structural collapse technician training

SCT App A 1

National Urban Search & Rescue Response System

Structural Collapse TechnicianStructural Collapse Technician Training

Structural Collapse Technician Training

Jan09

Appendix C:

Metal Burn Cutting

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Unit Objectives

The student will understand the the capabilities and limitations of all the capabilities and limitations of all the types of metal burning that can be used types of metal burning that can be used in US&R operations in US&R operations

Understand how to efficiently and safely Understand how to efficiently and safely cut and remove multiple pieces of steel cut and remove multiple pieces of steel from a debris pilefrom a debris pile

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Enabling Objectives Discuss how to conduct a site hazard analysisDiscuss how to conduct a site hazard analysis

Select appropriate PPE Select appropriate PPE Select the most efficient metal burning equipment based on Select the most efficient metal burning equipment based on

needs of an incidentneeds of an incident

Discuss safety practices associated with the different Discuss safety practices associated with the different metal burning equipmentmetal burning equipment

Identify hazardous situations found when cutting and dentify hazardous situations found when cutting and burning on a debris pile burning on a debris pile Understand the safety practices to minimize risk to Understand the safety practices to minimize risk to

rescuers.rescuers.

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Enabling Objectives Discuss the use & setup of the various types of Discuss the use & setup of the various types of

metal burning equipment based on safety, metal burning equipment based on safety, material type & thicknessmaterial type & thickness

Identify special issues involved withCompressed gas cylindersOxy / acetylene—use and safetyGasoline / oxygen operation

Discuss proper breakdown, storage and Discuss proper breakdown, storage and shipping methods for the metal burning shipping methods for the metal burning equipment in FEMA US&R Cacheequipment in FEMA US&R Cache

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Topics to be discussed Oxy/Fuel process & SafetyOxy/Fuel process & Safety Personal Protective Personal Protective

EquipmentEquipment Types of Metal Burning Types of Metal Burning

EquipmentEquipment Oxy/AcetyleneOxy/Acetylene Oxy/GasolineOxy/Gasoline Exothermic/Oxygen LanceExothermic/Oxygen Lance Plasma ArcPlasma Arc

Storage & shipping methodsStorage & shipping methods

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Oxy Fuel Process

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General Safety Guidelines Metal burning requires strict compliance with

all manufacturer’s safety guidelines Biggest causes of injury

Burns from hot material or ultraviolet raysBreathing toxic materials

Wear full PPE at ALL TIMESWear UV rated eye protectionUse proper respiratory protection

Work in 2 person teams

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Structural Collapse TechnicianStructural Collapse Technician Training General Safety Guidelines (cont.) Inspect all equipment prior to

use for damage and leaks Have a fire extinguisher or Have a fire extinguisher or

small hose line available for small hose line available for spot firesspot fires

Hydrate oftenHydrate often Consider the reaction of your

actions before and while and while cutting a piece of steel or cable

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Be aware of heavy equipment and Be aware of heavy equipment and other people working above and belowother people working above and below

Have a safety person watch the Have a safety person watch the area for fire and other hazardsarea for fire and other hazards

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The tender is the burner’s second set of eyes The tender is the burner’s second set of eyes because the person burning is focused on the because the person burning is focused on the

progress of the cutprogress of the cut

Two Person Team

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Personal Protective EquipmentPersonal Protective Equipment In addition to the Std n addition to the Std

US&R PPEUS&R PPE Shaded eye protection Shaded eye protection

Leather gauntlet gloves Leather gauntlet gloves

Respiratory protection Respiratory protection ( Organic Vapor)( Organic Vapor)

Consider the PAPRConsider the PAPR

The level of protection will The level of protection will be dependant on the be dependant on the Situation and type of Metal Situation and type of Metal to be removedto be removed

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4 different scenarios requiring PPE selection4 different scenarios requiring PPE selection

