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Prepared by Thomas Van Hooser (CSP, CPEA, OHST, CHST). This bulletin was prepared for nonprofit, educational purposes only. Not responsible for wrong application of this information. Always comply with statutory, site specific safety procedures and equipment manufacturer precautions for welding equipment and operations. Personnel who use welding equipment must be trained and qualified. This includes supervisors and those responsible for safety surveillance. Designated Competent Person(s) must be assigned to provide oversight to all welding operations to include random inspections of equipment and to monitor personnel to ensure that proper and safe practices are being complied with.

DANGER

USEFUL REFERENCES ON THIS SUBJECT: https://pubs.aws.org/content/free_downloads/AWS_Z49.1_SAFETY_IN_WELDING_AND_CUTTING_AND_ALLIED_PROCESSES.pdf

http://www.vrd.com.au/index.php?option=com_content&view=featured&Itemid=101

https://submissions.swa.gov.au/SWAforms/Archive/model-whs-2nd-set/Documents/202%20ZRID%20Pty%20Ltd%20-%20Attachment%20A.PDF

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9855

https://www.aws.org/standards/page/safety-health-fact-sheet

https://wtia.com.au/wp-content/uploads/2015/02/tgn-m-02-voltage-reducing-devices.pdf

http://ielectricalsolutions.yolasite.com/resources/SDF-AS%201674.2%202007.pdf

http://www.hse.gov.uk/welding/electrocution.htm

Testing is required to identify leaks

NO

VOLTAGE REDUCTION DEVICES (VRDs) FOR WELDING WORKS

31 August ‘18

Here is information on recommended use of VRDs during SMAW (stick) Welding in/around hazardous locations and/or

when welding in awkward positions:

• What is a VRD? A VRD is a hazard-reducing device for welding equipment, which greatly reduces the risk of electric shock from the welding circuit when not welding. Welding power sources generally have an Open Circuit Voltage (OCV) in the ranges of 113V d.c. or 90V a.c., depending upon the machine being used. This voltage is currently legal and in normal (dry) conditions may be safe. The only trouble is that construction sites are not normal (i.e. confined spaces, damp/wet/high humidity conditions, cramped and awkward conditions, adjacent activity, changing conditions, etc.).

• How does a VRD operate? Once the arc is broken, a welding machine fitted with a VRD will automatically drop the OCV to 15 to 30V. See references below for addition information. Note: Welders and helpers can be exposed to electrical shock when changing electrodes or in contact with defective/live parts of the welding circuit. Electric shock from a welding power source can cause serious internal injuries/fatalities to welders (i.e. ventricular fibrillation, loss of balance and falls or inability to escape power source).

• OSHA requirement? OSHA (CFR 1926.350 (j), references Consensus Standard ANSI Z49.1 (par. 11.2.2 & 11.2.3) which states: “If a significant amount of work time is spent in electrically hazardous conditions, the use of automatic controls is recommended to reduce the no-load voltage to a value not to exceed 38 volts rms ac or 50 volts direct current (dc) at rated input voltage”. Note also that OSHA has a general duty clause that requires employers to identify and correct work place hazards”. Note: VRDs are required at several international locations such as Australia and several members of the European Union.

• Procedures and work plans: Consider use of VRDs in project risk assessments and work plans to ensure optimum safe welding conditions in hazardous areas. Check all welding machines prior to use, especially for work in hazardous areas, to verify that VRDs have been properly installed and are in proper working order. The use of VRDs does not replace all other welding safety precautions and requirements.

EXAMPLES OF HAZARDOUS WORK THAT SHOULD BE PROVIDED WITH VRDs TO PROTECT THE WELDER FROM

ELECTRICAL SHOCK.

Example of an external VRD that can be connected to an existing welding machine.

Example of internal VRD that can be retrofitted to an existing welding machine. New machines often have VRDs installed.

Confined space welding offers multiple hazards.

Task plans should include use of VRDs, emergency stops, dry insulation mats, etc.

Task plan failed to identify multiple hazards with this activity. Work was stopped.

Welder is not insulated from steel ground path.

Another good practice is to provide an emergency isolation switch near the weld site which will kill power should the need arise or when the welder, or others, get into any life-threatening situation. This is especially important where the welding machine is remote from the weld site.

Example of work condition that should employ use of VRDs. Include in Risk Assessments.

