TaikishadeMxicoS.A.deC.V.hasadoptedtheenclosedTKSSafetyManualinitsentirety.Herein,the followingshallbeconsideredinterchangeable: TKSIndustrialCompanyisinterchangeablewithTaikishadeMxicoS.A.deC.

V TKSisinterchangeablewithTMX

TKS SAFETY MANUAL

850 Stephenson Hwy., Suite 710 Troy, MI 48083-3000 Phone: (248) 577-1100 Fax: (248) 577-1133

Page 1 of 200 QSP 6.51 Rev. 1/20/04

TKS Industrial Company Safety Manual Table of Contents

I. II. III. IV. V.

Memorandum, Statement of Safety Commitment..................................5 Forward .......................................................................................................6 Users Guide .................................................................................................7 Safety Responsibility ..................................................................................8 Safety Plan...................................................................................................9 A. B. C. D. E. Goal........................................................................................................9 Objectives..............................................................................................9 Strategies .............................................................................................10 Tactics..................................................................................................11 Safety Organization... ........................................................................12 1. Responsibilities .............................................................................12 2. Organization Chart......................................................................14 F. Schedule...............................................................................................14

VI.

Project Safety Program ...........................................................................16 A. B. C. D. E. F. G. H. I. J. Project Management ..........................................................................16 Subcontractor Responsibility............................................................16 Subcontractor Requirements Summary..........................................17 Required Safety Meetings ............................................................18 Required Paperwork for Subcontractor Safety Documentation ..18 Safety Implementation Sequence......................................................20 TKS Safety Representative................................................................21 Project Area Safety Audit .................................................................22 TKS Established Termination Procedure .......................................22 Job Hazard Analysis (JHA) ..............................................................23

VII.

Project and Safety Program Orientation Outline.................................24 A. Subcontractor Safety Orientation ....................................................24 B. Project Orientation (Owner Required)............................................26 C. Site Plan...............................................................................................28
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VIII. IX.

Basic Safety Rules.....................................................................................29 Accident Prevention Policy......................................................................42 A. B. C. D. E. F. G. H. Purpose ................................................................................................42 Responsibility......................................................................................42 Accident Procedure ............................................................................43 Accident Reporting ............................................................................44 Accident Investigation Procedure.....................................................45 Authorization for injured to work....................................................46 Accident Corrective Action...............................................................46 Accidents in Adjacent Work Areas..................................................47

X.

Fire Prevention Policy..............................................................................51 A. B. C. D. Overview..............................................................................................51 Fire Prevention ...................................................................................51 Welding/Hot Permits(Welding, Burning, Cutting, Grinding, Etc.)54 Temporary Storage Buildings...........................................................58

XI. XII. XIII. XIV. XV. XVI. XVII. XVIII. XIX. XX. XXI. XXII. XXIII.

Emergency Procedure and Evacuation Plan.........................................64 Lockout/Tagout/Blockout........................................................................67 Hazardous Communication Program ....................................................72 Confined Space Entry ..............................................................................90 Area Cleaning .........................................................................................130 Building Protection: Owner's Property Protection ............................132 Site Security Program............................................................................135 Drug Policy..............................................................................................139 Helicopter Lift Policy .............................................................................144 Painting Safety........................................................................................149 Personal Protective Equipment (PPE).................................................153 Equipment Inspection Program............................................................162 Slips, Trips and Falls Prevention Policy ..............................................167
Page 3 of 200 QSP 6.51 Rev. 1/20/04

XXIV. XXV. XXVI. XXVII. XXVIII. XXIX. XXX. XXXI XXXII XXXIII.

Ladder and Scaffold Safety ...................................................................171 Job Site Inspection Categories ..............................................................175 Temporary Handrail Design.................................................................187 Sample Fuel Storage Area .....................................................................188 Crane Signals ..........................................................................................190 Crane Reach Capacity... ........................................................................191 Suggested Tool Box Safety Meetings Topics .......................................192 Safety Manual Forms.............................................................................195 Acknowledgement Letter.......................................................................196 Index ........................................................................................................197

Page 4 of 200 QSP 6.51 Rev. 1/20/04

II.

FORWARD This TKS Industrial Company safety program and safety manual has been approved by Mr. Suguru Kimura, President. The original version of this safety program was developed by TKS Industrial Company in 1986 with a major revision in 1992. The 1992 revision was developed in association with Cecil R. Smith, Dr. P.H., Chief, Division of Environmental and Occupational Health & Safety at the Ohio State University, reviewed by Faye Thompson, Ph.D., Director of Environmental Health & Safety at the University of Minnesota, Steve Hardy, UAW Unit Health & Safety Representative, the St. Paul Building Trades Council, Mr. Alfred Schmitt and the associated building trades members. Although there has been no major revision to the safety manual since 1992, certain portions have been expanded, clarified in part with various format changes having been made. The revised safety manual revisions are listed as follows: 1994 Edition, Revision 5 dated 6/4/97, Revision 6 dated 1/1/98, Revision 7.5 dated 7/1/2000, Revision 7.5 dated 10/25/2000, and this Revision 7.6 dated 1/1/2001.

Page 6 of 200 QSP 6.51 Rev. 1/20/04

III.

USERS GUIDE This TKS Industrial Company Safety Manual has been written for all TKS Associates stating our safety policy in a form that can be used for quick reference by our project teams. These policies apply to all of our personnel including those located in our offices, fabrication facility, project sites etc. This manual has also been written to provide an understanding of the TKS safety commitment to our Customers, TKS Associates, and Subcontractors. To avoid misunderstanding, this manual has been written as if directed specifically toward our Subcontractor. However, the provisions of this manual apply to all TKS Associates. In the context of this Safety Manual the word "Subcontractor" should be read as & includes all TKS Associates, subcontractors, lower tier subcontractors, vendors, suppliers and their employees who provide services or goods to TKS for our projects.

All forms provided in this Safety Manual are SAMPLE FORMS ONLY. The actual forms are included in the TKS Safety Manual Forms Section of the Compact Disk.
Disclaimer: Nothing in this Safety Manual is intended to infer that TKS or its Subcontractors or Lower Tier Subcontractors shall provide a full time, onsite safety representative. A full time, on-site safety representative will only be provided if required by the owner. In any event, designated Safety Representatives will be identified as having responsibility for safety requirements and maintenance of safety records for TKS, each subcontractor, and each Lower Tier Subcontractors.

TKS is fully committed to safety.

Page 7 of 200 QSP 6.51 Rev. 1/20/04

IV.

SAFETY RESPONSIBILITY As a part of your contractual obligation with TKS, all Contractors, Subcontractors, Vendors, Suppliers etc. (Subcontractor) shall implement, coordinate and enforce, a comprehensive, uniform site Safety and Accident Prevention Program. The Subcontractor's Safety and Accident Prevention Program will be submitted for TKS review and file at or prior to the project's Pre-mobilization Meeting. In addition to the Safety and Accident Prevention Program, each Subcontractor shall provide a written Lockout/Tagout Procedure, Confined Space Entry Program, Employee Right To Know Program (Hazardous Communication), and appropriate Material Safety Data Sheets (MSDS). The Subcontractor will ensure compliance with all applicable regulations, standards, specifications and procedures of OSHA, all other Federal, State and Local regulating agencies, this TKS Safety Program, and the Owner's Safety Policy. The Subcontractor will also attend and conduct regularly scheduled safety meetings to increase safety and hazard recognition awareness. He will also provide specialized training and provide skill training and other safety training to their tradesmen and employees. TKS will monitor safety, only. Safety is the responsibility of the Subcontractor. However, this Safety Manual is intended to supplement the individual programs of each Subcontractor in order to coordinate the overall project safety effort. Each Subcontractor is ultimately responsible, regardless of tier, for providing a safe and healthful work place. Disclaimer: The performance of Safety and Project Orientations, Safety Audits, Safety Reviews, Safety Inspections, Safety Meetings, Site Safety Tours, Safety Warnings, Maintenance of Safety Documentation and Files and any other safety activity conducted or other specific actions taken by TKS and/or the Owner, including security, will not relieve the Subcontractor's sole responsibility for Safety Program development, implementation, enforcement for corrective procedures and implementation (action), the provision of skill trained and safety trained tradesmen and adequate supervision for the Project by the Subcontractor.

