Occupational Health and Safety Management System

                                          Crane Hazards 

Major Causes of Crane Accidents

•         Contact with power lines

•          Overturns

•          Falls

•          Mechanical failures

How Do Accidents Occur?

•         Instability – unsecured load, load capacity exceeded, or ground not level or too soft

•         Lack of communication - the point of operation is a distance from the crane operator or not in full view of the operator

•         Lack of training

•         Inadequate maintenance or inspection

Who is at Risk

•         Operators

•         Persons at Crane Site

Definitions

•         Crane – Consists of a rotating structure for lifting and lowering horizontally on rubber tires or crawler treads

•         Hoist - Used to lift and lower load.

•         Boom – An inclined spar, strut, or other long member supporting the hoisting tackle

•         Boom stops – A device used to limit the angle of the boom at its highest position

•         Brake – To slow or stop motion by friction or power

•         Block – Sheaves or grooved pulleys in a frame with hook, eye and strap

•         Jib – Extension attached to the boom point to provide added boom length for lifting specified loads.

Types of Cranes

•         Mobile

•         Hydraulic

•         Overhead

•         Gantry

•         Tower

Crane Hazards

•         Improper load rating •         Excessive speeds •         No hand signals •         Inadequate inspection and maintenance •         Unguarded parts •        Unguarded swing radius

•         Working too close to power lines •         Improper exhaust system •         Shattered windows •         No steps/guardrails walkways •         No boom angle indicator •         Not using outriggers

Planning Before Start-Up

•         Level the crane and ensure support surface is firm and able to support the load

•         Contact power line owners and determine precautions. Know the location and voltage of overhead power lines.

•         Know the basic crane capacities, limitations, and job site restrictions, such as the location of power lines, unstable soil, or high winds.

•         Make other personnel aware of hoisting activities.

•         Barricade areas within swing radius.

•         Ensure proper maintenance and inspections.

•         Determine safe areas  to store materials and place machinery.

Competent Person

The competent person must inspect all machinery and equipment prior to each use, and during use, to make sure it is in safe operating condition.  

If it needs fixing, take it out of service and don’t use it until it is fixed

Load Capacity - Speed – Warnings

•         Make sure the crane operator can see the:

•          

Ø   Rated Load Capacities

Ø   Operating Speeds

Ø   Special Hazard      Warning or Instruction

Know the Weight of the Load

•         Refer to shipping ticket or other documentation

•         Ensure lift calculations are correct

•         Ensure load is within load chart rating for boom length and load radius of crane

•         Crane is rated by the maximum weight it will lift at a minimum radius and minimum boom length – the further from its center point, the less it will lift

Load Limiting Factors

•         Not level

•         Wind

•         Side loads

•         On its wheels

•         Lifting over the side

•         Use of extensions, jibs and other attachments

•         Limits of wire rope, slings and lifting devices

Mobile Cranes – Lifting Principles

•         Center of Gravity

•         Leverage

•         Stability

•         Structural Integrity

Load Example – 30 ton crane

•         Will lift 60,000 pounds at 10 feet from the center pin of the crane

•         Based on level surface, no wind, and outriggers fully extended

•         At 25 feet from the center pin with an 80 foot boom, the capacity is only 14,950 pounds

•         At 74 feet from the center pin, the capacity is only 4,800 pounds

Annual Inspections

Inspection of the hoisting machinery must be made by a competent person

The employer must maintain a record of these inspections

What to Inspect

•         Correct air pressure and no leaks

•         Tires properly inflated

•         Clearance for tail swing

•         Wire rope wear

•         Physical damage to crane

•         Loose or missing hardware, nuts, or bolts

•         Fluid leaks

Training

•         Operators:

Ø  must qualify on specific crane type

Ø  Must include on-the-job training

•         Supervisor / competent person

Summary

•         An unstable load, lack of communication, lack of training, and inadequate maintenance or inspection is major contributors to crane accidents.

•          Operators or others working in the area can be victims to “struck by" and "caught in" injuries.

•          Contact with power lines causes many accidents.

•          A competent person must inspect a crane regularly to insure it is in proper order.

 Planning and training reduces accidents.

                               Managing Mobile Crane Hazards

This presentation is recommended for the site supervisor or safety person. Workers around cranes – laborers, carpenters, supervisors – are at more risk than crane operators are for deaths or injuries. Whether you are a crane rental service, a general contractor, or a company whose employees sometimes work around cranes, you have responsibilities. Critical topics include selection of a crane, daily inspections, communication between site management and the crane operator, and supervision of the crane operator. Also covered are basic crane components and their functions, hazards associated with crane operations, and regulations that address the hazards.

Introduction

Key Concepts:

n  Causes of crane related injuries.

n  Crane related incident facts.

n  Occupational Safety and Health Administration (OSHA).

n  Industry consensus standards for mobile cranes.

n  Mobile crane operations and responsibilities.