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Personal EquipmentPersonal Equipment Crescent wrenchCrescent wrench Striker/spare flintStriker/spare flint Tool belt Tool belt Tip CleanersTip Cleaners Spare Tips Spare Tips Marking Paint Marking Paint Tape Measure Tape Measure SoapstoneSoapstone

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Oxy-AcetyleneOxy-AcetyleneMost common Oxy-fuel ProcessMost common Oxy-fuel Process

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Oxy/Acetylene Advantages

Commonly used in many industriesCommonly used in many industries Wide variety of accessory equipmentWide variety of accessory equipment

DisadvantagesHas wide flammable limitsLimited by the withdrawal rate of 1/7 per hrLimited by the withdrawal rate of 1/7 per hr

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Oxy-Acetylene - Safety Oxy-Acetylene - Safety PracticesPractices Do not operate Acetylene above 15 PSIG Do not operate Acetylene above 15 PSIG

Do not withdraw more than 1/7 of the cylinder Do not withdraw more than 1/7 of the cylinder contents per hour contents per hour

Do not drain all of Do not drain all of cylinder contentscylinder contents Keep components and Keep components and area clear of grease, oil and area clear of grease, oil and other oxidizers/flammablesother oxidizers/flammables

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Oxy-Acetylene - Safety Oxy-Acetylene - Safety PracticesPractices Always operate with cylinder secured in Always operate with cylinder secured in

an upright positionan upright position Do not operate without Flashback Do not operate without Flashback

Arrestors and reverse flow check valvesArrestors and reverse flow check valves Always perform a Always perform a mechanical check for mechanical check for leaking componentsleaking components

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A small Leak can create a BIG A small Leak can create a BIG eventevent

This event was caused by a leaking 12 This event was caused by a leaking 12 cubic ft. acetylene cylinder similar to cubic ft. acetylene cylinder similar to

what may be carried in your US&R cachewhat may be carried in your US&R cache

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Oxy Acetylene EquipmentOxy Acetylene Equipment

Acetylene cylinderAcetylene cylinder

Must be stored & operated in upright positionMust be stored & operated in upright position

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Acetylene CylinderAcetylene Cylinder

Compressed to a pressure of 200-250 PSIGCompressed to a pressure of 200-250 PSIGUnstable in a gas form if above 15 PSIGUnstable in a gas form if above 15 PSIG

Open cylinder 1 to 1 ½ turnsOpen cylinder 1 to 1 ½ turns

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Oxygen CylinderOxygen Cylinder Compressed to a pressure of 2250 PSIGCompressed to a pressure of 2250 PSIG Must be secured at all times Must be secured at all times Must be capped in an upright position Must be capped in an upright position

for transport or when not in usefor transport or when not in use

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Alternative oxygen sources - Liquid Alternative oxygen sources - Liquid OxygenOxygen

The The DewarDewar can can evaporate 4500 Cu. Ft. evaporate 4500 Cu. Ft. of gas from a liquid of gas from a liquid contained in cylinder contained in cylinder External evaporator may External evaporator may

be needed be needed Must be kept in an Must be kept in an

upright positionupright position

The The GreenGreen compressed compressed cylinder contains about cylinder contains about 250 Cu. Ft. of Oxygen250 Cu. Ft. of Oxygen

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Liquid Oxygen - DewarLiquid Oxygen - Dewar

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Compressed Oxygen Compressed Oxygen TrailerTrailer Used when a Used when a

large Demand is large Demand is needed needed

A tube style A tube style Trailer Cannot be Trailer Cannot be easily moved easily moved around a sitearound a site

May not be May not be readily availablereadily available

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Oxy Acetylene EquipmentOxy Acetylene Equipment Acetylene Regulator Oxygen RegulatorAcetylene Regulator Oxygen Regulator