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Prepared by Thomas Van Hooser (CSP, CPEA, OHST, CHST). This bulletin was prepared for nonprofit, educational purposes only. Not responsible for wrong application of this information. Always comply with statutory, site specific safety procedures regarding overall welding safety. Personnel responsible for work site safety surveillance need to be alert for safe welding practices and to take immediate action with supervision to eliminate hazards and to give positive reinforcement for desired conditions and practices.

USEFUL REFERENCES ON THIS SUBJECT: https://view.officeapps.live.com/op/view.aspx?src=http%3A%2F%2Fwisha-training.lni.wa.gov%2Ftraining%2Fpresentations%2FErgo4Welders.ppt http://ielectricalsolutions.yolasite.com/resources/SDF-AS%201674.2%202007.pdf https://app.aws.org/technical/facts/Z49.1-2005-all.pdf http://safety.lincolnelectric.com/ https://www.lincolnelectric.com/assets/US/EN/literature/E205.pdf https://www.osha.gov/SLTC/weldingcuttingbrazing/ http://www.hse.gov.uk/welding/electrocution.htm https://www.labour.gov.hk/eng/public/os/C/arc_welding.pdf

Testing is required to identify leaks

NO

INSULATING THE WELDER FROM ELECTRICALLY CONDUCTIVE PATHS

21 Sept. ‘18

EXAMPLES OF POOR AND GOOD WELDER INSULATION PRACTICES:

NO! OK

CASE HISTORY: A welder, in direct contact with conductive metal parts and wearing poor attire and defective footwear, was pulling a live faulty welding cable over his shoulder and received a fatal shock. Welder not insulated from electrical ground path. Source: AS 1674.2 (excellent reference).

During the pre-work size up process, welders need to ensure that no part of their body is placed in a position that would complete a conductive path for the passage of electrical current.

As a precaution against electrical shock and electrocution, welders need to insulate themselves from electrical ground paths before welding takes place under the following conditions:

• Welding in damp/wet locations. • Welding inside metal confined spaces. • While positioned on the workpiece being welded.

Dry insulation mats (nonconductive material) must be provided between the welder and the conductive path. This will insulate and protect the welder from electrical incidents. The mat must be large enough to offer effective protection to the welder and the welder’s helper if exposed to the same hazard.

Note that a welder’s PPE is not specifically designed to prevent electric shock. It does, however, provide some protection. Electrical resistance of damp or contaminated clothing (including gloves) is reduced, making the risk of electrical shock possible.

Dry wood mat.

Proper attire (dry and in

good condition) helps to

protect the welder from

hot work debris and minimizes

contact with electrically conductive

paths.

A welders shoe. Danger!

OK

CASE HISTORY: While inside a metal confined space, a kneeling welder accidentally contacted his face with his live electrode causing current flow through his torso to knees and was electrocuted. The confined space was wet from recent rain water and welder was not insulated from conductive path. Source: AS 1674.2 (excellent reference).

Remember the 3 I’s of safety: INSPECT – INSPECT- INSPECT.

Workers are unsafely positioned on the

workpiece being welded.

Welder has properly positioned himself on a dry wooden mat.

How often is welder PPE inspected on your work site?

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Prepared by Thomas Van Hooser (CSP, CPEA, OHST, CHST). This bulletin was prepared for nonprofit, educational purposes only. Not responsible for wrong application of this information. Always comply with statutory, site specific safety procedures regarding prohibited uses of concrete reinforcing steel. Personnel responsible for work site safety surveillance need to be alert for rebar abuses and to take immediate action with supervision to eliminate the hazard. Field fabricated devices must be properly engineered meeting industry standards and approved by Project Management with documentation available on site.

DANGER

USEFUL REFERENCES ON THIS SUBJECT: https://files.asme.org/catalog/codes/printbook/31013.pdf https://cstools.asme.org/csconnect/CommitteePages.cfm?Committee=C44000000 https://sizes.com/materials/rebar.htm http://www.crsi.org/index.cfm/basics https://en.wikipedia.org/wiki/Rebar https://www.regulations.gov/contentStreamer?documentId=OSHA-2010-0058-0040&attachmentNumber=1&contentType=pdf http://www.crsi.org/index.cfm/basics/rebar-properties https://precast.org/2016/07/beginners-guide-lifting-devices/ https://precast.org/plant-resources/technical-services/precast-concrete-technical-faqs/ http://daytonsuperior.com/docs/default-source/handbooks/precast-handbook.pdf?sfvrsn=2ff1d560_168

Testing is required to identify leaks

NO

NON-STANDARD USE OF CONCRETE REINFORCING BARS (REBAR)

21 September ‘18

What are load capacities and safety factors of the above noted anchors/lifting

devices? Items were removed

from site and destroyed.

