General Safety Rules For Fabs

GENERAL SAFETY RULES FOR STRUCTURAL S T E E L FA B R I C AT O R S
SAFETY
General Safety Rules for Structural Steel Fabricators
AMERICAN INSTITUTE OF STEEL CONSTRUCTION, INC. One East Wacker Drive, Suite 3100 Chicago, Illinois 60601
2004 by American Institute of Steel Construction, Inc. All rights reserved. This publication or any part thereof must not be reproduced in any form without permission of the publisher.
Disclaimer
This publication is intended to present practical work rules to assist in achieving a higher level of employee safety in shops that fabricate structural steel. This publication is not intended to replace or supersede federal, state, or locally mandated safety standards. Compliance with the general rules set out in this publication does not assure compliance with OSHA or other safety standards. Trained safety professionals should be consulted for application of the general rules presented in this publication to individual fabrication facilities.
Contents
SECTION PAGE Foreword............................................................................................ iv 1. Personal Protection .................................................................. 1 2. General Safety Rules ................................................................ 8 3. Cranes and Hoists .................................................................. 14 Electric Overhead Cranes (Cab Operated) ..............................114 Floor Operated Cranes and Hoists ..........................................118 Standard Crane Signals ............................................................224 Alloy Chain Capacities ..........................................................126 4. Material Handling ................................................................127 5. Punching and Shearing ........................................................ 35 6. Reaming and Drilling ............................................................ 37 7. Fitting and Bolting ................................................................ 41 8. Arc Welding ..........................................................................143 9. Flame Cutting (Burning), Cambering and Heat Straightening ........................................................ 47 10. Chipping and Grinding ........................................................ 53 11. Machine Shop ........................................................................ 57 12. Mobile Equipment ................................................................ 59 Railway ....................................................................................159 Fork Lifts, Tow Motors, Trucks, etc. ....................................162 Straddle Carriers ......................................................................164 13. Electrical Work ...................................................................... 66 14. Maintenance and Repair ...................................................... 69 15. Radiation (X-ray, Cobalt, etc.) ............................................ 72 16. Housekeeping .......................................................................... 75 17. Use of Ladders ...................................................................... 76 18. Scaffolds .................................................................................. 79 19. Hydraulic and Mechanical Jacks ........................................ 87 20. Painting ....................................................................................188 21. Abrasive Blasting .................................................................. 91 22. Fire Prevention ...................................................................... 94 23. Off the Job Safety ................................................................ 98
1st PrintingJune 1981 2nd PrintingJanuary 1990 1st Revision, 1st PrintingNovember 2000 Publication Number F502(10M1100) 2000, American Institute of Steel Construction. All rights reserved.
A MERICAN I NSTITUTE
OF
S TEEL C ONSTRUCTION
Personal Protection 1
Foreword
In the interest of safety, this Manual was developed by a committee drawn from members of the American Institute of Steel Construction (AISC). Careful consideration was given to the problems peculiar to the Fabricating Industry, recognizing that many of the variable conditions encountered in the industry do not lend themselves to narrowly defined regulations. Therefore, it is intended that the Manual should be interpreted and administered with sound judgment consistent with good safety practices. AISC has compiled this booklet to help its members achieve the humanitarian and economic benefits of an effective safety program. These recommendations reflect the experience of steel fabricators as well as the suggestions of employees, supervisors, and safety specialists throughout the steel fabricating industry. Mostly they are common sense precautions that all workers should take. They are, of course, subject to local instructions, regulations, and codes where applicable. The success of any accident prevention program is to a great extent dependent on the interest and wholehearted support of supervision. It is the first line supervisor who has the greatest burden of responsibility in putting the recommendations into practice. Workers should expect to receive the benefit of the supervisor's knowledge and know that strict compliance will be expected of them. In return, it is expected that the supervisor will have the cooperation of the workers and that they will constantly use thought and care to perform their work safely. Make sure you understand the safest way of doing your work. Do not hesitate to ask when in doubt. Pay particular attention to General Safety Rules and Material Handling Rules, as well as the sections which apply to your work. Your safety and welfare is of vital interest to your family, fellow workers, and management. With your complete cooperation we can reach the goal of Safety for All. Report Every Injury Promptly, No Matter How Slight
1. Personal Protection
Wear clothes and protective accessories suitable for the work at hand.
1.1
Wear clothes that are suitable for your work. Buttoned long sleeve shirts should be worn when burning, welding, grinding, or performing other types of work where sparks or hot metal are present or where the work involves the handling of acid, galvanizing, etc. Be sure that any clothing you wear is not of a highly flammable material. Cotton and wool and fire-retardant treated cloth is recommended where flame, heat, or sparks are present. Special precautions are necessary with respect to certain types of thermal underwear. Clothing made with synthetic fiber should be selected and worn with caution. Synthetic fibers melt at lower temperatures and increase the potential severity of a burn injury. It is advisable to wear steel-toed safety shoes or boots on the job. Metatarsal (instep) protection is highly recommended.
1.2
1.3
Steel-toed Boot
Metatarsal Boot
Lets All Work Together for Safety
iv
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2 General Safety Rules for Structural Steel Fabricators
1.4
The wearing of an approved hard hat (safety cap/hard hat, but not a bump cap) is recommended.
1.7
Pants guards (clips, elastic, or rubber bands) should be worn by employees performing operations where the pants legs could be caught by a revolving drill or reamer bit. ANSI approved type eye protection is required in all plant areas. Face shields or similar protection should be worn in addition to basic eye protection when grinding, chipping, burning or doing other work where there is an unusual hazard from flying particles. Described below are a few types of recommended eye protection. AISC makes no recommendation as to specific manufacturers; however, all safety glasses should meet ANSI Standard Z87.1, Eye & Face Protection. Heavy Impact Goggles provide protection from heavy impact, dust, smoke, cinders, and welding glare. May be worn with or without spectacles. Not suitable for continuous close-up exposure to welding glare.
1.8
Hard Hat
Bump Cap
1.5
Generally, gloves should be worn except when operating lathes, milling cutters, boring mills, drill presses, or other types of machinery with revolving spindles or cutting tools or where they may interfere with the safe operation of control buttons on floor or platform-operated cranes. Neckties, loose, torn or ragged clothing create a special hazard when operating lathes, drill presses, reamers, and other machines with revolving spindles or cutting tools, and shall not be worn while working.
1.6
Heavy Impact Goggles
Burner Goggles provide protection from light and sparks from burning torch, impact, dust, cinders and weld glare. May be worn with or without spectacles.
Burner Goggles
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Face Shields provide protection from impact, dust, cinders and welding glare. Not adequate for continuous close-up exposure to welding operations. Use in conjunction with general-purpose spectacles for heavy impact work, chipping, grinding, pickling and galvanizing operations. (Note: Also available in shaded lens and frames.)
frame readily adjusts to face, so this is particularly suitable for dust protection. May be worn with or without spectacles. Does not protect from weld glare. Not suitable for heavy impact. Note: Shaded lens available, but refer to above-noted comments for clear spectacles.
Cover-all Plastic Monogoggles
1.9
Face Shield
General Purpose Spectacles (Clear) provide protection from light or medium impact, dust and cinders. Does not protect from weld glare. Face shield must be used in conjunction with general-purpose spectacles when performing other heavy impact work. Note: Also available with shaded lens, but attention is directed to the consequential reduction of visible light when they are used. (See Rule 1.9.)
Welders are required to wear approved safety glasses in addition to welding helmet. When welders are regularly working very close to one another, it may be desirable to use safety glass lens having a shade value of 1.5 or 1.7. (Note: These shaded lenses have equal resistance to ultraviolet light transmittance, but they have a loss of 38% and 50%, respectively, in visible light. Thus, while some glare reduction will be achieved, the visible light reduction may present an unacceptable, unsafe condition.) Unless contact lenses have to be worn for medical reasons (such as following a cataract operation) they should not be worn in the shop, because dust and other contaminants may cause secondary problems of irritation, itching, watering and infection. (Also see Rule 8.7.) Fall protection is required when working aloft. Lanyards shall be anchored to an appropriate tie off point except when moving or changing work locations or when working from permanent walkways, platforms, etc., equipped with guardrails. Inspect fall protection equipment before each use. Notify your supervisor immediately if any defects are found in the safety equipment. Always wear a life vest when working on floating equipment or while engaged in any work over the water.
A MERICAN I NSTITUTE S TEEL C ONSTRUCTION
1.10
1.11
General Purpose Spectacles
1.12
Cover-All Plastic Monogoggles (Clear) provide protection from light or medium impact, dust and cinders. Soft vinyl
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1.13
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1.14
Respirators, suitable to the type of work being performed, must be worn when power wire brushing, spray painting, sand or grit blasting, burning or welding on painted surfaces, etc. Respirators shall be maintained in accordance with the manufacturers recommendations. Respirators should not be transferred from one person to another until they have been cleaned and sterilized. Turn in any respirator that seems to be defective. (Under special circumstances, such as burning steel coated with paint in confined areas, welding in confined areas, or spraying epoxy paints, air line respirators are recommended. Check with your supervisor before starting such work.) Respirators, including disposable dust mask type equipment, should be NIOSH or Bureau of Mines approved.
Ear Muffs
Dust Mask
Disposable Ear Plugs
Insert-type Ear Plugs
1.16 1.17
Air Line Respirator
Rings or other jewelry should not be worn in the shops or yards. Pure oxygen should not be used for ventilation or cooling purposes.
Cartridge Type Respirator
1.15
Proper fitting earplugs or muffs must be worn where hazardous noise situations exist. Some form of ear protection should also be worn where there is an unusual hazard of sparks, molten metal or flying particles from welding, burning or gouging.
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General Safety Rules 9
2. General Safety Rules