Do not operate above 15 PSIGDo not operate above 15 PSIG

Regulates gas down to its working pressureRegulates gas down to its working pressure Stand off to side when opening cylinder Stand off to side when opening cylinder Regulator screw should be backed out and turn Regulator screw should be backed out and turn

freely before opening cylinderfreely before opening cylinder

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Flashback ArrestorsFlashback ArrestorsFlashback ArrestorFlashback Arrestorprevents a fire from prevents a fire from burning back to the burning back to the cylindercylinder

Check valvesCheck valvesCheck valve allows gas Check valve allows gas to flow in one directionto flow in one direction

A quick connect acts as A quick connect acts as a check valvea check valve

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Hoses are Color CodedHoses are Color CodedAlso threaded differently depending on applicationAlso threaded differently depending on application

Oxygen is Green with Right-Hand threads

Fuel Gas is Red with Left-Hand threads

All fuel gas equipment has a groove on the All fuel gas equipment has a groove on the fitting to indicate Left-Hand threadsfitting to indicate Left-Hand threads

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Structural Collapse TechnicianStructural Collapse Technician Training Hoses Get Abused in Debris PileAre exposed to sharp edges, etc.Inspect for cracks/burns & other wear

Make sure hoses are rated for the fuel and Make sure hoses are rated for the fuel and proper tip sizeproper tip size

Keep clean from grease/oil & other oxidizersKeep clean from grease/oil & other oxidizers

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TorchesTorches Various lengths/styles and head anglesVarious lengths/styles and head angles Some are made for welding and have a Some are made for welding and have a

cutting attachmentcutting attachment The size of the tip not the torch length The size of the tip not the torch length

determines the thickness of the cutdetermines the thickness of the cut

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Torch TipsTorch Tips

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Tip Selection ChartTip Selection Chart

A 145 cu. ft. cylinder should not have a A 145 cu. ft. cylinder should not have a withdrawal rate of more than 21 SCFHwithdrawal rate of more than 21 SCFHRefer to the chart above for safe tip sizeRefer to the chart above for safe tip size

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Oxy-Gasoline - PetrogenOxy-Gasoline - Petrogen

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Oxy-Gasoline - PetrogenOxy-Gasoline - Petrogen Advantages:Advantages:

Can cut steel that is up to 14 in. thickCan cut steel that is up to 14 in. thickWill cut through various sized air gapsWill cut through various sized air gapsLess likely to fuse itself back togetherLess likely to fuse itself back togetherNot limited by the fuel cylinder sizeNot limited by the fuel cylinder size

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Oxy-Gasoline - PetrogenOxy-Gasoline - Petrogen Disadvantages:Disadvantages:

Equipment is not available locallyEquipment is not available locallyRescuers must understand that the Petrogen Rescuers must understand that the Petrogen

torch setup, tuning and usage is different torch setup, tuning and usage is different than the oxy-acetylene setupthan the oxy-acetylene setup

Failing to understand the differences will Failing to understand the differences will produce poor cutting results produce poor cutting results

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Petrogen Safety PracticesPetrogen Safety Practices Always perform a check for leaksAlways perform a check for leaks When checking for a fuel leak look for When checking for a fuel leak look for

liquid fuel on the ground and couplingsliquid fuel on the ground and couplings Secure fuel tank in the upright position Secure fuel tank in the upright position

Fuel cannot flow with tank on its sideFuel cannot flow with tank on its side

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Petrogen Safety PracticesPetrogen Safety Practices A flashback arrestor should be used on A flashback arrestor should be used on

the oxygen line. the oxygen line. One is not required for the fuel lineOne is not required for the fuel line

Do not operate fuel tank below 10 psiDo not operate fuel tank below 10 psi

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Petrogen Equipment Petrogen Equipment Fuel TankFuel Tank Holds 2.5 gallons of fuelHolds 2.5 gallons of fuel

