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CENTER FOR WORKFORCE DEVELOPMENT

Version :: CUCWD 106 :: Rev 1 2013

This material is based upon work supported by the National Science Foundation under Grant Number DUE-1104181. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the National Science Foundation.

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Copyright © 2013 Clemson University Center for Workforce Development. All Rights Reserved.

* License information for illustrations and photographs can be found in the Attribution Table within the Open Text for each course module.

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CENTER FOR WORKFORCE DEVELOPMENT 4SAFETY

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4 Safety at Facilities

» Identify the main causes of workplace calamities and describe the regulations and standardsthat should be implemented to prevent workplace calamities

» Explain the procedures involved in a well prepared evacuation plan, and apply these proce-dures to a real-world scenario

» Summarize the OSHA requirements for emergency response, and justify the need for such re-quirements in the workplace

» Define the four fire classifications and develop fire prevention and extinguishing plans that areappropriate for each classification

» Explain the importance of each OSHA sanitation regulation and differentiate between thetypes of workplace inspections

OBJECTIVES

Why do most workplace calamities occur and what regulations can be implemented to prevent these calamities?

What procedures should be included in an evacuation plan?

What are the OSHA requirements for emergency response, and why are these requirements an important step in establishing a safe work environment?

What is the definition of each fire classification and how can employees prevent or extinguish each type of fire?

Why are the OSHA sanitation regulations important and what is the difference between each type of workplace inspection?

The learner will be able to:

ORIENTING QUESTIONS

INTRODUCTIONCreating a safe, healthy, and efficient workplace is always a challenge during the designing or modification of facilities. The complexity of these challenges increases when it involves large and diverse machines (i.e. forklifts) or extreme working conditions like those found in a furnace or steel manufacturing industry. Certain mishaps, occupational diseases, and fires are avoidable if proper actions are taken during the earliest planning stages. 1



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» The nature of the processes and materials» Maintenance» Mechanical handling equipment, and» Working conditions

The main causes of calamities resulting in loss of life and property damage are insufficient planning during the processing, storing, maintaining, and transporting of the dangerous materials.

The precautionary measures that could be suggested include:

» Designing new buildings with the state of the art technologies that reduce damage andbroken glass during hazardous times

» Isolating processes that involve hazardous substances in another building with fewer oc-cupants

» Reducing congestion of the workplace by arranging equipment so that they do not crossover

» Including personal facilities like lunch rooms and rooms for medical services or treatmentof injuries

4.1.1 CODES AND STANDARDS

When designing a facility, it is important to adhere to the codes and standards that have been set forth, although these codes only establish a minimum requirement and must often be exceeded. The voluntary safety codes developed by various organizations establish standards for structures and equipment. For example, specifications for the construction of floor and wall openings are provided by the American National Standard Institute under the title Safety Code for Floor and Wall Openings, Railings and Toe Brands. Similarly the standards for proper electrical wirings and installations are covered in the National Electrical Code, issued by the National Fire Protection Association (NFPA). The NFPA also developed the codes and standards for fire extinguishers, flammable liquids, and gases. The Illuminating Engineering Society (IES) has published prac-tices on industrial lighting.

Some of the key design aspects that we need to consider are briefly discussed in this chapter. These design aspects include the location of buildings and structures, flow diagrams, equipment layout, electrical equipment, storage, illumination, emergency exits, personal facilities, and signs and color coding.

4.1.0 Buildings and Other Fac

Several major factors influence decisions regarding the size, shape, and type of buildings and structures. These factors include:



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4.1.2 WALKING AND WORKING SURFACES

Very often, the hackneyed nature of walking and working surfaces leads to their negligence, which, in turn, compromises the safety of the employees. Prevention of accidents on these surfaces would lead to a substantial decrease in the number of injuries occurring in the indus-try. While different types of surfaces have different sets of safety standards and requirements, a few general guidelines specify that all surfaces must be kept dry and uncluttered.

Studies have shown that trips and falls represent some of the largest causes of injuries in the workplace. Hence all walking and working surfaces should be maintained to provide a clear and neat condition to help prevent accidents and injuries. This module discusses the Occupational Safety and Health Admin-istration (OSHA) required characteristics and properties of the following walking and working surfaces. OSHA’s standards for walking and working surfaces apply to all permanent places of employment, except where only domestic, mining, or agricul-tural work is performed

A personal fall protection system is recommended by OSHA for the workers who are exposed to vertical drops of 6 feet or more. A fall protection system protects employees in the event of a fall and assures that they are able to rescue themselves. Personal fall protection systems have a life line that attaches to the building structure. Personal fall protection systems have a life line that attaches to the building structure. Normally such systems will have sufficient strength to withstand twice the force of the impact from a falling worker.