Be constantly on alert for unsafe conditions or acts and report such to your supervisor.
2.10
Do not pile material or equipment so that it obstructs safety equipment. Crane ladders, fire fighting equipment, exits, electrical panels, switch boxes, stretchers, etc., must be kept free of obstructions at all times. Aisles and roadways must be kept clear. Use a good ladder equipped with safety feet. Always use both hands when going up or down a ladder. Be sure that the ladder is properly secured, both top and bottom. Where a ladder cannot be secured, a person must hold it while anyone is climbing, descending or working from it. (Refer to Section 17 for Ladder Safety Requirements.) Never point a compressed air hose or tool at anyone or use compressed air for dusting clothing. Be as familiar as possible with surrounding areas, presence of other employees, and operation so that you can foresee possible dangers. Be familiar with in-plant emergency telephone communications, first aid stations, emergency shower and eye wash stations, stretcher locations, fire extinguisher locations, and emergency exitways. Never stand over an airline, hydraulic line, or any line under pressure. If an air hose breaks, do not go near it or attempt to grab it until the air pressure is shut off. Properly barricade floor openings, open manholes, machine foundations, and pits for repair purposes, and close them as soon as possible. Where the lighting is poor, a red light should be installed in addition to the barricade. If the sides of a trench or excavation do not appear to be firm and secure, notify your supervisor immediately. Crewmembers and authorized personnel only are permitted to ride railroad cars, locomotives, cranes, trucks and other mobile equipment. Flammable liquids such as gasoline, solvents, etc., must be handled in approved safety containers with flame arrestors. Never oil, remove guards or attempt to repair machinery while it is in motion. Do not climb on machinery while oiling or greasing, always use a ladder if practical. Only authorized personnel should make repairs of machinery.
2.11 2.1 Keep work area in clean and orderly condition with necessary equipment and material neatly arranged. Do not allow drift pins, bolts, weld rod stubs, or small material to accumulate on the shop floor or in the work area. Place paper sacks, lunch papers, etc., in containers provided. It is important that every employee keep his own work place clean and obstacle free. If you are in doubt about the safe or proper way to do a job, get instructions from your supervisor before proceeding. Be constantly on the alert for unsafe conditions or acts and report such to your supervisor. Horseplay is not permitted. Do not distract or interfere in any way with a person performing his job. Do not leave your work area unless your work or personal needs require it. Running through the shops or any part of the plant is prohibited except in an emergency. Always use designated aisles and walkways. Be alert for tripping hazards such as railroad tracks, hose, cable, rough or uneven surfaces, and projecting material. Using, possessing, or being under the influence of any intoxicant or illegal drug is prohibited at all times. Legal drugs that impair or compromise work performance will result in the worker being sent home. Thoroughly cleanse the skin after working with oil, grease, paint or chemicals. Failure to do so may result in skin trouble. Do not walk, crawl, or stand beneath suspended loads at any time or pass between swinging loads and fixed objects. 2.16 2.14
2.12 2.13
2.2 2.3 2.4 2.5 2.6
2.15
2.7
2.17 2.18
2.8
2.9
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2.19
Use the right tool for the right job; its easiest and safest. Never hammer with a wrench, pry with a file, etc. Never use a hardened steel hammer to strike punch dies, spindle holder or other hard tools. Use a soft-head hammer. Be sure wrenches are the proper size for the nut or head of bolt. Observe all signs, barricades, etc., concerning radiographic and x-ray work. When using a wrench, pinch bar or turning dog, position yourself so that if the tool slips, you will not fall or otherwise be injured. When moving about the plant, be alert for locomotive engines, forklifts, and other mobile equipment. Be particularly alert for such equipment at blind corners or when crossing railroad tracks. Where possible, allow at least a ten foot clearance when moving or working around railroad cars. If oil, grease, paint, or any other slippery substances are spilled on the floor, wipe them up immediately, or use approved absorbents, so that you or others will not slip or fall. Operate only equipment that your supervisor has authorized you to use and only in the area in which you have been directed to work. All safety guards must be in place before operating any machine or equipment. Only authorized personnel may remove guards. They must be replaced as soon as the work is completed and before the machine is put back into operation. Equipment must be locked out prior to starting any repairs or maintenance. Never attempt to open the switch or operate equipment that is under repair. (Repairmen testing equipment may operate it with guards removed provided adequate precautions are taken.) Make sure equipment is in a zero energy state before repairs are started. Never tie down, block out, or otherwise make inoperative any type of safety device or guard.
2.28
Stay well in the clear of loads being moved or handled by any type of conveyance. Be sure to keep your hands and body clear of moving parts of machinery or equipment. Rule 2.30 Check for the safety of all persons before operating any machinery or equipment.
OBEY ALL NO SMOKING
SIGNS
2.29
2.20 2.21
2.30
2.22
Never smoke in the templet, carpenter, or paint shops, storehouse, oxygen or acetylene storage areas, oil house, gasoline or diesel filling stations or any other area where smoking is prohibited. Do not attempt to brake or slow down moving machinery with your hands or a makeshift device. Use the machine brake if it has one, otherwise wait for it to stop of its own accord. Observe all caution and danger signs that are posted in the plant or shop areas. Also pay attention to all warning signals of cranes and other material handling equipment. Avoid wearing oily or paint-soaked clothing. If your garments become coated with such substances, keep away from fires or operations where hot metal or sparks may ignite the clothing. When assembling steel members with crane or hoist, always have sufficient number of bolts or pins in the piece to totally secure it before unhooking the crane or hoist. Similarly, when disassembling steel sections, always leave a sufficient number of bolts or pins in the member to fully secure it until the lifting equipment is completely hooked to the piece and supporting the load. All tools, whether company property or personally owned, should be maintained in first-class condition. Tools with loose or mushroomed heads or defective handles should be repaired or replaced immediately. If temporary scaffolds are needed, be sure the scaffold is safe and adequate for the work. Use only approved type scaffold boards. Inspect scaffold daily for defects. (See Section 18 on Scaffolds.)
2.31
2.23
2.32
2.33
2.24
2.25
2.34
2.26
2.35
2.27
2.36
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2.37
When welding, burning, etc., in confined areas, special means of ventilation may be required. Check with your supervisor before working in such areas. (See Section 8 on Arc Welding.)
Rule 2.38
2.45
Use caution when using a maul so that you do not strike yourself or another. When driving out pins, knocking out rivets, etc., be sure that you and other men are in the clear in the event the maul misses or glances off the pin or material. When handling material with a hoist or crane, avoid pulling the material toward you. Push it away from you. You will then be in a position to get in the clear should the need arise. When using air tools, always turn off the air at the outlet to relieve pressure before disconnecting hose. Never use your finger to check the alignment or condition of holes in material. When a drift pin becomes exceptionally tight or frozen in a hole, it should be burned off and drilled out of the hole. Do not continue to batter the pin with a maul and backout punch or with pneumatic equipment, as this may shatter the pin and cause further spalling. Only qualified welders shall weld supports for staging or scaffolding, or make welds attaching lifting hitches, lugs, etc. Avoid any prying action on welds supporting scaffolding. Make frequent inspection of drift pins, steel wedges and striking tools for indications of wear such as mushrooming, spalls, and cracks. Do not use any such tools that are in bad order. Turn them in for repair or for scrapping. Do not weld on hand hammers, sledges, wrenches, or any other hardened steel tools. Keep air hose, electric cable, etc., clear of hot slag or other hot material. When using tubular or other types of tiered scaffolding, be sure that each tier of the scaffold is tied to the structure to prevent overturning. The lending of tools, machinery, equipment, or other company property to contractors working in the plant should be avoided. Lending of such items should require the written approval of the plant manager.
2.46
DONT USE...
MAKESHIFT WORK PLATFORMS
2.47 2.48
2.38
Do not use a bolt keg, bucket or any other makeshift device as a work platform or for access to other elevations. Use ladders or approved type scaffolds for such work. Observe all posted speed signs when operating mobile equipment in the plant. When using C or other types of holding clamps, be sure they are sufficiently tight to prevent slippage of material. Do not overtighten by using a pipe or wrench for additional leverage. Clamp or otherwise secure small or light material before attempting to ream, drill, grind, etc.
Rule 2.42
2.49
2.39 2.40
2.50
2.41
2.51
ATTENTION:
ONLY DO AUTHORIZED PERSONNEL ELECTRICAL WORK
!
2.52
2.42
Only authorized personnel are permitted to do electrical work. Do not use electric extension cords, weld leads, etc., unless they are properly insulated. Avoid using electrical equipment while standing on damp or wet surfaces or when hands are wet. Always disconnect cord at the receptacle or shut off current before attempting to remove or replace a broken light bulb. All electrical equipment must be properly grounded. Report any defects to your supervisor.
2.53
2.43
2.54
2.44
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Cranes and Hoists 15
2.55
When you are relieved from a job that has unusual, partially concealed, or concealed hazards, immediately inform the person relieving you that such hazards exist. Be specific. Flagmen or watchmen assigned to protect personnel doing maintenance work, etc., shall not engage in conversation or other activities which would interfere with their assignment. 3.3 3.4 3.5
2.56
and vision tests are recommended. In some situations State and or Federal law require physical examinations. Operators should at least meet the minimum physical qualifications specified in ANSI B30.2, Overhead and Gantry Cranes. Board or leave your crane only at authorized locations. When leaving the cab to get off the crane, place controllers in the off position and open all switches. While repairs are being made, or when you go on top of the crane, place controllers in off position, open all switches, and lock the main switch(es) where possible. Where not possible, place danger signs. Keep boom (beam) blocks and hooks a safe height above the floor. During the time that the crane is unattended, always have the load resting on the ground. (See Rule 3.33.) Do not carry materials up or down a ladder; use a hand line, attaching it to the structure, never to your person. Keep both hands free Do not when going up or down ladders. throw or An operator shall not eat or read while actually engaged in operating a crane. Liquids are not allowed in the crane cab at any time.
Rule 3.9
3. Cranes and Hoists

Use cranes as they are intended to be used. Be aware of people near loads and do not move loads over people.
3.6 These instructions are for the purpose of increasing safety, efficiency, and proper operations of cranes. As a crane operator, you play an important part in operations and have a great responsibility for the safety of others. Read these rules carefully and become thoroughly acquainted with them. Keep the book handy for ready reference. Cooperate with the other men on the floor. See that your cranes are kept clean and in good repair. Run them so as to prevent delays and accidents. Suggestions for improvement of safety or efficiency will be appreciated.
3.7
3.8
drop anything from the cranes cab.
Electric Overhead Traveling Cranes (Cab Operated)

3.1 Only a regularly authorized and fully qualified operator shall operate any cab-controlled crane. The operator must pass the company medical examination, examinations to prove that he can operate the equipment safely, and he must be familiar with equipment parts and their uses. (Exception: Learner may operate under direct supervision of authorized operator and both should be in the cab at the same time. Repairman or inspector may operate only if fully qualified and authorized.) Crane operators should have a pre-employment physical examination and vision test. These tests should be repeated on a regularly scheduled basis. Annual physical examinations
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3.9 3.10 3.11 3.12 3.13
Do not drop or throw anything from the cab. Horseplay is prohibited. A fire extinguisher shall be available in each cab. Familiarize yourself with its use. Do not argue with men on the floor. Any disagreement must be taken up with the supervisor. You are responsible for the daily inspection and for reporting unsafe conditions of your crane. Report any electrical, mechanical or other defects immediately to your supervisor. (Notify the relieving operator of any problems.) Examine and test controllers prior to placing them in operation for each shift. They must be kept in good working
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3.2
3.14
order. When controllers are equipped with latches holding them in neutral position, these latches must be kept in working condition. 3.15 Cleanliness of crane, cab or pulpit is your responsibility. Use containers for trash and waste. Unnecessary articles should not be kept in or on cranes. Test limit switches and brakes, and make a visual inspection of cables at the start of each turn, and at any time they seem not to be in good order. Remove all loose objects, such as nuts and bolts, from cranes and walkways. Report any defects or temporary obstructions on walkways, stairs and ladders.
3.18
Use standard signals as shown on the chart, Rule 3.77. Take signals from only one man at a time. Ordinarily, lifts should not be made without a signal. The member of the floor crew who gives the signal must always make sure that everyone is in the clear. Do not overload the crane or sling. When in doubt as to the weight of a lift, consult your supervisor. (Also see Rule 3.78 for chart of alloy chain capacities.) Do not close main switch until you are certain the controllers are centered. Move controller step-by-step, allowing motors to speed up gradually, except for magnetic type controllers which are timed and stepless. Before starting to lift, center trolley and bridges over the load. Side pulls must not be made except on instructions from the supervisor. Do not use trolley or bridge motors to pull railroad cars or buggies, unless the hoist falls are reaved to pull the load with only vertical motion of the falls and no side motion. Do not make lifts or move your crane, regardless of signals, if in your judgment someone is in a position to be injured. Always obey an emergency stop signal. Before lifting, determine so far as possible whether load is properly hooked up. This is a joint responsibility of the operator and the men on the floor. Use your warning signal sufficiently to warn people in the path of the load. Do not carry loads over people. Do not use limit switch to stop hoist. Limit switches are for emergency purposes only. Do not operate hoist while limit switches are inoperative. When limit switches are inoperative, only operate with extreme care. The repairs to the limit switches should be made as soon as possible. If power goes off, immediately place controllers in off position and pull out the switches.
3.19
3.16
3.20 3.21
3.17
3.22
3.23
3.24
3.25 3.26 3.27 3.28
Rule 3.18
3.29
Use standard signals only.
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3.30 3.31
Do not operate bridge or trolley until load is hoisted free of the floor. When moving trolley or bridge, keep loads and chains high enough to clear all obstructions. Be sure that hooks are fastened back into the chain or ring wherever possible. Do not carry extra chains on the crane hook while moving loads. Do not set a load in an unsafe place. Loads should be set down on blocking and chains pulled out by hand. Lower a load or magnet to the ground or floor before leaving crane. When two or more cranes are used in handling a load, time your moves carefully to avoid possible confusion; use only one signalman. Do not bump another crane. Do not allow anyone to ride on a load, a hook, a lifting device, or chains. Proceed with caution when a repairman places temporary bumpers such as rail stops, on the track. The repairman should notify you when the bumpers are placed. Warning signs shall be placed on the ground and/or in another visible location during repairs. Bumping into runway stops is prohibited. Oxygen, acetylene or other high-pressure tanks are not to be carried by cranes except when securely fastened in a suitable carrier such as a cradle, or a platform with sides. Wood blocks or short lengths of steel should not be carried loosely on tops of loads. Outside crane operators, when leaving at the end of their turn, shall set the bridge brake or lock it in some approved manner. Capacities shall be marked on both sides of the equipment where the letters and/or numbers can be easily seen from the ground.
Floor Operated Cranes and Hoists

The following safety rules apply to power-operated cranes controlled from a floor or platform, such as jib, monorail, overhead travelling gantry, stiff leg derrick, hoists, etc. 3.43 3.44 3.45 Only qualified employees designated by the supervisor shall be permitted to operate such equipment. Do not make a lift or move equipment if anyone is in a position to be injured. Familiarize yourself with the handles of control ropes so that you can tell without looking which is the hoisting and which is the lowering control. Each control rope shall be marked to indicate the direction it controls. Similarly, when using pendant controls, familiarize yourself with the location and function of each button. The function of each button should be indicated on the pendant control. Never raise a load before chains are securely hooked and the hookers hands and feet are free and in the clear. Do not raise hooks before the unhooking is completed, and be especially alert for lugs or brackets on the members that may foul the hooks and cause the load to turn over. Remember when a bundled load is picked up that the material will tend to nest and create pinch points. Similarly, when a load is landed, it will tend to roll or spread out. Make certain you and others are alert and in the clear of such movements. Keep all parts of the body away from lifts being raised or lowered. When starting or stopping movements of bridge and trolley, move controls step by step, allowing motors to speed up or slow down gradually, except for magnetic type controllers which are timed and stepless. When raising or lowering a load, proceed slowly and make sure the load is under control. Before starting to hoist, the trolley shall be centered over the load. Side pulls (where load block is not hanging plumb) are not permitted except under specific direction of the supervisor.
3.32 3.33 3.34
3.35 3.36 3.37
3.46
3.47
3.38 3.39
3.48
3.40 3.41
3.49 3.50 3.51
3.42
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3.52
Do not use trolley or bridge motors to pull railroad cars or buggies unless the hoist falls are reaved to pull the load with only vertical motion of the falls and no side motion. Take slack out of chains or slings gradually. No load shall be carried over people. If anyone is in the path of travel, stop and clear the area. Do not allow anyone to ride a load, hook, lifting device or chains, except for inspecting wire rope under controlled conditions. When gloves may interfere with safe operation of the control buttons, they should not be worn. Stand in the clear so that if load swings, slips or spills, you will not be injured. Make sure hook block and attachment will clear adjacent equipment or material. When unhooking material, always clear hooks and chains; hold them away from material that can be tipped over if the empty hook should catch. Do not drag slings, chains, etc., along the floor. Do not carry extra chains in the crane hook. Wood blocks or short lengths of steel should not be carried loosely on tops of loads. Capacities shall be marked on both sides of the equipment where the letters and/or numbers can be easily seen from the ground. Do not overload the crane, hoist, or sling. When in doubt as to the weight of a lift, consult your supervisor. (Also see Rule 3.78 for chart of alloy chain capacities.) Such equipment shall not be used to carry oxygen, acetylene, or other high-pressure cylinders unless carried in an approved carrier. Bumping into runway stops is prohibited. Never bump another crane.
3.69 3.70 3.71
A path should be provided for travel of the person operating overhead travelling cranes with pendant controls. Report to the supervisor defective or missing safety equipment and mechanical or electrical defects without delay. When letting go of control pendant, do not allow it to swing freely. Avoid leaving operating ropes or control cables hanging in passageways. Unstable equipment located out of doors shall be secured against wind movements. Limit switches shall be checked at the beginning of each shift or turn that the equipment is used. Do not use limit switch to stop hoist. Limit switches are for emergency use only. Means for effecting an automatic return to the off position should be provided on controls of floor-operated cranes and monorail hoists. At all times, use due care and sound judgment in the operation of such equipment to prevent injury to any person, damage to equipment or material.
3.53 3.54 3.55 3.56
3.72 3.73
3.57 3.58 3.59 3.60
3.74
3.75
3.61 3.62 3.63 3.64
3.65
3.66
3.67 3.68
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Crawler, Locomotive and Truck Cranes
3.76
The above signals apply to cranes moving on rubber tired wheels or on caterpillar treads, as well as on tracks. When operating near electric power lines extreme care should be taken that the boom or load line does not touch the power line. Operators should keep all parts of the equipment at least 10 feet distant from a 50 kv line, and add 0.4 inches distance for each 1 kv over 50 kv. Should the boom or hoisting cable come in contact with a power line, the operator should not climb down from the cab to the ground while the rig is energized.
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Standard Crane Signals
HOIST. With forearm vertical, 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, move arm back and forth.
EMERGENCY STOP. Both arms extended, palms down, move arms back and forth.
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.
MAGNET IS DISCONNECTED. Crane operator spreads both hands apart, palms up.
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Material Handling 27
3.77
When handling material by crane, it is an absolute requirement that the proper signal be given the crane operator. Hookers-up should never overload. See that the load is properly balanced before giving signal to craneman to make any further move. Keep your hands in the clear at all times and stand in a safe position as the load is moved. Crane operators should watch out for persons working below and keep loads, chains and hooks clear of men and materials.
4. Material Handling
Block stack and secure material to avoid tipping and shifting.
4.1
Alloy Chain Capacities