                           Crane-Related Injuries

n  Electrocution from contacting overhead power lines.

n  Caught-in, compressed or crushed in rotating or moving parts and/or the swinging superstructure of the crane.

n  Struck by an object, such as a falling, failing or swinging load.

Crane Incident Facts

n  At least one crane incident has occurred in each month in1997- 1999.

n  Deaths to workers not operating cranes exceeded crane operator fatalities by 12 to 1.

n  Non-fatal injuries to non-crane operator exceeded non-fatal injuries to crane operators by 79 to 23

Mobile Crane Operations and Responsibilities

n  Crane Owner (Construction company)

n  Crane Operator

n  Site Supervision

                 

Crane Owner Responsibilities

                       

Include, but are not limited to:

n  Ensure that the entire crew is well trained, experienced and competent to operate the particular crane and all related functions.

n  Ensure proper maintenance of the crane.

n  Ensure that site supervision is aware of their responsibilities and in particular what work must be done to prepare the site for the crane operation.

Crane Operator Responsibilities

  

Include, but are not limited to:

n  Be totally familiar with load charts and all crane functions listed in the operator’s manual.

n  Know all applicable regulations for crane operations.

n  Inspecting and maintaining the crane regularly.

n  Check site conditions and coordinate all activities with site supervision.

Site Supervision Responsibilities

Include, but are not limited to:

n  Providing a well prepared working area for the crane before it arrives on the job.

n  Determine the correct load weight and radius and informing the operator (site supervision should know the maximum radius, load weight and lift height of each “pick” before ordering the crane).

n  Ensure that all personnel involved in the operation understand their jobs, responsibilities and absolute necessity for 100% safety.

Learning Opportunity

1.   The majority of crane related incidents and injuries involve these three (3) things:

2.   What two (2) consensus standards are important resources for the safe operation of cranes and the use of rigging devices?

3.   What are (2) responsibilities for each of the following:

u Crane Owner

u Crane Operator

u Site Supervisor

Electrical Safety - Construction

Electricity – How it Works

•         Electricity is the flow of energy from one place to another

•         Requires a source of power: usually a generating station

•         A flow of electrons (current) travels through a conductor

•         Travels in a closed circuit

Electrical Terms

•         Current -- electrical movement (measured in amps)

•         Circuit -- complete path of the current. Includes electricity source, a conductor, and the output device or load (such as a lamp, tool, or heater)

•         Resistance -- restriction to electrical flow

•         Conductors – substances, like metals, with little resistance to electricity that allow electricity to flow

•         Grounding – a conductive connection to the earth which acts as a protective measure

•         Insulators -- substances with high resistance to electricity like glass, porcelain, plastic, and dry wood that prevent electricity from getting to unwanted areas

Electrical Injuries

There are four main types of electrical injuries:

•         Direct:

Ø Electrocution or death due to electrical shock

Ø Electrical shock

Ø Burns

•         Indirect - Falls

Electrical Shock

An electrical shock is received when electrical current passes through the body.

You will get an electrical shock if a part of your body completes an electrical circuit by…

•         Touching a live wire and an electrical ground, or

•         Touching a live wire and another wire at a different voltage.

Shock Severity

•         Severity of the shock depends on:

Ø Path of current through the body

Ø Amount of current flowing through the body (amps)

Ø Duration of the shocking current through the body,

•         LOW VOLTAGE DOES NOT MEAN LOW HAZARD

Dangers of Electrical Shock

•         Currents above 10 mA* can paralyze or “freeze” muscles.

•         Currents more than 75 mA can cause a rapid, ineffective heartbeat -- death will occur in a few minutes unless a defibrillator is used

•         75 mA is not much current – a small power drill uses 30 times as much

* mA = milliampere = 1/1,000 of an ampere

Burns

•         Most common shock-related injury

•         Occurs when you touch electrical wiring or equipment that is improperly used or maintained

•         Typically occurs on hands

•         Very serious injury that needs  immediate attention

Falls

•         Electric shock can also cause indirect injuries 

•         Workers in elevated locations who experience a shock may fall, resulting in serious injury or death

Electrical Hazards and How to Control Them

        Electrical accidents are caused by a combination of three factors:

Ø Unsafe equipment and/or installation,

Ø Workplaces made unsafe by the environment, and

Ø Unsafe work practices.

