of every 12”.

� Should a flashback occur and burn the hose, discard that length of hose.

� Use only hose and connections made specifically for oxy-acetylene welding and cutting.

� Do not use white lead, oil, grease, or other pipefitting compounds for making joints.

� Always protect hoses from damage or interference and from being trampled on or run over. Avoid tangles and kinks, and place hoses so they will not be tripped over. Connections might be pulled off or cylinders and equipment might be pulled over by a sudden strong tug on the hose. Do not allow hoses to come in contact with oil or grease because it deteriorates the rubber and constitutes a hazard with oxygen. Protect hoses from flying sparks, hot slag, or other hot objects and open lames.

24.5 General Precautions for Welders � Inspect all tools and equipment prior to using. Worn or damaged hoses,

welding leads, and other equipment with defects affecting safe operation must be repaired prior to use or discarded.

� Do not weld, cut, or grind drums, containers, or hollow structures that have contained toxic or flammable substances until they have been thoroughly cleaned and purged and tested with a gas meter.

� Unless welding is performed on un-coated carbon steel. Respiratory protection may be required.


Rev. 2 July 2011 24-6

� Do not stand in water when using an arc-welder; instead, stand on a dry platform made of wood or some other non-conductive material.

� Do not dip electrode holders in water to cool them.

� Keep your body insulated from the work and the electrode holder during welding operations.

� Wear the proper goggles or a welding hood with a filter lens to protect against flashburn and flying objects.

� Always wear a face shield with glasses or goggles when chipping or grinding.

� Do not leave welding rod in electrode holder when through welding.

� When working in aerial lifts do not discard used welding rod by throwing it to the ground. Keep a bucket or some other means to properly dispose of the rod.

� Do not have any repairs within 10 ft. of the electrode holder on welding leads.

� Rubber boot protectors shall be provided on all welding leads where they make connections at the welding machine.

� Welder helpers must wear filter lenses of the same grade as the welder.

� Welders must wear safety glasses with side shields under the welding hood during gas welding or cutting.

� Welders must wear hard hats while welding when overhead hazards exist.

� Close the valve of the gas cylinder before removing the regulator, and then release all gas.

� Keep all gas cylinders in their upright position and secured against falling during use, transportation, and storage. All cylinders (empty or full) must have valve caps in place when not in use.

� Torches must be lit with a friction lighter or other approved device and not by matches or from hot work.

� Do not move cylinders by their valves or use them for any purpose for which they are not designed.

� Both the oxygen and the acetylene or fuel gas lines must be equipped with flashback arrestors.

24.6 Ventilation � All welding performed in confined spaces must be well ventilated at the

minimum rate of 2000 cubic feet per minute per welder.

� Local ventilation is the preferred method of extracting welding fumes from work areas.


Rev. 2 July 2011 24-7

24.7 Fire Watch During hot work operations, a fire watch is required whenever one or more of the following conditions exist:

� The location is where potential minor fire may exist.

� Combustible material, including wood, paper, or debris, is closer than 35 ft. from the welding operation.

� Easily ignitable materials are present in the work area, including those materials 35 ft. or more from the welding operation.

� Walls or floor openings exist with 35 ft. of the welding operation.

� Combustible materials exist on the opposite side of any wall, roof, or partition closer than 35 ft. of the welding operation, including metals that can conduct heat.

� All welding operations are performed above ground level unless a thorough assessment has been performed by the supervisor and it has been determined that no fire hazard exist.

24.7.1 Duties of a Fire Watch A fire watch plays an important role in the safe execution of a job. It is the duty of the supervisor to see that employees are instructed as to what their duties are and to the location of the safety equipment to be used in case of an emergency.

Before any employee is used as a firewatch, they shall be thoroughly trained as to their duties and responsibilities and shall acknowledge this training by their signature. The following are guidelines for firewatching:

� Knowing what is going on around you

� Stay alert

� Be aware of other work going on in areas around you, especially line breaking, spills, leaks, etc.

� Stay in contact with the employees. Make it a point to know what they are doing.

� Know where emergency equipment is located and how to use it.

� Know where fire-fighting equipment is located and check it before beginning work.

� Do not use unit fire extinguishers for fire watch. Check one out of the tool room.

� Know where the nearest phone, radio, or control room is located in case of an emergency.


Rev. 2 July 2011 24-8

� Know where the welding machines and oxygen and acetylene bottle are located and how to turn them off.

� Keep the area around your job site clean at all times. Do not allow trash, material, and tools to pile up.

� Never leave you job unattended.

� Stay within sight of your job

� If you must leave, either stop the hot work or have another trained person take over

� In case of a spill, fire, leak, evacuation, or other emergency, perform all of the following:

� Tell the people on your job.

� Shut off all machines and gas cylinders.

� Make sure everyone is properly evacuated.

� Notify emergency personnel and supervision immediately.

� Fire watch personnel are responsible for their jobsites, and it is part of their job to report unsafe conditions and unsafe acts to supervision immediately.

� Fire watch personnel may be required to wear a color-coded vest while on duty to identify themselves.

� Demonstrate the proper operation of a standard dry chemical fire extinguisher and warn workers not to activate it until actually needed.

24.8 First-Aid Equipment First-aid equipment will be maintained at the sites that are designated first-aid facilities (see First-Aid section)

24.9 Welder Qualifications and Training All welders, prior to use of such equipment, will be trained in accordance with the requirements of this procedure.