Neglecting safety is neglecting Project responsibility.

Page 8 of 200 QSP 6.51 Rev. 1/20/04

V.

SAFETY PLAN A. Goal It is the goal of the TKS Industrial Company to provide a safe project site with Subcontractors and team members who have a clear understanding of safety principals, have a safety oriented work ethic, understand their individual rights to know, are well trained in safety procedures, are skill trained, are perceptive to potential workplace hazards, are motivated to complete each project task safely for project completion with good quality, on schedule and within budget, while minimizing personal injury, eliminating suffering, reducing schedule time losses and financial losses due to preventable personal injuries and unnecessary property damage. B. Objectives 1. 2. 3. To establish and maintain a safe and healthy workplace. To prevent personal suffering due to project site accidents. To prevent financial loss due to project site accidents, including personal injury and property damage. To promote a positive health and safety attitude that flows throughout the project from management to team members and from customer to team members. To insure that team members/tradesmen are encouraged to pursue personal and professional development through continuous skill and safety training programs designed to increase safety awareness while promoting the proper use of tools and equipment. To coordinate development of subcontractor and team member safety awareness. To complete project requirements safely and on schedule. To provide a quality installation representative of: a. The Engineering and Construction Management of TKS Industrial Company The fabrication and installation of TKS and it's Subcontractors
Page 9 of 200 QSP 6.51 Rev. 1/20/04

4.

5.

6.

7. 8.

b.

c.

The craftsmanship of the members of the Building Trades (the point of quality and safety control) in accordance with the concept of Total Quality Management

C.

Strategies 1. Develop an understanding of safety responsibility through specific safety training, skill training and safety meetings. Emphasize and require pre-planning for accident prevention. Require development of a Safety Program by each Subcontractor that includes continuous site safety audits, tool and equipment usage evaluations, on-going safety training, basic safety procedures, accident procedures, job hazard analysis, Employee Right to Know, Confined Space Entry, Lockout/Tagout/Blockout, etc. Establish a plan for safety education and the promotion of safety management through safety meetings, safety audits and a positive management approach. Continued development of a safety program with policies that are clear, concise and understandable, freeing team leaders and team members from repetitive decisions regarding common and repetitive safety problems in accordance with the concept of Continuous Quality Improvement (CQI). Provide a detailed, realistic and achievable project schedule for effective coordination of project installation requirements. Outline the duties and responsibilities of the project team members and other parties on the project. Eliminate improper working practices that might impact employees well being, project schedule and budget, and/or have a negative impact on the environment, through Subcontractor provided skill training. Coordinate work to minimize the negative impacts of joint occupancy. Require Subcontractor provided safety orientation that will reinforce, not replace nor substitute for the skill training and safety training provided by the Subcontractors and trades union organizations. Complete Job Hazard Analysis and conduct safety audits to help team members Identify hazards associated with their jobs and assist in the development of techniques for controlling these hazards to reduce accidents
Page 10 of 200 QSP 6.51 Rev. 1/20/04

2. 3.

4.

5.

6.

7.

8.

9. 10.

11.

and near misses resulting in physical suffering for tradesmen and loss of schedule time and financial resources for the project. 12. Provide a designated representative to conduct safety audits and assist Subcontractors and team members with safety compliance. Select Subcontractors who have a good safety record and have demonstrated a willingness to cooperate and encourage safe working practices and conditions. Select TKS Associates for project site assignments, who have demonstrated an understanding of proper project site safety requirements.

13.

14.

D.

Tactics 1. Continuous Enforcement of the Following Subcontract Requirements: a. b. c. Housekeeping (Area Cleaning) Enforcement Coordination of work through detailed schedule development. Continuous evaluation of schedule and work progress to insure proper project coordination. Project Coordination designated to reduce stacked trades, joint occupancy and other interference's which may impact job task and project effectiveness, while increasing accident potential. Safety Orientation provided by the Subcontractor to new employees. Daily project site safety audits. Safety and equipment inspections. Supervise employee use of tools and equipment to help insure proper, safe utilization for avoidance of potential accidents and near misses.

d.

e.

f. g. h.

2.

Safety Meetings as part of the on-going safety training program encouraging group discussion of safety issues. a. Daily - Morning Gang Box Safety discussions with employees by Subcontractors

Page 11 of 200 QSP 6.51 Rev. 1/20/04

b.

c. d.

e. f. g. 3.

Daily - Safety Instruction for the proper and safe utilization of tools by tradesmen. This training will be provided by the Subcontractor. Weekly - Construction Meeting with safety review Weekly - Tool Box Safety Meeting with employees by Subcontractors (employee attendance sheets with signatures are required) Bi-Monthly - Contractor Safety Meetings Monthly - Union Steward Safety Meetings Monthly - Safety Committee Meetings

Use professionally developed video presentations to increase safety awareness, when possible. Immediate correction of site safety problems. Provide Safety Handouts at safety meetings identifying areas of safety concern. Enforcement of Subcontractor Requirements. Attention to detail at every level of project requirements by associates, tradesmen, Subcontractor and TKS.

4. 5.

6. 7.

E.

Safety Organization Each Subcontractor will appoint a qualified safety person to assist the organization listed in the following: a. b. c. 1. Full Service Construction Manager- Safety Representative Subcontractors - Safety Representative Employees - Union Steward

Responsibilities a. Full Service Construction Manager - Safety Representative 1. 2. 3. 4. To insure compliance by all parties with the principles of the Project Safety Program and Safety Manual. To receive the Subcontractor Safety Manual. To determine that the Subcontractor Safety Program has been implemented and is apparently being enforced. Assist all Subcontractors in pre-planning their operations to prevent personal injury or property damage through proper project coordination. Chair the Project Safety Meetings.
Page 12 of 200 QSP 6.51 Rev. 1/20/04

5.

6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Chair the Union Steward Safety Meeting. Issue Safety Bulletins as prepared for the Project. Insure project cleanliness. Investigate serious accidents Direct the abatement of hazardous conditions. Make formal safety tours. Review the safety of the project on a daily basis with the Owner and all Subcontractors. Take the lead in recognition and abatement of hazardous situations. Issue safety violation notices. Maintain the safety and insurance files (Safety Meeting Minutes, Accident Reports, Training Certification, Insurance Certificates etc.).

b.