4.1.3 SAFE-GUARDING OPEN FLOORS AND PLATFORMS

Open floors and platforms are those areas that are not covered and are used to raise workers, including places like working floors, aisles, stairways, maintenance platforms, ladders, dock boards, scaffolds, elevators, and man lifts. These areas are prone to safety hazards if proper safety measures are not employed. Various types of these open floors and platforms are dis-cussed in this section along with a brief description about safety measures.

4.1.3.1 Floors and Aisles

Probably the most common surfaces at a workplace, floors are the cause of a large number of hazardous events. Floor openings and holes must be guarded to prevent material, em-ployees, and personnel from falling through and causing injuries. The best method of guard-ing the floors is the use of railings, toe boards, screens, or cover plates.

Aisle ways are provided for the quick movement of people and material across different parts of a building. As there is the transfer of a large number of resources, it is imperative that the aisle ways are safe for use. One of the most common hazards occurring on aisle ways is the overload of material beyond the safe limit and the resulting blocking



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and cluttering of the path. For the purpose of vehicular traffic, aisle ways need to have a minimum clearance of three feet from the width of the requisite number of vehicles. Two-way traffic can lead to potential cluttering and overload, and the necessary width of two-way aisle ways reduces the available space. Hence, it is generally suggested that the aisle ways allow the flow of one way traffic.

4.1.3.2 Stairways

Stairways are another set of surfaces that are potentially dangerous. The minimum width of a stairway needs is 22 inches while the maxi-mum width isn’t specified. OSHA regulations specify a precise set of riser height (height of each step) and tread run (length of each step) dimensions depending on the angle of ascent. It is imperative that dif-ferent sets of riser heights and runs are not mixed as this could lead to potentially serious injuries. The safety guidelines also specify that all stairways be equipped with handrails, the placement of which is dependent on the width of the stairway

4.1.3.3 Maintenance Platforms

Mechanized movement on maintenance platforms often causes damage to platform surfaces. The concrete may become chipped, and grooves in the concrete surface may cause power or hand trucks to run off the dock or into other employees or material. For these reasons angle iron or channel iron protection should be pro-vided at the edge of the platform, and it should be well maintained. Badly furrowed platforms may be reinforced with concrete or epoxy cement. Wood platforms should be checked for decay or dry rot, loose or uneven planking, weakened or cracked supporting planks and maintenance should be conducted immediately should any of these things be found.

4.1.3.4 Ladders

Portable ladders are generally purchased and not manufactured in-facility. If they are to be manufactured, the ANSI (American National Standards Institute) must be consulted to ensure that these ladders adhere to their guidelines. Por-table ladders are often job-specific, and manufacturers specify the nature of the job for which these ladders can be used. During the inspection process, it must be ensured that the ladders are free from structural defects such as knots, cross grain, compression wood, and pitch pockets. To avoid decay and deterioration, the ladders are often coated with sealants like varnish. To ensure safety over an extended period of time, the ladders must be in-spected periodically, often on a quarterly basis. If any defects are found, the ladder must immediately be removed from service and the necessary steps must be taken to ensure that the defects are removed. The defec-tive pieces should be tagged appropriately so that workers do not use it.



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While portable ladders are used to provide a wider range of movements, fixed ladders are present to provide access to specific locations that need to be accessed often. All fixed lad-ders must be equipped with cages or wells unless the ladders provide access to towers, wa-ter tanks, and chimneys. In those cases, ladder safety devices, appliances that will prevent the fall of a person in case he or she loses his or her footing, must be used. Very often, the use of ladder safety devices is advocated even over cas, as they will help in arresting a fall.

All ladders must be inspected periodically, kept in good condition at all times, and must be free from sharp edges, splinters, oil, grease, or other defects which would affect their use. When working around overhead electrical wires only ladders with fiberglass side rails are permitted, no aluminum or wood ladders. Also, workers should always extend the ladder at least 3 feet above roof level and face the ladder at all times. To prevent injury, a bucket should be used to transfer tools up and down the ladder.

4.1.3.5 Miscellaneous Facilities

Dock Boards

Dock boards, portable and powered bridge plates, are often used when there is a need to bridge the gap between trucks and a dock. The dock boards need to be strong enough to carry the load applied and must be secured in position by an-chor. They also need to be equipped with devices that prevent slipping, and handholds are generally provided to allow for safe handling.

Scaffolds

Scaffolding is the material that supports a temporary, elevated working platform used to support workers or materials. Due to higher stability and ease of assembly, it is generally recom-mended to use metals as scaffolds. Depending on the amount of weight they can bear, scaffolds can be classified as light duty, medium duty and heavy duty.

When movement of the scaffold is required, manually propelled scaffolds are used. Apart from the ease of transportation, the parts of these scaffolds can often be broken down manually.

As with most working surfaces, the manufacturer specifies the regulations applicable to the equipment. Most regulations suggest that scaffolding be tied off on a truss to allow for more stability.