Concrete bucket

Rebar manbasket

Rebar tire cage

Rebar deadman anchor

Weld repair of rebar deadman anchor. 1st anchor broke under stress. Danger!

Rebar O-ring

Guy wire anchor

NO!

Such conditions dictate investigation into root causes and

follow-up corrective action.

Rebar deadman anchor

Pulley with welded rebar

anchor

Rebar is used to reinforce concrete by holding it together. Most grades of rebar are high tensile strength, brittle and can shatter under dynamic/shock loading conditions making its use questionable when used outside its intended purpose. Additionally, welding on rebar compounds safety concerns.

Rebar is not suitable and is not safe in the fabrication of tools/devices, lifting gear, deadman anchors, etc. Such devices must meet good engineering and quality practices and fabricated in accordance to relevant industry and statutory standards. Proper materials must be used, safety factors and safe working loads (SWL) established along with proof load testing, physical markings, user instructions and backup certification documentation.

Here are direct quotes from various industry standards relating to this subject:

• ANSI A10.9-1983 (Safety Requirements for Construction and Demolition Operations - Concrete and Masonry Work): “Section 3.5 Prohibited Uses of Reinforcing Steel: 3.5.1 Reinforcing steel shall not be used as guy attachment at deadmen anchorage points. 3.5.2 Reinforcing steel shall not be used as hooks or stirrups for scaffolding, nor shall it be used as a load bearing member of any lifting device”.

• OSHA - CFR 1926 Subpart Q – Appendix A: ANSI A10.9-1983 is an OSHA referenced consensus standard.

• ASME Standards: B30.20.2010 Below The Hook Lifting Devices, BTH-1-2011 Design Of Below The Hook Lifting Devices and ASME B107 Hand Tools & Accessories. Documents are available from ASME.

• Concrete Reinforcing Steel Institute (CRSI): OSHA Docket 2010-0058 (26 June 2012) Q21: “Rebar itself should never be used as a hook or loop or part of a rigging link. Only engineered products should be used for connecting cables or other bracing members”.

• US Dept of Interior - Bureau of Reclamation: Section 25.3.6 Health & Safety Standards: “Prohibited use: Do not use reinforcing steel as guy attachments at deadmen or other anchorage points for scaffolding hooks, for stirrups or as a load-bearing member of any lifting device”.

• National Precast Concrete Association (NPCA): “Use of rebar as lifting devices is not recommended. Properly engineered and fabricated lifting inserts shall be used in concrete works that have an adequate safety factor of four (4), SWL and certification markings. Lifting hardware shall be capable of supporting at least five (5) times the max load”.

DO NOT USE REBAR OUTSIDE ITS INTENDED PURPOSE IN REINFORCING CONCRETE!

Rebar used in makeshift rigging

Field fabricated tools do not meet material and quality standards. Not to be trusted. DANGER!

DO NOT USE MAKESHIFT DEVICES!

DA

NGE

R

s !

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Prepared by Thomas Van Hooser (CSP, CPEA, OHST, CHST). This bulletin was prepared for nonprofit, educational purposes only. Not responsible for wrong application of this information. Always comply with statutory and site-specific safety procedures regarding safe use of electrical appliances. Supervisors are required to ensure workers using electrical equipment and tools are qualified and that effective inspection and maintenance practices are in place. Field Safety Personnel verify compliance.

DANGER

USEFUL REFERENCES ON THIS SUBJECT: https://www.osha.gov/SLTC/etools/construction/electrical_incidents/ powertools.html http://www.oshatraining.com/cmsdocuments/OSHA_Training_Toolbox_ Talk_-_Basic_Electrical_Safety__–_Double_Insulated_Tools.pdf https://www.et.byu.edu/sites/default/files/electrical_grounding_0.pdf https://ourpastimes.com/how-do-double-insulated-tools-work-12346076.html https://www.dir.ca.gov/dosh/dosh_publications/Electrical_Safety.pdf https://www.manualslib.com/manual/48080/Dewalt-D28402.html https://www.ndltap.org/resources/safety/downloads/201007_PowerTools.pdf https://www.osha.gov/Publications/osha3007.pdf

Testing is required to identify leaks

NO

HAZARDS OF DOUBLE INSULATED ELECTRICAL TOOLS

3 October ‘18

Arrows show entry points (vents) where foreign material can enter and build up thereby creating hazards. Debris can also enter cracks in the insulation or loose screws/connections.