Subcontractor Safety Representative 1. 2. Maintain a safe, clean work area. Insure that all work is performed in a safe manner with all OSHA, federal, state and local requirements adhered to at all times. Assist the TKS Project Safety Representative in recognition and abatement of hazardous situations. Provide continuing safety education to all Subcontractor employees by conducting Tool Box Safety Meetings on a weekly basis (with a copy of these minutes and signed attendance sheet provided to the TKS Safety Representative). Providing skill and safety training and proper supervision for work completion. Effectively utilize and instruct employees in pre-planning, recognition and abatement of hazards. Investigate accidents and thefts by gathering facts, names of witnesses and writing proper detailed reports. Assist the TKS Safety Representative in the investigation of injuries and accidents. On a daily basis, review the safety of the project with the TKS Safety Representative. Assist the TKS Safety Representative in maintaining the Safety Bulletin Board, safety signs, barricades, handrails, guardrails and all other employee protection. Insure that employees are wearing appropriate Personal Protective Equipment (PPE) and maintaining a safe work environment. Maintain safety and insurance files

3. 4.

5. 6. 7. 8. 9. 10.

11.

12.

Page 13 of 200 QSP 6.51 Rev. 1/20/04

c.

Employees 1. 2. 3. Employees are the point of quality and safety control. Employees are the point for the implementation of project safety. Perform all work utilizing the proper techniques for the proper use of tools and equipment in a manner to prevent accidents to themselves and other employees. Alert the Safety Representative and supervisors to unsafe and dangerous situations. Cooperate with and follow the principles of the Project Safety Program and Manual. Abide by all OSHA, Federal, State and Local codes, regulations and requirements.

4. 5. 6.

2.

Organization Chart The Subcontractor will provide and maintain an updated organizational chart with after normal working hours telephone contact information provided to TKS.

F.

SCHEDULE 1. Schedule development is dependent upon a well thought out plan, based on sound engineering principles and a good installation sequence. This plan must include development of an organization capable of meeting project requirements, safely. Although time may be at a premium, this crucial step must be completed carefully. A schedule detailed by event, sequenced for completion, and man loaded on a time line is required to insure that scheduled work requirements are achievable and may be completed safely in relation to other work scheduled in the same or an adjacent work area. Although finite, properly developed schedules are dynamic with built-in flexibility. They have to be understood, monitored and managed to be effective. Good schedule control provides a means to recognize opportunities to safely move the project ahead of schedule or return to schedule other areas that may have slipped.

2.

3.

4.

Page 14 of 200 QSP 6.51 Rev. 1/20/04

5.

Schedule: Two weeks from the award of the contract date, the Subcontractor will provide TKS with a man loaded, detailed schedule, sequenced by task for project completion. One purpose for this schedule is to insure that work sequences with other contractors will not conflict in such a manner to create unnecessary safety hazards.

Flexibility is found in detail.

Page 15 of 200 QSP 6.51 Rev. 1/20/04

VI.

PROJECT SAFETY PROGRAM

TKS Industrial Company (TKS) and TKS' Safety Representative will be dedicated to the premise that a safe working environment is to be maintained at all times. Unsafe conditions must be corrected immediately. A. Project Management 1. The Project Manager is fully responsible for safety enforcement for the project. This safety manual represents TKS Safety Policy and as such may only be changed or modified by TKS executive management. The Subcontractor is fully responsible for the project safety included in his portion of the work. Nothing in this manual will relieve the Subcontractor of his sole responsibility for safety. OSHA: It is the policy of TKS not to require a search warrant for an OSHA inspection. Neglecting Safety is Neglecting Project Responsibilities. B. Subcontractor Responsibility 1. The Subcontractor is responsible for employee, Owner and public safety for their portion of the work. It is to be understood by each Subcontractor that the safety and health of all persons involved with this project is essential to the goal of successful project completion. Teamwork and coordination are vital to meeting project objectives. The Subcontractor cooperation and support in this effort is required. Subcontractor will provide a written safety program which they will enforce to ensure continuous safety compliance during the execution of their work. It is the responsibility of each Subcontractor to provide skill trained and safety trained tradesmen (craftsmen and workers) for project installation requirements.

2.

3.

4.

2.

3.

4.

Page 16 of 200 QSP 6.51 Rev. 1/20/04

a.

b. c.

Subcontractor will provide specific training for Supervisors, Electrical Tradesmen, Pipe Fitters, Welders, Fire Watch, Cutting and Grinding Personnel, Cleaning Personnel and Painters, and Confined Space Entry authorized attendants, entry supervisor and team members. An Employee Right to Know Program will be included in the Subcontractor's safety program. A Confined Space Entry Program will be included in the Subcontractor's safety program.

5.

Each Subcontractor will be required to supply a designated safety representative for each shift of work being conducted. This safety representative must be onsite for the entire shift or be immediately available by phone or radio contact. This safety representative must be trained in all aspects of the site safety program and be well versed in safety requirements of their particular trade. The Subcontractor safety representative will be responsible for all aspects of the safety program, be in direct contact with the TKS Industrial Company Safety Representative, be responsible for the action and safety of their team members, complete all paper work as required by the safety procedure manual, have a basic understanding of first aid and CPR, have responsibility for team member training, Tool Box Meetings, etc. Accident Investigation, Reporting Procedures and Analysis (Accidents, Injuries and Near Misses). Each person who has received training will acknowledge that he has read, understands and agrees in writing with the Basic Safety Rules and the other provisions of this manual and certify that he has attended the safety orientation which will be presented by the Subcontractor. A copy of this agreement will be provided to TKS, which will be maintained in the Safety Orientation Acknowledgments File. TKS may survey and verify that each person is abiding by these rules.

6.

7.

8.

C.

Subcontractor Requirements Summary 1. 2. 3. 4. 5. 6. 7. Develop, implement and enforce a written safety program Supply a designated safety representative Comply with all provisions of the TKS and Owner safety programs Comply with all OSHA, federal, state and local mandates and regulations Actively participate in the safety program by attending and conducting scheduled safety meetings Develop team member safety awareness Aggressively audit the safety procedures of the team members

Page 17 of 200 QSP 6.51 Rev. 1/20/04

8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Cooperate will all other contractors and Subcontractors with the implementation and enforcement of their safety program Complete required accident investigation reports Communicate with TKS Industrial Company regarding safety concerns Maintain a Tool Box Safety Meeting Minutes File with a copy provided to TKS Maintain an Accident File with a copy provided to TKS Subcontractor provided job trained and skill trained tradesmen Provide safety trained tradesmen Provide Material Safety Data Sheets (MSDS) prior to the introduction of a chemical onto the project site Provide a written lockout and tagout procedure Provide a written Confined Space Entry Program Provide a written Hazardous Communication Program, Employees Right to Know Provide a written inspection plan for equipment and tools, including the replacement policy.

D.

Required Safety Meetings: 1. 2. 3. 4. 5. 6. 7. Pre-Bid Meeting - Explanation of Safety Program Expectations Pre-mobilization Meeting - Safety Review and Site Requirements Daily - Safety Inspections Weekly - Tool Box Meeting with Employees by Subcontractor Weekly - TKS Construction Meeting Bi-Weekly - Project Coordination Meeting with Safety Review Monthly - Safety Committee Meeting (Union Stewards)

E.

Required paperwork Subcontractor Safety Documentation 1. Accident Reports a. b. 2. Personal Injury See Section IX

Incident Report a. b. Building Damage See Sections XIV.

3.

Insurance Certificates a. b. c. d. Workman's Compensation Property Damage and Liability Automobile See Tabular Section 3, General Terms & Conditions
Page 18 of 200 QSP 6.51 Rev. 1/20/04

4.

Safety Orientation Acknowledgment Letters a. b. These will be signed by employees. See Section XIII.

5.

Certificates of Training for Tradesmen a. b. c. d. e. f. Welding Fire Watch Fire Extinguisher Equipment Operation Confined Space Entry Other

6.