Elevators

In order to assist with vertical transportation, elevators are used as a means of hoisting and lowering. Information that is



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essential for the safe operation and maintenance of elevators is provided in the ANSI Safety Code for Elevators, Dumbwait-ers, Escalators and Moving Walks. All elevator openings must be provided with sufficient protection and the maximum speci-fied load must not be exceeded. Moreover, elevators must only be operated by designated persons. Elevator safety devices should also not be overridden or made inoperable.

Man Lifts

The main hazards in the use of man lifts include:

» The rider may be carried over the top

» Cannot make a stop and exit from man lift during the timeof emergency

» The operators head or shoulders may strike the edges ofthe floor openings

OSHA standards require that all man-lifts be equipped with guardrails that open outwards. The platform should be designed in a way that prevents the workers from slipping or falling. Oth-er specifications like driving speed, belt requirements, platform requirements, driving protection, and emergency ladder are specified as per OSHA standards.

Boiler

Safety in a boiler room is of utmost importance as an accident in such a situation can be potentially fatal. OSHA regulations attempt to prevent accidents before they occur. Possible is-sues like steam hazards and coal dust accumulation must be investigated immediately upon notice. In addition to having knowledge about boiler room safety regulations, all workers must undertake a series of safety steps before they enter the boiler room. Severe penalties are imposed on employers who do not adhere to these safety regulations.

Loading Docks

Falls from loading docks are potentially fatal, especially while using a forklift. As a result, most of the safety regulations sur-rounding loading docks focus on the safe usage of forklifts. The overturning of forklifts, debris on the floor, chemical spills, and trailer creep are some of the various hazards that can be present on a loading dock. Equipment such as dock boards, dock plates, dock signaling devices, and dock levelers are used to ensure safety on a loading dock.



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Walkways

Walkways are defined as passages that connect two buildings, and though they are typically outdoors, they can be totally enclosed or covered. Walkways and ramps should be equipped with standard railings consisting of a top rail, intermediate rail, and post, and should have the specified height as mentioned by the ANSI. Walkways should also have mirrors to prevent blind spots, and should be free of added traction if they need to be cleanable.

4.1.4 HOUSEKEEPING REQUIREMENTS

Housekeeping involves keeping the work ar-eas, passageways, and stairs free of all kinds of debris during the course of construction, alterations, and repairs. There needs to be a facility for the safe removal of debris and com-bustible scrap. For the disposal of trash and other refuse, containers need to be provided and emptied at frequent intervals. Containers for inflammable or hazardous wastes must be equipped with covers. Poor housekeeping is one of the causes of accidents and hazards. Each employee should be made aware that it is their responsibility to maintain good housekeeping in his or her area and to promptly report unsafe floor conditions like tears in the carpet or holes in the floor. Spills should be wiped up immediately or isolated by using barricades or warning signs.

4.1.4.1 Spills

A spill is defined as, but not limited to, the release, leak, discharge or unauthorized disposal of any oil or hazardous substance onto the air, water, or land. All spills must be cleaned up in order to provide a safe workplace for employees, to prevent water pollution, to allow safe and proper disposal, and to minimize adverse environmental impact.

Clean Up Procedures

In the event of a spill, the area must be evacuated immediately, and the supervisor and appropriate medical and safety personnel must be contacted immediately. Protective equipment, including respiratory protection, must be worn if needed. In order to reduce the chance of splash or spreading of the spilled chemical, loose spill control materials should be placed over the entire spill area. However, care must be taken to ensure that all spill control materials are replenished as soon as possible. The following processes should be adhered to during the event of spills:



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Liquid Spills In the event of liquid spills, drain the spill by using a pump to store the liquid in a safe sink, absorbing the spill with suitable materials, or neutralizing the spill with a compatible solid.

Powder Spills If the spill is in power form like pesticide powder, then sweep or vacuum up the spill.

Once the cleanup is completed, the area and the materials used to clean up the spill must be removed and stored in a safe place.

Preventing and Reducing Spills

In order to prevent or reduce spills following plans should be followed:

» A proper audit must be conducted regarding the storage and transport of materials.» Follow proper procedures while transferring, transporting, and storing hazardous

materials.» Provide training to the employees on the possible causes for spills.» Label the containers with possible hazards caused by the materials that could

cause the spills.

Activity 4.1.1

» Complete the following sentences:

1. Open floors and platforms are those areas that are not covered and areused to raise workers, including places like ___________________,______________, ______________, ____________________, _____________,_____________________, ______________, _____________________, and____________________.

2. The main causes of calamities resulting in loss of life and property damage are ______________________________________, ____________, _________________, and__________________________________________.

3. OSHA’s standards for walking and working surfaces apply to all __________________________________, except where only ____________, ____________, or __________________________________________.

4. All ladders must be inspected periodically, kept in good condition at all times, andmust be free from _________________, ____________, _________, ___________,or other ____________ which would affect their __________.

