CHAPTER 8:

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A. Workshops, Vehicle Bay and Welding Policies 

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1. Policy

2. Responsibilities

1. Supervisor (of a shop or any area where fixed or portable powered or unpowered machines and tools are located)

1. Is responsible for being familiar with all procedures for safe use and guarding of machines, personal protective equipment required, shielding against possible injury to other employees or visitors. Enforces safe practices.
   
2. Trains new employees by providing and requiring manuals to be studied, personally instructing and requesting the assistance of employees already experienced and familiar with required safety precautions.
3. Posts signs indicating the use of powered machines by "Authorized Personnel Only" and requires the employees under their supervision to assist in the enforcement of this policy.
4. Provides appropriate marking of shop floor areas to identify safe walking areas.
5. Makes periodic inspections of shop areas and other industrial areas. Carries out risk assessment where appropriate. Notes all deficiencies and initiates corrective actions.
6. Ensures that all painting operations or other operations involving potentially hazardous vapors are conducted in well ventilated areas. Asks assistance from the Site Safety Advisor in making this determination and to provide necessary protective equipment and respirators, when appropriate.
 

2. Employee
1. Who is physically or otherwise unfit shall not operate hoists, cranes, manlifts or other lifting equipment.
   
2. Complies with OSHA standards, JAC policies and good safe practices when using fixed and portable power tools, equipment and hand held equipment.
3. Cleans up when finished using equipment to the extent necessary to maintain a clean and safe environment.
4. Maintains the tools, equipment and work area in an orderly and safe manner.
5. Trains new users of equipment at the request of the supervisor.
6. Assists the supervisor in identifying and marking shop floor areas to identify safe walking areas.
7. Shall not use or permit use of defective equipment or tools in disrepair. Malfunctioning equipment and damaged hand tools shall be reported and repair made before using the equipment or tools. If repairs are not possible the equipment or tools shall be discarded.
8. Immediately draws to the attention of the supervisor, any potential hazards in the work place. Seeks further guidance on any safety related issues about which they feel unclear.
 
3. Site Safety Advisor
1. Draws the attention of relevant staff to any areas in which OSHA standards, JAC policies and good safe practices are not being implemented.
   
2. Assists supervisor and employee in defining hazards and designating safe practices.
3. Conducts routine and periodic inspection of shop areas for compliance to OSHA standards and JAC policies.
4. Conducts periodic inspections of hand tools and portable power tools.

3. Shop Procedures Including Helifier and Vehicle Bays

1. Persons entering the shop and helifier bay shall stay within the yellow lined walkways unless explicitly authorized to leave them by the Facility Maintenance Manager. In the vehicle bay and in the helifier bay staff should be aware of potential hazards from metal stock (which has sharp edges). None of these locations are intended to be general access areas.  In addition there is no permanent designated safe access through the vehicle bay. Potential hazards in these areas can be expected to change daily without notice.
   

• Perforated shoes, sandals or cloth sneakers are expressly prohibited. Closed toe shoes shall be worn at all times when in these areas.

2. When machining operations are being undertaken which might pose a hazard to personnel passing through the workshops, signs shall be posted on the doors to the workshops warning of hazardous work in progress.  Persons wishing to enter the shop area when these signs are posted shall stay within the yellow lined areas and wear safety glasses with side shields along with proper footwear as noted above.

3. Only properly trained employees authorized by the Facility Maintenance Manager or Site Safety Advisor may use general shop machines, fixed and portable power tools and other hand held equipment. No one is allowed to use fixed or portable powered shop machines or welding equipment without sufficient training to the Facility Maintenance Manager's satisfaction.

4. All portable and fixed powered shop machines and tools shall be equipped with approved guarding devices. Guards are to be in place while using the machine. Equipment shall also be properly electrically grounded before use.

5. Abrasive wheel machinery (grinders) shall be properly guarded at all times. The work rest shall be checked and adjusted before each use.

6. In any operation where the stock is stationary it shall be clamped down (attempting to hold stock with hands shall not be permitted).

7. Personal protective equipment shall be provided in accordance with Chapter 3.

8. No flammable materials (paints, solvents, chemicals) shall be stored within the immediate area of any burning or welding operation. All flammable materials shall be stored in OSHA and JAC approved cabinets and shall be returned there after each working day.

9. Any employee using portable or fixed tools shall not wear loose articles (e.g. lanyard and eyeglass retainers), clothing or jewelry. Anyone with long hair shall tie back the hair or wear acceptable hair protection while operating equipment.