Hazardous Communication Program a. b. c. OSHA required, Employees Right to Know Acknowledgment of Training and Personal Understanding Letter See Section XIII.

7.

Material Safety Data Sheets (MSDS) a. b. OSHA required, as part of the Employees Right to Know Program See Section XIII

8.

Confined Space Entry Program a. b. c. d. OSHA required, Acknowledgment of Training Letters Confined Space Inspection Forms Confined Space Entry Permits See Section XIV

9.

Lockout/Tagout/Blockout Program a. b. Tagout Log Book maintained by the TKS Safety Representative See Section XII

10.

Equipment Inspections a. Suggested forms are found in Section XXII

11.

Drug Testing File a. b. Policy Discussion If required by contract, forms will include:
Page 19 of 200 QSP 6.51 Rev. 1/20/04

c. d. e. f. 12.

TKS and Subcontractor Company Authorization Employee Testing Waiver Drug Test File See Section XVIII

Helicopter Flight Plan a. b. c. d. If required for project. TKS Planning Form Federal Aviation Administration (FAA) Flight Plan, if required. See Section XIX

13. 14. 15.

Safety Violation File Tool and Equipment Maintenance Schedule and Inspection File Welding Permits a. b. c. d. e. f. g. Daily Work Area Permits File Retrofit Projects During and Following Paint Line Charging During and After Facility Launch Fire Permits Hot Work Permits Section X

16.

Equipment Tool Lists a. See Section XVII

F.

Safety Implementation Sequence 1. Pre-bid and Bid Clarification Meetings: will be conducted for competitive pricing and contract award. Past safety performance will be considered in the establishment of the Bidders List and selection of the Subcontractor. Safety will be stressed in each of these meetings. Schedule: Two weeks from the award of the contract date, the Subcontractor will provide TKS with a man loaded, detailed schedule, sequenced by task for project completion. One purpose for this schedule is to insure that work sequences with other contractors will not create unnecessary safety hazards. Pre-mobilization Meeting: Thirty days prior to the Subcontractor's mobilization, the Subcontractor will attend a Pre-mobilization Meeting with TKS to discuss project requirements, schedule, security and safety. At this
Page 20 of 200 QSP 6.51 Rev. 1/20/04

2.

3.

meeting, the Subcontractor will provide TKS with their safety program and safety manual. 4. Upon mobilization, the Subcontractor will initiate their Safety Program including: a. b. c. d. e. f. g. 5. Project and Safety Orientation (see Section VII) Tool Box Safety Meetings (see Section XXX) Skill Training (see Section VI) Safety Training (see Section VI) Site Safety Audits (see Section VI) Equipment Inspection Program and etc. (see Section XXII) Hazardous Communication Program (see Section XIII)

Upon or prior to mobilization, the Subcontractor will attend TKS Construction Meetings, Coordination Meetings and Safety Meetings. The Subcontractor will comply with all sections of this safety manual from the date of the award of the contract, with all provisions included in their Bid/Proposal. Project Close Out Meeting Following completion of the project, a Project Close Out Meeting will be conducted to review the project, including safety. This information will be considered for future project award and contract decisions.

6.

7.

Site safety problems are to be corrected immediately.

G.

The TKS Safety Representative 1. 2. 3. A TKS on site Safety Representative will be designated for each project. The responsibility for safety compliance remains with each Subcontractor. The TKS Safety Representative will review the safety programs of each Subcontractor. The Subcontractor's liability for safety will not be lessened nor diminished by TKS efforts to conduct safety program reviews and for making recommendations. The TKS Safety Representative shall not be required to make exhaustive nor continuous safety inspections and safety audits to check safety
Page 21 of 200 QSP 6.51 Rev. 1/20/04

4.

precautions, procedures and programs in connection with the project safety. This is the sole responsibility of the Subcontractor. 5. The performance of such inspections by the TKS Safety Representative shall not relieve the Subcontractor of their responsibilities for the safety of persons and property, and for compliance with all OSHA, federal, state and local statutes, rules, regulations and orders applicable to the conduct of their work.

H.

Project Area Safety Audit and Equipment Inspections 1. A safety and health survey of work operations, equipment, storage areas and facilities shall be conducted daily by the Subcontractor. Unsafe or unhealthy acts or conditions will be noted and shown to the supervisor in charge for corrective action. TKS will also make periodic safety inspections. Unsafe or unhealthy acts or conditions will be noted with serious or repetitive violations documented on a Safety Violation Notice, which shall be given to the Subcontractor's Safety Representative for corrective action. In case of imminent danger when a condition or practice exists which could reasonably be expected to cause death or serious physical harm or extensive damage to property, it will be the policy of TKS to STOP that portion of the work affected until the hazardous conditions are corrected. If work is stopped for these reasons, it is agreed that TKS will not accept nor pay for any additional charges or extra charges for the stopped work. The Subcontractor agrees to this statement as part of the contractual obligation.

2.

3.

I.

The TKS established termination procedure for safety violations for all employees is as follows: The Subcontractor shall be expected to discipline and/or remove employees who violate established rules and regulations. This shall include immediate termination for serious violations such as use of or possession of intoxicants or illegal drugs, fighting, misconduct and refusal to follow safety and health rules. a. b. c. d. First Warning -Verbal Warning Second Warning -Written Notice Third Warning -Immediate Dismissal No Warning-For Serious Safety Violations

Any employee knowingly violating Mandatory Safety Rules will be removed from this project and will not be able to return.

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J.

Job Hazard Analysis (JHA) A Job Hazard Analysis is prepared for each specific job or operation required to complete a task. A JHA is required for new tasks or tasks that are hazardous or have a possibility for accident occurrence. 1. Steps to a Job Hazard Analysis: a. b. c. d. 2. Break the job into specific steps. Identify the hazards at each step. Develop procedures to eliminate hazards. Provide employee training for employee awareness of the hazard.

Criteria for Job Selection: a. b. c. d. Frequent history of accidents. Severity of past accidents. Potential severity of possible accidents. New jobs.

3.

Uses of a JHA a. b. c. d. e. f. g. h. i. Self reference guide. Training for new employees. Equipment maintenance check lists. Accident analysis. Worker/Supervisor coordination. Increase awareness. Increase safety Safety Training Skill Training

Page 23 of 200 QSP 6.51 Rev. 1/20/04

VII.

PROJECT AND SAFETY PROGRAM ORIENTATION OUTLINE A. Subcontractor Safety Orientation: 1. The Subcontractor will provide a site safety orientation for all of their employees, tradesmen, visitors etc. The orientation will be submitted for TKS review. If project requirements specify the project orientation as discussed in Section B., then the Subcontractor may modify his safety orientation by eliminating areas of duplication from his orientation as approved by TKS. However, the responsibility for a proper understanding of project safety requirements is still the responsibility of the Subcontractor. a. Safety Program Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. b. Team Member Safety & Health Awareness Training Safety Procedures Program Accident Procedures Program Mandates & Compliance's: OSHA, MSDS, & HAZMAT Lockout/Tagout/Blockout Procedures Program Area Cleaning Requirements Fire Protection Program Subcontractor/Vendor Rules Summary Subcontractor & Tradesmen Responsibilities Helicopter Lifts Requirements Job Hazard Analysis Confined Space Entry Program

2.

Subcontractor Orientation 1. Project Orientation a. b. c. d. Introduction Statement of Purpose Statement of Mission/Scope/Goals Project Orientation - Colored Building Layout

Page 24 of 200 QSP 6.51 Rev. 1/20/04

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 2.