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4.2.0 Emergency Exits

Emergencies that result in the damage of properties and people can arise at any time and from many causes. During the time of emergencies like fire, explosions, and spills, it is always advis-able to evacuate the building as soon as possible. The safety hazard associated with the evacu-ation plan is that if people become panicked and rush to exit the building, it could be more dangerous than the original hazard. Proper planning of emergency exits at appropriate places to avoid this rush is required for a safe and healthy work place. An emergency exit is a special exit that allows the faster evacuation of a building or facility during the time of emergencies like fire and explosions.

4.2.1 EMERGENCY ALARMS AND PROCEDURESThe alarm system is designed to warn employees about a necessary emergency plan and/or to give employees time to arrange for a safe exit from the workplace. There are two main types of alarms: visual or audible. It is essential that the alarm is clear and loud enough to convey the intended message to the employees. Examples of au-dible alarms are bells, horns, sirens, and workplace announcement systems. Visual alarms use steady, flashing, or strobe lights to alert workers about a possible emergency or evacuation system. These alarms are used when noise levels are high in a particular environ-ment.

4.2.2 EVACUATION PLANS, EXIT ROUTES, AND HINDERING HAZARDS

A well prepared evacuation plan must be prepared for the workplace. The evacuation plan must designate at least one primary and one secondary exit. These exits must be indicated by nearby “exit” signs. The exits must not be placed in restrooms or in narrow passages. Moreover, the exits must be placed away from rooms with hazardous materials. The use of elevators to reach an emergency exit is prohib-ited, as elevators can lead to time delays and further hazards. Floor plans must also indicate exits with wheelchair access and the em-ployee’s current location.

4.2.3 REQUIREMENTS AND STANDARDS FOR EMERGENCY RESPONSE

According to OSHA standards, the requirement for emergency response plans include:» Emergency Escape procedures and emergency escape route assignments» Procedures to be followed by employees who operate critical plant operations» The chain of command or line of authority that needs to followed during the time of

emergency



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The shutdown procedures should be properly designed for the time of emergency. These are required for industries that have boilers, reactor vessels, chemicals, and powered equipment, thereby reducing the probability of a secondary damage in the event of evacuation.

Activity 4.2.1

» List the two types of emergency alarms and provide examples of each alarm type.

Activity 4.2.2» Place a check next to the statements which accurately complete the following sentence:

A well-planned emergency response plan should:

designate at least one primary and one secondary exit

ensure that exits are also placed in restrooms and narrow passages

indicate the proper elevator to use during an emergency

indicate exits with wheelchair access

include emergency escape procedures and emergency escape route assignments

designate a chain of command or line of authority

outline shutdown procedures in the event of evacuation.

4.3.0 Fire Safety

In this section, various causes and dangers of fire are discussed along with fire prevention techniques and firefighting equipment. The major hazards of fire include loss of life or injury to employ-ees and property damage due to the fire. Fire also results in destruction of business records and involves costs for reconstruc-tion of the facility. The major causes of fire include three essen-tial elements classified as the oxidizing agent (e.g. oxygen), the combustible material (e.g. gasoline, kerosene), and the source of ignition (e.g. a cigarette light or electric spark).



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4.3.1 CLASSIFICATION OF FIRE AND PREVENTION METHODS

Fires are organized into classes, and each class is designated based on the combustible mate-rial that causes the fire. The knowledge of fire classification is essential to ensure use of the correct extinguishing agent for the material on fire. Accidental fires are divided mainly into 4 classes:

Class A — Class A fires involves fire from solids such as coal, wood, paper, or some plas-tic which produce glowing embers. The Class A type of fire is also known as ordinary com-bustibles. The Class A fire could be contained by extinguishing the flames using water or by isolating the combustible from the supply of oxygen using foam from a fire extinguishers.

Class B — Class B fires includes gases and liquids that must be vaporized for combustion to occur. The combustible fuels under this category include gasoline, diesel, ethanol, metha-nol, and similar liquids and gases that ignite easily. Since these liquids float on water, it is not advisable to use water to extinguish a Class B fire. Water aids in spreading of the fuel farther, causing extensive damage. The best method to fight these kinds of fires is smother-ing the fire using foam from sodium bicarbonate or potassium carbonate. An extinguisher with dry chemical flame retardant chemicals that stops the chemical reaction should be used in Class B fires.

Class C — Class C fires include the combustion of any of the fuel involved in the class A or Class B but also includes electrical components or materials near electrically powered equipment, like fires from short-circuits and overloaded electrical circuits. Class C fires can-not be extinguished with water since electricity is involved in the cause of fire. Fire extin-guishers that use non-conductive substances like carbon dioxide or PKP (Purple – K Pow-der) should be used.

Class D — Class D fires involve the combustion of magnesium, aluminum titanium, zirco-nium, and other easily flammable metals. For Class D fires also, water cannot be used as an extinguishing agent since water serves to energize the flame. The most effective way to com-bat class D fires is to use dry powder extinguishing agents to absorb the heat and smother the flames.