Metal fragments and other debris were found inside this double insulated grinder during maintenance. Manufacturers dictate periodic internal tool inspections. When was the last time your tool technician did an internal inspection?

Example of debris entering vents, cracks in the tool housing or from missing screws.

Tools and appliances manufactured with non-metallic (dielectric) cases are called double-insulated and can be identified by the double box symbol shown above. Double insulated electrical tools are designed so that the inner parts are isolated physically and electrically from the outer housing. Unlike metal case appliances, the National Electrical Code (NEC) does not require a grounding conductor.

Although general industry considers double insulated tools superior to metal case tools in preventing a shock, it is important for users to understand that shock hazards can still exist when using them.

HAZARDS & PRECAUTIONS OF USING DOUBLE INSULATED TOOLS & APPLIANCES:

• Inspect all tools and equipment before use and report defects to supervision for corrective action. Never use damaged or defective tools. Only trained persons are authorized to use power tools.

• Electrical tools must never be exposed to wet or damp conditions or used with wet hands. This borders on danger!

• Over time dirt/dust/lint/oil, metallic/conductive particles can enter the tool housing through the cooling vents, cracks in the casing or loose screws/connections. Such foreign material can lodge inside the tool thereby voiding the designed insulation properties.

• An electrically conductive path is created should water or liquid (including profuse perspiration) enter the vents and contact internal energized parts. Without a grounding conductor, the tool user would become a conductor of electricity and would receive a shock or be electrocuted if positioned against conductive object(s).

• Tool manufacturers specify weekly “blow outs” of air vents with clean, dry air by designated person(s).

• All electrical equipment used on construction sites must be protected by Ground Fault Circuit Interrupters (GFCI). This includes double insulated tools and appliances. GFCI’s also protect the user from damaged, frayed or broken cords.

• Always follow statutory requirements and manufacturer’s instructions for proper use, inspection, maintenance and storage of electrical tools and appliances.

TESTING DOUBLE INSULATED TOOLS: To check the insulation condition of double insulated tools, the designated competent person connects a megohmmeter between each power conductor and any exposed metal part of the tool. Resistance test results must be low – a few hundred ohms or less – which is normal. Never use tools that are damaged or with poor insulation properties.

Source: https://justalittlefurther.com/insulation-testing/

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Prepared by T. Van Hooser (CSP, CPEA, OHST, CHST). This bulletin was prepared for nonprofit, educational purposes only. Not responsible for wrong application of this information. Personnel who use load securing devices must be trained and qualified. This includes supervisors and those responsible for field safety surveillance.

DANGER

USEFUL REFERENCES ON THIS SUBJECT: https://www.youtube.com/watch?v=XGtOnLSG6cc https://www.thecrosbygroup.com/wp-content/uploads/2014/03/264.pdf https://www.osha.gov/pls/imis/AccidentSearch.search?acc_keyword= %22Load%20Binder%22&keyword_list=on https://www.wstda.com/products/standards.cfm https://www.ntc.gov.au/heavy-vehicles/safety/load-restraint-guide/ https://www.ntc.gov.au/Media/Reports/(E62BE286-4870-ED95-1914- 1A70F3250782).pdf https://www.nrspp.org.au/resources/load-restraint-guide-2018/ https://www.worksafenb.ca/docs/HA_Load-Binder-Safety.pdf https://www.worksafe.qld.gov.au/forms-and-resources/films/safely -securing-loads-of-trucks

Testing is required to identify leaks

HAZARDS OF LEVER OPERATED CHAIN LOAD BINDERS

16 October ‘18

NO

Experienced construction personnel are all too familiar with serious injuries caused by Lever Operated Chain Load Binders. These types of binders are used to secure cargo to transport vehicles. These type binders are under significant stress when engaged. When the lever is released, there is a tremendous uncontrolled release of stored energy.

These types of binders are often improperly used by inexperienced and untrained personnel by positioning themselves in the LINE-OF-FIRE when the lever is released. Common injuries include MSD’s, fractures (face, teeth, hands and arms), or other serious injuries. Near misses often go unreported.

IMPORTANT PRECAUTIONS FOR USING LEVER OPERATED CHAIN LOAD BINDERS:

• Operate per statutory requirements, manufacturer’s instructions and site procedures.

• Users must be trained and authorized. Wear proper PPE to include gloves, safety glasses and hard hats. Users must also conduct a pre-use inspection to identify defects.