Control – Close Openings

•         Junction boxes, pull boxes and fittings must have approved covers

•         Unused openings in cabinets, boxes and fittings must be closed (no missing knockouts)

Hazard - Overhead Power Lines

•         Usually not insulated

•         Examples of equipment that can contact power lines:

Ø  Crane

Ø  Ladder

Ø  Scaffold

Ø  Backhoe

Ø  Scissors lift

Ø  Raised dump truck bed

Ø  Aluminum paint roller

Control - Overhead Power Lines

•         Stay at least 10 feet away

•         Post warning signs

•         Assume that lines are energized

•         Use wood or fiberglass ladders, not metal

•         Power line workers need     special training & PPE

Hazard - Inadequate Wiring

•         Hazard - wire too small for the  current

•         Example - portable tool with an extension cord that has a wire too small for the tool

Ø The tool will draw more current than the cord can handle, causing overheating and a possible fire without tripping the circuit breaker

Ø The circuit breaker could be the right size for the circuit but not for the smaller-wire extension cord

Control – Use the Correct Wire

•         Wire used depends on operation, building materials, electrical load, and environmental factors

•         Use fixed cords rather than flexible cords

•         Use the correct extension cord

Hazard – Defective Cords & Wires

•         Plastic or rubber covering is missing

•         Damaged extension cords & tools

Hazard – Damaged Cords

•         Cords can be damaged by:

Ø Aging

Ø Door or window edges

Ø Staples or fastenings

Ø Abrasion from adjacent materials

Ø Activity in the area

•         Improper use can cause shocks, burns or fire

Control – Cords & Wires

•         Insulate live wires 

•         Check before use

•         Use only cords that are 3-wire type

•         Use only cords marked for hard or extra-hard usage

•         Use only cords, connection devices, and fittings equipped with strain relief

•         Remove cords by pulling on the plugs, not the cords

•         Cords not marked for hard or extra-hard use, or which have been modified, must be taken out of service immediately

Permissible Use of Flexible Cords

DO NOT use flexible wiring where frequent inspection would be difficult or where damage would be likely. 

Flexible cords must not be . . .

•          run through holes in walls, ceilings, or floors;

•          run through doorways, windows, or similar openings (unless physically protected);

•          Hidden in walls, ceilings, floors, conduit or other raceways.

Grounding

    Grounding creates a low-resistance path from a tool to the earth to disperse unwanted current. 

   

    When a short or lightning occurs, energy flows to the ground, protecting you from electrical shock, injury and death.

Hazard – Improper Grounding

•         Tools plugged into improperly grounded circuits may become energized

•         Broken wire or plug on extension cord

•         Some of the most frequently violated OSHA standards

Control – Ground Tools & Equipment

•         Ground power supply systems, electrical circuits, and electrical equipment

•         Frequently inspect electrical systems to insure path to ground is continuous

•         Inspect electrical equipment before use

•         Don’t remove ground prongs from tools or extension cords

•         Ground exposed metal parts of equipment

Control – Use GFCI (ground-fault circuit interrupter)

•         Protects you from shock

•         Detects difference in current between the black and white wires

•         If ground fault detected, GFCI shuts off electricity in 1/40th of a  second

•         Use GFCI’s on all 120-volt, single-phase, 15- and 20-ampere receptacles, or have an assured equipment grounding conductor program. 

Control - Assured Equipment Grounding Conductor Program

Program must cover:

Ø All cord sets

Ø Receptacles not part of a building or structure

Ø Equipment connected by plug and cord

Program requirements include:

Ø Specific procedures adopted by the employer

Ø Competent person to implement the program

Ø Visual inspection for damage of equipment connected by cord and plug

Hazard – Overloaded Circuits

Hazards may result from:

•         Too many devices plugged into a circuit, causing heated  wires and possibly a fire

•         Damaged tools overheating

•         Lack of over current  protection

•         Wire insulation melting, which may cause arcing and a fire in the area where the overload exists, even inside a wall

Control - Electrical Protective Devices

•         Automatically opens circuit if excess current from overload or ground-fault is detected – shutting off electricity

•         Includes GFCI’s, fuses, and circuit breakers

•         Fuses and circuit breakers are over current devices. When too much current:

Ø  Fuses melt

Ø  Circuit breakers trip open

Power Tool Requirements

•         Have a three-wire cord with ground plugged into a grounded receptacle, or

•         Be double insulated, or

•         Be powered by a low-voltage isolation transformer

Tool Safety Tips

•         Use gloves and appropriate footwear

•         Store in dry place when not using

•         Don’t use in wet/damp conditions

•         Keep working areas well lit

•         Ensure not a tripping hazard

•         Don’t carry a tool by the cord

•         Don’t yank the cord to disconnect it

•         Keep cords away from heat, oil, & sharp edges

•         Disconnect when not in use and when changing accessories such as blades & bits

•         Remove damaged tools from use

Preventing Electrical Hazards - Tools

•         Inspect tools before use

•         Use the right tool correctly

•         Protect your tools

•         Use double insulated tools

Clues that Electrical Hazards Exist 

•         Tripped circuit breakers or blown fuses

•         Warm tools, wires, cords, connections, or junction boxes

•         GFCI that shuts off a circuit

•         Worn or frayed insulation around wire or connection

Lockout and Tagging of Circuits

•         Apply locks to power source after de-energizing

•         Tag deactivated controls

•         Tag de-energized equipment and circuits at all points where they can be energized

•         Tags must identify equipment or circuits being worked on

Safety-Related Work Practices

To protect workers from electrical shock:

Ø Use barriers and guards to prevent passage through areas of exposed energized equipment

Ø Pre-plan work, post hazard warnings and use protective measures

Ø  Keep working spaces and walkways clear of cords

Safety-Related Work Practices

•         Use special insulated tools when working on fuses with energized terminals

•         Don’t use worn or frayed cords and cables

•         Don’t fasten extension cords with staples, hang from nails, or suspend by wire.

