OCCUPATIONAL SAFETY AND HEALTH

For Technologists, Engineers, and Managers

Ninth Edition

David L. GoetschVice-President Emeritus and Professor

Northwest Florida State College

330 Hudson Street, NY, NY 10013

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Library of Congress Cataloging-in-Publication DataNames:­Goetsch,­David­L.,­author.Title:­Occupational­safety­and­health­for­technologists,­engineers,­and­managers­/­David­L.­ ­ Goetsch,­vice-president­emeritus­and­professor,­Northwest­Florida­State­College.Description:­Ninth­edition.­|­Boston­:­Pearson,­[2019]­|­Includes­ bibliographical­references­and­index.Identifiers:­LCCN­2017008628|­ISBN­9780134695815­|­ISBN­013469581XSubjects:­LCSH:­Industrial­safety—United­States.­|­Industrial­hygiene—United­States.Classification:­LCC­T55­.G586­2019­|­DDC­658.4/08—dc23­ ­ LC­record­available­at­https://lccn.loc.gov/­ 2017008628

1­ 17

ISBN­10:­ ­ 0-13-469581-XISBN­13:­978-0-13-469581-5

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iii

PREFACE

BACKGROUNDThe­ field­ of­ occupational­ safety­ and­ health­ has­ undergone­ significant­ change­ over­ the­past­three­decades.­There­are­many­reasons­for­this.­Some­of­the­more­prominent­­reasons­include­ the­ following:­ technological­ changes­ that­ have­ introduced­new­hazards­ in­ the­workplace;­proliferation­of­health­and­safety­ legislation­and­corresponding­regulations;­increased­ pressure­ from­ regulatory­ agencies;­ realization­ by­ executives­ that­workers­ in­a­ safe­ and­ healthy­workplace­ are­ typically­more­ productive;­ health­ care­ and­workers’­­compensation­ cost­ increases;­ increased­ pressure­ from­ environmental­ groups­ and­ the­­public;­ a­ growing­ interest­ in­ ethics­ and­corporate­ responsibility;­professionalization­of­health­and­safety­occupations;­increased­pressure­from­labor­organizations­and­employees­in­general;­rapidly­mounting­costs­associated­with­product­safety­and­other­types­of­litiga-tion;­and­increasing­incidents­of­workplace­violence.

All­of­these­factors,­when­combined,­have­made­the­job­of­the­modern­safety­and­health­professional­more­challenging­and­more­important­than­it­has­ever­been.­These­factors­have­also­created­a­need­for­an­up-to-date­book­on­workplace­safety­and­health­that­contains­the­latest­information­needed­by­people­who­will­practice­this­profession­in­an­age­of­global­competition­and­rapid­technological­change.

WHY WAS THIS BOOK WRITTEN AND FOR WHOM?This­book­was­written­to­fulfill­the­need­for­an­up-to-date,­practical­teaching­resource­that­focuses­on­the­needs­of­modern­safety­and­health­professionals­practicing­in­the­workplace.­It­is­intended­for­use­in­universities,­colleges,­community­colleges,­technical­schools,­and­corporate­training­settings­that­offer­programs,­courses,­workshops,­and­seminars­in­occu-pational­safety­and­health.­Educators­in­such­disciplines­as­safety­engineering,­engineer-ing,­industrial­technology,­manufacturing­technology,­industrial­engineering,­engineering­technology,­ occupational­ safety,­management,­ and­ supervision­will­ find­ this­ book­ both­valuable­and­easy­to­use.­The­direct,­straightforward­presentation­of­material­focuses­on­making­the­theories­and­principles­of­occupational­safety­and­health­practical­and­useful­in­a­real-world­setting.­Up-to-date­research­has­been­integrated­throughout­in­a­down-to-earth­manner.

ORGANIZATION OF THE BOOKThe­text­contains­31­chapters­organized­into­five­parts,­each­focusing­on­a­major­area­of­concern­for­modern­safety­and­health­professionals.­The­chapters­are­presented­in­an­order­that­is­compatible­with­the­typical­organization­of­a­college-level­safety­and­health­course.­A­standard­chapter­format­is­used­throughout­the­book.­Each­chapter­begins­with­a­list­of­learning­objectives­and­ends­with­a­comprehensive­summary.­Following­the­summary,­the­chapters­ include­ review­questions,­key­ terms­and­concepts,­ and­endnotes.­Within­most­chapters­are­case­studies­to­promote­classroom­discussion,­as­well­as­at­least­one­safety­fact­or­myth.­These­materials­are­provided­to­encourage­review,­stimulate­additional­thought,­and­provide­opportunities­for­applying­what­has­been­learned.

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iv Preface

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HOW THIS BOOK DIFFERS FROM OTHERSThis­book­was­written­because­in­the­age­of­global­competition,­safety­and­health­in­the­workplace­have­changed­drastically.­Many­issues,­concerns,­and­factors­relating­specifi-cally­ to­modern­workplace­environments­have­been­given­more­attention,­greater­depth­of­coverage,­and­more­illumination­here­than­other­textbooks.­Some­of­the­areas­receiving­more­attention­and­specific­occupational­examples­include:

■ The­Occupational­Safety­and­Health­Act­(OSH­Act)­and­Occupational­Safety­and Health­Administration­(OSHA)

■ Standards­and­codes ■ Laws­and­liability ■ Stress-related­problems ■ Life­safety­and­fire­hazards ■ The­evolving­roles­of­health­and­safety­professionals ■ Health­and­safety­training ■ Human­factors­in­safety ■ Environmental­issues­and­ISO­14000­standards ■ Computers,­robots,­and­automation ■ Ethics­and­safety ■ Bloodborne­pathogens­in­the­workplace ■ MRSA­in­the­workplace ■ Product­safety­and­liability ■ Ergonomics­and­safety ■ The­relationship­between­safety­and­quality ■ Workplace­violence ■ Workers’­compensation ■ Repetitive­strain­injuries­(RSIs) ■ Terrorism­threats­in­the­workplace ■ Safety-first­corporate­culture ■ Off-the-job­safety

NEW TO THIS EDITIONThe­ninth­edition­of­Occupational Safety and Health­ is­ a­major­ revision­encompassing­new­regulations,­revised­regulations,­and­other­new­and­updated­material­of­importance­to­students­of­occupational­safety­and­health.­Specifically,­the­following­revisions­were­made­in­the­ninth­edition:

CHAPTER 1:

1. Added­information­on­the­Triangle­Fire­as­a­famous­accident.2. Added­a­section­about­safety­applying­to­all­work­sectors:­manufacturing,­food­­service,­retail,­hospitality,­health­care,­etc.