Construction Area - Site and Building Plans Personnel Entrance and Parking Areas Building and Construction Area Access Customer Offices Site Offices Customer Security Requirements Locations of Emergency Telephones Life Safety Devices Break Areas Designated Smoking Areas Personal Protective Equipment Facility - Restroom, Eyewash and Emergency Shower Stations, etc. Staging and Laydown Areas Fuel Storage Area Location Dumpster Location and Waste Removal Policy Safety Bulletin Board Location First Aid Station Location Hospital Location

Safety Orientation a. Safety Policy Requirements 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. b. c. d. e. f. Pre-Bid and Pre-mobilization Meetings Safety Meetings including Tool Box Meetings Safety Training Safety Audit Daily Construction Cleaning Accident Investigation and Reporting Employee Skill and Safety Training and Sign-Off Immediate Correction of Safety Problems Documentation Communication Safety Violation Policy

Accident Procedures Fire Extinguisher Training - Type and Operation Fire Watch - TKS Requirements Emergency Response and First Aid Employee Right to Know Program

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1. What is MSDS? 2. How to read and understand a Material Safety Data Sheet 3. Purpose of MSDS d. Location of MSDS sheets. g. h. i. j. k. B. Confined Space Entry Program Lockout/Tagout/Blockout Electrical Ground Fault Protection Asbestos Project Site Safety Tour

Project Orientation (Owner Required) 1. Potential Contract Requirement Although it is the responsibility of each Subcontractor to ensure that all individuals, before beginning work on the project, attend a mandatory Subcontractor provided Project Orientation and Safety Orientation, a Customer or TKS Project Orientation may also be required. This potential additional safety requirement is discussed in this section. The contract should be checked for this additional requirement as discussed in this section. 2. Responsibility If required, a project safety orientation will be provided by TKS. However, this orientation in no way relieves the Subcontractor of his responsibility of providing project, job and skill training, safety training and the supply of properly skill trained and safety trained tradesmen for project work. NOTE: Any employee removed for a safety violation will not be able to return to the project. 3. Orientation The Project Safety Orientation will include job site policies, project rules, safety and accident procedures owner security requirements and may be recorded on a VCR tape for clarity and uniformity. The approximate running time for a taped presentation will be one hour and thirty minutes. After viewing the orientation tape, there will be a review of the overall site and building plan view posted on the wall, which will be followed by a project site tour. In addition to the above, the following may be included:

Page 26 of 200 QSP 6.51 Rev. 1/20/04

a.

Safety Orientation Tapes (International Training Systems) 1. 2. 3. 4. Contractor Safety Orientation Lockout/Tagout/Blockout The MSDS: Cornerstone of Chemical Safety Fire Extinguisher: First Line of Defense

b.

Employee Safety Training Identification Sticker Depending upon project requirements, construction hard hat stickers or another employee identification mechanism may be issued to all persons upon completion of the safety orientation and successful completion of the optional testing requirement. These numbered stickers will be placed on hard hats. The employees names and numbers will be filed with the TKS Safety Representative for project identification purposes with the list forwarded to plant security. If required, the hard hat safety sticker or other identification badge will be required to allow that person on the construction site. The safety identification sticker or badge must be worn on employee's hard hat at all times while on the site as project site identification and for site access.

c.

Employee's Safety Orientation Regardless of the projects geographic location, each Subcontractor shall comply with the Minnesota Occupational Safety and Health Standards for the construction industry (M.O.S.H.A.) regulation which states that all employers shall instruct each employee in the recognition and avoidance of unsafe conditions and the regulations applicable to their work environment.

d.

Basic Safety Orientation Policy Each person that visits or works on this project shall attend a Basic Safety Orientation established by the Project Manager. Attendance is mandatory and records shall be kept of all attendees and will be filed with the Project Manager. The focus of this orientation shall be the Project Safety Guidelines, Basic Safety Rules, Employee' s Responsibilities and Employees Right to Know. Each employee shall receive a copy of specific Safety Rules and Regulations and a copy of the TKS Accident Prevention Manual will be available for review.

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e.

Trade Safety Orientation In addition to Basic Safety Orientation by TKS, as discussed in this section, each Subcontractor shall provide employees with a Trade Safety/Skill and Job Training Orientation before beginning work. This orientation shall include specific Basic Safety Rules (See Section VIII of this manual) and potential hazards in the Subcontractor's area of control and the use of personal protective equipment (PPE). Attendance at this training is also mandatory.

f.

Handouts 1. 2. 3. 4. 5. 6. Emergency Procedures Fuel Storage Area Requirements Safety Rules and Procedures Project Clean Up Program TKS Accident Prevention Manual excerpts Fire Extinguisher Locations

C.

Site Plan A plan view of the Owner's facility, colored to identify work areas/construction areas, building access, facilities, security, laydown and staging areas, parking and etc. is a valuable tool for the Project and Safety Orientation. When accompanied by a project tour, it provides a means for tradesmen orientation and reduces confusion which may lead to unsafe circumstances or accidents

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VIII. BASIC SAFETY RULES A. Mandatory Safety and Health Rules 1. All TKS Associates, Subcontractors and tradesmen are required to know the mandatory safety and health rules, discussed below, prior to the beginning of any work on a TKS project. Attendance at a Subcontractor provided project and safety orientation is required. TKS will monitor safety only. Safety is the responsibility of the Subcontractor and each employee. During the performance of the Subcontractor work, the Subcontractor must meet and comply with all OSHA, Federal, State, Local and other construction and safety standards, specifications, regulations and requirements. Each Subcontractor is responsible for compliance with this Safety Program and Safety Manual by their employees, lower tier Subcontractors, Vendors, Suppliers and Visitors regardless of tier. Any person not directly involved with the onsite construction of this Project will not enter the project site without first going to the TKS Field Office to check-in and obtain a hard hat, which is to be returned to the TKS Project Office upon departure from the project. Each tradesman before beginning work on the construction site will receive a mandatory safety orientation provided by the Subcontractor as follows: 1. 2. 3. 4. 5. 6. 7. 8. a. Project Orientation Accident and Emergency Procedures Safety Program Procedures Manual Review Mandatory Health and Safety Rules Established Programs Confined Space Identification and Entry Procedures Lockout/Tagout/Blockout Employee Right to Know (MSDS)

2.

3.

4.

5.

6.

The safety orientation will be presented by the Subcontractor. Each person will acknowledge that he has read, understands and agrees in writing with these rules. A copy of this agreement will
Page 29 of 200 QSP 6.51 Rev. 1/20/04

be provided to TKS and is included in the Forms Section of this manual. b. The TKS Safety Representative will maintain the signed Safety Orientation Acknowledgments in a file and will survey and verify that each person is abiding by these rules (Safety Orientation Acknowledgment Form.see Forms).

7.

The Site Safety Regulations provided by the Owner, Full Service Management Contractor, TKS Industrial Company, and Subcontractor shall be strictly obeyed. Each Subcontractor will have and enforce a safety program as part of their company policy. TKS shall not make exhaustive nor continuous inspections to check safety precautions and programs in connection with the work of each individual Subcontractor. This is the Subcontractor's responsibility. The safety inspections performed by TKS shall not relieve the Subcontractor or Trade contractor of their responsibilities for the safety of persons and property, and for compliance with OSHA, federal, state and local statutes, rules, regulations, and orders applicable to the conduct of the work. A copy of the Subcontractor's Safety Manual is to be provided to TKS at or prior to the Pre-mobilization Meeting, prior to Subcontractor's arrival on the project site and prior to the start of Subcontractor's work. These manuals will be kept in the TKS field office. Each Subcontractor is required to immediately report to the TKS Safety Representative any unsafe conditions which they consider the responsibility of others. The TKS Safety Representative will coordinate the corrective action with the responsible parties. Employees shall report all unsafe practices and conditions to their supervisor immediately. Upon notification of an unsafe act or condition, the Subcontractor will immediately correct the safety violation. Repeat offenders will be removed or replaced. A list of employee names of Subcontractor personnel to be on the job site is to be submitted to the Project Manager and updated on a daily basis. This requirement is included for emergency notification purposes.