Preventing Electrical Hazards – Planning

•         Plan your work with others

•         Plan to avoid falls

•         Plan to lock-out and tag-out equipment

•         Remove jewelry

•         Avoid wet conditions and overhead power lines

Avoid Wet Conditions

•         If you touch a live wire or other electrical component while standing in even a small puddle of water you’ll get a shock. 

•         Damaged insulation, equipment, or tools can expose you to live electrical parts.

•         Improperly grounded metal switch plates & ceiling lights are especially hazardous in wet conditions.

•         Wet clothing, high humidity, and perspiration increase your chances of being electrocuted.

Preventing Electrical Hazards – PPE

•         Proper foot protection (not tennis shoes)

•         Rubber insulating gloves, hoods, sleeves, matting, and blankets

•         Hard hat (insulated - nonconductive)

Preventing Electrical Hazards – Proper Wiring and Connectors

•         Use and test GFCI’s

•         Check switches and insulation

•         Use three prong plugs

•         Use extension cords only when necessary & assure in proper condition and right type for job

•         Use correct connectors

Training

Train employees working with electric equipment in safe work practices, including:

•         Reenergize electric equipment before inspecting or repairing

•         Using cords, cables, and electric tools that are in good repair

•         Lockout / Tag out recognition and procedures

•         Use appropriate protective equipment

Summary – Hazards & Protections

Hazards	Protective Measures
•         Inadequate wiring •         Exposed electrical parts •         Wires with bad insulation •         Ungrounded electrical systems and tools •         Overloaded circuits •         Damaged power tools and equipment •         Using the wrong PPE and tools •         Overhead powerlines •         All hazards are made worse in wet conditions	•         Proper grounding •         Use GFCI’s •         Use fuses and circuit breakers •         Guard live parts •         Lockout/Tagout •         Proper use of flexible cords •         Close electric panels •         Training

Summary

Electrical equipment must be:

Ø  Listed and labeled

Ø  Free from hazards

Ø   Used in the proper manner

Ø   

If you use electrical tools you must be:

Ø  Protected from electrical shock

 Provided necessary safety equipment

Fall Protection

Falls in Construction

·        Falls are the leading cause of deaths in the construction industry.

·        Most fatalities occur when employees fall from open-sided floors and through floor openings.

·        Falls from as little as 4 to 6 feet can cause serious lost-time accidents and sometimes death.

• Open-sided floors and platforms 6 feet or more in height must be guarded.  

Fall Protection

This presentation will discuss:

•         The working conditions that prompt use of fall protection

•         Options that are available to protect workers from falls

At the end of this topic, you will be able to:

•         List at least four methods of fall protection available for protecting workers

•         State the main criteria that prompts use of fall protection for construction workers

Fall Protection Options

·       Personal Fall Arrest System (PFAS)

·       Guardrails

·       Safety Net

Personal Fall Arrest Systems

•         You must be trained how to properly use PFAS.

•          PFAS = anchorage, lifeline and body harness.

1.   Safety Line Anchorages Must be independent of any platform anchorage and  capable of supporting at least 5,000 lbs. per worker

2.   Guardrails :- Top rails between 39 and 45 inches tall

Toeboards at least 3 1/2 inches high

•          Top Rail

•         Mid- Rail

•         Toe board

3.  Safety Nets

Place as close as possible, but no more than 30 feet below where employees work

When Fall Protection is Needed

•         Walkways & ramps

•         Open sides & edges

•         Holes

•         Concrete forms & rebar

•         Excavations

•         Roofs

•         Wall openings

•         Bricklaying

•         Residential Construction

Good Work Practices

•         Perform work at ground level if possible

    Example: building prefab roofs on the ground and lifting into place with a crane

•         Tether or restrain workers so they can't reach the edge

•         Designate and use safety monitors       (This is less desirable of all the systems)

•         Use conventional fall protection

Training

Employers must provide fall protection training

The training is to teach you:

Ø  How to recognize hazards

Ø  How to minimize hazards

The training must cover:

Ø  Fall hazards

Ø  Fall protection systems

Ø  Use of fall protection devices

Summary

•         If you can fall more than 6 feet, you must be protected

•         Use fall protection on:

Ø walkways & ramps, open sides & edges, holes, concrete forms & rebar, excavations, roofs, wall openings, bricklaying, residential construction

•         Protective measures include guardrails, covers, safety nets, and Personal Fall Arrest Systems

power tools 

Hazards

Workers using hand and power tools may be exposed to these hazards:

Ø  objects that fall, fly, are  abrasive, or splash

Ø  harmful dusts, fumes, mists, vapors, and gases

Ø  frayed or damaged electrical cords, hazardous connections and improper grounding