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Preface v

3. Added­the­following­to­the­time­line:­Hawthorn­Light­Experiment,­Gilbreth’s­Motion­Study,­and­ergonomics.

4. Added­information­on­the­Chemical­Safety­Board.5. Added­information­on­ergonomics­and­CTDs­as­a­trend­in­safety­in­the­1990s.6. Added­information­on­the­West­Fertilizer­Company­tragedy.

7. Added­information­on­whether­the­accident­rate­has­decreased­because­America­has­lost­so­many­manufacturing­jobs.

CHAPTER 2:

1. Moved­“Heat­Burns­and­Chemical­Burns”­sections­to­Chapter­19.

2. Moved­“Repetitive­Strain/Soft­Tissue­Injuries”­section­to­Chapter­10.

3. Added­a­reference­year­to­Figures­2–1,­2–2,­and­2–3­so­students­know­when­the­data­were­compiled.

4. Added­a­brief­section­on­OSHA­reports­and­logs­here­(and­reference­where­they­­appear­in­detail­in­Chapter­6).

5. Converted­Figure­2–4­into­a­chart.6. Added­a­link­to­Bureau­of­Labor­Statistics­for­more­detailed­information.

CHAPTER 3:

1. Bolded­the­sentence­about­Heinrich’s­Theory­being­discounted­by­contemporary­research­for­emphasis.

2. Added­information­on­James­Reason’s­Swiss­Cheese­Model­of­accident­causation.

3. Revised­Figure­3–1­as­a­simple­checklist.4. Changed­the­section­on­“Drugs­and­Accident­Causation”­to­“Individual­Factors­and­Accident­Causation”­(include­drugs,­depression,­obesity,­fatigue,­personality,­etc.).

CHAPTER 4:

1. Added­information­on­the­importance­of­the­employee­on­safety­teams­and­the­­employee’s­role­in­safety.

2. Replaced­Figures­4–9­and­4–10­with­photographs.

CHAPTER 5:

1. Added­information­about­the­growth­of­manufacturing­in­China.2. Strengthened­the­definition­of­competitiveness­and­Figure­5–1.3. Added­a­section­on­how­OSHA­and­other­government­regulations­affect­the­­competitiveness­of­American­companies.

CHAPTER 6:

1. Added­information­on­indirect­costs­of­OSHA­fines­(bad­PR,­loss­of­goodwill,­­corporate­image,­legal­fees,­paperwork,­etc.).

2. Replaced­Figure­6–4­with­instructions­for­finding­consultation­services­in­your­state.3. Revised­Figure­6–6­to­include­website­­addresses­for­each­agency­instead­of­street­­addresses.

4. Updated­the­OSHA­standard­subparts­to­ensure­they­are­up­to­date.5. Added­information­on­where­the­fines­go­when­OSHA­collects­them­and­discussion­plus­examples­about­the­size­of­fines.

CHAPTER 7:

1. Replaced­Figure­7–1­with­a­figure­showing­how­students­can­access­workers’­com-pensation­information­for­their­states.

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vi Preface

2. Added­information­on­Workers’­Compensation­abuse­(employees­trying­to­take­­advantage­of­the­system).

3. Replaced­Figure­7–2­with­a­photograph.

CHAPTER 8:

1. Added­information­about­why­safety­professionals­who­do­accident­reports­need­ to­be­familiar­with­common­causes­of­accidents­(added­to­the­“Common­Causes­of­ Accidents”­section).

2. Added­a­section­on­“Who­Is­responsible­for­reporting.”

3. Added­an­accident­investigation­exercise­to­the­end­of­the­chapter.

CHAPTER 9:

1. Added­information­about­warning­labels­(when­to­have­them,­how­to­design­them,­do­they­work,­etc.).

CHAPTER 10:

1. Added­information­on­ergonomic­assessment­tools­such­as­NIOSH­guidelines,­RULA,­and­REBA.

2. Moved­section­on­“lifting”­from­Chapter­15­to­this­chapter­and­expanded­the­content­of­the­section.

3. Expanded­the­section­on­“Human­Factors­and­Safety.”4. Added­information­on­choosing­which­workstations/operations­to­evaluate­for­­ergonomics­to­the­section­on­“Worksite­Analysis­Program.”

5. In­the­section­titled­“Training­and­Education,”­referred­students­to­Chapter­12­and­recommended­using­training­materials­from­OSHA.

6. In­the­section­on­“Identifying­Specific­Ergonomic­Problems”­added­material­on­“an-thropometry”­(body­size).

7. In­the­section­on­“Cumulative­Trauma­Disorders”­added­information­on­analysis­tools­including­RULA,­REBA,­HAL,­and­strain­index,­etc.).

CHAPTER 11:

1. Explained­how­the­list­of­“common­causes”­can­be­used­and­how­it­relates­to­the­rest­of­the­chapter.

2. Added­explanations­for­the­strategies­for­dealing­with­stress.3. Added­physiological­measures­of­stress­(heart­rate,­pupil­dilation,­perspiration,­etc.).4. Added­information­about­24/7­use­of­technology­and­multitasking­as­causes­of stress.