Equal to a 250 cu.ft. Equal to a 250 cu.ft. acetylene cylinderacetylene cylinder

Has a pressure relief on the Has a pressure relief on the filler capfiller cap

Has a safety valve on the Has a safety valve on the pressure gauge & fuel valvepressure gauge & fuel valve

Use the freshest fuel availableUse the freshest fuel available

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Various lengths/styles and head anglesVarious lengths/styles and head angles The size of the tip not the torch length The size of the tip not the torch length

determines the thickness of the cutdetermines the thickness of the cut

Petrogen Equipment - Petrogen Equipment - TorchesTorches

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Petrogen Equipment Petrogen Equipment Torch TipsTorch Tips Tip has two piecesTip has two pieces Fuel enters the tip as a Fuel enters the tip as a

mist /atomized gasoline mist /atomized gasoline oxygen mixtureoxygen mixture

Has oxygen and pre heat Has oxygen and pre heat ports similar to Oxy-ports similar to Oxy-AcetyleneAcetylene

If tuned properly, fuel If tuned properly, fuel entering tip should keep entering tip should keep tip cool as it vaporizestip cool as it vaporizes

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Structural Collapse TechnicianStructural Collapse Technician Training Petrogen Petrogen Equipment Equipment Tip Tip ChartChart Serves as a basic Serves as a basic

starting pointstarting point Settings will depend on Settings will depend on

operator experienceoperator experience You are not limited by You are not limited by

the 1/7 per hour rulethe 1/7 per hour rule Tip does not need to be Tip does not need to be

as clean a for oxy-as clean a for oxy-acetylene tipacetylene tip

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Petrogen EquipmentPetrogen EquipmentA big advantage of theA big advantage of thePetrogen is that is canPetrogen is that is canbe fully broken down be fully broken down and repaired in field and repaired in field with a spare parts kit.with a spare parts kit.

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Structural Collapse TechnicianStructural Collapse Technician Training Petrogen Equipment - Petrogen Equipment - Poor Poor PracticePractice Operator Error caused Operator Error caused

this overheated this overheated equipment equipment

Typically caused by too Typically caused by too close of a coupling close of a coupling distance or tuning the distance or tuning the torch too leantorch too lean

A coupling distance of A coupling distance of ½” is a good safe ½” is a good safe starting pointstarting point

Heat transferred from Heat transferred from Tip & overheated mixerTip & overheated mixer

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Exothermic TorchExothermic TorchExothermic uses a consumable rod with Exothermic uses a consumable rod with oxygen pushing through the rod. Its primaryoxygen pushing through the rod. Its primaryFunction is to melt the materialFunction is to melt the material

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Exothermic TorchExothermic Torch

AdvantagesCan burn through almost anything

Disadvantages:Operator must wear full PPEOperator must wear full PPE Large spark showers of molten metalArea of work must be free of combustibles

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Oxygen LanceOxygen Lance Uses exothermic technology but uses a Uses exothermic technology but uses a

much thicker and longer consumable rodmuch thicker and longer consumable rod This allows the operator to be at a safer This allows the operator to be at a safer

distance away from the material being cutdistance away from the material being cut

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Plasma Arc Plasma Arc - Electric arc & Compressed air Advantages

Can cut ferrousCan cut ferrous & non ferrous metal & non ferrous metal Burns cleanBurns clean

Low slag & sparksLow slag & sparks

Disadvantages:Systems that can burn thicker material Systems that can burn thicker material

are large + heavy are large + heavy Also require 220v to operateAlso require 220v to operate

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Basic Torch Handling SkillsBasic Torch Handling Skills Make yourself as comfortable as possibleMake yourself as comfortable as possible

Try to work the torch like a pool cue or Try to work the torch like a pool cue or pivot using your hand or material/debris pivot using your hand or material/debris as a pivot pointas a pivot point

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Estimating Steel Weight - Area MethodEstimating Steel Weight - Area Method Steel weighs 490 lbs

per cubic ft Steel 1” thick weighs

490pcf / 12” = 40.8 psf For steel weight per

square foot use:1” thick Use 40 lbs¾” Use 30 lbs½” Use 20 lbs¼” Use 10 lbs

12”12”

12”

1”12”12”

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Area Method Examples 1 & 2

Flanges = 24”x 5” Flanges = 24”x 5” Web = 12”x 3.5 inchesWeb = 12”x 3.5 inches

36”x 2” 36”x 2”

36”x 2” 36”x 2”

Example 1

Example 2

12”x 2” 12”x 2”

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Area Method Example - 1 What is weight of this 36ft long steel section?