Basic Tool Safety Rules

•         Maintain regularly

•          Use right tool for the job

•          Inspect before use

•          Operate according to manufacturers’ instructions

•          Use the right personal protective equipment (PPE)

•          Use guards

Hand Tool Hazards

Hazards are usually caused by misuse and improper maintenance

Do not use:

Ø  wrenches when jaws are sprung

Ø  impact tools (chisels and wedges) when heads have mushroomed

Ø  tools with loose, cracked or splintered handles

Ø  a screwdriver as a chisel

Ø  tools with taped handles – they may be hiding cracks

Hand Tools - Protection

·        Use PPE, such as safety goggles and gloves

·        Keep floor surface where working free from debris and tripping or slipping hazards

·        Keep cutting tools sharp

Power Tools

·        Must be fitted with guards and safety switches

·        Extremely hazardous when used improperly

·        Different types, determined by their power source:

Ø  Electric

Ø  Pneumatic

Ø  Liquid fuel

Ø  Hydraulic

Ø  Powder-actuated

Switches

Hand-held power tools must be equipped with one of the following:

Constant pressure switch

shuts off power upon release

Examples: circular saw, chain saw, grinder, hand-held power drill

On-Off Switch

Examples: routers, planers, laminate trimmers, shears, jig saws, nibblers, scroll saws

Power Tools - Precautions

•         Disconnect tools when not in use, before servicing and cleaning, and when changing accessories

•           Keep people not involved with the work away from the work

•           Secure work with clamps or a vise, freeing both hands to operate the tool

•           Don’t hold the switch button while carrying a plugged-in tool

•           Keep tools sharp and clean

•           Consider what you wear – loose clothing and jewelry can get caught in moving parts

•           Remove damaged electric tools & tag them: “Do Not Use”

Power Tools – Precautions ( Electric Cords )

·        Don’t carry portable tools by the cord

·        Don’t use electric cords to hoist or lower tools

·        Don’t yank cord or hose to disconnect it

·        Keep cords and hoses away from heat, oil, and sharp edges

Electric Power Tools

To protect a worker from shock, these tools must:

Ø   have a 3-wire cord plugged into a grounded receptacle

Ø   be double insulated, or

Ø   be powered by a low-voltage isolation transformer

Electric Tools – Good Practices

•         Operate within design limits

•          Use gloves and safety shoes

•          Store in a dry place

•          Don’t use in wet locations unless approved for that

•          Keep work areas well lit

•          Ensure cords don’t present a tripping hazard

Abrasive Wheels and Tools

May throw off flying fragments

Equip with guards that:

Ø  Cover the spindle end, nut, & flange projections

Ø  Maintain proper alignment with the wheel

Ø  Don’t exceed the strength of the fastenings

Guard so that a minimal amount of the wheel is exposed

Inspecting Abrasive Wheels

Before mounting:

Ø  inspect closely for damage

Ø  perform sound- or ring-test to ensure free from cracks / defects

To test:

Ø  tap wheel gently with a light, non-metallic instrument

Ø  if wheel sounds cracked or dead, do not use it because it could fly apart

Abrasive Wheel Use

To prevent cracking:

•          fit the wheel on the spindle freely 

•          tighten the spindle nut enough to hold the wheel in place without distorting the flange

Let the tool come up to speed prior to grinding or cutting

Don’t stand in front of the wheel as it comes up to full speed

Use eye and/or face protection

Abrasive Wheel Work Rests

·        Keep work rests not more than 1/8th inch from wheel surface

·        This prevents jamming the work between the wheel and the rest, which may cause the wheel to  break

·        Don’t adjust wheel while it’s rotating

Guarding

·        Guard exposed moving parts of power tools

·        Guard belts, gears, shafts, pulleys, sprockets, spindles, flywheels, chains, or other moving parts

·        Never remove a guard when a tool is in use

Summary

Hazards are usually the result of improper tool use or not following one or more of these protection techniques:

Ø  Inspecting the tool before use

Ø  Using PPE (Personal Protective Equipment)

Ø  Using guards

Ø  Properly storing the tool

Ø  Using safe handling techniques

 Procedural Process for Welding, Cutting and Grinding

 

Electrical Safety – connections.

Protective Measures

•          Proper grounding

•          Use GFCI’s(ground-fault circuit interrupter)

•          Use fuses and circuit breakers

•          Guard live parts

•          Lockout/Tag out

•          Proper use of flexible cords

•          Close electric panels

•          Training

Hazards

•          Inadequate wiring

•          Exposed electrical parts

•          Wires with bad insulation

•          Ungrounded electrical systems and tools

•          Overloaded circuits

•          Damaged power tools and equipment

•          Using the wrong PPE and tools

•          Overhead power lines

•          All hazards are made worse in wet conditions

Summary

Electrical equipment must be:

Ø   Listed and labeled

Ø   Free from hazards

Ø   Used in the proper manner

If you use electrical tools you must be:

Ø   Protected from electrical shock

Ø   Provided necessary safety equipment

DEVELOPED: Safety Officer Tariq Maayta .S.S. Department

20-03-2011                                                 ŞENER ARDA İNŞAAT

Table of Contents

1. Scope& Purpose

2. Reference Documents & Standards

3. Responsibilities

4. Procedural Process for Welding, Cutting and Grinding

5. Records

SCOPE & PURPOSE

This document provides the information necessary to ensure that welding, cutting, grindingand associated activities are carried out in a safe and efficient manner, without harm topersonnel or damage to equipment and the environment.