5. Added­information­about­Employee­Assistance­Programs­(EAPs)­and­company­well-ness­programs­for­dealing­with­stress.

CHAPTER 12:

1. Added­information­about­training­available­from­the­OSHA­Training­Institute­(OTI).2. Added­information­about­OSHA’s­nationwide­network­of­training­centers.

CHAPTER 13:

1. Expanded­the­explanations­of­risk­reduction­strategies.2. Updated­the­“Emergency­Preparedness”­section­to­show­the­new­“holistic­approach”­and­the­breadth­of­events­safety­professionals­might­have­to­respond­to.

3. Strengthened­the­“Emergency­Response”­section.

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Preface vii

CHAPTER 14:

1. Added­information­about­how­a­given­type­of­machine­guard­is­chosen.2. Added­information­on­advanced­sensors­and­Bluetooth­technology.

CHAPTER 15:

1. Dropped­“Lifting”­from­the­title­to­this­chapter,­and­moved­the­section­on­lifting­to­Chapter­10.

2. Changed­title­to­“Falling,­Impact,­Acceleration,­and­Vision­Hazards­with­Associated­PPE.”

CHAPTER 16:

1. Added­information­on­CLO­as­a­unit­for­measure­for­PPE­temperature­protection.2. Added­a­section­on­OSHA­recommendations­and­guidelines­for­temperature­hazards.3. Added­a­note­to­“Chemical­Burns”­explaining­why­it­is­in­this­chapter­and­not­in­the­chapter­on­fire­safety.

CHAPTER 17:

1. Added­a­note­that­refers­students­to­Chapter­20­for­coverage­of­“Confined­Spaces.”2. Added­information­on­29­CFR­1910­Subpart­H­(OSHA’s­standards­on­pressure­hazards).

CHAPTER 18:

1. Added­information­about­power­cords,­surge­strips,­and­daisy­chains.2. Made­minor­updates­and­corrections­to­the­text.

CHAPTER 19:

1. Added­information­about­the­number­of­fire­extinguishers­needed,­how­to­choose­the­type,­and­where­they­should­be­located­in­a­facility.

2. Moved­sections­on­“Chemical­Burns”­and­“Heat­Burns”­from­Chapter­2­to­this­­chapter.

3. Added­information­to­the­“egress”­section­about­lighting­and­signage.4. Strengthened­the­material­on­“egress.”

CHAPTER 20:

1. Added­information­to­describe­TWA­in­more­detail.

2. Removed­the­underline­from­the­TWA­side­of­the­equation.

CHAPTER 21:

1. Added­material­and­photos­on­signage.2. Made­minor­corrections­to­the­text.

CHAPTER 22:

1. Added­a­section­about­“earbuds”­from­handheld­devices­and­potential­hazards.2. In­the­section­on­“Hazard­Levels­and­Risks”­added­information­from­Chapter­16­on­calculating­TWA­and­TLV.

3. In­the­section­on­“Vibration­Hazards”­added­information­about­tools­insulation,­tool­mounting,­and­job­rotation.

4. In­the­section­on­“Noise­Control­Strategies”­added­information­on­specific­engineer-ing­controls­(e.g.,­mufflers,­insulation,­wall­panels,­and­sound­absorption).

5. Added­information­about­calculating­noise­reduction­rating­(NRR)­and­how­to­­evaluate­PPE­based­on­the­NRR.

6. Moved­the­section­on­“Fit­Testing”­to­earlier­in­the­chapter.

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viii Preface

CHAPTER 23:

1. Added­a­new­section­on­emerging­technologies­such­as­Google­Glasses.2. To­the­section­on­“Impact­of­Automation­on­the­Workplace”­added­material­about­how­the­change­from­physical­work­to­automated­work­shifts­safety­concerns­from­physical­risk­to­repetitive­strain­injuries.

3. To­the­section­on­“VTDs­in­Offices­and­Factories”­added­information­about­OSHA­tools­and­checklists­that­are­available­to­evaluate­workstations.

4. Added­material­on­the­expanded­use­of­laptops,­tablets,­and­handheld­devices.5. Added­material­on­automated­vehicles.

CHAPTER 25:

1. Added­a­section­on­“active­shooter”­response.2. Added­a­section­on­“reporting­suspicious­activities.”

CHAPTER 26:

1. Added­information­on­“whistleblowers”­and­how­companies­can­protect­them.2. Added­a­section­about­“Professional­Codes­of­Conduct”­(such­as­the­one­used­by­NSPE).3. Took­out­the­statement­“If­something­is­illegal­it­is­also­unethical”­since­this­is­open­to­philosophical­debate.

CHAPTER 27:

1. Added­more­explanation­of­FMEA­and­HAZOP.

2. Added­information­on­LOPA.

CHAPTER 28:

1. Added­a­brief­section­on­organizational­culture­and­safety,­and­referred­students­to­Chapter­31­for­more­detail.

2. Added­material­about­the­organization’s­mission­statement­as­it­relates­to­safety­and­how­the­safety­policy­is­related­to­management­policy­(i.e.,­performance­appraisals,­rewards­and­recognition,­and­firing).

3. To­the­section­on­“Safety­Rules­and­Regulations”­added­an­example­of­a­rule/regulation.­To­the­section­on­“Visual­Awareness”­added­material­about­the­requirements­relating­to­signage­and­COLORS.

4. To­the­section­on­“Employee-Management­Participation”­added­material­on­how­a­participative­culture­helps­safety.

5. To­the­section­on­“Teamwork­Approach­to­Promoting­Safety”­added­material­on­the­role­of­the­team­in­promoting­a­safety­culture.