2” Steel = 2 x 40 psf = 80 psfArea per ft = 2 x 3 sq ft + 2 x 1 sq ft = 8 sq ftWeight per ft = 8 x 80 = 640 plfTotal weight = 640 x 36 = 23,040 lbs

Exact weight = 652.8 plf (only 2% off)

Pl 36" x 2"

Pl 36" x 2"

Pl 12" x 2" ea end

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Area Method Example - 2 What is weight of this 20ft long steel section?

2 Flanges 40 psf x 5” x 2 ft x 2 = 800 plfWeb 40psf x 3.5” = 140Weight per ft = 800 + 140 = 940 plfTotal weight = 940 x 20 = 18,800 lbs

Exact weight = 958.8 plf (only 2% off)

Pl 24" x 5"

Pl 24" x 5"

Pl 12" x 3.5”

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Area Method – Round Tube Shapes Get area by: Circumference x Length

Either Measure distance around w/ tape or

Multiply Diameter x 3 (exact is 3.14)

Think - cut & unfold tube

Weight per ft is 3 x Diameter x Wt, per sq ft

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Structural Collapse TechnicianStructural Collapse Technician Training Area Method - Pipe & Tube Example What is weight of this 16ft long steel pipe?

12” Diameter x ½” thick½” Steel = 20 psf Area per ft = 3 x 1 = 3 sq ftWeight per ft = 3 sf x 20 = 60 plf, Total = 960 lbExact weight = 61.4 plf (only 2% off)

For Sq Tube use 4 x Size x Wt per sq ftFor 8” Sq. x ¼” thick x 16ft (10psf for ¼”)Wt per ft = 4 x 8”/12”x 10psf = 26.7 plf, 427lbFrom AISC Hbk = 25.8 plf (only 4% off)

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Other clues for Steel WeightOther clues for Steel Weight Numbers painted on steel at the Mill / ShopNumbers painted on steel at the Mill / Shop

First number is Depth in InchesFirst number is Depth in InchesSecond is Weight Per Foot in PoundsSecond is Weight Per Foot in PoundsThird is Length in FeetThird is Length in Feet

Usually located near the endUsually located near the endMay be covered with other paint May be covered with other paint

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Shipping & Storage MethodsShipping & Storage Methods All torches & hoses purged of All torches & hoses purged of

combustible fuelcombustible fuel Remove quick disconnects if used to Remove quick disconnects if used to

completely remove fuelcompletely remove fuel Store Petrogen torches, hoses & fuel Store Petrogen torches, hoses & fuel

tanks in a ventilated shipping boxtanks in a ventilated shipping box Regulators are fragile and should be Regulators are fragile and should be

stored in protective oil free hard casestored in protective oil free hard case Refer to IATA and local guidelines for Refer to IATA and local guidelines for

shipping compressed gasesshipping compressed gases Acetylene torches can be stored in a Acetylene torches can be stored in a

oil free hard caseoil free hard case

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Review Unit Objectives

The student will understand the the capabilities and limitations of all the capabilities and limitations of all the types of metal burning that can be used types of metal burning that can be used in US&R operations in US&R operations

Understand how to efficiently and safely Understand how to efficiently and safely cut and remove multiple pieces of steel cut and remove multiple pieces of steel from a debris pilefrom a debris pile

structural collapse technician training

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