• Operate binders while on the ground. Make certain footing is secure. The lever must always be pressed downward.

• Never use a cheater pipe (handle extender) to increase leverage while tightening chain. The binder is overloaded if more than one person operates the lever. Additionally, the pipe could fly off the handle when the lever is released.

• Binders must be equal to or greater than the working loads of cargo chain and other cargo securing hardware.

• To prevent lever disengagement during travel, wrap the loose end of the chain around the lever or tie wire around both the chain and lever. A lock-out device is preferred and will eliminate the potential danger of loos cargo. This practice is often overlooked by operators.

• Be aware, when releasing the binder, of the potential of uncontrolled energy from the stretched chain. The lever must be released using a steel pry bar under the lever pressing upward or by using the open hand under the lever and push upward. All personnel in the immediate area must keep out of the line-of-fire from the moving handle.

• Use ratchet type binders for overall safer operations.

NO

CHEATER PIPE: Use of cheater pipes can overstress the binder and chain. Never use them!

LEVER OPERATED LOAD BINDER. These types of binders are often improperly used resulting in serious injuries and near misses. Persons do not know how to use them or are unaware of their hazards. Use with caution!

RATCHET LOAD BINDER. These types of binders are preferred and are safer than lever operated binders. OK

DANGER

Certifying agencies require Safe Working Load (SWL) markings on binders along with the manufacturer’s name and a serial number. The SWL must never be exceeded. Binders must be compatible with, or exceed, the working load of chain and other hardware that secures cargo. If the weakest link fails the cargo will shift creating multiple transport and road hazards.

Always follow the manufacturer’s instructions on safe and proper use of the binder.

Compliances to user instructions are mandatory. Additionally, all binders must be inspected by a designated competent person(s) on a periodic basis to confirm safe condition, proper use, trained personnel and maintenance routines. Pre-use inspection by users are required to identify defects.

NEVER USE DEFECTIVE EQUIPMENT!

x

Use a lock-out device to secure chain to the lever or wrap a wire around the chain and lever. This will prevent accidental disengagement of the lever and subsequent cargo shifts. Danger!

TEACH – DON’T PREACH!

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Prepared by T. Van Hooser (CSP, CPEA, OHST, CHST). This bulletin was prepared for nonprofit, educational purposes only. Not responsible for wrong application of this information. Always comply with statutory, manufacturer, and site safety procedures on proper design and application of wheel blocks. Persons responsible for safety surveillance must be knowledgeable of wheel blocking requirements and take immediate corrective actions on unsafe observations.

DANGER

USEFUL REFERENCES ON THIS SUBJECT: https://www.sae.org/standards/content/j348_199006/ https://itstillruns.com/size-wheel-chocks-7316911.html https://www.cldhandlingsystems.com/how-to-choose-the-right-size-wheel-chocks.html https://checkers-safety.com/wp-content/uploads/2017/08/Wheel-Chock- Guidelines-8-pg_web.pdf https://www.beacontechnology.com/PDF/OSHA_WHEEL-CHOCKS.pdf https://en.wikipedia.org/wiki/Wheel_chock#How_to_use_wheel_chocks

Testing is required to identify leaks

SIZING OF WHEEL CHOCK BLOCKS

29 October ‘18

NO

These photographs show improvised wheel chock block conditions and poor practices common to many construction sites, world-wide. Such conditions reflect a lack of knowledge of wheel block design, improper usage, and lack of hazard identification skills.

Worker

Chock blocks are necessary to immobilize construction equipment from rolling when the operator is not at the controls. Operators are required to shut down equipment and engage the parking brake before leaving their equipment. Brakes, however, can fail and operators can make mistakes. Serious accidents can be expected when wheel blocking requirements are poorly written or do not exist.

CONDITIONS WHEN CHOCK BLOCKS ARE NECESSARY TO PREVENT WHEEL MOVEMENT:

• When required by project procedures, statutory requirements, and by equipment manufacturer specifications. Note: JSAs must address wheel blocking for equipment operations.

• When parked on poor or unlevel ground surfaces. • When equipment is being serviced, cleaned, repaired, or

inspected. • When material is being loaded or unloaded. • Emergency situations or conditions that require blocking. • When common sense dictates.

It is common to see improvised, undersized, and poor-quality wheel blocks on construction sites. Rocks, dunnage, soft wood, etc., are often used to block wheels from rolling. Use of such materials reflect a lack of management control over equipment safeguards and lack of knowledge on wheel blocking. This is especially true relating to the sizing of blocks.