Working load limits for heat treated grade 80 alloy steel chains, in pounds
Single Types S or C 90o Chain Size 7/32 9/32 3/18 1/2 5/8 3/4 7/8 1 1 1/4 2,500 4,100 7,300 13,000 20,300 29,300 39,900 52,100 81,400 4,300 7,100 12,600 22,500 35,000 50,500 69,000 90,000 141,000 3,550 5,800 10,300 18,400 28,500 41,500 56,500 74,000 115,000 2,500 4,100 7,300 13,000 20,300 29,300 39,900 52,100 81,400 1,300 2,100 3,800 6,700 10,500 15,200 20,700 27,000 42,100 60o Double-Branch Type D
45o
30o
15o
Before entering any railroad car, see that the track is protected with a blue flag or other approved type warning device so that the railroad crew will not couple to the car. Any applicable federal standards should be followed. No one shall remove a flag or other approved type warning device except the person who places it. (Exception: In the event that such person does not remove his blue flag or device and cannot be located, the supervisor, after making a thorough check of the track in question, may remove the flag or device.) When working in drop-end gondolas, check the condition of the latches and hinges on the end gates. Be sure the end gate is properly secured so that it will not fall when material is moved. Use extreme caution when raising or lowering the end gates. Employees shall not remain in cars when they are being moved. Do not stand or walk on sides of cars and do not attempt to step or jump across the end gates when going from one car to another. Men must get out of the car when conditions of car, material, or both do not enable them to assume a safe position. Insofar as possible, hookers should move to the opposite end of the car from that where material is being loaded or unloaded after chains or other lifting devices are properly hooked.
4.2
4.3 4.4
4.5 3.78 Refer to the above chart to check alloy chain capacities. (See Rules 3.19, 3.65, and 4.11.)
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4.6
When manually removing any blocking or other dunnage from cars or trucks, employees must see that no one is in the area where material will be thrown or placed. When loading or unloading trucks, all drivers must be out of the cab and in the clear of any loading operations, except when the cab is equipped with a protective roof. Similarly, outside truck drivers are not permitted on the bed or trailer of the truck during loading operations. If the driver must inspect the load and tie-down arrangement, all loading operations must be suspended during this inspection. In carrying loads with other workmen, always give adequate warning of any action on your part, such as dropping your end of the load. Keep in step; it makes the load easier to handle.
4.9
4.7
When lifting, bend the knees, elbows tight against the body, and keep the back nearly vertical. Then grasp the object firmly and raise by straightening the legs. In this way, the work is done by the leg muscles and strain is relieved from the weaker back muscles. Always get help for lifting where the load is too heavy for one person. When piling material, build a solid sturdy pile. Make sure there is a firm foundation and do not pile the material so high that an unsteady pile results. In piling pipe, round bars, or other materials that may roll, be sure to use a sufficient chock at the base of the material. Determine the weight of the load and select the proper size and type of hooks, chains, etc. Be familiar with capacity charts of such equipment. (See Rule 3.78 for chart of alloy chain capacities.) Always stand clear of the load so that if it swings, slips, or spills, you will not be injured. Do not stand between material that could be struck by a moving load. Keep hands and feet clear of pinch points. Be alert for nesting or rolling of material as it is raised or lowered or when landing on skids, blocks or buggies.
4.10
4.8
4.11
4.12
4.13
Rule 4.9
Equalize the strain. A MERICAN I NSTITUTE

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4.15
Be alert for kinks in chains. Knots in chains are not permitted. Protect chains or slings with softeners where they pass over sharp corners or edges. Be sure that all chains, hooks, shackles, etc., are in good condition. Always use proper bolt or pin with shackles. Do not use common fitting bolts. Inspect frequently and report any defects to your supervisor. Never land material too close to ends of skids or other supports where it may fall. Keep bolts or pins in the ends of skids or provide other means to prevent material falling off. Moving material on skids requires care. Moving one piece may cause other pieces to fall. It is the duty of the signalman and operator to see that no one is in danger. Stack detail material so that it will not fall. When necessary to step over skids or to walk across material on skids, do so with caution. Avoid bumping your shin or knee and be alert for bolts, dogs, pins, blocks, oil, etc. that may cause you to fall. When moving shop buggies by hand, be certain that feet and hands are in the clear. Do not make contact with other loads to stop buggies. Push buggies from rear wherever possible, and face direction of travel. When taking loaded buggies through doorways of shop or congested areas, always send a man ahead to clear the track and warn others of the approaching buggy. Load shop buggies in a safe manner. Never exceed safe heights and always use side stakes, keeper plates, pins, or other means on buggies to secure the load. Be alert for any unexpected turning or movement of suspended loads or stacks of steel. Use blocking as required: Minimum of 4 x 4 on angles, beams, tees, channels, zee bars, etc. Be sure material is adequately supported on skids, blocks, or buggies. Use only hardwood blocking that is in good order. In stacking material, blocks must be placed directly over each other and insofar as possible at right angles to the material. Blocks must be of sufficient length and uniform
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4.16
4.17
4.18
4.19 4.20
4.21
4.22
4.23
Rule 4.14
Always grasp above the load.
4.24 4.25
4.14
Always grasp chains or slings above the load (above the hook if possible) when holding slack before hoisting. If necessary to guide load with your hand, be sure your fingers and hands are on the outside of the material or otherwise positioned so that they cannot be caught inside the material or between the load and adjacent material.
4.26
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size to hold the stack securely, but not long enough to engage other stacks. Avoid the use of small multiple lengths of blocking to make up a single length. 4.27 In stacking material, if at all possible, keep material of the same size stacked together. This makes a more stable pile and conserves space. Do not pile extra-long material on top of short material. Not more than 25 percent of the total length of the top material should overhang the material under it. If necessary to pile small beams on top of larger beams, blocks must be placed between the flangesnot across the flanges. Using wood blocks for bridging between individual members or between stacks of material is prohibited. When stacking a heavy lift of beams or girders with the flanges horizontal, always use 6 x 6 or two 4 x 4 blocks side by side at each blocking point. Do not leave blocking, chains, cable, hose or tools lying about the floor after you are finished with them. Keep aisles and areas between skids clear and free of tripping hazards. Maintain good housekeeping standards at all times. Use a hoist or crane where loads are too heavy to handle by hand. Maintain a good handhold and footing when handling material by hand. Be alert for sharp edges and burrs or for material that may be hot from burning, welding, grinding, etc. When turning material with a hand dog or pinch bar, position yourself so that if the tool slips you will not fall or otherwise be injured. In turning material on skids, always turn material in a direction away from yourself. Keep the areas near railroad or industrial tracks clear. A clearance of 30 inches from industrial tracks and 5 feet from the nearest rail of a railroad track must be maintained. When handling material by crane, standard crane signals must be used. Always be sure that the crane operator can see you. (Refer to standard crane signals, Rules 3.76 and
3.77.) Only one person at a time should give hand signals to the crane operator. 4.38 Be sure that loads will clear all equipment and other obstacles before giving the crane operator a signal to move. See that other employees are in the clear before moving any loads. Avoid overloading equipment or lifting devices. Place chains and hooks so that loads are equally distributed and balanced. The block and trolley must be directly over the load. See that loose bolts, washers, nuts, blocks, etc., are off loads before they are moved. Be certain that all plate hooks, dogs, etc., are properly hooked before allowing loads to be hoisted. Plate clamps, alligator clamps, grab clamps or screw clamps must not be used to make a vertical lift of more than one plate or piece of steel at a time. Use clamps, grabs and hooks as intended. Use double chains when lifting rods or pipe and see that each chain is properly secured around the load. Loads must not be carried over railroad cars or other vehicles in motion. No load should be carried over people. When unhooking material, be sure the chains are completely clear of the lift before signaling the craneman to hoist. When load is set down, allow sufficient slack in the chains to permit the load to settle. Do not reach under the load to remove the chains. Pull the chains free of the load by hand before signaling to hoist. Be alert for lugs, brackets, wing plates, etc., on the blind side that may engage hooks or chains and tip the member over. Brace or clamp girders and other high members, which are in an upright position, to the skids or rails before releasing the crane hooks. Before cleaning, painting, heating, or straightening girders in upright position, be sure they are properly braced or clamped to prevent overturning. A minimum of 4 clamps is required. Additional clamps should be used on extra-long pieces.
4.28
4.39
4.29
4.40
4.30 4.31
4.41 4.42 4.43 4.44
4.32
4.33 4.34
4.35
4.45
4.36
4.46
4.37
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Punching and Shearing 35
4.47 4.48 4.49
Keep bolts, pins, washers, etc., in containers. Do not allow them to accumulate on the shop floor. Do not stack material across the sides of trays, or from one tray to another. Do not make side pulls with a crane or hoist except when properly authorized by your supervisor. Do not use trolley or bridge motors to pull railroad cars or buggies unless the hoist falls are reaved to pull the load with only vertical motion of the falls and no side motion. Whenever possible, blocking must be in place before crane moves into position to lower load. When placing blocks under loads, hold the blocks so that your fingers are to the sides of the block and not between the block and the load. It is prohibited to ride on crane hooks, chains, lifting devices or loads being carried by cranes, except for inspecting wire rope under controlled conditions, Do not pile material in aisleways or passageways. Keep material behind designated aisle lines. Hookers and material handlers are responsible for the weight of the lifts moved by cranes. They must familiarize themselves with the capacity of the cranes; they must be able to estimate the weight of lifts; they must know the capacity of hooks, clamps and chains, etc., used. As an additional precaution, crane operators are instructed not to move a lift which, in their opinion, is unsafe, but must immediately notify the supervisor. When operating a crane in the vicinity of gantries, hoists or other projecting handling equipment, always check to see that the crane and load will clear the equipment before making any moves. Insofar as possible, beams should be stored in the various shops with the web horizontal rather than vertical. This makes for more stable piling. When separating or spreading material, use a pry bar or spud wrench rather than your hands. Where beams or other materials are nested together, stand at the ends so you will be in the clear if material falls or turns over.
4.57
When loading material on trucks or trailers, use temporary sidestakes, chocks or other suitable means to contain material until chain binders are fastened. Stand clear of binder handle. Do not add pipe extension to handle. Small or loose material must be wired, banded or placed in trays or on pallets before sending from shops for shipping or painting. When working around piles of beams or other material, avoid crossing over skids or between stacks of material. Use regular walkways or cross at ends of skids. Tag lines should be used for turning and handling of large members, and for any other situations where supervision deems necessary.
4.58
4.59
4.50
4.60
4.51
4.52 4.53
5. Punching and Shearing

Inspect equipment regularly. Do not load equipment beyond its capacity.
4.54
5.1 5.2 5.3 5.4
Make certain guards are in place on all foot switches on punches. Know the capacity of your machine with respect to thickness of material and sizes of holes. Frequently check your machine for defective dies and punches or shear blades. Lock out main switches and safely block the treadle before changing punches or dies, or shear blades, or before making any repairs.
4.55
4.56
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Reaming and Drilling 37
5.5
When a machine has been turned off for repairs or adjustment, lockout devices or tags must be used to make sure it will not be turned on except by the repairman. Be certain that the punch and bottom die are in proper alignment to avoid breakage. Also make certain the setscrew, which holds die in block, is tight. Punches that are broken off in material should be burned out when possible. Do not attempt to use your hands to remove the broken punch. Do not attempt to drive out such pieces with a maul and backout punch or drift pin. Notify your supervisor if sound in punching is a sharp, ringing one. The steel may be silicon or other hard alloy that requires special attention. Keep fingers out of the area of cutting edges and other exposed moving parts. When punching detail on close gage, be sure you grasp the piece at the sides and keep your fingers clear of pinch points. For close work use templet clamps. After positioning material for shearing, keep hands and fingers clear while blade is cutting. Be alert for whipping ends, etc. Hands must not be used to remove chips, rust or other material from the machines. Use a brush or other suitable means. Keep machinery clean, free of tools, slugs, rags and scrap.
5.15
Stay within the capacity of all hoists and lifting devices, chains, hooks, etc. be familiar with capacities for such lifting equipment. When using special grab hook chains or other equipment for rolling material, make certain the hook is properly secured. Be especially alert when slacking off to reposition the chain or hook. Load material safely so that it can be unloaded and handled safely at the next workstation.
5.6
5.16
5.7
5.17
5.8
5.9 5.10
6. Reaming and Drilling