4.3.2 FIRE EXTINGUISHING AGENTS AND PROPER USE

The types of fire extinguishing agent to be used in the event of a fire depends on the class of fire. The fire extinguishers are appropriately color coded to indicate that which class of fires could be extinguished with that fire extinguisher. The list of commonly used fire extinguishing agents is discussed below.

Water — Water is the most common and abundant form of fire extinguishing agent. Water can be used only in case of Class A type of fires. Since water is conductive, it cannot be used for Class B or Class C fires.



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Multi-Purpose Dry Chemical — The chemical used in this type of fire extinguisher is monoammonium phosphate. This agent is used mainly in schools, general offices, hospitals, and homes. The multipurpose could be used for Class A, B, and C type fires. The chemical causes corrosion if not removed after the fire is put out.

Halotron — Halotron is a clean and environmental friendly fire extinguishing agent for stream-ing and local application. It is a non-conducting, volatile agent that does not leave any residue after application on fire, so cleanup is not required for this type of fire extinguishing agents. The chemical is ozone friendly on vaporization. This is used in case of class A, B and C type fires.

Regular Dry Chemical — The chemical used in this type of fire extinguisher is sodium bicarbonate. The chemical is non-corrosive, non-toxic, non-conductive, and easy to clean up.

Carbon Dioxide — This type of fire extinguisher is used in Class B and Class C type fires and is environmentally friendly. Extinguishers that use carbon dioxide as an extinguishing agent could be used in places such as computer rooms, labs, food storage areas, and other contami-nation sensitive areas.

Purple K Powder — The chemical used in Purple K powder is potassium bicarbonate and is non-conductive and non-corrosive. This type of fire extinguishing agents are applied for Class B and Class C type fires and are primarily used in military facilities and oil companies.

Foam — To extinguish flammable liquids, foam extinguishers are used since it floats on top of the liquids and prevents explosions. It is cleaned by washing away with water after fire is put out.

Although there are different types of fire extinguishers, the operation of most of these is similar. The proper usage of the fire extinguisher can be memorized easily by using the acronym “PASS” as a quick reference.

P — PULL the pin at the top of the extinguisher

A — AIM at the base of the fire and not on top of the flame

S — SQUEEZE the lever slowly to release the extinguishing chemical

S — SWEEP from side to side

4.3.3 EMERGENCY EVACUATION PLANS

Emergencies like the release of toxic substances, hurricanes, tornado, fire, blizzards, and other similar hazards should be anticipated by the management, and necessary precautions must be made to make the work place safer. The emergency evacuation plan provides a more effec-tive method to achieve employee safety and health in an emergency. Employers should provide employees with the procedures they should follow during the time of emergency. Employees



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should also receive proper training on how to evacuate the building safely. Mock drills should be conducted at regular intervals and sirens and alarms should be tested and updated fre-quently.

During the time of emergency, employees must know the type of evacuation that is necessary, and each employee must be aware of his duties and responsibilities. The designated “safe place” should be clearly identified in the evacuation plan. The employees must also be given proper training on the possible emergencies that could happen at their facilities.

It is the duty of the employer to make sure that there are suffi-cient numbers of employees who will be in charge for the evacua-tion plan in case of emergencies available at all times during work hours. These evacuation wardens should be given proper training, and they are responsible for checking out all the enclosures that are accessible.

Employees should be aware of the hazardous and flammable prop-erties of the chemicals that are used in their facilities. Because they spread fire rapidly, there are regulations and standards for the control of the accumulation of the flammable and combustible waste materials. For example, a large accumulation of paper or used boxes poses a vital fire hazard. This type of materials may be easily ignited by electric sparks or cigarettes.

Activity 4.3.1» Complete the following table:

Fire Classification Description Proper Extinguishing Agent

A

B

C

D

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» Portable water supply for drinking, washing, and food preparation» Adequate disposal of sewage and garbage» Adequate personal service facilities» Hygienic food services» Acceptable level of heating and ventilation

Sanitation must be properly managed and effectively integrated with production and maintenance if it is to be safe, efficient, orderly, and economical.

Proper sanitation of facilities ensures that water is not contaminated in-plant or during its transfer from the water supply sources. The standards mentioned in the National Plumbing Code ensure that the integrity of the drinking water system is maintained throughout the plant. Sanitation also ensures that hazards from insects and rodents are identified and proper ac-tions are taken to control them. OSHA regulations specify the required number of wall-hung, elongated-bowl flush toilets with open front seats based on the number of employees working in that facility. The personal service facilities should be provided with at least a minimum daily janitorial service as a part of the managed plant sanitation function.

Sanitation also ensures the controlling of contamination of foods. Perishable foods and drinks like dairy products, egg products, meat, and fish should be kept at or below 40º F except while preparing or being served to the employees.

4.4.0 Sanitation

Sanitation is defined as the process of providing a safe, clean, and healthy environment for humans by removing waste that is hazardous to humans. Sanitation is required to keep the work environment clean and well equipped for employee comfort and convenience. The main areas for promoting health and sanitation in an industry are listed below.