According to wheel block manufacturers, the size of the tire is the basic “rule of thumb” for determining the correct size chock block. The size of the block should be a minimum of ¼ of the tire’s height (see example below). The angled face of the block is approximately 45 degrees or as specified by the equipment manufacturer or the Designated Competent Person based on tire diameter.

Energy Isolation Procedures and Equipment Operating Procedures must be clear on use of wheel chock blocks along with specifications for field fabrication.

x

x

x

The width of blocks should measure ¾ width of the tire or greater. Height of block is ¼ the wheel height. Source: Monster Motion Safety – Wheel Chock Guidelines.

Proper design and sizing of wheel blocks will prevent truck movement and eliminate incidents.

OK

EXAMPLE: WHEEL DIAMETER ÷ 4 = MINIMUM EFFECTIVE HEIGHT OF THE WHEEL BLOCK. Note: The design and manufacture of wheel blocks should comply with Society of Automotive Engineers Standard SAE J348 (Wheel Chocks). The Project Engineer and/or the designated Competent Person (CP), must also consult the equipment manufacture on specific block sizing. Hardwood should be used when fabricating wooden blocks after review of equipment weight and wood compression data. Brightly colored blocks will increase visibility. Attach a rope to the block to facilitate handling and for proper stowage on the rig. Always use chock blocks in pairs.

Example of improper sizing of wheel block compared to the size of the wheel. The block is also soft wood. This block is ineffective in preventing any significant movement of the equipment.

DANGER!

Note: All unsafe conditions and practices were corrected by the observer at time of inspection.

EXAMPLE

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Prepared by T. Van Hooser (CSP, CPEA, OHST, CHST). This bulletin was prepared for nonprofit, educational purposes only. Not responsible for wrong application of this information. Always comply with statutory, manufacturer, and site safety requirements. Supervision and persons responsible for safety and health surveillance must be knowledgeable of this subject and spot check welding activity for overall compliance to safe work conditions and practices.

USEFUL REFERENCES ON THIS SUBJECT: http://buildingsaferinri.org/wp-content/uploads/2016/04/ANSI.Z87.1.2003.pdf https://app.aws.org/technical/AWS_Z49.pdf https://webstore.ansi.org/Standards/ISEA/ANSIISEAZ872015 https://en.wikipedia.org/wiki/Welding_helmet http://www.weldinghelmetgenius.com/making-your-welding-helmet-last-longer-care-tips/ https://iwws.net/files/literature_flyers/wh8912_jasic_helmet_manual.pdf

THE WELDER’S MASK “BACK-PLATE” AND MASK INSPECTIONS

1 November ‘18

During a past field survey on an international construction project, two welders were found with a glass “back plate” in their masks. Although both were wearing safety glasses under their masks both welders were not aware that a safety lens was also required at the window closet to their eyes.

DANGER!

The lens closest to the welder’s eyes must meet Z87 Standards.

PLANE GLASS

NOTE: Welders are also required to wear Z87 safety glasses with side shields under their welding masks.

x

The survey revealed similar concerns, site-wide. Several experienced welders said the plastic lens scratches too easily and takes too much time to replace. The majority of welders, helpers and field safety personnel were not aware of the requirement. The survey also revealed that spare safety lenses were not provided in stores. Immediate corrective action was taken with management, along with JSA modifications, store surveys, discussions during safety meetings and emphasis during pre-work/job start talks.

The following standards require a safety “back-plate” on the welding mask’s WINDOW closest to the welder’s eyes.

• OSHA 29 CFR 1926.102 (Eye and Face Protection) • OSHA/ANSI Standard Z49.1 (Safety in Welding & Cutting) • OSHA/ANSI Z87.1 (Eye/Face Protection Standards) • EN or UK Standards relating to welding/cutting and PPE • MANUFACTURER’S User Manual and Warning Labels

This precaution is necessary to protect the welder’s eyes from impact hazards when the window is raised during work. A polycarbonate lens is normally used to meet the requirement. The back-plate safety lens requirement is not well known or is often overlooked in construction, especially international locations.

ADDITIONAL INFORMATION RELATING TO WELDING MASKS AND THE REQUIRED PRE-USE INSPECTION:

• Welders are also required to wear approved safety glasses with side shields under the hood as an additional safeguard against impact hazards.

• The safety back-plate and safety glasses are required to meet ANSI Z87.1 standards or international equivalent.

• Unless otherwise approved, welding masks do not provide sufficient protection from impact hazards such as exploding grinding wheels. Welding masks should not be used for grinding unless so designed.