The purposes of this procedure are to:

�� provide procedures and guidance for managing welding/cutting/grinding operations.

�� demonstrate compliance with applicable regulations governing welding/cutting/grindingoperations.

The activities covered by this document include the:

• Storage and maintenance of welding/cutting/grinding equipment.

• Preparations and precautions to prevent fire and explosion (including the safe storageand handling of equipment).

• Preparations and precautions to be taken during specific welding/cutting/grindingactivities, e.g., welding in confined spaces, etc.

REFERENCE DOCUMENTS & STANDARDS

The Conditions of Contract

The Employer’s Requirement

Occupational Health & Safety Management Systems - Specification

HS Manual

HS Plan

Occupational Health and Safety Legislation

Project Management Procedure for Control of Quality Records

Procedure for Confined Space

Procedure for Fire Safety

Waste Management Procedure

Procedure for Permit to Work

Procedure for Personal Protective Equipments

RESPONSIBILITIES

Construction Managers / Site Managers

Construction Managers / Site Managers have overall responsibility for the safe use ofwelding/cutting/grinding equipment on their sites and shall:

• employ suitably competent and experienced personnel.

• issue relevant Permit to Work.

• apply approved procedures for cutting and welding.

Site Engineer

Site Engineer is responsible for the safe execution of welding/cutting/grinding within his areaof authority and shall:

• inspect the work site before welding/cutting/grinding is permitted and at least once perday during the work.

• ensure that welding/cutting/grinding equipment is maintained in satisfactory operatingcondition and in good repair.

• ensure that welding/cutting/grinding activities are carried out under the appropriatesupervision.

• ensure safe usage of the welding/cutting/grinding equipment’s.

• determining the nature and quantity of combustible materials and hazardous areaspresent at the work site.

• obtain a Permit to Work from the Site Manager.

• ensuring that fire protection and extinguishing equipment are properly located at thesite.

• making a final check of the work site 30 minutes after the completion ofwelding/cutting/grinding operations.

• ensuring that combustibles are safe from ignition by:

�� moving the work to a location free from dangerous combustibles, or,

�� having the combustibles moved to a safe location, or,

�� having the combustibles properly shielded against ignition.

• ensuring wherever possible that any operation that might expose combustibles to therisk of ignition is not scheduled during welding/cutting/grinding activities.

Welder

Welders employed on the work shall be certified.

Welder shall:

• ascertain any hazards associated with the required task before commencing workincluding preparation of the work area and removal of any organic coatings.

• cut or weld only where conditions are safe.

• After finishing work, ensure nothing is burning or smoldering near the work site.

• make sure welding cables are attached or connected as close to the job as is safe toprevent possible stray currents.

• make sure no welding cables are connected to mechanical equipment.

• Correct safety equipment is at hand i.e. fire extinguishers, fire-blanket and screening.

• check that area is hazard free before commencement and at regular intervals.

• clean up the work site regularly in order to prevent piling up of waste materials.

PROCEDURAL for WELDING, CUTTING and GRINDING

Electric Arc Welding Equipment

Electrical Hazards and How to
Control Them

Electrical accidents are caused by a combination of three factors:

Ø  Unsafe equipment and/or installation,

Ø  Workplaces made unsafe by the environment

Ø  Unsafe work practices.

Preventing Electrical Hazards - Tools

•          Inspect tools before use

•          Use the right tool correctly

•          Protect your tools

•          Use double insulated tools

Preventing Electrical Hazards - Planning

•         Plan your work with others

•         Plan to avoid falls

•         Plan to lock-out and tag-out equipment

•         Remove jewelry

•         Avoid wet conditions and overhead power lines

Preventing Electrical Hazards - PPE

•         Proper foot protection (not tennis shoes)

•         Rubber insulating gloves, hoods, sleeves, matting, and blankets

•         Hard hat (insulated - nonconductive)

Welding Sets

All welding sets shall be maintained in good condition and adequate capacity.

Under no circumstances shall the welder:

• connect and disconnect the welding device from the electricity supply network whenthe connection is anything other than a plug and socket.

• repair electro-welding machines (such repairs shall be carried out by a competentelectrician only).

Cables and Connections

Ø  All cables, connectors and terminations shall be maintained in good condition, and be ofadequate capacity.