10. Before any employee performs service or maintenance on a machine or equipment where the unexpected energizing, start up or release of stored energy could occur and cause injury, the machine or equipment shall be made safe. This shall be accomplished by locking out and tagging out energy isolating devices, and otherwise disabling the machines or equipment. Further details are given in Chapter 13.

11. Clean-up after using powered equipment or hand tools shall be done immediately following use of apparatus.

12. Good housekeeping shall be maintained in the shop area. Material shall be stored such that it does not present hazards to personnel. Scrap stock and swarf shall be cleaned from floor, work benches and machines following each job and at the end of each day.

13. Hoist/crane/manlift/lifting equipment safety: this chapter section C.

14. Air hoses shall not be disconnected until pressure is securely turned off at its source and they have been bled.

15. When working on materials or coolant that potentially generate harmful fumes, adequate ventilation and exhaust devices shall be used.

16. To prevent unauthorized personnel from using machinery, all machinery electrical power sources shall be locked in the "off" position when not in use by authorized personnel.

17. Off hours use of machinery is restricted to authorized operators only with the express consent of the Facility Maintenance Manager. The Facility Maintenance Manager shall have sole discretion to determine the conditions for such use.  They are responsible to assure that appropriate safety equipment and procedures are used during this operation.

18. All shop floor safe walking areas which are identified by yellow floor lines shall be kept clear at all times.

4. Oxygen/Acetylene Welding and Cutting Procedures

1. Only trained employees, whose regular duties as assigned by their supervisors include welding and cutting, shall perform this work.

2. Adjustment or repair of gauges, valves, accessories or safety devices by unqualified personnel is prohibited.

3. Acetylene shall not be used for welding or cutting at pressures exceeding 15 psig.

4. Acetylene cylinder valves shall not be opened more that one full turn, and the wrench shall be left on the valve stem so that the valve can be closed quickly if necessary.

5. Oxygen cylinder valves shall be opened fully and made hand-tight against the back seat.

6. Mixing gases in cylinders, refilling cylinders, or using cylinders for any use except their original purpose is prohibited.

7. Fire extinguishers shall be easily accessible to all employees performing welding or cutting operations.

8. Screens or shields shall be used for the protection of persons, equipment or combustible material exposed to sparks or falling objects; a fire-watch shall be posted where necessary, with an adequate extinguisher and signaling device.

9. When working on lead, zinc or other materials that could generate harmful fumes, adequate ventilation and exhaust devices shall be used. When ventilation is not practical or feasible, respiratory protection shall be used.

10. Proper eye protection along with safety shoes and appropriate protective gear shall be used.

5. Arc Welding Procedures

1. Only trained employees,whose regular duties as assigned by their supervisors include arc welding, shall perform this work.

2. When welding, employees shall wear adequate masks or hoods with proper eye protection, gloves and leather aprons as minimum protection; these shall be supplemented with hard hats, safety shoes and other protective gear where warranted.

3. Everybody near the welding area shall be protected from eye flash-burns by use of partitions, screens or other appropriate methods.

4. Welding cables, cords and leads shall be secured so as not to cause tripping. Electrode studs shall immediately be disposed of in a safe container.

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B. Powered Industrial Trucks 

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1. Policy

2. Responsibilities

1. Supervisor
1. Ensures all operators of powered industrial trucks are properly trained in the operation of the vehicles.
2. Regularly inspects vehicles and vehicle systems.


2. Employee
1. Inspects daily the powered industrial vehicle in accordance with section B5 before it is used .
2. Does not use a malfunctioning vehicle. Reports any defects or malfunctions to the supervisor immediately.
   
3. Operates equipment safely and in accordance to operating instructions.
4. Wears appropriate protective equipment at all times.
5. Uses seat belt when operating vehicle.
   
 
3. Site Safety Advisor
1. Maintains records of employee training.
2. Periodically and routinely inspects vehicles and vehicle operations.
3. Provides training programs for use and operation of the vehicles.

3. General Training Requirement

1. All operators shall successfully complete a forklift training course, which includes formal training (video and written test), practical training (practical exercises) and evaluation (operators performance in the workplace).
   
   The operator is required to:

• Point to and explain the following controls: lift, tilt, forward and reverse gears.
• Perform all driving and loading/unloading maneuvers deemed necessary by the examining official.