Do not misuse machinery. Do not use equipment that does not appear to work as intended.
5.11
5.12
6.1
5.13
Check the machine frequently for any defects and turn in any equipment that appears to be in bad order. Check the electrical cable for breaks or loose connections, proper grounds, etc. Be sure that the handles are tight and free of any breaks. Poor operation may indicate that the tool is defective. Electrical shorts and failure of the machine to stop when the switch is turned to off position are specific examples of defective equipment. Do not use a bit with dull edges, burrs, or nicks. Such bits should be turned in to the tool room. When using gantry drills or reamers, be sure that everyone is in the clear before moving the gantry. To prevent kickback in the event the bit lodges, safety bars should be used on portable reamers, where possible.
6.2
Rule 5.14
Keep floors clean of tripping hazards.
6.3 6.4
5.14
Keep the floor around your machine clean, dry and free of tripping hazards.
6.5
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Reaming and Drilling 39
6.6 6.7
Portable reamers should have a deadman (constant pressure) control. Never wear any loose or ragged clothing while reaming, and keep all parts of the body away from the rotating spindle and bit. Trouser guards should be worn as needed by gantry drill or reaming operators. Never fasten the switch on a reamer or drill in the on position. Never use your hands to guide the reamer bit into the material or to slow down the rotation of the bit or the reamer spindle.
6.10
Two people are required for the operation of the standard hand reamer. Never attempt to operate with only one person. Always coordinate your movements so that the machine is under complete control at all times. Maintain a firm grip on the handle, good footing, and be alert for sudden kickbacks of the machine. Handle reamers with care. Never drop them or land other material on top of reamers, as such practices will easily damage the equipment. Never attempt to place or change a drill or reamer while the spindle is still revolving. Be extremely cautious when necessary to work above floor level, such as when working from scaffold or from the top of fabricated members. Make certain that your work platform or area is adequate in every respect. A safety bar should be used under these conditions. Use a stick to remove chips or cuttings from rotating drills. Never use your hands. When reamers are not in use, they should be placed on stands or at other designated spots. Keep bit straight in hole while entering, reaming or drilling, and removing, so that unit will not stick or bind. Do not remove one handle for close corner reaming without permission from your supervisor. When one handle is removed, the other must be supported against steel to prevent its turning. Clamp or otherwise secure small or light material before attempting to ream or drill. Never attempt to keep the material in position by holding it with your hands or by standing on it. Do not apply excessive pressure so as to speed up the cutting action of the bit, as this will often cause the bit to lock in the hole. Apply only sufficient pressure so that the tool cuts in a normal manner. When drilling or reaming through exceptionally thick material, the bit should be removed occasionally and the
6.8 6.9
6.11
6.12 6.13
6.14 6.15 6.16 6.17
6.18
6.19
Rule 6.10
6.20
Use two people on a reamer.
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Fitting and Bolting 41
chips cleaned out. If chips are allowed to accumulate, the bit may become jammed. 6.21 6.22 If the machine starts to vibrate excessively, it should be stopped, repositioned, and started again. Electric cables and extension cords should be placed where they will not present a tripping hazard or be subjected to damage from mobile equipment. Never attempt to remove a broken drill or reamer bit with a backout punch, center punch, drift pin or hammer. Use safety chain on magnetic drills when drilling in a horizontal position. Do not use a steel hammer or other hard object to seat the bit and socket. Use a wood block or a soft hammer to wedge the socket and bit into the machine. Be sure that the flat edge of the socket is in proper alignment with the flat edge of the reamer or drill bit. Use properly fitted wrenches and do not work with wrenches that have worn or sprung jaws. Also, inspect the fitting bolts for worn or misshapen nuts and heads from which wrenches are likely to slip. Do not use a wrench as a hammer. In horizontal reaming, the reamer handles should be held at or near waistline elevation. If possible, avoid reaming with handles above the shoulders or overhead. In so far as possible, both workers should stand at the same elevation and be approximately the same height. When reaming into a box section, be sure no one is inside who could be caught when bit goes through.
7. Fitting and Bolting

Use tools of the correct size. Control detail material that can fall or tip.
6.23 6.24 6.25
7.1
Use only proper size wrenches. Return misfit or defective wrenches to the tool room for replacement. Do not work with wrenches that have worn or sprung jaws. Do not alter, repair, or allow any welding to be done on fitting wrenches. Inspect fitting bolts for worn or misshapen nuts and heads from which wrenches are likely to slip. Do not use a wrench as a hammer. Keep material piled in an orderly manner. Do not leave your tools lying around for others to trip over. If temporary scaffolds are needed, be sure the scaffold is safe and adequate for the work. Use only approved scaffold boards. Inspect scaffolds daily for defects. The supervisor prior to use must approve each scaffold. (See Section 18 on Scaffolds.) When using a hydraulic jack, be certain that it is secure and centered on the blocking and load. Keep the jack perpendicular to load to avoid kickout or slipping. Be sure the footing and ram are free of oil or grease. (Refer to Section 19 for rules concerning use of jacks.)
Rule 7.5
7.2 7.3
6.26
6.27
7.4
6.28
Use caution when placing detail material.
7.5 7.6
Place detail material so it will not slip or fall. When assembling girders, etc., in an upright position, the stiffeners should be placed on the floornot leaned up against the web or other material. Clamp or otherwise secure fillers to hold them to web plates, preparatory to bolting or drifting. Never remove the last bolt
7.7
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Arc Welding 43
holding a fill to web plate until you have checked the area and are sure that everyone is in the clear. 7.8 Detail material such as stiffeners and fillers that are too heavy to safely handle by hand should be handled by crane or hoist. Maintain good handhold and footings when manually handling detail material. Be alert for sharp edges and burrs. Check grinder for guard and grounding before using and be sure the cables do not present a tripping hazard for you or others. Open valves gradually on air hose or tools so as to avoid sudden kickback. When bolts or drift pins are being knocked out, care shall be taken to keep them from falling. Bolts, nuts, washers, and pins shall not be thrown. They shall be placed in bolt buckets or other approved containers and raised or lowered by using a line when they cannot be passed from hand to hand. Impact wrenches shall be provided with a locking device for retaining the socket. Never use wire, nails or spikes to hold the socket on impact wrenches. Instead, use the standard pin or other locking device provided. Impact wrenches must be disconnected from the power source before they are adjusted or repaired. Airline hose sections shall be tied together or a quick disconnect couplet shall be used to join the sections. Containers shall be provided for storing or carrying bolts or drift pins. Employees shall be instructed in the proper care and use of bolting equipment and in the proper method of bolt installation and tightening. The air hose shall not be used to pass impact wrenches from one employee to another. If the impact wrench cannot be handed from one employee to another, a rope shall be provided to pass the wrench.
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7.21 7.22
Open-end or spanner wrenches with sprung openings shall not be used. Leverage devices, such as pipe extensions, shall not be used to give greater leverage to an open-end or spud wrench. If the wrench is designed for use with a pipe extension, only an approved length of pipe shall be used. Open-end wrenches shall have jaw openings that match the bolts being tightened. Shims shall not be used to adjust the jaw opening.
7.9 7.10
7.23
7.11 7.12 7.13
8. Arc Welding
Avoid shock and heat hazards. Safeguard eyesight.
7.14 7.15
STOP :
8.1 8.2
Welders Study Section 8!
7.16 7.17 7.18 7.19
Keep gloves, shoes, clothing and other protective apparel as dry as possible, so as to avoid electric shocks. When welding in confined areas, special means of ventilation may be required. Check with your supervisor before working in such areas. When welding material that may give off dangerous toxic fumes such as lead alloy and paint. Bureau of Mines or NIOSH approved respirators must be worn unless the fumes are adequately removed by artificial ventilation. Check with your supervisor before welding under such conditions. Welding equipment should be used only with in its rated capacity.
8.3
7.20
8.4
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Arc Welding 45
8.5
Welding should be stopped if any abnormal equipment condition arises. Work should not be resumed until authorized by the supervisor. Only qualified and authorized persons shall repair welding equipment. Contact lenses shall not be worn while welding. (Also see Rule 1.10.) Welders are required to wear approved safety glasses in addition to welding helmet. When welders are regularly working very close to one another, it may be desirable to use safety glass lens having a shade value of 1.5 or 1.7. (Note: These shaded lenses have equal resistance to ultraviolet light transmittance, but they have a loss of 38% and 50%, respectively, in visible light. Thus, while some glare reduction will be achieved, the visible light reduction may present an unacceptable, unsafe condition.) Welders should inspect the area in which they are to work to be sure that it is clear of objects which might fall or which otherwise might cause injury when vision is obstructed by the welding helmet. Welders must use caution to avoid electric shock from welding equipment and from other sources. When handling the electrode holder or cable, the welder must avoid electrical contact between his body and objects connected to the work or ground of the welding circuit. Rules 8.11 through 8.16, below, are especially important in preventing electric shock. Welders must not stand in water while changing welding electrodes in the electrode holder. Welders must not handle the electrode holders from two different machines at the same time. Electrode holders must not be dipped in liquids to cool them. When a welding machine is in operation, the cable should not be looped over the shoulders or around any part of the body.
8.15 8.16 8.17 8.18
Welders should not wear rings, metal wristbands, or other jewelry. Welders shall not change polarity of the welding machine while welding is in progress. When welders carry electrodes on their person, they should be in a proper container. Electrodes shall be removed from the electrode holder when welding is interrupted for other activity or when the equipment is left unattended. The power supply to welding machines or welding transformers shall be shut off when work is completed, when the equipment is to be left unattended, or when the equipment is to be moved. Any discomfort or injury to the eyes or other parts of the body caused by exposure to ultraviolet rays from the arc or by welds slag or scale should be reported to the supervisor, and the welder should obtain medical treatment. When welding is done in areas not ordinarily used for such work, screens should be used to protect other workers and passersby from the radiation from the arc. Persons in the vicinity should be warned against watching or looking directly at the welding arc. Welders should place welding cable, ventilating hose, and other equipment so that it is clear of high voltage power cables, steam lines, moving shafting, ladders, and stairs. Welding current return circuits or grounds must carry their current without hot or sparking contacts, without heating of conductors or their joints, and without passage of current through equipment or structures which might be damaged or made unsafe by the welding current or its voltage. In particular, welding current must not be allowed to pass through: Acetylene, fuel gas, oxygen, or other compressed gas cylinders. Tanks or containers used for gasoline, oil, or other flammable material.
8.6 8.7 8.8
8.19
8.20
8.9
8.21
8.10
8.22
8.23
8.11 8.12 8.13 8.14
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Flame Cutting (Burning), Cambering, and Heat Straightening 47
Pipes carrying compressed air, steam, gases, or flammable liquids. Conduits carrying electrical conductors. Chains or wire ropes. Metal handrailings or ladders. Machines, shafts, bearings, or weighing scales. 8.24 Welding electrode stubs must not be thrown on floors, decks, staging, or scaffolds. They shall be collected in a container for safe disposal. Welders must avoid starting fires. Before starting to weld, the vicinity in which the welding is to be done must be inspected carefully. Combustible material shall be moved away or shielded from all heat with fireproof material. Where welding is being done on a floor, deck, wall, bulkhead, or other partition, the welder must be sure there is no fire hazard on the opposite side. A fireguard shall be posted if any hazard is present. No welding shall be done in or near areas where there may be flammable materials, explosive gases or vapors. No welding or preheating is to be done on or in any tank, pipeline, compartment, or container which has contained flammable material until it has been thoroughly purged and cleaned, and approval given by your supervisor. Any openings that might allow flammable gas or vapor to leak into the structure shall be sealed securely before any welding is started. Ventilation sufficient to keep the space purged of flammable gases or vapors shall be supplied when any welder is required to work inside such a tank, pipeline, compartment, or container. If welding is to be done only on the outside of the structure, the interior shall be purged continuously with steam or inert gas to prevent any fire or explosion.
9. Flame Cutting (Burning), Cambering, and Heat Straightening

Wear PPE meant for cutting. Handle cylinders carefully.
8.25
9.1
Use standard burning goggles or approved burning face shield recommended for this type of work. (Refer to Rule 1.8 on eye protection.) Wear proper gloves and shirts with long sleeves when burning. High-top shoes or boots and trousers without cuffs are recommended. Clips or elastic bands around the bottom of the trousers will help prevent slag entering the shoes. Avoid burning while wearing ragged or oily clothes. Respirators suitable for the type of work being performed should be worn, as recommended in Section 1 on Personal Protection. Should the material you are cutting give off irritating fumes or smoke, notify your supervisor immediately. Use the proper names of gases when referring to them: that is, acetylene, oxygen (not air), MAPP, carbon dioxide, etc. Keep burning hose and other equipment arranged in an orderly manner, so that they will not be knocked over, run over, or present a tripping hazard. Use no oil, grease, or any other lubricant on apparatus. Burning equipment does not need lubrication. Oil or grease in the presence of oxygen under pressure may react violently. Do not handle cylinders or apparatus while hands, gloves, or clothing is greasy. Inspect the torch, hose, regulators, etc. frequently. Do not attempt to tape burning hose. Defective equipment should be turned in for replacement or repaired by qualified personnel.
9.2
8.26 8.27
9.3
9.4 9.5 9.6
9.7
9.8
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9.9 9.10
Use leak test solution (soapy water) to test for leaks. Do not use compressed air, gas or oxygen to blow out burning hoses, clean burning equipment, or purge gas pipelines. Ordinary compressed air may contain moisture and oil. Never interchange regulators, hose, and other burning apparatus. Use equipment according to manufacturers recommendations. Make certain that all connections are secure, and all fittings tight. Dont force connections that do not fit. Cylinders shall be repaired only by the manufacturer or qualified vendor. Only trained personnel should manifold cylinders. Manifolds should be installed per manufacturers instructions. Do not leave the valves of empty cylinders open. Close the valve before replacing valve cap. All cylinders, empty or full, should be stored away from open flame, furnaces, radiators, flammable and volatile liquids, or other hot places. In hot weather they should be protected from the suns rays as much as is practical. Cylinders should be stored, transported and used in an upright position. In storing, secure them with a chain or bar to prevent toppling. See that protection caps are in place when cylinders are not in use or are being moved. (Use of upright burning buggies is recommended.) Cylinders containing different gases should be stored in separate locations or separated by flameproof dividers. Cylinders should not be handled roughly; do not drop them or permit them to fall or strike other cylinders or material violently. 9.20
9.11
9.12 9.13 9.14
9.15 9.16
Rule 9.20
Transport cylinders with care.
9.17
Cylinders should not be lifted or transported by slings, magnets, or hooking onto cap. Use a cradle, platform, buggy, or other safe, suitable means. Never use cylinders as rollers or supports. These are devices that may be easily damaged and are not designed for such use. Do not allow cylinders to come in contact with live wires or ground wires from electrical equipment. Welding current must not be allowed to pass through cylinders. Never permit any open flame to come into contact with any part of a cylinder. Never open the valve on any cylinder near sparks, flame, or other welding and cutting work. Leaking cylinders should be: (1) kept away from flame, sparks, and other potential fire sources; (2) taken outside building away from possible sources of ignition; (3) properly
9.21
9.18 9.19
9.22
9.23
9.24
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tagged to explain trouble; and (4) immediately reported to your supervisor. 9.25 If a cylinder catches fire at the valve, the valve should be closed, if possible. If it catches fire at another point, the area should be vacated and the fire department called. Never use gases from the cylinders without using regulators to reduce the pressure. Before installing the regulator, crack the valves of the cylinders momentarily to clear the valves of any dust, dirt, or other foreign material that may have accumulated during storage. If a regulator shows excessive creep (pressure building up when torch valves are closed), close cylinder valves and have regulator repaired. Keep a clear space between cylinders and the work so that regulators and cylinder valves can always be reached quickly in event of trouble. Do not pull or jerk on the regulator with the hose when moving to a new position. Never use a torch to warm up freezing regulators. Never test pressure by holding torch tip against your hand or fingers. Before lighting the torch, when burning or cambering, always open valves and check gauges to insure that you have proper pressure. Lack of pressure in either line may result in an explosion in the hose. Before lighting the torch, look around to make sure that flame, sparks, or hot metal will not be likely to start a fire. Keeping the area clear of paper, rubbish, and other flammables will help to prevent fires. Make certain that hot slag or sparks will not fall on or strike people, scaffold ropes, safety lines, any hose, flammable substances or materials. Protective shields should be used when necessary.
9.36
Use a standard friction-spark lighter or stationary pilot flame to light torch. Never use a match, cigarette, cigarette lighter, etc. Do not re-light torch on hot work in a pocket or small confined space. Use the lighter. (In re-lighting a torch from hot metal, the gases do not always ignite instantly, and, in a small pocket, ignition may be violent.) Never leave a torch inside a vessel or closed container. Do not take cylinders into confined spaces. A leak might result in a disastrous explosion or fire. When stopping work for an hour or longer, close the cylinder valves and release the pressure in the regulators. Make certain the torch is out and valves are closed tightly when its not in use. Never burn on any closed container that has held flammable substances, such as gasoline, oil, or solvents. Vapors accumulated or generated within such containers may cause a violent explosion. All containers and gas lines must be fully purged before any burning is started. Do not burn over or near spray painting of any kind, whether or not the sprayed material is flammable. The same precautions apply where cleaning solvents or other flammables are being used. When burning any piece, be sure you will not fall when cutting is being done or is completed. Be sure that piece burned off will not fall or swing and strike you or others. Do not saw off the limb you are sitting on. Never do any burning on a concrete floor, because of the possible explosion of the concrete. If practical, raise the material to be cut at least 12 inches above the concrete or shield the concrete from the flame. Never do any cutting or burning with material lying on the cylinders.
9.37
9.26 9.27
9.38
9.39
9.28
9.29
9.40
9.30 9.31 9.32 9.33
9.41
9.42
9.34
9.43
9.35
9.44
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Chipping and Grinding 53
Oxygen, Acetylene or Other Flammable Gas Distribution Systems