Ø  To avoid long lengths of welding cables the machine shall be sited asclose as possible to the workplace.

Ø  All cables shall be run as not to pose tripping hazard andthey will also be run carefully across safe routes to prevent damages wherever applicable.

Ø  The welding lead is the conductor carrying the welding current from the point of supply to theelectrode holder.

Ø  Welding leads and returns shall be fabricated of flexible, tough rubbercovered cables, using approved cable couplers where necessary.

Ø  Leads shall be properly terminated and cable couplers and terminations shall be of adequatecapacity.

Ø  Welding leads shall be inspected daily for any damage. In the case of worn or torn cablesheaths, or flattened or kinked cables, the affected part shall be removed.

Ø  Welding return leads shall always be used to prevent uncontrolled welding currents passingback from the work-site to the generator through the structure and/or plant items. This couldgive rise to sparks or cause damage to bearings in machines, etc.

Ø  Particular attention shall be paid to welding returns when welding on pedestal crane booms,so that currents cannot pass through main slew bearings.

Note: It is prohibited for welders to commence or continue welding operations withdamaged cables, starting devices or electrode holders. Splices are not allowed inwelding cables.

Electrodes and Electrode Holders

Ø  Electrode holders shall be provided with a handle of tough, insulating non-ignitable materialwith a guard disc of similar material between the hand of the operator and the projecting lineportion.

Ø  A fully insulated holder or hook should be provided for the live electrode holder when not inuse.

Ø  Placing live electrode holders on gloves or face screens or handing them up by the electriccable where it could come in contact with other equipment etc., shall be discouraged.

Warning: Electrode holders under voltage shall not be left unattended.

Grounding and Bonding

Ø  For all Alternative Current (AC) welding transformers, the transformer low voltage windingmust not be earthed but the transformer case must be effectively bonded to a groundingsystem adjacent to the equipment.

Ø  The Direct Current (DC) welding output of all AC driven DC welding generators shall not begrounded.

Ø  The machine frame shall be effectively bonded to ground.

Ø  For engine driven DC welding generators, no earth connection must be applied to thegenerator output terminals.

Ø  The work piece must be bonded to earth by means of a heavy section conductor havingsuitable clamped or bolted connections.

 Welding and Cutting - Hazards and Precautions

Personal Protective Equipment

Ø  Personnel engaged in, or working in close proximity to, welding, cutting, chipping andgrinding operations must use the appropriate protective clothing/equipment, e.g., goggles,face shields, welding helmets, welding screens, fume masks, gloves, and leather aprons

Ø  The need for protective clothing against sparks and pieces of hot metal depends upon theposition of the arc in reference to the welder’s body.

Ø  For some classes of welding, e.g., where the welder is standing at a bench, the head screenand gauntlets may well provide sufficient protection.

Ø  A thick apron of leather or other suitable material may be needed if the welder is sitting at hiswork position, where molten metal may fall upon his thighs and legs.

Ø  If the arc is above the level of his shoulders or overhead, complete protection for the head,arms and upper part of the body is necessary.

Ø  Proper PPE shall be used. Goggles face shields, welding helmets, welding screens, fumemasks, gloves, leather aprons shall comply with EN standards.

Additional Protection for Electric Arc Welding

Ø  Gloves or gauntlets made of non-ignitable material are required for shielding the hands andarms from spark and heat radiation of the welding arc.

Ø  Leather gloves and gauntlets give noprotection against electrical hazards. In particular, for electric arc welding, oiled or greasedclothes and gloves shall not be worn.

Ø  There shall be no electric welding on structures containing pre-stressing, other than inexceptional situations. In such exceptional situations, all necessary measures shall be taken to prevent adverse effects.

Fumes and Gas

Welding, cutting, grinding etc., can produce toxic fumes and gases, the composition of whichdepends on welding temperature, arc intensity, electrode material and the gas mixture beingused. Therefore, it must be ensured that:

• If natural ventilation is not sufficient power ventilation is to be provided.

• Respiratory protection is to be provided.

Warning: Respiratory protection must be worn where the welding or burning ofcadmium alloys or a cadmium-coated material takes place.

Fire and Explosion Prevention

• Welders and helpers must always be alert to the danger of fire and explosion. Fireprotection and extinguishing equipment shall be properly located at the site.

Restrictions on Welding and Cutting

Cutting or welding is only permitted in areas that have been made fire safe.

Cutting or welding shall not permit:

• In areas not authorized by the Site Manager.

• In the presence of explosive atmospheres, e.g., mixtures of flammable gases, vapor,liquids, or dusts with air.

Approved Welding and Cutting Areas

Within the confines of an operating plant or building, the cutting and welding work area shallbe either:

• A specific area designed and approved for such work, i.e., a maintenance shop, or,

• An outside location, essentially free of combustible and flammable materials, andsuitably segregated from any hazardous areas.

Where work cannot be moved practically, as in most work, the area shall be made fire safeby removing combustibles or protecting combustibles from ignition sources.