2. Refresher training shall be conducted at least every three years; or when necessary, e.g. if the following occur:

• an operator is involved in an accident or near-miss accident
• an operator has been observed operating the vehicle in an unsafe manner
• an operator has been determined to need additional training as a result of an evaluation
• an operator is assigned to a different type of truck
• there are changes in the workplace that could affect the safe operation of the truck

4. Operating Rules and Practices

1. Unauthorized personnel shall not be permitted to ride on or operate powered industrial trucks.
   

2. Safeguard pedestrians at all times. Do not drive a truck up to anyone standing in front of a stationary or fixed object (e.g., a bench or parked vehicle).

3. Do not allow anyone to stand or pass under the elevated portion of any truck or lift.

4. Do not allow anyone to ride the forks.

5. Do not put arms or legs between the uprights of the mast or outside the running lines of the truck.

6. Obey all safety signs and markers.

7. When you park the machine or leave it unattended, lower the forks so that they are flat on the ground. Controls shall be neutralized, power shut off, brakes set, key or connector plug removed. Block wheels if truck is parked on an incline.

8. Maintain a safe distance from edges, ramps, and platforms.

9. Be sure of sufficient head room under overhead installations, e.g. lights, pipes, and sprinkler systems.

10. Use an overhead guard as protection against falling objects.

11. Use a load backrest extension whenever necessary to minimize the possibility of the load or part of it falling rearward.

12. Never exceed trucks' rated capacity.

13. Never travel with load above five feet.

14. Avoid sudden stops and starts when loaded.

15. Do not use fork extensions.

16. Report to supervisor all accidents involving personnel, building structures, and equipment.

5. Daily Operational Checks

The following items shall be checked daily by the forklift truck operator before and at the end of each work shift:
1. Battery plug connection.
2. Battery charge.
3. Brakes.
4. Lights.
5. Horn.
6. Hour meter.
7. Steering.
8. Tires.
9. Hydraulic controls.
10. Other conditions.

6. OSHA 100 Hour Forklift Maintenance Inspection

The forklift 100 hour inspection is required and shall be performed by a qualified mechanic in accordance with the instructions kept by the Facility Maintenance Manager.

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C. Hoist/Crane/Manlift/Lifting Equipment Safety 

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1. Policy

2. Responsibilities

1. Supervisor

Ensures all operators of hoists, cranes, manlifts, lifting equipment, and manbasket are properly trained in the operation of the equipment.  

2. Employee

1. Inspects hoists, cranes, manlifts, lifting equipment and manbasket before it is used.
2. Does not use malfunctioning or damaged equipment. Reports any defects or malfunctions to the supervisor immediately.
   
3. Operates the equipment safely, and in accordance with operating instructions.
4. Wears/uses appropriate protective/safety equipment at all times.
5. Ensures control zones (e.g. hard hat areas) are set up where required.

3. Site Safety Advisor

1. Provides training programs for use and operation of equipment.
2. Maintains records of employee training.
   
3. Maintains yearly inspection record. 

4. Facility Maintenance Manager 

1. Schedules yearly inspections by certified inspectors.
2. Maintains an inventory of the below-the-hook rigging and lifting devices.
3. Ensures that all equipment are inspected on a monthly basis and updates records.
   
4. Witnesses load tests for new or modified equipment.
5. Maintains an inventory of manually operated hoists (chain operated, lever operated)
   

3. General Training Requirements

1. All operators shall attend a training course on the specific equipment that they are required to operate.

2. During the training course the operator is required to:

1. Point to and explain the equipment controls.
2. Perform all necessary equipment functions for the examining official.
3. Explain all necessary safety procedures for the examining official.

4. Operating Rules and Practices

1. Manlifts

1. Visually inspect manlift before it is used.  Do not use equipment if it is defective. Report any defects to supervisor.

2. Check for overhead obstructions and electrical lines.

3. Ensure that load on the manlift is within the manufacturers rated capacity.

4. Ensure that outriggers and stabilizers are used if the manufacturer’s instruction so requires.

5. Ensure that all gates to work platform are closed.

6. The operator and passenger(s) at the work platform position shall wear a harness and be connected to the manlift with a lanyard.

7. Railings, ladders or any other device in or on the work platform shall not be used to achieve additional working height or reach.

8. Any loading which includes a horizontal load shall be avoided unless the manlift is designed for that application.

9. Observe whether there are any defects in the equipment during all operations, and stop and correct them as necessary.

10. Secure tools and equipment. 

2. Hoist and Cranes

1. Visually inspect equipment before it is used. Report any defects to supervisor. Do not use equipment if it is defective.