CHAPTER 29:

1. Added­new­section­on­“sustainability.”2. Revised­the­title­to­reflect­broader­coverage­than­just­ISO­14000.

CHAPTER 30:

1. Added­a­section­warning­against­Lean/Six­Sigma­teams­removing­safety­processes­and­devices.

2. Made­minor­corrections­to­the­text.

CHAPTER 31:

1. Added­information­on­hiring­employees­who­“fit”­into­the­culture.2. Added­information­about­BP­and­the­Deep­Water­Horizon­tragedy­to­illustrate­ a­bad­culture.

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Preface ix

ABOUT THE AUTHORDavid­L.­Goetsch­is­Vice-President­Emeritus­of­Northwest­Florida­State­College­and­pro-fessor­of­safety,­quality,­and­management.­In­addition,­Dr.­Goetsch­is­president­and­CEO­of­ the­ Institute­ for­Organizational­Excellence­ (IOE),­ a­private­ consulting­firm­dedicated­to­ the­ continual­ improvement­ of­ organizational­ competitiveness,­ safety,­ and­ quality.­ Dr.­Goetsch­is­cofounder­of­The­Quality­Institute,­a­partnership­of­the­University­of­West­Florida,­Northwest­Florida­State­College,­and­the­Okaloosa­Economic­Development­Coun-cil­and­founder­of­the­Leadership­Institute­of­Northwest­Florida­State­College.

ACKNOWLEDGMENTSThe­author­acknowledges­the­invaluable­assistance­of­the­following­people­in­developing­this­book:­Dr.­Lissa­Galbraith,­Florida­A&M/Florida­State­University,­for­the­material­she­contributed­on­electrical­and­fire­hazards­in­the­first­edition;­Harvey­Martin,­health­and­safety­manager­of­Metric­Systems­Corporation­in­Fort­Walton­Beach,­Florida,­for­providing­up-to-date­research­material;­and­the­following­reviewers­for­their­invaluable­input:­Steven­A.­Freeman—Iowa­State­University;­ JoDell­K.­Steuver—Purdue­University;­ and­Ottis­E.­Walizer—Minot­State­University.­Special­acknowledgment­goes­to­Larry­D.­Leiman­for­his­contributions­in­updating­all­OSHA­standards.

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xi

INTRODUCTION

SAFETY VERSUS HEALTHThe­title­of­this­book­intentionally­includes­the­words­safety­and­health.­Throughout­the­text,­the­titles­“safety­and­health­professional,”­“safety­and­health­engineer,”­and­“safety­and­health­manager”­are­used.­This,­too,­is­done­by­design.­This­approach­underscores­the­point­that­the­field­of­occupational­safety­has­been­broadened­to­encompass­both­safety­and­health.­Consequently,­managers,­technical­personnel,­and­engineers­in­this­field­must­be­knowledgeable­about­safety­and­health­and­be­prepared­to­oversee­a­corporate­program­that­encompasses­both­areas­of­responsibility.

Safety­and­health,­although­closely­related,­are­not­the­same.­One­view­is­that­safety­is­ concerned­with­ injury-causing­ situations,­whereas­ health­ is­ concerned­with­ disease-­causing­conditions.­Another­view­is­that­safety­is­concerned­with­hazards­to­humans­that­result­from­sudden­severe­conditions;­health­deals­with­adverse­reactions­to­exposure­to­toxic­or­otherwise­dangerous­hazards.­Both­of­these­views­are­generally­accurate­in­portray-ing­the­difference­between­safety­and­health.­However,­the­line­between­these­two­concepts­is­not­always­clearly­marked.

For­example,­on­the­one­hand,­stress­is­a­hazard­that­can­cause­both­psychological­and­physiological­problems­over­a­prolonged­period.­In­this­case,­it­is­a­health­concern.­On­the­other­hand,­an­overly­stressed­worker­may­be­more­prone­to­unintentionally­forget­safety­precautions­and­thus­may­cause­an­accident.­In­this­case,­stress­is­a­safety­concern.

Because­professionals­in­this­evolving­field­are­likely­to­be­responsible­for­safety­and health,­ it­ is­ important­ that­ they­have­a­broad­academic­background­covering­both.­This­book­attempts­to­provide­that­background.

This­ broadening­ of­ the­ scope­ of­ the­ profession­ does­ not­mean­ that­ specialists­ in­safety­and­health­are­not­still­needed.­They­are.­Chapter­4­shows­how­today’s­safety­and­health­manager­is­a­generalist­who­often­heads­a­team­of­specialists­such­as­safety­engi-neers,­health­physicists,­industrial­hygienists,­occupational­nurses,­occupational­physi-cians,­and­risk­managers.­In­order­to­manage­a­team­of­specialists­in­these­various­areas,­safety­and­health­managers­must­have­the­broad­and­comprehensive­background­that­this­­book­­provides.