8.

9.

10.

11.

12.

13.

14.

15.

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16.

A designated supervisor must be on site during all working hours and indicated on the personnel list. The Subcontractor Supervisor will maintain an emergency notification list of Subcontractor supervisors and off-site management personnel with site and after hours telephone numbers. This list is to be provided to TKS and updated as required. The project will be monitored daily by TKS and the Owner for safety violations. Subcontractors will advise their personnel that if a serious situation occurs the Subcontractor's work will be stopped until the situation is corrected. Following the stoppage of work, an incident report will be filed by the Subcontractor's company and by the person who stopped the work. In any event, these safety inspections do not relieve the Subcontractor of his responsibility to monitor and maintain a safe project site. The fact that the work was stopped will not be used as a basis for an extra charge to TKS or the Owner. The Subcontractor and vendor personnel are not permitted in areas of the plant or department other than their assigned work area(s), break area, restroom, and approved routes between these areas. Unless specifically authorized in writing, firearms and explosives are prohibited within the construction area. The use or possession of intoxicants or drugs on the job is prohibited. Any employee reporting for work or later becoming intoxicated or under the influence of alcohol or drugs will not be allowed to work and will be administered disciplinary action which could result in immediate termination. Subcontractors may be assigned a TKS approved vendor staging/work area. This area is to be used for all equipment, tool cabinets, and construction materials. Tool cabinets and equipment may be moved to the job site on a daily basis. These items must be returned to the assigned staging area at the conclusion of each days work. A designated parking area for company vehicles will be assigned. No other area is to be used. Vehicles are not to be brought inside the building without permission of the Project Manager. Each Subcontractor is responsible to plan all work to prevent personal injury or damage to property, employees or public. At each weekly Construction Meeting a safety report will be delivered by the TKS Safety Representative. This report will discuss safety problems
Page 31 of 200 QSP 6.51 Rev. 1/20/04

17.

18.

19.

20.

21.

22.

23.

24.

25.

and concerns and provide topical information for Subcontractor's Weekly Tool Box Safety Meetings. 26. At their discretion, the Project Manager or the Project Construction Manager may conduct daily or weekly safety meetings with all Subcontractor personnel assigned to the project. These meetings will be held at a location and time designated as convenient to TKS, and will not last more than 30 minutes from the stated starting time. Weekly Tool Box Safety Meetings will be held each Monday, by the Subcontractor, with original reports delivered to the TKS Field Office before noon on that day. Each person present at the safety meeting will sign the form. An outline (lesson plan) for the meeting will be listed on the back of the form (Tool Box Safety Meeting Form. See Forms). Daily Gang Box Pre-work Meeting where job assignments and job site conditions are discussed will also include a safety message for the day. Each Subcontractor must have a scheduled maintenance program for all tools and equipment. Unless authorized, do not attempt to repair or tamper with equipment that is not functioning properly. Report malfunctions to your supervisor for immediate repair. Subcontractors will conduct safety equipment checks of electrical cords, welding lead, equipment, vehicles, tools, etc. on a daily basis and throughout the day. It is the Subcontractor's responsibility to insure thorough safety inspections and maintenance, a safe working area and equipment meeting all applicable TKS, Owner, OSHA, federal, state and local construction and safety standards. Each Subcontractor is fully responsible for the safety and instruction in safety for all his employees, including proper and safe usage of tools and equipment which are used in the Subcontractor's trade. Misuse of tools and equipment or circumventing safety devices can result in injury. Do not use make-shift or jury-rigged" tools or equipment to perform your job. This will be cause for immediate dismissal. Keep all machinery guards, guardrails and other protective devices in place. Tradesmen involved with the performance of elevated work will be protected by handrail/guardrail, safety belts and tied off, and/or safety nets in accordance with TKS, Owner, OSHA, federal, state, local and other regulations and requirements.

27.

28.

29.

30.

31.

32.

33. 34.

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35.

All floor openings or uncured concrete must be covered or have good rails/barricades around the perimeter. If a floor opening is covered by plywood or other temporary cover, it must be secured against slipping or movement and be clearly marked "FLOOR HOLE, DO NOT REMOVE". NEVER COVER FLOOR/PLATFORM OPENINGS/HOLES WITH CARDBOARD! ! !

36.

All elevated platforms must have permanent or temporary handrails installed immediately following and during expanded installation, in accordance with OSHA. (See Temporary Handrail Design Tabular Section.) Temporary handrails and barricades must be provided by the Subcontractor in accordance with job site OSHA requirements for elevated platforms, holes, hatches and pits. Temporary Handrail: Any guardrails around pits and/or mezzanines must be replaced immediately, if they have to be removed for any reason. Let your supervisor know if an area is not adequately protected before mobilizing in an area that requires handrails or guardrails. Loose handrail must be tightened. No more than 8 inches of lateral movement of the wire rope handrail over an 8' foot span is acceptable For any work being completed on an elevated surface, at building truss level or below: a. b. The area below the work will be cordoned off with rope and signs or safety tape to keep personnel out of the area. If welding, cutting, grinding or burning is being completed at these elevated levels, then an additional fire watch will be stationed at the lower level.

37.

38.

39.

40.

41. 42. 43.

This is a "No Smoking" project! Smoking may only be permitted in designated smoking areas, if available. The Paint Plant will be classified as a no smoking area. There are no designated smoking areas outside the plant. Violators will be escorted off the premises. Smoking will not be permitted at any time on the roof of the facility.

44.

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45.

It is the responsibility of the Subcontractor to require their employees to use appropriate personal protective equipment (PPE) at all times as required by TKS, Owner, OSHA, federal, state and local codes and regulations. All personnel will wear appropriate Personal Protective Equipment (PPE)/safety equipment at all times, including proper clothing, eye protection, hearing protection, hard hats, fall protection and etc. as required in accordance with appropriate standards, including OSHA. Each Subcontractor shall enforce the wearing of hard hats. These hard hats must meet the ANSI Z89.1-1969 regulations. This construction project will be a hard hat project throughout its entirety (construction through start-up). Violators will be removed from the project. Hard hats meeting ANSI Z892-1971 are required for high voltage, shock & burn hazards. OSHA sites the following reasons for the wearing of hard hats, to prevent head injuries from: a. b. c. d. e. Falling objects Flying objects Electrical shock Bump hazards NOTE: Hard Hats are also required by TKS for employer identification. Subcontractor company logos are required on all hard hats.

46.

47.

48.

49.