2. Ensure that the hoist or crane is not loaded beyond its rated load except for load test purposes.

3. The operator shall not engage in any activity that will divert attention while actually engaged in operating the crane or hoist.

4. The operator is responsible for operation of the crane or hoist. If required, an appointed person shall direct the crane operation by approved hand signals. 

5. The operator shall obey a stop signal at all times, no matter who gives it.

6. Before leaving a crane or hoist unattended, the operator shall land any attached load, place controllers in the off position, and open the main line disconnect device of the specific crane.

7. The operator shall not close the main switch until certain that no worker is on or adjacent to the crane, and all controllers are in the off position.

8. If power goes off during operation, the operator shall immediately place all controllers in the off position. As soon as practical, any suspended load shall be landed or secured. Before the crane is put back into use, operating motions shall be checked for proper direction.

9. Before the operator performs any maintenance work on the crane, the operator shall lockout and tagout the main switch in the de-energized position. Further details are given in  Chapter 13.

10. When lifting the chains of the chain hoist in the Measuring Machine Laboratory (JAC Room 71) over the door frame between the lab and the loading bay, staff should stand on a ladder to ensure it is done in a controlled manner.

3. Lifting Equipment (below-the-hook rigging and lifting devices e.g. slings, chain slings)

1. Visually inspect lifting equipment before it is used. Report any defects to the supervisor. Do not use equipment that is damaged.

2. The weight of the load shall be within the rated capacity of the lifting equipment.

3. Lifting equipment such as slings shall always be protected from being cut by sharp corners, sharp edges, protrusions or abrasive surfaces.

4. Slings shall not be shortened with knots or bolts or other makeshift devices.

5. Slings used in a basket hitch shall have loads balanced to prevent slippage.

6. Lifting equipment shall be securely attached to their load.

7. Hands or fingers shall not be placed between the lifting equipment and its load while the lifting equipment is loaded.

8. Shock loading is prohibited.

9. A sling shall not be pulled from under a load when the load is resting on the sling.

10. Alloy steel chain slings shall have permanently affixed durable identification, stating size, grade, rated capacity, reach and serial number.

11. Synthetic web slings shall have an affixed identification tag stating rated capacities for each type of hitch, size and serial number.

12. Lifting equipment shall be stored properly after each use to prevent damage.
    

4. Manbasket

1. Manbaskets shall only be used for the express purpose they are supplied for and no other operation.

2. Visually inspect manbasket before it is used. Do not use manbasket if it is defective. Report any defects to the supervisor.

3. Hoisting of the manbasket shall be performed in a slow, controlled, cautious manner with no sudden movements of the crane.

4. The manbasket shall have a permanently affixed plate which indicates the weight of the manbasket and its rated capacity.

5. The manbasket shall not be loaded in excess of its rated load capacity.

6. A meeting attended by the crane operator, signal person(s) (if necessary for the lift), employee(s) to be lifted and person responsible for the task to be performed shall be held before work begins to review the lift procedures and work at hand.

7. The trial lift with the unoccupied manbasket loaded at least to the anticipated lift weight shall be made from ground level, or any location where employees will enter the platform to each location at which the manbasket is to be hoisted and positioned. This trial lift shall be performed immediately prior to placing personnel in the manbasket. The operator shall determine that all systems, controls, and safety devices are activated and functioning properly, that no interference exists, and that all configurations necessary to reach the work locations shall allow the operator to remain under the 50 percent limit of the hoist’s rated capacity.

8. After trial lift the manbasket shall be inspected to ensure that it is secure and properly balanced. Personnel shall not be hoisted unless the following conditions are met:

• Hoist ropes shall be free of kinks
• The primary attachment shall be centered over manbasket
• Hoisting rope shall be properly fitted on drum and sheaves
  

9. Personnel occupying the manbasket shall use a body harness system with lanyard appropriately attached to the lower load block on the overhaul ball or onto a structural member within the manbasket capable of supporting a fall impact for employee using the anchorage.

10. Personnel shall keep all parts of the body inside the manbasket during raising and lowering

11. Before personnel exit or enter a manbasket that is not landed, it shall be secured to the structure where the work is to be performed, unless securing it to the structure creates an unsafe situation.

12. Tag lines shall be used unless their use creates an unsafe condition.

13. The crane operator shall remain at the controls at all times when the manbasket is occupied.

14. Personnel being hoisted shall remain in continuous sight of and in direct communication with the operator or signal person.