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xiii

BRIEF CONTENTS

PART 1 HISTORICAL PERSPECTIVE AND OVERVIEW 1

1 Safety and Health Movement, Then and Now 3

2 Accidents and Their Effects 18

3 Theories of Accident Causation 29

4 Roles and Professional Certifications for Safety and Health Professionals 49

5 Safety, Health, and Competition in the Global Marketplace 73

PART 2 LAWS AND REGULATIONS 85

6 The OSH Act, Standards, and Liability 87

7 Workers’ Compensation 139

8 Accident Investigation and Reporting 165

9 Product Safety and Liability 184

PART 3 THE HUMAN ELEMENT 203

10 Ergonomic Hazards: Musculoskeletal Disorders (MSDs) and Cumulative Trauma Disorders (CTDs) 205

11 Stress and Safety 243

12 Safety and Health Training 256

13 Violence in the Workplace 285

PART 4 HAZARD ASSESSMENT, PREVENTION, AND CONTROL 305

14 Mechanical Hazards and Machine Safeguarding 307

15 Falling, Impact, Acceleration, and Vision Hazards with Appropriate PPE 329

16 Hazards of Temperature Extremes 360

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xiv Brief Contents

17 Pressure Hazards 376

18 Electrical Hazards 389

19 Fire Hazards and Life Safety 410

20 Industrial Hygiene and Confined Spaces 441

21 Radiation Hazards 483

22 Noise and Vibration Hazards 499

23 Computers, Automation, and Robots 526

24 Bloodborne Pathogens and Bacterial Hazards in the Workplace 538

PART 5 MANAGEMENT OF SAFETY AND HEALTH 559

25 Preparing for Emergencies, Disasters, and Terrorism 561

26 Ethics and Safety 587

27 Hazard Analysis/Prevention and Safety Management 601

28 Promoting Safety 623

29 Environmental Safety 641

30 TSM: Total Safety Management in a Quality Management Setting 663

31 Establishing a Safety-First Corporate Culture 676

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xv

CONTENTS

PART 1 HISTORICAL PERSPECTIVE AND OVERVIEW 1

1 Safety and Health Movement, Then and Now 3Developments­before­the­Industrial­

­Revolution­ 4

Milestones­in­the­Safety­Movement­ 5

Tragedies­That­Have­Changed­the­Safety­­Movement­ 6

Role­of­Organized­Labor­ 9

Role­of­Specific­Health­Problems­ 10

Safety­and­Health­Standards­Apply­to­More­than­Just­Manufacturing­ 11

Development­of­Accident­Prevention­­Programs­ 12

Development­of­Safety­Organizations­ 12

Safety­and­Health­Movement­Today­ 14

Integrated­Approach­to­Safety­and­Health­ 14

New­Materials,­New­Processes,­and­New­­Problems­ 15

Rapid­Growth­in­the­Profession­ 15

Does­Moving­Manufacturing­Jobs­Overseas­Reduce­the­Accident­Rate?­ 15

2 Accidents and Their Effects 18Costs­of­Accidents­ 18

Accidental­Deaths­in­the­United­States­ 19

Accidents­versus­Other­Causes­of­Death­ 20

Work­Accident­Costs­and­Rates­ 20

Time­Lost­because­of­Work­Injuries­ 21

Deaths­in­Work­Accidents­ 21

Work­Injuries­by­Type­of­Accident­ 21

Death­Rates­by­Industry­ 22

Parts­of­the­Body­Injured­on­the­Job­ 23

Estimating­the­Cost­of­Accidents­ 24

Global­Impact­of­Accidents­and­Injuries­ 26

OSHA­Reports­and­Logs­ 27

3 Theories of Accident Causation 29Domino­Theory­of­Accident­Causation­ 29

Human­Factors­Theory­of­Accident­­Causation­ 32

Accident/Incident­Theory­of­Accident­­Causation­ 34

Epidemiological­Theory­of­Accident­­Causation­ 35

Systems­Theory­of­Accident­Causation­ 37

Combination­Theory­of­Accident­ Causation­ 40

Behavioral­Theory­of­Accident­Causation­ 41

Individual­Factors­and­Accident­ Causation­ 42

Management­Failures­and­Accident­­Causation­ 43

Obesity­and­Accident­Causation­ 44

Swiss­Cheese­Model­of­Accident­ Causation­ 45

Summary­of­Accident­Causation­Models­and­Applications­ 45

4 Roles and Professional Certifications for Safety and Health Professionals 49Modern­Safety­and­Health­Teams­ 49

Safety­and­Health­Manager­ 50

Engineers­and­Safety­ 57

Industrial­Hygienist­ 62

Health­Physicist­ 62

Occupational­Physician­ 63

Occupational­Health­Nurse­ 64

Risk­Manager­ 64

Employees­and­Safety­ 65

Certification­of­Safety­and­Health­ Professionals­ 65

Other­Safety­and­Health-Related­ Certifications­ 69

Emerging­Role­of­Safety­Professionals­ 69

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5 Safety, Health, and Competition in the Global Marketplace 73Competitiveness­Defined­ 73