• Welding masks and lenses must be physically marked to the standard to which it is compliant. Never use non-standard, unapproved equipment.

• Compliance to manufacturer user information is mandatory. The user’s manual will provide important information on proper use, care, storage, and cleaning instructions.

• Ensure all lenses are the proper shade and are clean and free of scratches, cracks and distortion. Clean lenses with soft tissues.

• Before welding, hold the mask up to a light source and check for cracks or other defects that will defeat the mask’s opaque properties. UV and IR light are very hazardous to the eyes and skin.

• Check the mask’s suspension system for damage or deterioration. Periodically changeout and/or clean the suspension system. Frequently clean the inside of the mask with mild soap and water to prevent the growth of bacteria.

• Helpers must wear the same protection as the welder. d l f l

Hand held face masks are for use by supervisors and inspectors to check on work. These types of masks must also meet the required standards. x This subject is a good audit item for all projects.

TEACH – DON’T PREACH!

!

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Prepared by T. Van Hooser (CSP, CPEA, OHST, CHST). This bulletin was prepared for nonprofit, educational purposes only. Not responsible for wrong application of the information. Always comply with statutory, manufacturer, and site safety requirements on mobile equipment inspections and maintenance. Supervision, and persons responsible for safety surveillance are responsible for checking field conditions to ensure that good industry practices are being complied with. Management must ensure that viable inspection and audit systems are in place to identify and correct unsafe conditions and practices.

IMPORTANT AND USEFUL REFERENCES:

https://www.fifthwheel.com/pdfs/literature/LT-149_UltraLTInstructions.pdf https://www.youtube.com/watch?v=VPJ1biinnx8 https://www.youtube.com/watch?v=DqUPZTifQ7M https://www.youtube.com/watch?v=NEDf0H86RT0 https://en.wikipedia.org/wiki/Fifth-wheel_coupling https://www.arkansastrucking.com/images/ATA_Presentation_-_SAF.pdf https://www.jostinternational.com/wp-content/uploads/2016/10/LT-SK37U-01-Installation-37U-5th-Wheel.pdf http://proceedings.asmedigitalcollection.asme.org/proceeding.aspx?articleID=1727310 https://www.overdriveonline.com/how-to-maintain-a-fifth-wheel/

INSPECTING THE 5thWHEEL ASSEMBLY 19 November ‘18

PHOTOS SHOW COMMON UNSAFE CONDITIONS WITH 5thWHEEL ASSEMBLIES WHERE POOR INSPECTION AND MAINTENANCE PROGRAMS

ARE ALLOWED TO EXIST:

Grease and grime accumulation hides defects and are clear evidence of no or poor operator daily inspections and poor maintenance. practices.

Audits of heavy equipment maintenance programs revealed no or poor 5thWheel lock testing program and no test devices on site.

Lack of proper Truck 5thWheel and Trailer Kingpin inspections may lead to serious road accidents should the 5thWheel assembly fail.

The author of this document has completed numerous inspections and formal audits of construction equipment worldwide. Although overall inspections revealed satisfactory conditions with trucks and trailers there was a general lack of inspection and maintenance of the 5thWheel Assembly, to include Kingpins.

These photographs show common types of hazardous conditions found during these inspections. Lower tier subcontractors accounted for many of the deficiencies.

Lack of inspection and poor maintenance of the 5thWheel assembly can result in serious road accidents should the truck separate from trailer. DANGER!

HERE ARE SUGGESTED AUDIT ITEMS TO HELP IDENTIFY ROOT CAUSES OF POOR INSPECTION

AND MAINTENANCE PRACTICES:

Manufacturer’s manuals available at the equipment’s service facility. Confirm if a site-specific Equipment Inspection and Maintenance Procedure is in place and includes 5thWheel and Kingpin inspection/maintenance/testing. Perform random field inspections to verify requirements. Preventative Maintenance (PM) schedules are prepared and are compatible with the manufacturer’s schedule. Confirm if PM is actually being performed and confirm if the record keeping system is up-to-date and valid. Job Safety Analysis (JSA) is prepared and includes pre-use inspection requirements, operating protocols, etc. Regular discussion of topic at Tool Box Safety Meetings.