Area Preparation and Housekeeping

Ø  Fully charged and operable fire extinguishers, appropriate for the type of possible fire, shallbe available at the work area..

Ø  Work must be screened to prevent sparks from flying outside the immediate welding areaand all combustible material must be removed or covered with fire resistant material.

Ø  Combustible materials such as paper clippings, wood shavings, or textile fibers on the floorshall be removed.

Ø  Waste electrodes and other wastes shall be collected and disposed according WasteManagement Procedure.

Ø  Housekeeping shall be done after welding,cutting and grinding activities.

Ø  If welding is to be carried out on a metal wall, partition, ceiling, or roof, precautions shall betaken to prevent ignition of combustibles on the other side due to conduction or radiation ofheat. The preferred precaution is to relocate combustibles.

Warning: Do not wet down floors where electric arc welding or burning equipment is tobe used.

Removal of Slag:

Slag shall not be cleaned from newly welded joints until it has had time to cool. Safetygoggles must be used for slag removal.

Unattended Welding Equipment

Ø  Blowpipes and hoses, if not in use, shall not be left in vessels or enclosed spaces. Ifblowpipes and hoses cannot be removed from the space, the connections must bedisconnected at the cylinders.

Ø  Whenever equipment is to be left unattended, gas cylinder valves shall be shut.

Ø  Electrical power supply for welding machines shall be switched off and disconnected. Anydiesel driven welding sets (Generators) shall be shut down...

Work Using Scaffolding

Gas cutting or welding operations involving the use of scaffolding is allowed only after takingmeasures to prevent the scaffold boards from ignition and molten metal falling on peoplebelow.

Confined Spaces

All personnel involved in welding/cutting/grinding operations in confined spaces must complywith the requirements of this procedure and the requirements defined in:

• Procedure for Permit to Work

• Procedure Confined Space

In particular, when welding or cutting in a confined space:

• Forced ventilation where appropriate shall be maintained in the space at all times.

• Gas monitoring shall take place as stated in Confined Space Procedure during weldingoperations inside the confined space.

• Organic coatings shall be removed prior to any welding and cutting.

• Gas cylinders shall not be taken into the space at any time; they shall be sited outsidethe space with the hoses laid through suitable transits and protected from damage.

• Welding transformers shall not be placed inside the space; they shall be sited outsidethe space with the cables laid through suitable transits and protected from damage.

• Where work in confined spaces takes place over several days, welding hoses andequipment shall be removed from the space overnight in case of gas build-up due toleakage.

Welding - Specific Types

All personnel are fully aware of the type of welding to be used and the safe workingprocedures for each type of welding.

Manual Metal Arc Welding

• Correct usage of PPE.

• Local Exhaust Ventilation in confined spaces.

• Trained in correct methods of manual handling if equipment has to be moved.

• Reduce exposure by taking regular breaks or rotate with other team members.

TIG Welding

• Correct use of PPE.

• Local Exhaust Ventilation in confined space entry especially taking in to mind this type ofwelding involves the use of asphyxiating gas i.e. Argon.

• Sharpening Tungsten’s must be undertaken on a pedestal grinder with local exhaustventilation.

• Grinding wheels to be redressed regularly.

The above are two examples of type of welding others such as MIG, Flux Cored, and

Brazing to be supplied by welding company

Grinding

In the grinding operation points shall be considered;

• Correct usage of PPE.

• Changing discs employees must be certified to mount abrasive wheels.

• Maintenance / segregation – Use of appropriate warning signs to demarcate areas.

• Good Housekeeping.

Instructions for Grinding

• Gloves, protective goggles with face shields, hearing protection shall be used at grindingworks.

• Grinding screens shall be used in order to protect the employees from sparks.

• Safety harness shall be worn when grinding works are carried out at elevated places.

• Grinding stone and related connections and cables shall be checked before the start ofgrinding operations.

• Defective grinding machine shall not be used.

• Grinding machine should not be left on the ground while it runs.

• Grinding operation shall not be carried out at places where combustible, flammable andexplosive materials are stored and used.

Storage of Cylinders

Cylinders shall be

Ø  Stored in a safe, dry, well-ventilated place prepared and reserved for that purpose.

Ø   Flammable substances such as oil and volatile liquids or corrosive substances shall not be stored in the same area.

Ø   Oxygen cylinders and flammable gas cylinders shall be stored separately.

Ø  All cylinders shall be chained or otherwise secured in an upright position.

Ø  To prevent rusting, cylinders stored in the open shall be protected from ground contact, extremes of weather, or contact with water.

Ø  “No Smoking in the storage area” shall be posted to the storage area.

Ø  Empty and full cylinders must be stored separately with empty cylinders.

 RECORDS

Related records for this procedure shall be maintained according to Project Management

Procedure for Control of Quality Records.

         

DEVELOPED: Safety Officer, Tariq Maaytah .                    S.S. Department

03/20/2011            ŞENER ARDA İNŞAAT