9.45 9.46 No repairs or alterations shall be made on pipelines except by authorized employees under direct supervision. When performing any work near these lines, be extremely careful that the lines are not damaged. Be extremely careful when using a burning torch so as to avoid cutting into lines. Under no circumstances shall these lines be used as supports for hoisting material, nor shall other attachments be made with out proper authorization. In case of an emergency, turn off the nearest valve upstream from the source of trouble. When a burning station is not in use, the valve should be closed and plug cap replaced. Avoid directing a stream of sparks or molten metal against the pipeline or burning stations. Use a proper regulator when using pipelines. Do not attach any equipment to the burning stations that is not fitted for that purpose. Open flames and fires, etc., are prohibited in the vicinity of oxygen, acetylene, or other flammable gas pipeline stations. Fuel gas leaks at the burning station can usually be detected by odor. Shut off gas and report any leaks immediately to your supervisor.
10. Chipping and Grinding

Wear eye protection. Inspect tools and wheels daily. Treat bits and wheels with care.
Chipping
10.1 10.2 10.3 10.4 10.5 10.6 10.7 Inspect chisels and gun daily. Turn in any defective equipment for repair. Oil gun at least once a day. Inspect air hose for any loose connections. Keep hose out of aisles and in orderly fashion to prevent a tripping hazard. Where practical, shields should be set up to protect persons in the vicinity of a chipping operation from flying chips. Never point a chipping hammer at anyone. Never throw the tool down or use it as a hammer to remove chipped metal. Open the valves gradually on air hose or tools so as to avoid sudden kickback. Remove the chisel from the gun when not in use. Maintain safe footing and be sure that the material you are chipping is clamped or otherwise secured to prevent movement. Be alert for slippery spots when working inside of boxed sections, cylinders, etc. When chipping tack welds apart, hold chisel so that fingers will not be caught when the weld breaks.
9.47
9.48 9.49 9.50 9.51 9.52 9.53 9.54
10.8 10.9
Grinding
10.10 All abrasive wheels shall be equipped with an approved type guard. Inspect guard daily; have defects corrected before using the grinder. If the grinder cannot be used to grind a fillet, a different tool must be used. Guards should not be removed from any equipment while in use. Guards must be replaced immediately upon completion of that portion of the work.
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Chipping and Grinding 55
10.11 New abrasive wheels and guards are to be installed by authorized employees only. A tachometer should be used to test the machine speed each time a new wheel is installed. Tests should be made with wheel inside a test box. 10.12 The governor on each grinder should be checked a minimum of once each month by an authorized employee. 10.13 Inspect the abrasive wheels daily for any cracks or defects. Where any damage is evident, the wheel should be removed from service. 10.14 If there is any indication of excessive speed or malfunction of the governor, the tool must be taken out of service immediately. All repairs must be made only by authorized employees. 10.15 Avoid dropping the grinder on the floor or bench, bumping against material, or other careless handling which may damage the wheel. A wheel that has been dropped should be checked for damage. If in doubt, return the wheel to be checked inside a test box. 10.16 Make smooth grinding contact with the work. Avoid bumping or impact action. Dont jam portable grinder into corners, etc.the wheel may shatter. 10.17 Never force grinding so that the motor slows noticeably or the work gets hot. 10.18 When grinders are not in use, they should be stored in a safe place, preferably on a storage stand. They should not be stored on a raised surface where someone can trip over the air line and knock the grinder to the floor. 10.19 Allow the wheel to run idle a few seconds before applying to the work. 10.20 Keep in mind that the most constant causes of wheel breakages are: a. Improper mounting of the wheel. b. Improper speed. c. Abusive operation. d. Careless handling and storage.
10.21 Oil the governor daily or as recommended in the tool lubrication instructions. 10.22 See that the wheel is properly dressed at all times. Do not use a wheel with broken edges. 10.23 Do not stand directly in front of a stationary grinder when first starting up. 10.24 The maximum clearance allowed between the wheel and the tool rest is 1/8 inch. Do not attempt to make any adjustments to the tool rest while the grinding wheel is in motion. 10.25 In dressing tools, be sure to hold the tool to be ground firmly against the tool rest in front of the wheel. Side grinding is prohibited unless grinder is designed for that purpose.
Rule 10.26
Safety shields must be present when using grinders.
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Machine Shop 57
10.26 Safety shields must be present as recommended by the manufacturer when using stationary grinders. 10.27 Do not wear gloves when using stationary grinders. 10.28 Repairmen or toolroom attendants should observe the following: a. Ring Test and inspect each wheel for cracks or breaks. Never use a stone that has any indication of cracks or other damage. b. Check the maximum operating speed of the abrasive wheel (shown on manufacturers tag) against the machine speed. Machine speed must never exceed maximum operating speed of stone. c. Abrasive wheel should fit snugly, but not tight on the spindle or bushing. Never alter the hole in the wheel or force the wheel on the spindle. d. Tighten the nut only enough to hold the abrasive wheel firmly. e. If an abrasive wheel breaks, flanges and spindles should be carefully inspected for damage before a new wheel is mounted. f. Handle abrasive wheels carefully to prevent dropping, bumping or other action that is likely to cause damage. g. Abrasive wheels should be stored in a dry area in a room not subject to extreme temperature changes. Keep in mind that dampness or extreme temperature changes may effect the bonding of the wheels. h. Abrasive wheels must be stored in cabinets, racks or bins so as to protect them from chipping or breakage. The storage area should be accessible only to supervisory and authorized repair personnel.
11. Machine Shop

Keep hands and loose clothing away from moving or rotating equipment.
11.1 11.2 11.3
Stop all machines before adjusting, cleaning, oiling or repairing. Avoid talking with or otherwise distracting an operator of equipment while it is in operation. Use the right tool for the job. Do not use a hardened steel hammer to strike punch dies, spindle holders or other hardened tools or equipment. Use a soft hammer for such work. Always turn off the main switches when changing saws, drills, etc. Never attempt to place or change a drill or reamer while the spindle is still revolving. Do not tighten work on any machinery while the equipment or the material is rotating. Be sure that you have sufficient light to see what you are doing. A restricted area must be designated around machines with moving beds such as planers. Always place proper warnings. This same precaution applies to any machine to a noticeable extent, particularly when it extends into aisles, walkways, etc. Never use your hands to remove chips or shavings from a machine or work table. Use a brush, stick or other approved means. Do not place your hand or any part of your body on or in the moving parts of a machine.
11.4 11.5
11.6 11.7
11.8
11.9
11.10 Keep your hands from between the dies of a press which is in operation. Use tongs or other devices for handling the material.
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Mobile Equipment 59
11.11
Never leave tools so that they may creep, be thrown or fall when the machine is started.
12. Mobile Equipment

Only authorized personnel can operate mobile equipment. Use extra care when operating near blind spots.
11.12 Do not grasp a belt to start or stop a machine or attempt to shift a belt by hand. 11.13 Never crawl through or under a belt. 11.14 Do not rely on your hands to prevent material from turning while using a cutting tool. Always see that the material is properly clamped or secured. 11.15 Do not reach through or over a machine so that cutters or revolving parts come in contact with your body or clothing. Avoid wearing anything that may become entangled in moving parts. Do not wear gloves, jewelry, neckties, etc., when operating machinery. 11.16 Long hair should be tied back or otherwise covered or protected. (Very important for operation of rotating equipment.) 11.17 Never leave keys in chucks while working on lathes, etc. 11.18 Stop the lathe before removing tools from the tool post. 11.19 Do not allow chips or cuttings to accumulate around your machine. 11.20 All files shall be provided with wood or composition handles. 11.21 Use extreme caution when using sandpaper or emery cloth on rotating material. 11.22 When operating a drill press, avoid forcing or feeding the drill too fast. 11.23 Always make sure that all guards are in place before operating machines, except when it is necessary to operate the machine for making repairs.
12.1
Only authorized employees are permitted to operate mobile equipment. Operators using medication shall not operate equipment without the express permission of medical personnel or their supervisor. Crewmembers only are permitted to ride on locomotives, railroad cars, cranes, trucks, and other types of motorized equipment, except as authorized by supervision. Check brakes, flashing lights, horn, and steering at the start of each work shift. Report any defects immediately to your supervisor. Stop at all doorways, blind corners, roadway crossings, or other areas where an unusual hazard exists. Do not proceed until you are positive the way is clear. Always sound a warning signal (bell, horn, or whistle) when approaching people or where there is any unusual congestion of men and equipment. Be especially alert where there are unusual shop noises. Observe all posted speed limits. Be sure that you have your equipment under control at all times, and travel at speeds which will enable you to stop immediately in case of an emergency. Maintenance, repairs or adjustments are to be made by authorized personnel only.
12.2
12.3
12.4
12.5
12.6 12.7
12.8
Railway
12.9 Comply with regulations concerning blue flags and other safety devices that have been installed for the protection of workmen in cars or near railroad tracks.
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Mobile Equipment 61
12.10 Yard switching must not be done at a speed in excess of 15 miles an hour. 12.11 Do not make a flying switch; it is a very dangerous and unnecessary practice. 12.12 The person acting as brakeman must always ride the forward end while making a shift. He should ride on the side of the car with his feet on the stirrup and with his hands holding the grab irons. He normally should ride on the same side as the operator, so that he will be in a position to give signals. 12.13 When coming on or off the main running tracks, always throw the switch back to proper position. 12.14 Train crewmen, except operator, should use elastic bands or approved type leg bands around trouser cuffs, so as to minimize tripping hazards. 12.15 Use extreme caution when necessary to get on or off moving cars. Never attempt to get off or on a moving car in the immediate area of the switch stand. 12.16 Any defects in tracks or switches must be reported immediately. 12.17 Do not go between a locomotive and a car or between cars, for any purpose, when either is moving or when coupling is about to be made. 12.18 Couplings must be adjusted while cars are standing still and the brakeman must move to a safe position before signaling the operator to move. 12.19 Brakemen must never use their feet to adjust couplers. Use the hand for operating the coupling lever and stand facing the direction of the movement and engineer so that proper signals can be given. 12.20 Before shifting cars, the brakeman must make sure that everyone is in the clear and that there are no car pulls attached. 12.21 Cars should not be poled except where necessary, and then only with steel-bound poles provided on locomotives. The use of ordinary lumber is prohibited.
12.22 Never move the engine until the ground crew gives proper signal. Use standard railroad signals for engine operations. 12.23 The bell or whistle warning must be given at all crossings, intersections, crosswalks, or other areas where an unusual hazard exists. Be sure to check for overhead cranes and workmen before entering a area. 12.24 No running is permitted through shops or over tracks. Always step over rails-not on the ball of the rail. 12.25 Train crews must stop their train 50 feet from cars on which people might be working. Check for clear track, then proceed with caution. 12.26 Keep the platforms, ladders and steps clear of all tripping or slipping hazards. 12.27 Be sure that cars are properly braked before leaving them uncoupled from the engine. If necessary to place a wood chock under the wheels of a car, keep your fingers on top of the chock and away from the rail. 12.28 When getting on a moving locomotive, make sure that you have a firm grip on the hand grabs and that one foot is firmly placed on the step as you swing your body in toward the locomotive. 12.29 Allow plenty of room for safety when walking around the ends of standing railroad cars or locomotives. Always expect the equipment to move. 12.30 Turn angle cock, shutting off the air, before snapping or uncoupling the air hose. 12.31 Avoid blocking cross traffic. Break cars at crossings if train is to be parked without engine. 12.32 Be sure that brakes are set and the car is properly blocked when parked. 12.33 Be extremely cautious when moving in close clearance areas. This is particularly important when going around curves or when operating on parallel tracks. Be alert for any material that may be protruding on or near the tracks or from cars. Always face in the direction of travel.
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Mobile Equipment 63
12.34 Plant safety rules prohibit the placing of any material within five feet of an operating track. Report any safety violations of this nature immediately to your supervisor. 12.35 When throwing the switch lever, be sure that your hands and feet are in the clear of the switch ball. 12.36 Do not leave the locomotive engine unattended while motor is running. 12.37 Do not move cars that are loaded in an unsafe manner. Report any such conditions to your supervisor immediately. Before moving flat cars, check for any overhanging wire, banding or dunnage that might cause an accident. 12.38 Trainmen must be on guard to protect themselves against stopping, starting, lurch or jerk of the equipment. 12.39 Operators must not move the engine in either direction in the blind. Stop the engine immediately, with or without cars, when moving on hand signals if the signal disappears from view. 12.40 Operators are responsible for the proper management and care of the engine in their charge. Do not permit anyone to handle the engine and do not leave the engine while on duty, except in case of necessity or emergency. 12.41 Always check the front end of standing railroad car to insure that everyone is in the clear before bumping or coupling. 12.42 Situations not covered by these rules demand sound judgment in applying correct principles of safety. In case of doubt, always take the safe course.
12.45 Obey all speed limits, signals and signs. Slow down at intersections and railroad tracks. Sound the horn when approaching building entrances and exits or blind corners. Stop at all doorways, turns, railroad tracks, or other areas where an unusual hazard may exist. 12.46 Use extreme caution when operating in the vicinity of people. Keep your vehicle under control at all times, and operate at speeds that will enable you to stop immediately in the event of an emergency. 12.47 Be sure the loads are proper as to capacity, balance and projections. Use proper warning flag on extended loads. 12.48 When leaving vehicles unattended, be sure to shut off motor, apply brakes, and remove keys. Lower the forks on lift trucks. 12.49 Always shut off the motor when refueling. Smoking is prohibited when refueling, or in the vicinity of fuel tanks. 12.50 Fuel tanks must be properly clamped and secured. 12.51 Operators are responsible for the proper piling of material. Keep designated areas clear. 12.52 For normal operation of tractors, face the controls. For other movements, look in the direction of travel. 12.53 Do not make a move unless you are positive that you are not endangering anyones safety, or doing damage to material or equipment. 12.54 Do not drive or park under suspended loads. 12.55 Be sure the aisles or roadways over which you expect to travel are clear. Do not drive over obstacles or material which may cause the load to fall. 12.56 Use caution when boarding or leaving the vehicle. Use the steps or platforms provided. 12.57 Be sure the lift is landed on solid blocking or even flooring before lowering the load. Do not leave a load in an unstable or unsafe manner. 12.58 When using dock plates, be sure they are properly anchored. 12.59 Unsafe driving or horseplay is prohibited.
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Fork Lifts, Tow Motors, Trucks, and Mobile Equipment