Productivity­and­Competitiveness­ 74

Quality­and­Competitiveness­ 76

How­Safety­and­Health­Can­Improve­ Competitiveness­ 77

OSHA­Regulations­and­Competitiveness­ 79

Rise­of­the­Industrial­Sector­in­China­ 82

PART 2 LAWS AND REGULATIONS 85

6 The OSH Act, Standards, and Liability 87Rationale­for­the­OSH­Act­ 88

OSHA’s­Mission­and­Purpose­ 88

OSH­Act­Coverage­ 88

OSHA­Standards­ 90

OSHA’s­Record­Keeping­and­Reporting­ 95

Keeping­Employees­Informed­ 103

Workplace­Inspections­and­Enforcement­ 103

OSHA’s­Whistleblower­Program­ 104

OSHA’s­Enhanced­Enforcement­ Policy­ 105

Citations­and­Penalties­ 106

OSHA­Fines:­How­Much­and­Where­Does­the­Money­Go?­ 107

Appeals­Process­ 108

State-Level­OSHA­Programs­ 109

Services­Available­from­OSHA­ 110

Employer­Rights­and­Responsibilities­ 112

Employee­Rights­and­Responsibilities­ 114

Keeping­Up-to-Date­on­OSHA­ 115

Problems­with­OSHA­ 115

Other­Agencies­and­Organizations­ 117

OSHA’s­General­Industry­Standards­ 121

OSHA’s­Maritime­Standards­ 128

OSHA’s­Construction­Standards­ 130

Standards­and­Codes­ 131

Laws­And­Liability­ 131

OSHA’s­Stand­on­Safety­Incentives­ 134

7 Workers’ Compensation 139Overview­of­Workers’­Compensation­ 139

Historical­Perspective­ 141

Workers’­Compensation­Legislation­ 143

Modern­Workers’­Compensation­ 143

Workers’­Compensation­Insurance­ 145

Resolution­of­Workers’­Compensation­Disputes­ 146

Injuries­and­Workers’­Compensation­ 147

Disabilities­and­Workers’­Compensation­ 148

Monetary­Benefits­of­Workers’­Compensation­ 152

Medical­Treatment­and­Rehabilitation­ 153

Medical­Management­of­Workplace­Injuries­ 154

Administration­and­Case­Management­ 155

Cost­Allocation­ 156

Problems­with­Workers’­Compensation­ 156

Spotting­Workers’­Compensation­Fraud­and Abuse­ 157

Future­of­Workers’­Compensation­ 158

Cost-Reduction­Strategies­ 158

8 Accident Investigation and Reporting 165Types­of­Accident­Investigations­ 165

When­to­Investigate­ 167

What­to­Investigate­ 167

Who­Should­Investigate­ 171

Conducting­the­Investigation­ 172

Interviewing­Witnesses­ 173

Reporting­Accidents­ 176

Ten­Accident­Investigation­Mistakes­to Avoid­ 180

9 Product Safety and Liability 184Product­Liability­and­the­Law­ 184

Developing­a­Product­Safety­Program­ 188

Evaluating­the­Product­Safety­ Program­ 189

Role­of­the­Safety­and­Health­ Professional­ 190

Quality­Management­and­Product­Safety­ 191

Product­Safety­Program­Record­ Keeping­ 193

User­Feedback­Collection­and­ Analysis­ 194

Product­Literature­and­Safety­ 194

Product­Recalls­and­Safety­ Professionals­ 195

Warning­Labels­and­Product­Safety­ 196

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Contents xvii

PART 3 THE HUMAN ELEMENT 203

10 Ergonomic Hazards: Musculoskeletal Disorders (MSDs) and Cumulative Trauma Disorders (CTDs) 205Ergonomics­Defined­ 206

Human­Factors­and­Ergonomic­Hazards­ 206

Factors­Associated­with­Physical­Stress­ 208

Ergonomics:­A­Political­Football­ 210

OSHA’S­Voluntary­Ergonomics­Guidelines­ 210

Worksite­Analysis­Program­for­Ergonomics­ 213

Hazard­Prevention­and­Control­ 217

Medical­Management­Program­ 218

Training­and­Education­ 221

Common­Indicators­of­Problems­ 222

Identifying­Specific­Ergonomic­Problems­ 223

Ergonomic­Problem-Solving­Strategies­ 225

Economics­of­Ergonomics­ 230

Cumulative­Trauma­Disorders/Soft­Tissue­Injuries­ 232

Lifting­Hazards­ 236

Helpful­Assessment­Tools:­NIOSH,­RULA,­REBA,­and­HAL­ 238

Participatory­Ergonomics­ 240

11 Stress and Safety 243Workplace­Stress­Defined­ 243

Sources­of­Workplace­Stress­ 244

Human­Reactions­to­Workplace­Stress­ 247

Measurement­of­Workplace­Stress­ 248

Shift­Work,­Stress,­and­Safety­ 248

Improving­Safety­by­Reducing­Workplace­Stress­ 249

Stress­in­Safety­Managers­ 252

Stress­and­Workers’­Compensation­ 252

12 Safety and Health Training 256Rationale­for­Safety­and­Health­Training­ 256

Education­and­Training­Requirements­ 259

Safety­and­Health­Professionals­as­Trainers­ 262

Preparing­Safety­and­Health­Instruction­ 264

Presenting­Safety­and­Health­Instruction­ 265

Applying­Safety­and­Health­Instruction­ 270

Evaluating­Safety­and­Health­Instruction­ 271

Training­Supervisors­ 272

Training­New­and­Transferred­Employees­ 272

Job­Safety­Analysis­as­a­Training­Technique­ 274

Training­Opportunities­Available­ 277

Illiteracy­and­Safety­ 278

English­as­a­Second­Language­Training­Issues­ 281

OSHA­Standards­and­Training­ 281

13 Violence in the Workplace 285Occupational­Safety­and­Workplace­Violence:­

The­Relationship­ 285

Workplace­Violence:­Definitions­ 286

Legal­Considerations­ 286

Risk-Reduction­Strategies­ 288

OSHA’s­Voluntary­Guidelines­on­Workplace­Violence­ 290

Active­Shooter­Response­ 298

Role­of­Supervisors­ 299

Workplace­Violence:­Policy,­Plan,­and­Programs­ 299

Communicating­with­Personnel­in­the­Aftermath­of­a­Violent­Incident­ 301