All personnel shall wear shirts, long trousers and safety shoes at all times. No shorts, tennis shoes, etc., will be permitted on any TKS project. All personnel will wear safety glasses with side shields unless instructed otherwise by the Project Manager. Prescription glasses must be checked to insure that they are Safety Glasses with side shields. See OSHA 1926.102 for eye & face protection requirements. Shirts must be worn at all times. Shirts with buttons or zippers must be kept buttoned or closed. T-shirts will be required as a minimum during hot weather. Employees grinding or chipping concrete must wear proper respirators and eye protection. Dust from grinding concrete is a suspected "carcinogen". All injuries, no matter how slight, must be reported to your supervisor immediately with an accident report completed. If you are injured on the job and do not report the occurrence of an injury there will be no record of the injury and your company may not be responsible for medical expense incurred by you on your own.
Page 34 of 200 QSP 6.51 Rev. 1/20/04

50.

51.

52.

53.

54.

To submit false or fraudulent information when reporting an accident or injury is unlawful and will be cause for dismissal. Each field office will have and maintain a First Aid Kit. Offices with or without telephones shall have posted emergency telephone numbers and maps for the following: a. b. c. d. e. f. g. Plant Security A list of doctors and hospitals Ambulance Service Fire Department Police Department Tornado and Storm Shelters Office Evacuation Plan

55. 56.

All Gang Boxes shall contain a copy of this list. 57. Each Subcontractor, regardless of tier, shall have at least one qualified first aid person present on the project. The name of the qualified first aid person and date of certification shall be submitted to the TKS Safety Representative at the Pre-mobilization Meeting. Building and area access routes will remain clean and clear at all times. This is important in the event of emergency vehicles that are required. If aisles close for any reason, notify TKS immediately. Accident Procedure: a. b. c. d. e. f. g. h. Do not move the injured person. Contact the foreman. Contact TKS by radio on the emergency radio channel. TKS will contact Plant Security and the local emergency service if necessary. A medic will be dispatched to the accident. One person will take control of the accident area, and try to determine what happened. A second person will be sent to escort the emergency vehicles, doctor or nurse to the accident scene. If an ambulance or life flight is required, a person will be sent to make sure access aisles are open and then to escort the emergency equipment to the scene.

58.

59.

60.

A fire watch is required at any location where welding, grinding, cutting or other torch work is in progress. Under some circumstances, this may
Page 35 of 200 QSP 6.51 Rev. 1/20/04

include work which requires the use of drills and other electric power operated equipment. 61. Each person who will serve as a fire watch, welder, or use a cutting torch or grinder will be given instructions in the identification of fire classifications and the use of the fire extinguisher. Each individual who receives this training will sign a form stating that he has had and understands the training and the use of the fire extinguisher. The original forms will be delivered to the TKS field office (Fire Extinguisher Acknowledgment of Training Form....see Forms). All fire protection and emergency equipment must be plainly marked and must be kept free of obstruction for emergency use. Each project office shall be equipped with at least one 20 IBS. A.B.C. chemical fire extinguisher which is in good working order and have certification within three (3) months of the project start. A prominent sign directing personnel to the location of the fire extinguisher must be displayed. A 20 IBS. chemical type A.B.C. fire extinguisher and a water fire extinguisher will be present at each welding, grinding and/or cutting station/location. Once the facility begins pre-production painting, facility launch and related testing, "Daily Work Area Permits" will be used for closer coordination. At that time, all welding, torch work, or spark generating work must have a valid fire permit. A fire watch with a fire extinguisher must be stationed in the immediate area. If the fire work is being done on floor, ceiling, or wall, a fire watch must also be stationed on the opposite side and/or lower level. During this time period the plant may require "Hot Permits" or "Welding Permits" for this type of work. Fire Extinguisher and Fire Fighting Equipment Considerations a. b. c. d. e. f. g. Location (Employee notification) Proper Use (Training) Weekly Survey to insure charge (Maintenance) Emergency Use Only sign Maintain clear distance from all equipment and material. Certification of Fire Extinguisher (Tag updated as required). Existing building fire extinguishers are for emergency use only. These fire extinguishers are not to be used for Subcontractor fire watch.

62.

63.

64.

65.

66.

Page 36 of 200 QSP 6.51 Rev. 1/20/04

67.

Construction Cleaning: a. Subcontractor or vendor personnel shall clean the job site and the assigned staging area at the conclusion of each day's work. All areas are to be kept free of clutter, debris and scrap throughout the day. Trash and scrap are to be disposed of in a manner and place designated by the Project Manager. Keep waste, debris, and rubbish cleaned up. Place all lunch papers, cups, cans and other litter in trash receptacles. Discard and/or store oily rags, waste and similar combustible materials in metal containers provided for that purpose.

b.

68.

Dumpster Locations: a. b. c. d. Trash must be removed from the building daily. Trash is not to be stock piled. All trash must go into dumpsters. Dumpsters must be emptied frequently.

69.

Designated Break Area: a. b. c. The designated break areas within the building must be kept clean. Food catering trucks may be allowed. All break areas will have trash barrels and these must be used.

70.

Break area tables are to be cleared of trash at the end of break. Cigarette ashes and butts must be put in ashtrays. The break area is to be kept in a swept clean condition at all times. No eating or drinking is permitted anywhere except designated break areas. Restrooms are not designated break areas. Areas outside the building are not break areas. To eliminate tripping, slipping from loss of traction, and fire hazards, your area will be kept swept clean with all debris removed immediately. Also, equipment and material will be stacked neatly and not permitted to intrude on access routes or block emergency exits. If the Subcontractor's area is not cleaned upon request, TKS will clean the area and backcharge the Subcontractors organization. Subcontractor and vendor personnel are only permitted to chew tobacco in designated smoking areas. Spitting on floors is not permitted.

71.

72.

73.

74.

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75.

Fighting, gambling, horseplay and other misconduct are not permitted, nor shall threatening another employee be tolerated. Immediate termination will result from these activities. No telephone (except pay telephones) may be used without permission of he Project Manager. Ride only in vehicles designated for transporting personnel. OSHA 1926-601 (b) (8) requires motorized vehicles to have seats for any and all persons riding on vehicles. This means no riding on pick-up trucks, flat bed trucks, golf carts, fork lifts, cranes, backhoes, or other type motorized vehicles unless proper seats have been provided. Jumping on or off equipment or vehicles, either moving or stationary is prohibited. Only authorized and properly instructed and supervised personnel are permitted to operate equipment, vehicles, valves, electrical switches and similar machinery. Riding loads, slings, the ball crane hook, forklift forks or other material hoisting equipment is prohibited. It is the responsibility of each Subcontractor to provide adequate lighting for their work area for the safe and successful completion of their work. It is also their responsibility to maintain adequate lighting for safe passage. Whenever anyone is required to work on or in close proximity to electrical equipment or circuitry, appropriate tagging will be placed to identify all controls deactivating the circuit, and the circuit shall be locked out, when possible. Be alert at all times to conditions, work processes in your area and surrounding areas and with the presence of other workers and equipment so that you can foresee and avoid possible dangers. All personnel should keep clear of all equipment. Avoid pinch points and blind spots. Be alert and avoid swinging or suspended loads. Compressed gas bottles must be handled carefully. Always transport (full or empty) compressed gas bottles in an upright position. Never leave empty bottles laying on the ground, take them to the bottle storage racks. If a burning set is not in use, remove the gauge set, and install the cap on the compressed gas bottle.
Page 38 of 200 QSP 6.51 Rev. 1/20/04

76.

77. 78.

79.

80.

81.

82.

83.

84.

85.

86.

87.

88.