12.43 Inspect the vehicle at the beginning of shift. (Check safety equipment such as the lights, horn, brakes, steering.) Report any defects immediately to your supervisor. 12.44 Only qualified and designated employees are permitted to operate vehicles. No one except the operator is permitted to ride on such vehicles, except as authorized by plant management.
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Mobile Equipment 65
12.60 Avoid sudden stops except in an emergency. Such stops may dislodge the load. 12.61 Do not use bumper blocks to stop vehicle. 12.62 Watch the overhead clearance. Keep clear of the edges of loading docks or other elevated work areas. 12.63 Spread the forks to suit the load width. Lift, lower, and carry loads with the mast vertical or tilted back, never forward. 12.64 Never place your arms or legs between the uprights of the mast or outside the running lines of the vehicle. 12.65 Brake to a full stop before changing from forward direction to reverse or from reverse to forward. 12.66 For better vision with bulky loads, drive backward. 12.67 When moving shop buggies, the load should be pushed. If necessary to pull buggies, a chain or tow cable must be used to attach the buggy to the tractor or other vehicle. 12.68 Do not strike matches, use lighters, or any type of open flame around or close to battery compartments or gas tanks. 12.69 Keep the vehicle free of all objects and materials that are not essential to the normal and successful operation of the vehicle. 12.70 Be extremely careful when operating equipment over soft, rough or uneven ground, operate your vehicle at all times at a speed consistent with the load, roadway, aisle space, etc. Be constantly on the alert for people who may walk or move unexpectedly in front of your vehicle. 12.71 Remember: Pedestrians always have the right-of-way. 12.72 Do not allow other operations or people to distract you. Keep your mind on the job at hand at all times. 12.73 Seat belts must be worn at all times by the operator and the passengers.
12.75 Inspect the machine at the beginning of each shift. (Check lights, horn, steering, flashing lights, wheel alarms, etc.) Report any defects promptly to your supervisor. 12.76 Be sure that all special safety devices (flashing amber light and wheel alarms) are in good operating order. If they are not, do not operate the equipment. 12.77 Always sound the horn and be certain that the way is clear before moving the carrier in any direction. 12.78 Where there is an unusual congestion of personnel or material, or if carrier is required to enter into any operating facility, or there is a question of clearance, special precautions must be taken. 12.79 When a signalman is provided, the operator must await his signal before moving. 12.80 Headlights should be turned on before moving the carrier to alert anyone directly in front. 12.81 No one shall ride on the carrier unless such procedure is approved by the plant managers office. Where approval is granted, a seat alongside of the cab, to the right of the operator and located so that it will not interfere with his vision, shall be provided. This seat shall have armrests and a back. The seat shall be securely fastened, and a safety seat belt must be provided and used. 12.82 The rider must be in the seat before the carrier is moved, and he shall not move around on the carrier until it is stopped. 12.83 If the vehicle is to be left unattended, shut off the engine, set the brakes and lower the lifting forks to the ground.
Straddle Carriers
12.74 Only qualified and authorized drivers are permitted to operate this equipment.
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Electrical Work 67
13. Electrical Work

Avoid working on hot circuits. Follow the Lock out Tag out program.
13.11 When necessary to work on a hot circuit, always use rubber gloves and stand on a rubber mat if practical. 13.12 Never work on any circuit where surrounding areas are damp or wet until circuit has been completely killed and grounded. 13.13 Always use a voltage tester to determine voltage of any circuit, regardless of circuit voltage label.
13.1 13.2 13.3
Only authorized employees are permitted to do electrical work. Do not start any electrical installations, alterations, etc., unless you have authorization or proper supervision. If the job involves work on or near overhead cranes or runways, you must observe all safety rules with respect to such work. (Refer to Section 14 for rules on Maintenance and Repair.) Fall protection is required when working aloft. Lanyards shall be anchored to an appropriate tie off point except when moving or changing work locations or when working from permanent walkways, platforms, etc., equipped with guardrails. Do not use extension cords or electric hand tools with exposed wires. Turn them in for replacement or repair. Only authorized persons are permitted to enter a powerhouse or a substation. Shut off and lock all switches before starting to work on electrical equipment. Each person working on a circuit must use his personal lock to lock out a switch and no circuit shall be re-energized until all locks are removed. Make sure the machine is in a zero mechanical state. Do not handle tools or perform other work in such manner as to damage cables or wires in the vicinity. If in doubt, consult your supervisor. Assume that all circuits are live until they have been thoroughly checked and proven dead. Never work on a live circuit if it is possible and practical to de-energize the circuit.
13.14 Never screw a light bulb into a live socket. Disconnect the cord at the receptacle or throw switch. 13.15 Never energize a new installation without first placing voltage labels on electrical equipment. 13.16 No portable electrical equipment shall be installed or repaired without making proper grounding connections. If double insulated portable electric tools are used, proper identification labels shall be attached. 13.17 Do not touch a metal frame or case if it is ungrounded and you are in contact with ground or a grounded object. 13.18 Tag, mark, or post suitable signs to warn other workmen of possible dangers involved in the work. 13.19 Do not depend on insulated handles of tools to work on hot lines. Use rubber gloves, mats, etc., as required by plant safe work procedures. 13.20 Never leave a hot line unguarded or uninsulated in an area where other people could come in contact with it. 13.21 Do not depend upon insulationit may be defective. Take all precautions the same as though live parts were bare. 13.22 When working overhead, see that proper warning signs are placed so as to notify people below. Be sure that all hand tools, etc., are secured against falling. 13.23 Use only hand tools and equipment suited to the work being done, so as to reduce the danger of short circuits. 13.24 Use wooden ladders when working on or near live electric lines.
13.4
13.5 13.6 13.7
13.8
13.9
13.10 Treat low voltage circuits with the same respect as those of higher voltage.
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Maintenance and Repair 69
13.25 Report immediately to your supervisor any conditions of equipment or lines under test which may endanger life or property. 13.26 Do not use bare fingers or hands to determine whether a circuit is live. Never remove or replace fuses except by means of suitable appliances provided. 13.27 Before closing a switch, have full knowledge of the circuit and the reason for the switch being open. Be sure nobody is in a position to be injured when the switch is closed. 13.28 Never use a fuse heavier than the capacity of the circuit. Also never attempt to bridge a fuse. 13.29 Never tamper with any electrical wiring or apparatus. 13.30 Never install any wiring or make any other electrical installations that do not meet plant safety standards. 13.31 Remember: In dealing safely with electrical power, there is no such thing as being almost right. An electrical procedure or installation is either right or it is wrong.
14. Maintenance and Repair

Follow the Lock out - Tag out program. Only perform repairs that are sound and return equipment to a safe condition.
14.1
No maintenance, repairs or alterations should be started without authorization or proper supervision.
Rule 14.2
Lock out all sources of power and movement before working on machinery.
14.2
Lock out controls and switches before beginning repairs or maintenance on any machine. Only the person placing the lock is allowed to remove it. Never begin work until all
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Maintenance and Repair 71
moving parts of the machinery have stopped in a fixed position. Make sure the machine is in a zero mechanical state. 14.3 Repairs, adjustments or alterations to machines or equipment are to be made only by authorized employees who have been thoroughly instructed in the safe way to do the job. Notify the operator before starting such work. Haphazard repairs are prohibited; take time to set up safe scaffolding, ladders, and other rigging. Check all your tools and equipment to be sure they are in good order. Do not go on any overhead crane, crane runway, or building where work involved is near or at crane runway level, for any purpose, without permission from your supervisor and the supervisor in charge of crane operations. When working on or about crane runways, notify cranemen on that and adjoining runways and place rail stops as required. The department head should also be notified when the crane or runway is to be temporarily out of service. Use service lights where available. Before starting work on overhead cranes, pull and lock the main switches and place rail blocks where necessary. Barricade or flag the area below where required, so as to warn others of the danger zone. When making repairs to overhead cranes, the crane should be moved to a location where it will cause the least interference with other cranes and with other operations on the floor. If necessary to work around rotating shafts, couplers, etc., use extreme caution. Do not permit any part of your body or clothing to come into contact with the moving machinery. Hair should be tied back, covered, or otherwise protected.
14.12 Keep oil and grease away from all oxygen and acetylene equipment. 14.13 Fall protection is required when working aloft. Lanyards shall be anchored to an appropriate tie off point except when working from elevated work areas equipped with guardrails. 14.14 Spilled grease or oil must be cleaned up immediately. 14.15 When working overhead, use care to prevent tools and materials from falling. When repairs are completed, see that all loose objects are removed. 14.16 Rubber gloves must be thoroughly inspected and tested periodically and before being used on high-tension work. 14.17 Remove all loose equipment, especially when working overhead. Replace all guards, covers, and other safeguards prior to putting equipment back into service. 14.18 Keep fire extinguishers nearby when working on greasy machines or near combustible material. This is particularly important when you are burning or welding. 14.19 Areas where gases, solvents, and cleaning fluids are used should be well ventilated. Keep such flammables away from an open flame or an electric arc. 14.20 Special precautions are necessary in shutting down hydraulic or air-operated machinery. Check with your supervisor for instructions. 14.21 Handling of small tools, material, etc., from ground level to men working above shall be accomplished by the use of a hand line or a suitable type container. Tools and materials shall not be thrown from one level to the other. 14.22 Where planks are used to span girders or where other types of temporary scaffolds are needed, the supervisor in charge should follow the procedures as set forth in Section 18 on Scaffolds.
14.4
14.5
14.6
14.7
14.8
14.9
14.10 Treat all electrical circuits as though they were alive. 14.11 Always properly barricade floor openings, open manholes, machine foundations, and pits for repair purposes, etc., and close them as soon as possible. Where the lighting is poor, a red light should be installed in addition to the barricade.
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Radiation (X-Ray, Cobalt, etc.) 73
15. Radiation (X-Ray, Cobalt, etc.)