4.5.0 Inspections

Inspection is one of the principal means of identifying the cause for an accident, determining the safeguards for preventing those accidents, and providing a solution for protecting against hazards before accidents and personal injuries occur. Inspec-tion helps to sell the safety program to the employees. Regular inspections encourage individual employees to inspect their immediate work areas and enable the personnel of the safety department to interact with the individual workmen and to enlist their help in eliminating accidents.



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Systematic inspection is the basic tool for maintaining safe conditions and checking unsafe practices. When preparing for an inspection, it is advisable to analyze all accidents and loca-tions that are known to cause accidents. Safety inspections are classified into periodic inspec-tions, intermittent inspections, continuous inspections, and special inspections.

Periodic inspections are those scheduled to be made at regular intervals. Such inspections are made monthly, annually, or at other appropriate time intervals. General inspections cover those areas that no one visits and where no one gets hurt. General inspections are conducted before reopening a facility after renovation. Intermittent inspections are made at irregular in-tervals and are found commonly in almost all facilities. They include unannounced inspections of the facility or part of the manufacturing tools, keeping the supervisor alert in maintaining the safety of the facility.

In continuous inspections, a set of employees spend all their time observing certain equip-ment and operations. The main duty of these employees is to roam around the facilities and continuously observe operations and make adjustments and minor repairs. Special inspections are necessary because of the installation of new equipment or new processes, construction of new facility, or renovation of the existing model, or because of new hazards.

4.5.1 INSPECTION PROCEDURES

The procedure for conducting an inspection varies considerably in different companies. The person who performs the inspections should know all the policies of the company along with the prevailing OSHA and state standards. The main steps of inspection are found below.

» Contact head of the department and request his help» Observe the condition of compliance with established standards» Observe all violations of safety norms.» Follow all observations by a written report» Provide recommendation for the existing practices and policies that enhance the safety of

the working place.

Activity 4.5.1» Write the appropriate letter from the box provided next to each inspection description.

1. An inspector visits a company to check the installation of new equipment

2. An inspector schedules an annual inspection

3. An inspector maintains safe conditions by checking for unsafe practices

4. An inspector arrives for an inspection without the supervisor’s knowledge in orderto keep the supervisor alert in maintaining the safety of the facility

5. An inspector checks areas that no one visits and where no one has been hurt

6. Employees spend all their time observing certain equipment and operations.

a. Systematic Inspection b. Periodic Inspection c. General Inspectiond. Intermittent Inspection e. Continuous Inspection f. Special Inspection

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Key Concepts

» Workplace calamities often result from insufficient planning during the processing, storing, maintain-ing, and transporting of the dangerous materials. Regulations and standards help to prevent work-place calamities by:

— Ensuring that new buildings are designed with the state of the art technologies and adhere proper guidelines related to the location of buildings and structures, flow diagrams, equipment layout, electrical equipment, storage, illumination, emergency exits, personal facilities, and signs and color coding.

— Isolating processes that involve hazardous substances in buildings with fewer occupants

— Reducing congestion of the workplace by properly arranging equipment

— Including personal facilities (i.e. lunch rooms and rooms for medical services)

» Emergency response plans should adhere to OSHA requirements by including:

— Clear and detailed discussion regarding exit locations and regulations

— Emergency escape procedures and emergency escape route assignments

— Procedures to be followed by employees who operate critical plant operations

— The chain of command or line of authority that needs to followed during the time of emergency

— The shutdown procedures in the event of evacuation.

» The four fire classifications and the appropriate fire prevention and extinguishing plan for eachclassification include:

Fire from solids such as coal, wood, paper, or some plastic which produce glowing embers

Extinguished with water or by isolating the combustible from the supply of oxygen using foam from a fire extinguishers

Gases and liquids that must be vaporized for combustion to occur (i.e. gasoline, diesel, ethanol, methanol, and similar liquids and gases that ignite easily)

Extinguished by smothering the fire using foam from sodium bicarbonate or potassium carbonate or an extinguisher with dry chemical flame retardant chemicals that stops the chemical reaction. Never use water!

Combustion of any of the fuel involved in the class A or Class B but also includes electri-cal components or materials near electrically powered equipment, like fires from short-circuits and overloaded electrical circuits

Extinguished with fire extinguishers that use non-conductive substances like carbon diox-ide or PKP (Purple – K Powder). Never use water!

Combustion of magnesium, aluminum titanium, zirconium, and other easily flammable metals

Extinguished with dry powder extinguishing agents to absorb the heat and smother the flames. Never use water!