Conduct random inspection of equipment. Record deficiency and check item(s) against daily checklist and PM records. Question equipment operators and confirm their knowledge of the scope of pre-use inspections, hazards, safe operating practices, etc. Arrange re-training as necessary. Question Field Safety Inspectors and confirm if they randomly check 5thWheel assemblies along with the operator. Arrange re-training as necessary. Observe equipment operators and confirm proper completion of the pre-use inspection using a daily checklist. Confirm if the checklist includes the 5thWheel assembly.

Verify availability of lock test device(s), Kingpin gage(s), calibrated torque wrench(s), spare parts, etc.

Note: When conducting inspections and audits always ensure the report includes positive items as well as the items that need improvement. Render positive reinforcement to equipment operators and others for exhibiting desired performance.

Manufacturer’s schematic showing proper bolting of

5thWheel assembly to truck frame.

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5thWHEEL ASSEMBLY

Lock tester

Field inspections revealed multiple observations of poor to no operator inspections and inadequate maintenance programs. Numerous observations of loose or missing nuts/washers, damaged bolts, wrong grade bolts, broken welds, no proper torqueing of bolts, and improper bolt positioning.

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CONST

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Prepared by T. Van Hooser (CSP, CPEA, OHST, CHST). This bulletin was prepared for nonprofit, educational purposes only. Not responsible for wrong application of the information. Always comply with statutory, manufacturer, and site safety requirements regarding temporary electrical conditions on construction sites. Supervision, and persons responsible for safety surveillance are responsible for checking field conditions to ensure that good industry practices and work site requirements are being complied with. Management must ensure that viable inspection and audit systems are in place to identify and correct unsafe conditions and practices.

IMPORTANT AND USEFUL REFERENCES:

https://www.osha.gov/laws-regs/regulations/standardnumber/1926/1926.405 https://www.ecmweb.com/code-basics/making-temporary-installations-safe-all-trades https://community.nfpa.org/thread/36917 https://www.mikeholt.com/newsletters.php?action=display&letterID=1805 https://nebraskaneca.files.wordpress.com/2014/06/wiringpractices.pdf

SUSPENDING TEMPORARY ELECTRICAL CORDS & CABLES IN THE

VERTICAL POSITION 30 November ‘18

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It is common to see long vertical runs of self-supporting temporary electrical cords and cables on construction sites. This is especially common within industrial and high-rise facilities. The practice is not safe.

Here is important safety information on this subject:

• Electrical cords and cables are not designed to be self-supporting.

• OSHA/National Electrical Code requires proper supporting of electrical cabling described in CFR 1926.405 Subpart K (Electrical) and NEC Article 590 (Temporary Installations). Article 590 (J) presents clear details on cord support, cable assemblies, flexible cords and cables.

• Long, unsupported vertical runs of cords and cables can stretch conductors and insulation due to the weight of the cable. Stretching will damage insulation, elongate and heat up conductors.

• Weight of cabling will cause damage to insulation and expose bare conductors at unprotected termination points. Such conditions will create an electrical hazard to personnel and create stray current that may damage equipment or start a fire.

• Unsupported cords/cables will place strain on plugs and connectors resulting in their disconnection and subsequent falls form height.

• Designated Electrical Competent Persons (CPs) must review all arrangements and conduct regular field inspections to verify safe conditions and practices. Supervisors and field safety personnel must confirm inspection quality via frequent, random inspections.

welding cables routed from ground power sources up to construction work areas. Long vertical runs of self-supporting cords and cables can stretch conductors and insulation creating hazards.

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SUGGESTED METHOD TO SAFELY SUSPEND LONG RUNS OF TEMPORARY CORDS USING

VERTICAL ROPES:

UV resistant fiber rope or wire cable (ropes of adequate capacity).

UV resistant cable ties (tie wraps) positioned no greater than 10 feet apart or as specified by a Competent Person.

Welding cable connector or approved weatherproof cord connector. Strain must be relieved to prevent connector separation.

Safely secure the top end of rope to a solid anchor point using a shackle or other means approved by a Competent Person (CP).

At top end of the rope, route cords and cables horizontally to work area(s) using S Hooks. This

will keep foot paths clear and will protect the cables from damage.

Low voltage temporary electrical cord or welding cable.

Note 1: The Designated Competent Person (CP) will need to inspect overall conditions on a frequent basis and record inspection results. Users must make a pre-use inspection to verify safe conditions. Note 2: This arrangement could also be used to support long runs of horizontal cabling. Note 3: Job Safety Analysis (JSAs) should identify and address this hazard.

Bottom end of rope is placed at or near the power source.

Electrical cords must be under GFCI protection.

POWER SOURCE

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Example of temporary electrical cords and