Monitor all radiation exposure.
15.8
A controlled area should be established for each type of operation in which radiation devices are used. The boundary of this area shall be established at a distance from the radiation source so that the radiation along its perimeter shall not exceed two milliroentgens per hour (mrh). A barricade shall be provided about the controlled area. Blinking red lights and clearly visible signs showing the standard radiation symbol shall be placed along the perimeter. Target marking safety rope (alternating black and yellow colors) shall be used to indicate the controlled area. All individuals shall be cleared from this area before operating the radiation device and the area policed to prohibit entrance therein by any person.
15.9
15.1 15.2
The use and control of any radioactive materials or sources must be in accordance with State or Federal regulations. All individuals directly engaged in radiography should be equipped with a film badge and a pocket chamber or dosimeter. Each person shall wear the film badge (and pocket dosimeter or pocket chamber if such is required) that is specifically assigned to him, in such a manner as to accurately reflect his exposure. The loss of any personnel monitoring equipment shall be immediately reported to the supervisor and a proper replacement obtained before reentering a restricted area. Measurements of radiation dosage (exposure) should be made at an interval designated by plant management. A record of each individuals radiation (exposure) should be kept at the plant. A yearly summary of the record should be placed in the individuals personnel file. All personnel working with radiation sources or frequenting restricted areas shall immediately consult the supervisor when there is a question regarding radiation control or protection, performance of equipment, procedure or other such situations. No employee shall be permitted to perform radiography prior to having successfully completed a training program. Natural sources may be used only by licensed employees. No radiography shall be performed with sealed sources unless calibrated and operable survey instrumentation having a range of at least 2 milliroentgens per hour (mrh) through 1000 milliroentgens per hour is available and used. The operation of radiation equipment should be conducted by a management employee or should be performed under his direct supervision.
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15.10 Crane travel should be prohibited over the controlled area when the radiation device is in operation, unless a radiation survey has shown that the crane operator will not be exposed to radiation in excess of two milliroentgens per hour (mrh). 15.11 Whenever a remote-controlled source-handling device is used, the radiation intensity at the operators position shall be measured during the extension of the source to insure that it has not become immobile in the source tube. Following each exposure shot, the device shall be surveyed to insure that the source has been returned to the shielded position before anyone is permitted to enter the potential radiation area. 15.12 Radiation devices shall be secured under lock and key when not in use or unattended, to prevent their operation by unauthorized individuals. All containers for storing radioactive material when it is not in use must limit radiation to two milliroentgens per hour (mrh) measured at any point on the surface of the storage container. 15.13 Radium sources shall be stored in ventilated areas to prevent the accumulation of radon gas. 15.14 A record shall be maintained of all uses of sealed sources for radiographic purposes. Such records shall include a description of the exposure device or storage container, the identity of the user, the kind and quantity of the radioactive material, the location of and the date of use. An individual utilization log shall be maintained for each such device.
15.3
15.4
15.5
15.6
15.7
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Observe rules in Section 15
Housekeeping 75
This sign means Radiation: Beware
16. Housekeeping
Keep walkways clear. Put scrap and debris where it belongs.
16.1
RADIOACTIVE AREA
15.15 Should an emergency occur, radiation sources located in the affected area should be turned off if an x-ray machine, or returned to the storage container if a radioactive material source, provided such action does not jeopardize the safety of personnel. The area in which the emergency is located shall be immediately evacuated and only personnel qualified to take remedial action shall be admitted. 15.16 The disposal of radioactive materials shall be accomplished only by the return of the material to the original supplier or by other means approved by the Nuclear Regulatory Commission, or other governmental agency having such jurisdiction.
Good housekeeping is essential to a good safety record and is a vital part of any successful safety program. Simply stated, it means keeping your job and the surrounding area as clean and orderly as possible. Good housekeeping will enable you to do a better job with less chance of getting hurt.
Section 16
Good housekeeping means keeping on top of it each day!
16.2 16.3 16.4 16.5 16.6
Keep all materials out of aisles and walking areas. Return your tools and other equipment to their proper storage place after use. During use, keep them orderly. Clean up immediately any oil, water or other slipping substances that are spilled on the floor. Keep the shops clear of scrap steel, punchings, and shavings. Do not leave blocking, chains, cable, hose or tools scattered about the floor after you are through with them. Blocking should be piled in convenient places. Return all empty bottles, cans, or other containers to their proper place. Properly dispose of material such as empty paint cans, oily rags, etc., promptly. They can cause fires. Keep your locker neat and free of soiled clothing and trash. Pick up tripping hazards such as bolts, nuts, pins, weld rod stubs, pieces of scrap material, scrap wood, etc.
16.7 16.8
16.9
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Use of Ladders 77
16.10 Employees must not deface, mark, mar or destroy any building, machinery, warning signs, bulletin boards or any other equipment. 16.11 Keep all stairways, landings, etc., free of any tripping hazards. Report any instances of inadequate lighting to your supervisor immediately. 16.12 Place all trash or garbage in the proper container. 16.13 Keep lunch areas clean.
17.3
If possible, extend ladder at least 36 feet above the point where it is intended to reach. Do not work higher than the third rung from the top on straight ladders. Slant the ladder at about a 75-degree angle. (Base should be one-fourth of ladder length from wall or point directly under the top support). All straight and extension ladders should be equipped with safety feet. Do not use the fly section of an extension ladder without the base section. For overhead work, use a proper type of ladder. Do not use makeshift devices such as bolt kegs, steel drums, etc. If a ladder must be used near a door or a passageway, it must be properly protected. If possible, the door should be locked; otherwise, warning signs or barricades must be erected. Always face the ladder. Keep both hands free for holding on when going up or down. Use a hand line or other approved means for raising or lowering tools and materials. Use ladders that are of the correct length for the work involved. Avoid over-reaching to either side when working from a ladder. A good rule of thumb is to limit your reach to 12 inches beyond the side rails.
17.4
17.5
17.6 17.7
17. Use of Ladders

Secure ladders on firm level ground. Face the ladder and use two hands.
17.8
17.9
17.1
Inspect all ladders before use. Check the side rails and rungs for any defects. Be sure the ladder is free of oil, grease or other slippery material. Do not use a damaged or defective ladder. Tag or mark damaged or defective ladders Dangerous, Do Not Use and withdraw them from service for repair or destruction.
Rule 17.2
17.10 Remember that all metal ladders are conductors of electricity. Do not place them on or near live electrical lines. Assume all wires are hot until you are sure they are not. 17.11 Do not throw tools or materials up or down to a workman on a ladder. 17.12 Never attempt to slide down a ladder. 17.13 Do not use a ladder as a guy, brace, skid or for any purpose other than that for which it is designed. 17.14 Do not splice short ladders together to make a long ladder.
Secure all ladders on firm, level ground.
17.2
Place ladder on firm, level ground so that it will not sink or slip. Tie or otherwise secure ladders at the top. Where ladder cannot be secured, someone should hold it while anyone is climbing, descending or working from it. Make sure each rung has sufficient clearance for safe footing and grip.
OF
17.15 Made sure your hands and shoes are clean, dry and free of any grease, etc., before climbing a ladder.
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Scaffolds 79
17.16 Be extremely careful when working from a ladder in an area where overhead cranes or hoists are working. Be sure the crane operators are aware of your position. If necessary, check with your supervisor so that a safetyman can be stationed to protect you. 17.17 Avoid placing a ladder against a window sash. If necessary, lash a board to the ladder to provide bearing on the wall at each side of the window. 17.18 The top section of an extension ladder must always be lowered before moving from one location to another. 17.19 Do not paint a ladder and do not allow paint or other foreign material, which would cover up defects in the rungs, side rails, etc., to accumulate on the ladder. 17.20 Never lean a ladder against loose boxes, barrels, round objects, or other unsafe supports. 17.21 Be sure the top section of an extension ladder is locked securely before attempting to climb. Make sure rung locks are resting securely on rung. After rung locks are set, tie halyard snug so top part of ladder is secure.
18. Scaffolds
Assure all fasteners and members are in place. Do not overload the scaffold.
18.1 18.2 18.3
All scaffolds and work platforms must be inspected and approved by a competent person prior to use. Inspect scaffold boards, and supports before each use and report any defects to your supervisor. Guard rails and toe boards are required on all scaffolds and scaffold-related work platforms and walkways that are more than 10 feet above the ground or floor. Needle beam scaffolds, painter picks and other similar types are excepted from this rule. Guard rails, wherever used, should consist of a top rail or wire rope, approximately 42 inches high with a mid-rail or rope. Where supports for scaffolds, walkways, railings, etc., are welded, a welder who has been determined to be competent shall perform the welding. The supervisor in charge shall inspect the scaffold as well as the weld before putting it into use. Be sure to avoid prying actions on welds. Planks used for scaffolds should be of an approved type. The ends should be reinforced to prevent splitting. A 15/16inch hole may be bored in the center 6 inches from each end for use of drop bolts. Planks should overhang their end supports not more than 12 inches nor less than 6 inches, or should be fastened in place. Drop bolts should be used in the end of scaffold planks to prevent them from slipping off their supports. All scaffolds and work platforms should be at least two planks wide. Workers should not work from a single board. All swinging scaffolds should be tied into the structure to prevent swaying.
18.4
18.5
18.6
18.7
18.8 18.9
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Rule 18.10
Scaffolds 81
table on next page for length of span of the catenary cable between supports, size of cable, and sag required.
NEVER EXCEED
C A PA C I T Y ON A SCAFFOLD
18.10 The number of workers on a scaffold shall not exceed the number it is designed to carry. The combined weight of workers, tools, and material shall not exceed the capacity for which the scaffold is designed. 18.11 Fall protection is required when working aloft. Lanyards shall be anchored to an appropriate tie off point except when working from permanent walkways, platforms, etc., equipped with guardrails. 18.12 Where it is not possible to tie off safety lines to the structure, a lifeline should be rigged for this purpose. Lifelines may be vertical or horizontal. If vertical, use 3/4inch Manila rope. If horizontal, use a 5/8-inch wire rope, with proper sag. (See Cable Suspension Chart on next page.) Lifelines shall be suspended independently of the scaffold. 18.13 Tie off the lanyard, when possible, before getting onto the scaffold. Do not unfasten the line until you are off the scaffold. Workers shall not jump onto scaffolds. 18.14 Lanyards must be tied off at a level above the scaffold and should be kept as short as possible. Avoid sharp edges. 18.15 Keep scaffolds completely free of rivets, drift pins and other loose objects. Such items present a tripping hazard. 18.16 Scaffolds shall be kept free of ice, snow, mud, oil and other materials which may create a hazard. 18.17 Not more than two workers should be permitted on painters swinging scaffolds at one time, except where more than two stirrups with corresponding hooks, blocks, and ropes are used, in which case one additional worker may be permitted for each additional stirrup. 18.18 Where the scaffold is to be supported by catenary wire rope, some positive device must be used so there is no possibility that the platform can slip off the catenary cables. See the
18.19 Where the platform is not suspended, but is rested on bearings of some kind, such as part of the structure, special precautions must be taken to prevent its slipping from its bearings. 18.20 Where the scaffold is not suspended, consideration should be given to removing the stirrups if they constitute a tripping hazard.
Cable Suspensions for Scaffolds and Safety Lines
H T S L P
= = = = =
Horizontal Force from Load P in lbs. Tension in Cable (Assume T = H for small sags) Sag in feet Span length in feet Load in lbs. Then H = PL 4S
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Scaffolds 83
Tubular Steel Scaffolding Values of H* in lbs. per each 500 lbs. of Load (P)**
8.21 While the scaffold is in use by any person, it shall rest upon a stable footing and shall stand plumb. The casters or wheels shall be locked in position. Each tier of the scaffold should be securely tied to the structure.
Span (L) in feet 1 - 0 2,500 5,000 7,500 12,500 2 - 0 1,250 2,500 3,750 6,250
Sag (S) 3 - 0 835 1,670 2,500 4,170 5 - 0 500 1,000 1,500 2,500
18.22 All locking and connecting pins must be provided and used. If these items are not available, some positive means of tying the sections together must be employed. All wing nuts or locking devices shall be tight. 18.23 If the nature of the work is such as to require use of the fall protection, the safety line must be tied off independently of the scaffold. 18.24 Work platforms shall be tightly planked for the full width of the scaffold, except for necessary entrance openings. Planks should be secured in place. 18.25 No one is permitted to remain on the scaffold while it is being moved. 18.26 Freestanding towers must be guyed or otherwise secured to the structure. (See typical scaffolding sketches on the following pages.)
20 40 60 100
*H from weight of supporting rope is not included. **Values of H for higher loads P can be obtained by direct ratio. For example for Sag 1500 S = 2 feet and Load P = 1500 lbs. H = x 1250 = 3750 lbs. 500
Strength of Wire Rope with Factor of Safety of 4.

Dia. (inches) 5/8 3/4 7/8 1 Working Load (lbs.) 8,350 11,900 16,100 20,900
18.27 Scaffold erection, dismantling and user training must be conducted by a competent person prior to use.
Tubular Steel Scaffolding

18.21 While the scaffold is in use by any person, it shall rest upon a stable footing and shall stand plumb. The casters or wheels
A MERICAN I NSTITUTE S TEEL C ONSTRUCTION A MERICAN I NSTITUTE S TEEL C ONSTRUCTION
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Scaffolds 85
Bracket for Scaffold at Girder

Bracket for Scaffold at Girder
A Frame Scaffold Support
A Frame Scaffold Support
NOTE: All planking should be Douglas Fir 2 x 12 x 12- 0 rough, or of other material of equivalent strength. NOTE: 1) All planking should be Douglas Fir 2 x 12 x 12- 0 rough, or of other material of equivalent strength. 2) Bolts must be tightened securely before utilizing bracket as scaffolding.
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Hydraulic and Mechcanical Jacks 87
Safeway Tubular Scaffold
19. Hydraulic and Mechcanical Jacks