Class A

Class B

Class C

Class D

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4.1 National Electrical Code pg.2

Illuminating Engineering Society (IES) pg.2

Personal fall protection system pg.3

Aisles pg.3

Stairways pg.4

Riser height pg.4

Tread run pg.4

Maintenance platforms pg.4

Ladders pg.4

Dock boards pg.5

Scaffolds pg.5

Elevators pg.5

Man lifts pg.6

Boiler and boiler rooms pg.6

Housekeeping pg.7

Spills pg.7

Liquid spill pg.8

Powder spill pg.8

Emergency exit pg.9

Fire extinguishing agents pg.11

4.4 Sanitation pg.14

4.5 Inspection pg.15

Periodic inspection pg.15

General inspection pg.15

Intermittent inspection pg.15

Continuous inspection pg.15

Special inspection pg.15

» Sanitation is the process of providing safe, clean, and healthy environment for humans by:

— Maintaining the integrity of the drinking water system

— Implementing adequate disposal of sewage and garbage

— Providing adequate personal service facilities

— Maintaining hygienic food services

— Providing an acceptable level of heating and ventilation

— Ensuring that hazards from insects and rodents are identified and controlled

— Providing the required number of toilets based on the number of employees

— Providing at a minimum daily janitorial service

» Safety Inspections maintain safe conditions by checking for unsafe practices. These inspections are classified into four types of inspections:

— Periodic inspections - scheduled to be made at regular intervals (i.e. monthly, annually, or at other appropriate time intervals)

— General inspections - cover those areas that no one visits and where no one gets hurt.

— Intermittent inspections - unannounced inspections of the facility or part of the manufacturing tools to keep the supervisor alert

— Continuous inspections - a set of employees spend all their time observing certain equipment and operations.

— Special inspections - inspection of the installation of new equipment or new processes, construction of new facility, or renovation of the existing model, or because of new hazards

Key Terms

Further Study

1. OSHA Evacuation Planning Matrix http://www.osha.gov/dep/evacmatrix/evacplan_appb.html

2. American National Standards for Ladders - Safety Requirements http://webstore.ansi.org/RecordDetail.aspx?sku=ANSI+ASC+A14.3-2008#.UHdLPsVh2Bw

Key Concepts (cont.)

http://www.osha.gov/dep/evacmatrix/evacplan_appb.html



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18

» Aisles – Provided for the quick movement of people and material across different parts of a building

» Boiler Rooms – A room containing a boiler and related heating equipment.

» Continuous inspection – A set of employees spend all their time observing certain equip-ment and operations. The main duty of these employees is to roam around the facilities and continuously observe operations and make adjustments and minor repairs.

» Dock boards – Portable and powered bridge plates used to bridge the gap between trucks and a dock. Dock boards need to be adequately strong and secure and should be equipped with devices that prevent slipping.

» Elevators – A means of hoisting and lowering. Information that is essential for the safe operation and maintenance of elevators is provided in the ANSI Safety Code for Elevators, Dumbwaiters, Escalators and Moving Walks.

» Emergency exit – A special exit that allows for the faster evacuation of a building or facil-ity during the time of emergencies.

» Fire extinguishing agents – Types of fire extinguishing substances that vary depending on the class of fire.

» Fire safety – The implementation of fire prevention techniques and the use of appropriate firefighting equipment.

» General inspection – Inspections which cover those areas that no one visits and where no one gets hurt. These inspections are conducted before reopening a facility after renova-tion.

» Housekeeping – Keeping the work areas, passageways, and stairs free of debris, providing a facility for the safe removal of debris and combustible scrap, providing and emptying containers for the disposal of trash and other refuse, and providing and covering contain-ers for inflammable or hazardous wastes must be equipped with covers.

» IES – The Illuminating Engineering Society publishes practices on industrial lighting

» Inspection – The principal means of identifying the cause for an accident, determining the safeguards for preventing those accidents, and providing a solution for protecting against hazards before accidents and personal injuries occur

» Intermittent inspection – Inspections that are made at irregular intervals and are found commonly in almost all facilities. They include unannounced inspections of the facility or part of the manufacturing tools, keeping the supervisor alert in maintaining the safety of the facility.

» Ladders – All ladders must be inspected periodically, kept in good condition at all times, and must be free from sharp edges, splinters, oil grease, or other defects which would af-fect their use..

» Liquid spill – In the event of liquid spills, drain the spill by using a pump to store the liq-uid in a safe sink, absorbing the spill with suitable materials, or neutralizing the spill with a compatible solid.



4SAFETY

» Maintenance platforms – Mechanized platforms for maintenance use which often cause damage to platform surfaces. Angle iron or channel iron protection should be provided at the edge of the platform, and it should be well maintained.

» Man lifts – A mechanical device used to transport personnel from floor to floor on a plat-form that is moved using a power–driven endless belt moving in one direction.

» National Electrical Code – Code issued by the National Fire Protection Association (NFPA) which contains standards for proper electrical wirings and installations.

» Periodic inspection – Inspections which are scheduled at regular intervals (i.e. monthly or annually).

» Personal fall protection system – Protects employees in the event of a fall and assures that they are able to rescue themselves. Normally such systems will have sufficient strength to withstand twice the force of the impact from a falling worker.