PART 4 HAZARD ASSESSMENT, PREVENTION, AND CONTROL 305

14 Mechanical Hazards and Machine Safeguarding 307Common­Mechanical­Injuries­ 308

Safeguarding­Defined­ 310

OSHA’s­Requirements­for­Machine­Guarding­ 310

Risk­Assessment­in­Machine­Operation­ 311

Design­Requirements­for­Safeguards­ 313

Point-of-Operation­Guards­ 314

Point-of-Operation­Devices­ 316

How­to­Choose­a­Machine­Guard­or­Device­ 317

Machine­Guarding­Self-Assessment­ 318

Feeding­and­Ejection­Systems­ 318

Robot­Safeguards­ 319

Control­of­Hazardous­Energy­(Lockout/Tagout­Systems)­ 319

Permanent­Electrical­Safety­Devices­in­Lockout/Tagout­Programs­ 322

General­Precautions­ 325

Basic­Program­Content­ 325

Taking­Corrective­Action­ 326

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xviii Contents

15 Falling, Impact, Acceleration, and Vision Hazards with Appropriate PPE 329Causes­of­Falls­ 329

Kinds­of­Falls­ 330

Walking­and­Slipping­ 330

Slip­and­Fall­Prevention­Programs­ 333

OSHA­Fall­Protection­Standards­ 334

ANSI­Z359­Fall­Protection­Code­ 337

Ladder­Safety­ 338

What­to­Do­after­a­Fall­ 340

Monitor­Fall­Protection­Equipment­and­Know­Why­It­Fails­ 340

Impact­and­Acceleration­Hazards­ 340

Standing­Hazards­ 347

Hand­Protection­ 349

Personal­Protective­Equipment­ 352

Forklift­Safety­(Powered­Industrial­ Trucks)­ 354

16 Hazards of Temperature Extremes 360Thermal­Comfort­ 360

Heat­Stress­and­Strain­ 361

Cold­Stress­ 365

Burns­and­Their­Effects­ 368

Chemical­Burns­ 370

OSHA’s­Guidelines­for­Hazards­of­Temperature­Extremes­ 372

17 Pressure Hazards 376Pressure­Hazards­Defined­ 376

Sources­of­Pressure­Hazards­ 377

Boilers­and­Pressure­Hazards­ 378

High-Temperature­Water­Hazards­ 378

Hazards­of­Unfired­Pressure­Vessels­ 379

Hazards­of­High-Pressure­Systems­ 379

Cracking­Hazards­in­Pressure­Vessels­ 379

Nondestructive­Testing­of­Pressure­ Vessels­ 381

Pressure­Dangers­to­Humans­ 381

Decompression­Procedures­ 383

Measurement­of­Pressure­Hazards­ 383

Reduction­of­Pressure­Hazards­ 384

OSHA’s­Standard­and­Guidelines­for­Pressure­Hazards­ 385

Confined­Spaces­and­Pressure­Vessels­ 386

18 Electrical Hazards 389Electrical­Hazards­Defined­ 389

Sources­of­Electrical­Hazards­ 392

Electrical­Hazards­to­Humans­ 395

Detection­of­Electrical­Hazards­ 395

Reduction­of­Electrical­Hazards­ 397

OSHA’s­Electrical­Standards­ 399

Electrical­Safety­Program­ 400

Electrical­Hazards­Self-Assessment­ 401

Prevention­of­Arc-Flash­Injuries­ 402

Training­Requirements­for­Workers­ 403

Permanent­Electrical­Safety­Devices­ 404

Hazards­of­Power­Strips­and­Daisy­Chains­ 404

19 Fire Hazards and Life Safety 410Fire­Hazards­Defined­ 410

Sources­of­Fire­Hazards­ 413

Fire­Dangers­to­Humans­ 416

Detection­of­Fire­Hazards­ 416

Reduction­of­Fire­Hazards­ 417

Development­of­Fire­Safety­Standards­ 423

OSHA­Fire­Standards­ 423

OSHA­and­Fire­Prevention­Plans­ 424

OSHA’s­Requirements­for­Exit­Routes­ 425

Life­Safety­ 425

Basic­Requirements­ 426

Flame-Resistant­Clothing­ 428

Fire­Safety­Programs­ 429

Response­and­Fire­Drills­ 431

Explosive­Hazards­ 431

OSHA’s­Firefighting­Options­ 433

Self-Assessment­in­Fire­Protection­ 435

Hot­Work­Program­ 435

20 Industrial Hygiene and Confined Spaces 441Overview­of­Industrial­Hygiene­ 441

Industrial­Hygiene­Standards­ 442

OSH­Act­and­Industrial­Hygiene­ 443

Hazards­in­the­Workplace­ 446

Toxic­Substances­Defined­ 448

Entry­Points­for­Toxic­Agents­ 448

Effects­of­Toxic­Substances­ 450

Relationship­of­Doses­and­Responses­ 451

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Contents xix

Airborne­Contaminants­ 452

Effects­of­Airborne­Toxics­ 453

Effects­of­Carcinogens­ 454

Asbestos­Hazards­ 454

Indoor­Air­Quality­and­“Sick-Building”­Syndrome­ 457

Toxic­Mold­and­Indoor­Air­Quality­ 459

ASTM­D7338:­Guide­for­the­Assessment­of­Fungal­Growth­in­Buildings­ 460

Threshold­Limit­Values­ 461

Hazard­Recognition­and­Evaluation­ 462

Prevention­and­Control­ 463

NIOSH­and­Industrial­Hygiene­ 465

NIOSH­Guidelines­for­Respirators­ 466

Standards­and­Regulations­ 468

Environmental­Protection­Agency­Risk­Management­Program­ 469

General­Safety­Precautions­ 470

Nanoscale­Materials­and­Industrial­Hygiene­ 471

Confined­Space­Hazards­ 472

OSHA­Confined­Space­Standard­ 473

OSHA’s­Hazard­Communication­Standard­ 477

21 Radiation Hazards 483Ionizing­Radiation:­Terms­and­Concepts­ 483

Exposure­of­Employees­to­Radiation­ 485

Precautions­and­Personal­Monitoring­ 485

Caution­Signs­and­Labels­ 486

Evacuation­Warning­Signal­ 486

Instructing­and­Informing­Personnel­ 487

Storage­and­Disposal­of­Radioactive­Material­ 487

Notification­of­Incidents­ 487

Reports­and­Records­of­Overexposure­ 488

Notice­to­Employees­ 489

Nonionizing­Radiation­ 491

Electromagnetic­Fields­in­the­Workplace­ 493

OSHA’s­Standards­for­Health­and­Environmental­Controls­ 496