24.9.1 Protective Apparel Operators should protect themselves from sparks, flying slag, and flame brilliance at all times. Only select goggles with tempered lenses shaded No. 5 or darker to protect eyes from injury and to provide good visibility of the work.

Protective gloves, sleeves, aprons, and shoes should be worn to protect skin and clothing from sparks and slag.


Rev. 2 July 2011 24-9

Keep all clothing and protective apparel absolutely free of oil and grease.

Adjust clothing where necessary to keep out flying sparks and slag. Sparks may lodge in rolled-up sleeves, in pockets of clothing, or in cuffs of overalls or trousers. Keep sleeves and collars buttoned when necessary.

Health and Safety Program Steel Erection

Rev. 2 July 2011 25-1

25 Steel Erection

Purpose: The purpose of this procedure sets forth requirements for all Dematic Corp. installation sites to protect employees from the hazards associated with steel erection activities.

25.1 Construction Sequence Prior to the commencement of steel erection, the controlling contractor shall ensure that the steel erector is provided with the following written notifications:

� The concrete in the footings, piers, and walls and the mortar in the masonry piers and walls has attained, on the basis of an appropriate ASTM standard test method of field-cured samples, either 75 percent of the intended minimum compressive design strength or sufficient strength to support the loads imposed during steel erection.

Steel erection shall not commence unless you have received written notification that the concrete meets the above.

� Prior to the erection of a column, the controlling contractor shall provide

written notification to the steel erector if there has been any repair, replacement or modification of the anchor bolts of that column.

Anchor bolts shall not be repaired, replaced or field-modified without the approval of the project structural engineer of record.

25.2 Site Layout The controlling contractor shall ensure that the following is provided and maintained:

� Adequate access roads into and through the site for the safe delivery and movement of cranes, forklifts, 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 equipment.


Rev. 2 July 2011 25-2

25.3 Site-Specific Erection Plan Due to conditions specific to an individual installation site, a site specific erection plan shall be developed by a qualified person and be available at the work site, the plan must develop alternate means and methods that provide employee protection during steel erection activities.

Listed below are some guidelines and elements that will be required in a site-specific plan.

� Safety latches on hooks shall not be deactivated or made inoperable.

� No bundle of decking may be placed on steel joists until all bridging has been installed and anchored and all joist-bearing ends attached.

� Development of a site-specific erection plan may include a pre-construction conference, site inspection between the erector and the controlling contractor before the start of steel erection. The purpose of such conferences is to develop and review the site-specific erection plan that will meet OSHA requirements.

In developing a site-specific erection plan, a steel erector should consider the following elements:

� Sequencing of erection activity

� Material deliveries;

� Material staging and storage and coordination with other trades and construction activities;

� Crane selection description;

� Site preparation;

� Path for overhead loads, critical lifts, including rigging supplies and equipment.

� Stability considerations requiring temporary bracing and guying, connections, decking operations.

� A list of the qualified and competent persons.

� A description of the procedures that will be utilized in the event of emergency response or a rescue is necessary.

The above is an abbreviated list of the requirements for the site-specific plan, please consult your OSHA standard for further information that may be required.


Rev. 2 July 2011 25-3

25.4 Structural Steel Assembly During the final placing of solid web structural members, the load shall not be released from the hoisting line until the members are secured with not less than two bolts, or the equivalent at each connection and drawn up wrench tight.

Containers shall be provided for storing or carrying bolts, drift pins, and secured against accidental displacement when aloft.

Eye protection shall be worn in accordance with Dematic Corp. PPE requirements.

Cranes being used in steel erection activities shall be inspected prior to each shift by a competent person.

All columns shall be anchored by a minimum of 4 anchor bolts.

25.5 Metal Decking Covering floor holes requires:

� Covers capable of supporting twice the intended load of employees, materials & equipment

� Secured to prevent displacement

� Marked with “HOLE or COVER” in high visibility paint

� Gaps around columns filled where decking does not fit tightly

� Loose material on decking bundles must be secured

� Decking to be secured at the end of each shift

25.6 Fall Protection Fall protection must be in accordance with Section 18 “Fall Protection” of the Dematic Corp. Health and Safety Program. Employees working above 6 feet must be protected from falling.

Health and Safety Program Forms

Rev. 2 July 2011 26-1

26 Forms

Accident, Injury, or Illness Report (Supervisor)

Accident Investigation Form (Employee/Witness)

Aerial Lift Inspection Form

Aerial Lift Inspection Form (Spanish)

Assured Equipment Grounding Form

Crane Lift Plan Part I

Crane Lift Plan Part 2

Daily Crane Pre-Operation Checklist

Daily Jobsite Safety Inspection Form

Emergency Phone Numbers Form

Employee Notice of Reporting Accidents

First Aid Log

Fork Lift Inspection Form

Fork Lift Inspection Form (Spanish)

Job Hazard Analysis (JHA) Worksheet

Job Site Safety Meeting Report Form

Near Miss Investigation Report Form

Portable Ladder Inspection Form

Refusal of Medical Treatment Form

- Subcontractor Forms

Subcontractor Acknowledgment

Pre-qualification

Safety Compliance Terms

Safety Manual - Dematic Corp.

Documents

Transcript of Safety Manual - Dematic Corp.