» Powder spill – Spills in power form like pesticide powder should be swept or vacuumed.

» Riser height – Height of each step

» Sanitation – The process of providing safe, clean, and healthy environment for humans by removal of waste that is hazardous to human

» Scaffolds – Material that supports a temporary, elevated working platform used to support workers or materials.

» Special inspection – Inspections of the installation of new equipment or new processes, construction of new facility, renovation of the existing model, or an inspection of new haz-ards.

» Spills – The release, leak, discharge or unauthorized disposal of any oil or hazardous sub-stance onto the air, water, or land.

» Stairways – A set of steps that should be equipped with handrails and should adhere to OSHA regulations regarding the riser height and tread run.

» Tread run – Length of each step

This material is based upon work supported by the National Science Foundation under Grant Number DUE-1104181. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the National Science Foundation.

Copyright © 2013 Clemson University Center for Workforce Development. All Rights Reserved. 19



4SAFETY

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Attribution TablesOPEN TEXT, ASSESSMENT GUIDE & POWERPOINT

Author(s) Title Source LicenseMicrosoft Clipart

Health Insurance

http://officeimg.vo.msecnd.net/en-us/im-ages/MH900448730.jpg

With permission from Microsoft

Microsoft Clipart

Schematichttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900406830.jpg


Don Bray Safety Harness

http://commons.wikimedia.org/wiki/File:US_Navy_050823-N-9076B-002_Electronics_Technician_2nd_Class_Edwin_Dillaby,_left,_helps_a_chief_selectee_with_a_safety_har-ness_during_an_up_and_over_drill_were_the_selectees_climb_the_mast_and_come_down_the_other_side_aboard_USS.jpg

Public domain

Microsoft Clipart

Stairwayhttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900110881.jpg


New Zealand Defence Force

Maintenance Platform

http://upload.wikimedia.org/wikipe-dia/commons/0/05/20110217_AK_V1023933_0135_-_Flickr_-_NZ_De-fence_Force.jpg work platfortm

CC BY 2.0 Generic

Microsoft Clipart

Ladderhttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900405470.jpg


CUCWD Dock BoardsIllustration by CUCWD. Royalty free textures in illustration obtained from cgtecxtures.com

Microsoft Clipart

Scaffoldshttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900433122.jpg


Microsoft Clipart

Elevatorhttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900385977.jpg


Microsoft Clipart

Man Liftshttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900390429.jpg


Ashley Dace

Boiler Roomhttp://www.geograph.org.uk/pho-to/2326900

CC BY-SA 2.0

Wiki Commons

Loading Dockshttp://upload.wikimedia.org/wikipedia/en/1/1f/Warehouse_Loading_Dock.JPG

CC BY-SA 2.0

Microsoft Clipart

Walkwayshttp://office.microsoft.com/en-us/im-ages/results.aspx?qu=walkways&ex=1#ai:MP900179003|


Microsoft Clipart

House Cleaninghttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900400289.jpg


Microsoft Clipart

Alarmhttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900314277.jpg alarm

With permission by Microsoft

http://www.geograph.org.uk/photo/2326900

http://www.geograph.org.uk/photo/2326900



4SAFETY

21

Attribution TablesCUCWD Fire Exit Photo taken by CUCWD Benoît Derrier

Emergency Exithttp://commons.wikimedia.org/wiki/File:Emergency_exit_Stockholm_metro.jpg

CC BY 2.0 Generic

Microsoft Clipart

Firemanhttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900407334.jpg


Microsoft Clipart

Fire Extinguisherhttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900341704.jpg


Pieria Evacuation planhttp://upload.wikimedia.org/wikipedia/commons/4/47/Evacuation_route_sign3.jpg

Public Domain

Microsoft Clipart

Water Towerhttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900422668.jpg


Microsoft Clipart

Inspections http://officeimg.vo.msecnd.net/en-us/im-ages/MH900439299.jpg


Microsoft Clipart

Waste Disposalhttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900448699.jpg


Microsoft Clipart

Railsq http://officeimg.vo.msecnd.net/en-us/images/MH900430672.jpg


Thatsme2Industrial Lighting

http://upload.wikimedia.org/wikipedia/commons/0/01/Heavy_Duty_laundry_-_Ironer_line.jpg

CC BY-SA 3.0

Microsoft Clipart

Firehttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900400391.jpg


Microsoft Clipart

Waterhttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900399931.jpg


Microsoft Clipart

Mopshttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900385501.jpg


US. Dept. of Labor

Seal/Logohttp://commons.wikimedia.org/wiki/File:US-DeptOfLabor-Seal.svg

Public Domain; Logo images

restricted in some other countries

OSHA Logohttp://commons.wikimedia.org/wiki/File:US-OSHA-Logo.svg

Public Domain; Cannot be

altered as it is a Trademark

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