22 Noise and Vibration Hazards 499Hearing­Loss­Prevention­Terms­ 499

Characteristics­of­Sound­ 501

Hazard­Levels­and­Risks­ 502

Standards­and­Regulations­ 504

Workers’­Compensation­and­Noise­Hazards­ 509

Identifying­and­Assessing­Hazardous­Noise­Conditions­ 509

Noise­Control­Strategies­ 511

Vibration­Hazards­ 515

Other­Effects­of­Noise­Hazards­ 516

Corporate­Policy­ 516

Evaluating­Hearing­Loss­Prevention­Programs­ 518

Future­of­Hearing­Conservation:­Noise­Reduction­Rating­ 521

Distraction­Hazards­Introduced­by­Handheld­Devices­with­Earbuds­ 523

23 Computers, Automation, and Robots 526Impact­of­Automation­on­the­Workplace­ 526

VDTs­in­Offices­and­Factories­ 527

Human–Robot­Interaction­ 530

Safety­and­Health­Problems­Associated­with­Robots­ 530

Industrial­Medicine­and­Robots­ 532

Automated­Vehicles­in­the­Workplace­ 533

Minimizing­the­Safety­Problems­of­Automation­ 533

Challenge­for­the­Future­ 535

24 Bloodborne Pathogens and Bacterial Hazards in the Workplace 538Symptoms­of­AIDS­ 538

AIDS­in­the­Workplace­ 539

Legal­Concerns­ 541

AIDS­Education­ 544

Counseling­Infected­Employees­ 544

Easing­Employees’­Fears­about­AIDS­ 546

Protecting­Employees­from­AIDS­ 546

Hepatitis­B­Virus­and­Hepatitis­C­Virus­in­the­Workplace­ 547

OSHA’s­Standard­on­Occupational­Exposure­to­Bloodborne­Pathogens­ 550

Preventing­and­Responding­to­Needlestick­Injuries­ 554

Methicillin-Resistant­Staphylococcus aureus in the­Workplace­ 555

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xx Contents

PART 5 MANAGEMENT OF SAFETY AND HEALTH 559

25 Preparing for Emergencies, Disasters, and Terrorism 561Rationale­for­Emergency­Preparation­ 561

Emergency­Planning­and­Community­ Right-to-Know­Act­ 562

Organization­and­Coordination­ 563

OSHA­Standards­ 564

First­Aid­in­Emergencies­ 564

How­to­Plan­for­Emergencies­ 567

Planning­for­Workers­with­Disabilities­ 569

Evacuation­Planning­ 573

Customizing­Plans­to­Meet­Local­Needs­ 574

Emergency­Response­ 575

Computers­and­Emergency­Response­ 575

Dealing­with­the­Psychological­Trauma­of­Emergencies­ 576

Recovering­from­Disasters­ 577

Terrorism­in­the­Workplace­ 579

Reporting­Suspicious­People­and­Behaviors­ 581

Active­Shooter­Response­ 582

Resuming­Business­after­a­Disaster­ 583

26 Ethics and Safety 587An­Ethical­Dilemma­ 587

Ethics­Defined­ 588

Ethical­Behavior­in­Organizations­ 590

Safety­and­Health­Professionals’­Role­in­Ethics­ 590

Company’s­Role­in­Ethics­ 592

Handling­of­Ethical­Dilemmas­ 594

Questions­to­Ask­When­Making­ Decisions­ 594

Ethics­and­Whistle-Blowing­ 595

27 Hazard Analysis/Prevention and Safety Management 601Overview­of­Hazard­Analysis­ 601

Preliminary­Hazard­Analysis­ 602

Detailed­Hazard­Analysis­ 604

Hazard­Prevention­and­Deterrence­ 612

OSHA’s­Process­Safety­Standard­ 613

Risk­Assessment­ 616

Safety­Management­Concerns­ 617

Occupational­Health­and­Safety­Management­Systems­ 620

28 Promoting Safety 623Company­Safety­Policy­ 623

Safety­Rules­and­Regulations­ 625

Employee­Participation­in­Promoting­Safety­ 626

Safety­Training­ 626

Suggestion­Programs­ 626

Visual­Awareness­ 627

Safety­Committees­ 629

Personal­Commitment­to­Workplace­Safety­ 630

Employee-Management­cooperation­ 631

Incentives­ 632

Competition­ 632

Teamwork­Approach­to­Promoting­Safety­ 633

Persuasion­as­a­Promotional­Tool­ 636

Promoting­Off-the-Job­Safety­ 638

Organizational­Culture­and­Safety­ 639

29 Environmental Safety 641Safety,­Health,­and­the­Environment­ 641

Legislation­and­Regulation­ 642

Types­of­Environments­ 644

Role­of­Safety­and­Health­Professionals­ 645

Hazards­of­the­Environment­ 645

Hazardous­Waste­Reduction­ 650

Environmental­Management­System­ (EMS)­ 653

Sustainability­and­Environmental­Management­ 657

International­Organization­for­Standardization­(ISO)­ 658

ISO­14000­ 658

ISO­14001­Standard­ 658

30 TSM: Total Safety Management in a Quality Management Setting 663What­Is­QM?­ 663

How­Does­QM­Relate­to­Safety?­ 664

Safety­Management­in­a­QM­Setting­ 666

What­Is­TSM?­ 666

TSM­Defined­ 666

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Contents xxi

Translating­TSM­into­Action­ 667

Fundamental­Elements­of­TSM­ 668

Rationale­for­TSM­ 672

Implementing­TSM:­The­Model­ 672

Lean/Six­Sigma­and­Safety:­A­Warning­ 674

31 Establishing a Safety-First Corporate Culture 676Safety-First­Corporate­Culture­Defined­ 676

Importance­of­Having­a­Safety-First­Corporate­Culture­ 677

Globalization­of­Competition­and­Safety­ 678

How­Corporate­Cultures­Are­Created­ 679

What­a­Safety-First­Corporate­Culture­Looks­Like­ 680

Ten­Steps­for­Establishing­a­Safety-First­Corporate­Culture­ 680

Hiring­Employees­Who­“Fit”­into­a­Safety-First­Corporate­Culture­ 685

Tragic­Results­of­Corporate­Cultures­That­Ignored­Safety­ 686

Glossary 689Index 702

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