Prevent damage to hoses. Set jacks on solid supports at the proper angle.
19.1
NOTE: Height must not exceed four times the least base dimension unless scaffold is tied to the structure.
Safeway Tubular Scaffold
Check the ram and pump as well as hose for any leaks or other damage. Report any defects to the supervisor or to the repairman. Always select a jack of sufficient capacity. Never overload or exceed the capacity of the jack. Do not use cheaters to gain additional leverage. Make sure the jack is secure and centered on the blocking and load. Keep the jack perpendicular to load to avoid kickout or slipping. Be sure the footing and ram are free of oil or grease. Do not rely on jacks alone to support load on which men are working. Use hard wood blocking to support the load in case of jack failure. Use extreme caution to prevent damage to hydraulic hose. Do not kink or drag hose over material. Keep hose away from flames or hot objects. Repairs to hydraulic hoses, jacks and pumps are to be made only by authorized personnel. Do not carry hydraulic jacks by the hose and do not pull on hose to free the jack. Always stand clear of hose when pressure is applied so you will not be injured in case of hose failure. Fluid escaping through small hose and hydraulic equipment can cause serious injuries. While jacking horizontally, tie a rope on the jack when necessary to prevent the unit from falling.
19.2
19.3
19.4
19.5
19.6
NOTE: All planking should be Douglas Fir 2 x 12 x 12- 0 rough, or of other material of equivalent strength.
19.7 19.8
19.9
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Painting 89
19.10 Operate the jack slowly and with even strokes. Use caution that hands do not get caught between the handle and other nearby obstructions. 19.11 Keep hands and feet from under suspended loads while jacking. 19.12 Lower the jack slowly and carefully, taking care not to pinch the hose. 19.13 Consult with your supervisor if there is any question as to the safer operation of the equipment. 19.14 Do not weld lugs, brackets, etc., to jacks. 19.15 Do not rely on a rivet head, spud wrench or drift pin in a hole as support for base or ram of jack. Use steel brackets of proper design or hard wood blocking.
20.4 20.5
Wear gauntlet gloves, overalls, or other clothing that will give you the greatest protection from paint. Respiratory equipment with a NIOSH or Bureau of Mines approval must be worn when power wire brushing, spray painting, grit or sand blasting. Keep your respirator clean and in good working order. Change the cartridges and filters as often as necessary to provide proper protection. Respirators shall be maintained in accordance with the manufacturers recommendations. When the vapor can be detected, the filter should be changed on the respirator. Respirators must be sterilized before transferring to others. Report any defects in your respiratory equipment immediately to your supervisor. Face shields must be worn in addition to your regular safety glasses when power wire brushing. Take advantage of natural air movement so dust and spray will not blow back in your face. Do not keep your lunch with your working clothes. Do not eat, smoke, or chew while painting. Do not spray any kind of paint, oil or any flammable liquids near welding, burning or any other flame.
20.6 20.7 20.8 20.9
20. Painting
Prevent fire hazards. Avoid physical contact with wet paint and inhaling fumes by using PPE.
20.10 Spray painters must not spray toward each other or where there is any possibility of spray or vapor striking the head or face of any other people in the area. 20.11 Painting between girders or other large members is prohibited unless they are properly braced or clamped. Use girder clamps on girders wherever possible. Smaller pieces should be safely spaced or secured to prevent chain reaction toppling. 20.12 When airless spraying, nozzle tip must not be allowed to contact any part of the body. Also, when cleaning up the gun, be sure that the pressure is off, so that any accidental tripping of the trigger will not cause an injury. 20.13 Never point an air hose at another employee or use compressed air for dusting or cleaning your clothing. 20.14 Do not strike a match, smoke, or use any open flames around paint or other flammable materials. Observe all No Smoking signs which are posted around the plant.
OF
20.1
Read paint warning labels. Some paints contain hazardous material that might enter your system through the skin, the mouth, and the lungs. These harmful substances are taken into the system most commonly by inhalation, but just as readily in eating or putting the hands to the mouth. Obviously, personal cleanliness is most important. Wash carefully before you eat. Bathe daily. Change work clothes frequently. At least once each week is recommended. If you have any exposed cuts or sores, be sure they are properly bandaged before starting work.
20.2
20.3
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Abrasive Blasting 91
20.15 Always use safety cans with flame arresters for handling any flammable liquids such as naptha, solvents, etc. 20.16 Inspect your paint and spray equipment frequently. If any equipment is not in good working order, have it replaced or repaired by an authorized person. 20.17 If your clothing is covered with paint or solvents, do not stand or walk near salamanders or open fires. 20.18 Have a good handhold and footing when handling material by hand. Do not step or walk on material that has wet paint on it. Be extremely careful when handling material that has recently been painted. 20.19 When turning material with a hand dog or pinch bar, position yourself so that you will not fall or otherwise be injured if it slips. 20.20 Do not use compressed air to dry or clean small parts that are held in the hand. 20.21 Keep area adjacent to railroad tracks clear. A clearance of 30 inches from narrow gauge tracks and 5 feet from standard gauge tracks must be maintained. 20.22 Fall protection is required when working aloft. Lanyards shall be anchored to an appropriate tie off point except when moving or changing work locations or when working from permanent walkways or platforms equipped with guardrails.
21. Abrasive Blasting

Beware of the hazards of abrasive blasting. Avoid getting abrasive shot in the eye.
21.1 21.2 21.3
Only authorized employees are permitted in the Abrasive Blasting Area. All personal protective equipment, air supply to operator, etc., must be checked prior to use. A Bureau of Mines or NIOSH approved air-supplied sandblasting helmet or mask must be worn by all operators of abrasive blasting equipment, except where blasting operation is enclosed and separated from operator, as with Wheelabrator or Pangborn machines. Approved gauntlets and apron or coat should also be worn. The operator should have a physical examination (including x-ray) before assignment to this type of work, and at least annually thereafter. Operator should keep his hood on at all times when blowing loose abrasive from the material, shoveling abrasives, or performing other work which causes dust. If helpers or other personnel are exposed to dust from the operation, including cleaning up, they should wear approved protective equipment appropriate for the degree of exposure. This would include dust-type respiratory and tight-fitting eye protection. (See Rules 1.8 and 1.14.) The operator and helper (if required) should discuss the operation and their moves before starting the work. Operators and helpers should have signals worked out so as to coordinate the work and communications. Signals should be simple and easily understood. Check all hose connections, nozzle, etc., before starting work. Be alert for weak spots in the hose.
21.4
21.5
21.6
21.7 21.8
21.9
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Abrasive Blasting 93
21.10 Refer to rules on material handling. Be sure material is properly secured and spaced before starting blasting operations. 21.11 Small objects, loose blocking, etc., which might be driven through the air by the blast, should be removed prior to start of work. 21.12 The nature of the work requires that the operator be extremely careful of his footing and movements during blasting operations. 21.13 Abrasive materials should be removed from steel before handling or loading, so as to prevent slipping hazards. 21.14 Care must be used to keep lines from becoming entangled, cut, separated, or pulling the operator off balance. Special precautions should be taken when working from a ladder, scaffold, or above floor or ground elevations. 21.15 Operator must maintain firm grip and be in complete control of nozzle at all times, particularly when pressure is turned on. Never aim nozzle in the direction of anyone within the immediate area. Also keep hands away from the nozzle opening. 21.16 When shutting down the equipment, the operator should be positive that the hose pressure is relieved before turning away from the blasting area. 21.17 Blasting nozzles should be equipped with automatic cutoff valves or dead man controls in the event the operator loses control. 21.18 Blasting equipment should be grounded to prevent static sparks when it is used on tanks, etc., which contain or have contained volatile substances. Such tanks, etc., should be purged before blasting. 21.19 Sandblast hose should be equipped with an anti-static inner tube (natural gum treated with carbon black) to prevent electrical shock. 21.20 Steel to be blasted, if coated with red lead, epoxies, chromium, cadmium, or other toxic materials, may require special-type respirators. Check with your supervisor before starting work on such material.
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21.21 Dust from alloys containing titanium, magnesium, and some other metals may create a fire and explosion hazard. Check with your supervisor when blasting such metals. 21.22 When practical, blasting should be done in a separate structure, an area isolated by partitions, or in a restricted outside area. 21.23 All food and drink should be kept out of the blasting area. 21.24 Use a special blower unit of a type not involving internal lubrication to provide the helmet air supply. 21.25 Gasoline engine units are not recommended for use with air-supplied respirators. 21.26 If air is supplied to the helmet from plant compressed air lines or oil lubricated compressor, an air-cleaning device, pressure-regulating valves, and other items are recommended as set forth in NIOSH Specifications. 21.27 Anti-freeze, corrosion inhibitors, or such substances should not be added to compressed air systems from which air is taken for breathing purposes. 21.28 Air fed to the helmet should be at the pressure recommended by the respirator manufacturer. 21.29 Compressors supplying breathing air should not be operated near the exhausts of internal combustion engines, sewer manholes, abrasive blasting, painting, large electric arcs, or sources of smoke or other contaminants. Intakes should be provided with filters for removing contaminants in respirable-size range. 21.30 If rust inhibitives are used on material after blasting, precautions should be taken to protect against hazards resulting from breathing spray or contacting the solution. This is especially important if the solution contains either chromates or dichromates. The concentration of respirable dust or fume in the breathing zone of the operator shall be kept below the levels specified by the State or Federal Safety Standards.
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Fire Prevention 95
22. Fire Prevention

Know where fire control equipment is and how to use it. Report fire hazards.
22.8
When working on wooden docks or piers where burning or welding must be done, a stand-by hose line must be laid out and charged or connected to water hydrant. Area must be wet down thoroughly after burning or welding is completed. Use of salamanders is not recommended, but if they are used, they should be located only where there is good ventilation and they should be guarded.
22.9
22.1
In the event of a fire, you should know where the nearest fire extinguisher is located in your department. Learn where they are and what type of fire they are recommended for. Notify your supervisor if you notice any condition or act which you believe to be a fire hazard.
Rule 22.3
22.2
22.10 Do not clean clothing with oxygen, gasoline, solvents, or other flammable agents. A spark may ignite your clothing. If your clothing catches on fire, Do not run! Smother the flame. If necessary, roll on the floor or ground to put out the flame. 22.11 Do not use oil, gasoline, similar flammable liquids, or oxygen to start or increase the intensity of a fire. 22.12 Inspect fire extinguishers each month and annually.
ATTENTION:
KEEP FILLED
22.3 22.4
FIRE AT
EXTINGUISHERS ALL TIMES
How to operate a fire extinguisher
All extinguishers must be turned in for refilling, inspection and retagging after use. When fighting fires, the first few moments are the most important. The proper and prompt use of extinguishers at the start of a fire will often control the fire and avoid heavy losses. Carbon tetrachloride is banned as an extinguishing agent. Remove any carbon tetrachloride fire extinguishers from service, dispose of safely according to local or federal standards, and replace with an appropriate type extinguisher. Keeping your work area, lockers, etc., clean and free of rubbish will help in the prevention of fires. Fire equipment should be used only for preventing or controlling fires. Standpipes, hydrants, hoses, etc., should not be used for any other purpose, except with specific permission of the plant manager.
REMEMBER:
PASS
22.5
P = A= S = S =
P U L L THE PIN A I M T H E N O Z Z L E AT T H E B A S E O F THE FLAMES S Q U E E Z E TRIGGER WHILE HOLDING EXTINGUISHER UPRIGHT S W E E P EXTINGUISHER FROM SIDE TO SIDE, COVERING THE AREA OF THE FIRE WITH THE EXTINGUISHING AGENT
22.6 22.7
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Fire Prevention 97
Types of Fire Extinguishers, page 1 [image 22.12]
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Notes 99
23. Off the Job Safety

Drive safely.
Notes
At best, life is short. Accidental death and injury can make it even shorter. Therefore, preventing accidents is important, whether at home, on a hunting trip, at the beach, driving a car, or on the job. The following suggestions are for your safety away from your job: 1. When youre driving, concentrate on the road, your car, and other cars. Expect the worst and then maybe it wont happen. Wear seat belts and shoulder belts. 2. As a pedestrian . . . Look both ways before stepping from the curb. Cross at the intersection. Never step out from between parked cars. On highways, walk on the left side, facing traffic. 3. Watch your step. Keep steps and stairways clearthen walk them, dont run! 4. There is pleasure in doing-it-yourself, but dont do-yourselfin. Do it with care and dont over-do-it. 5. Things like gasoline, paint thinner, lye, kitchen cleaners, and bug sprays can do things like explode, burn, damage eyesight, hurt skin, poison the body. Handle all chemical products carefully and keep them up and out of reach of small children. 6. Teach your children safety habits. Watch out for cars when crossing the street, playing in the street, riding bikes. Keep knives and other sharp objects out of reach. Put away medicines. 7. Watch for fire hazards: worn-out wires, material too close to very hot items like stoves, electric heaters, irons, and candles; dont use worn-out appliances. 8. When you need help, ask for it quickly! Keep numbers of the Fire Department, Ambulance Service, and Police Department posted by your telephone. 9. Be alert; dont take chances!!! Accidents can happen to you anywhere watch out for them.
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Notes 101
Notes
Notes
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Notes 103
Notes
Notes
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Notes
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GENERAL SAFETY RULES FOR STRUCTURAL S T E E L FA B R I C AT O R S

General Safety Rules for Structural Steel Fabricators

Lets All Work Together for Safety

2 General Safety Rules for Structural Steel Fabricators

Heavy Impact Goggles

4 General Safety Rules for Structural Steel Fabricators

Cover-all Plastic Monogoggles

General Purpose Spectacles

6 General Safety Rules for Structural Steel Fabricators

Disposable Ear Plugs

Insert-type Ear Plugs

Cartridge Type Respirator

8 General Safety Rules for Structural Steel Fabricators

General Safety Rules 9

2. General Safety Rules

2.2 2.3 2.4 2.5 2.6

10 General Safety Rules for Structural Steel Fabricators

General Safety Rules 11

12 General Safety Rules for Structural Steel Fabricators

General Safety Rules 13

14 General Safety Rules for Structural Steel Fabricators

Cranes and Hoists 15

3. Cranes and Hoists

drop anything from the cranes cab.

Electric Overhead Traveling Cranes (Cab Operated)

3.9 3.10 3.11 3.12 3.13

16 General Safety Rules for Structural Steel Fabricators

Cranes and Hoists 17

3.25 3.26 3.27 3.28

Use standard signals only.

18 General Safety Rules for Structural Steel Fabricators

Cranes and Hoists 19

Floor Operated Cranes and Hoists

3.32 3.33 3.34

3.35 3.36 3.37

3.49 3.50 3.51

20 General Safety Rules for Structural Steel Fabricators

Cranes and Hoists 21

3.69 3.70 3.71

3.53 3.54 3.55 3.56

3.57 3.58 3.59 3.60

3.61 3.62 3.63 3.64

22 General Safety Rules for Structural Steel Fabricators

Cranes and Hoists 23

Crawler, Locomotive and Truck Cranes

24 General Safety Rules for Structural Steel Fabricators

Cranes and Hoists 25

Standard Crane Signals

26 General Safety Rules for Structural Steel Fabricators

Alloy Chain Capacities

28 General Safety Rules for Structural Steel Fabricators

Equalize the strain. A MERICAN I NSTITUTE

30 General Safety Rules for Structural Steel Fabricators

Always grasp above the load.

32 General Safety Rules for Structural Steel Fabricators

4.41 4.42 4.43 4.44

34 General Safety Rules for Structural Steel Fabricators