If compressed gas bottles are not in use and not on a cart, the bottles must be separated and secured to SEPARATE columns or posts. Store and use gas cylinders in a secure, upright position. Propane (L.P.) cylinders must not be allowed to remain in the work area, if they are not attached to a piece of equipment. Gas cans must be OSHA approved safety cans with a Spark Arrestor" screen in the spout. If they do not have a safety lid and a screen, they are to be removed from the job site. Do not use compressed air to "dust-off" yourself or clean any area. a. Compressed Air: A good rule to follow when using compressed air is to keep the pressure as low as is possible (if it can be adjusted) in order to do the job adequately. Hold the nozzle securely in order to prevent it from kicking, and never kink the line to cut off the air. Compressed Air: Under no circumstances should compressed air be used to clean clothing. A compressed air hose should never be pointed at yourself or at anyone else. Severe injuries and even death have been caused by workers with a misguided sense of humor who tried to be funny with compressed air.

89. 90.

91.

92.

b.

93.

Fuel Storage Area Location a. b. c. d. Fuel Storage Areas must remain free of paper. All engines are to be shut down during refueling. All fuel operations, while in progress, must be electrically bonded. The following signs must be on each tank: 1. 2. 3. 4. Contractor' s Name Type of Fuel No Smoking Danger/Flammable

A sample fuel storage area layout is included in the Sample Fuel Storage Area Tabular section of this manual. 94. Emergency Exits a. b. Know the location of emergency exits. Maintain clear distance between emergency exits, access doors and aisles from equipment and material.
Page 39 of 200 QSP 6.51 Rev. 1/20/04

95.

Safety Bulletin Board a. b. c. d. Location Items of importance will be posted. One side for safety items/other side for employee use. Proper care and organization is required.

96.

Hazard Communication Program, you have a right to know the chemicals and materials you are handling and to which you are exposed. You must be aware of the following: a. b. c. Location of M.S.D.S. sheets. Knowledge of Employee Right to Know Program. How to read and understand an MSDS.

Any employee who does not know this information must ask their supervisor immediately. If the employee still does not understand after the explanation he/she should see the Subcontractor's Project Manager. 97. Emergency Procedures a. b. c. 98. All employees will review. Will be posted at all office telephones. Will be posted at all gang box/break areas.

Safety Violation Policy: a. Verbal Warning 1. 2. 3. b. Employee Badge # and name are recorded. Foreman is notified. Superintendent is notified.

Written Warning 1. Written report will be filed with copies sent to: a. b. c. Employee Employee' s Company Business agent for that employee's trade union.

c.

Dismissal 1. Business agent will be called to job site.

Page 40 of 200 QSP 6.51 Rev. 1/20/04

2.

Union steward for that company will attend meeting. Subcontractor's representative or union steward will remove the employee.

99.

If any fines are levied against TKS because of Subcontractor violations, the Subcontractor will bear all financial responsibilities for TKS. Failure to follow these rules may result in individual violators being permanently removed from the job site. Repeated or serious violations will result in the Subcontractor or vendor being removed from the project.

100.

Page 41 of 200 QSP 6.51 Rev. 1/20/04

IX.

ACCIDENT PREVENTION POLICY A. Purpose Accident investigation is carried out to determine the cause or causes of an accident or a near miss so that appropriate action(s) can be taken to prevent reoccurrence of the accident. B. Responsibility ALL accidents including near misses must be investigated, not just those involving serious consequences, since severity is largely a matter of chance. 1. The Subcontractor's Project Manager and Safety Representative are responsible for investigation and reporting of accidents occurring with their work. The corrective measures necessary to prevent reoccurrence of similar accidents are the responsibility of the Subcontractor to the degree of their jurisdiction. The Subcontractor may be assisted in their investigation of the accident by the TKS Safety Representative. A copy of all accident reports are to be submitted to TKS by the Subcontractor. This report will include the accident reports, copies of the associated medical information, return to work authorization, pictures, sketches with dimensions etc. The TKS Safety Representative is responsible for reviewing the facts, monitoring corrective measures, and overseeing that the implementation of corrective measures proceeds as required. The TKS Safety Representative will investigate all serious accidents and report all pertinent facts and corrective measures to the Project Manager.

2.

3.

4.

5.

6.

If an accident occurs, be prepared to give Column X Column locations so the injured person can be found easily.

Page 42 of 200 QSP 6.51 Rev. 1/20/04

C.

Accident Site Control Procedure In the event of any accident involving personal injury or property damage, the Subcontractor shall immediately notify TKS of the accident 1. In the event of a personal injury accident, the injured employee will be examined, preferably by the site nurse. Off site treatment will be made available by the Subcontractor for any treatment as requested by the Project Manager, TKS, Owner, Site Nurse, Supervisor, First Aide Representative, or injured employee. The Accident Reporting Procedure will be followed. The following accident procedure will be utilized when a serious accident occurs. a. b. One person will take control of the accident scene. This person will try to determine what happened. One person will be designated to assist the injured person. 1. 2. c. d. e. f. g. Do not move the injured person! Contact the Foreman.

2.

h. i. j.

k.

Grid Coordinates will be identified immediately (Column X Column). A second person will be sent to notify TKS, by radio, if possible. TKS will immediately contact Owner Security. Owner Security will contact the local Emergency Service. A third person will be designated to insure that access aisles are not closed by equipment, materials or debris. He will then watch for and escort emergency equipment to the accident site. First Aid personnel, site nurse or others will be sent to the accident. There may be no emergency phones onsite. Personnel will not be permitted to linger in the accident area. Remember, this may be an emotional situation, and everyone is to be treated firmly, but with respect. In the event of an accident keep pertinent radio channels clear for communication.

TKS is to be notified immediately of the accident. TKS will notify Plant Security, if necessary. The Plant on-site safety representative, will also be contacted by TKS. TKS or Plant Security will call the local emergency service organization for any injury requiring medical attention.

Page 43 of 200 QSP 6.51 Rev. 1/20/04

D.

Accident Reporting 1. All accident reports required by OSHA, federal, state and local authorities will be filed by the Subcontractor with copies sent to TKS as soon as possible following the accident, but within the required time frame for the reporting agency. OSHA 200 & 100 forms will be updated and provided to TKS within 48 hours of the accident. Prompt accident reporting and proper distribution of complete and accurate reports is essential to protect the injured employee, Subcontractor, TKS and the Owner. This information and other documentation are necessary for legal and moral obligations to be fulfilled, to correct the accident cause, to prevent reoccurrence of similar accidents through appropriate analysis and corrective procedures implementation, for future safety planning, etc. As soon as practical, the Subcontractor will file with TKS a written First Report of Accident, furnishing as much information concerning the accident as is available (within minutes of the accident). This report, with a cover letter, must be sent to the TKS home office to the attention of Mr. Robert Tipple, Vice President of Operations. As soon as practical, within the following twenty-four (24) hours, the Subcontractor shall furnish TKS with a written detailed report stating the extent of damage, names of persons involved or witnessing the occurrence, names of employers or persons involved, names of attending physicians, diagnosis and prognosis, and subsequently any other information required by the Subcontractor or the authorities concerned, such as OSHA, the State Environmental Protection Agency and/or other regulating authority. The foreman in the area and each witness to the accident including the victim, if possible, will fill out an accident report. The injured employee is to be interviewed on the scene, even if only limited information can be obtained. This is essential. Following receipt of all accident reports and interview information, the Subcontractor's Project Manager will write a cover letter clarifying all the facts and submit the letter and all reports, including pictures, to TKS. Multiple Injuries & Fatal Accidents: The OSHA area office is to be contacted by telephone or in person within 8 hours of the accident or notification of the accident. See OSHA Part 1904.

2.

3.

4.

5.

6.

Page 44 of 200 QSP 6.51 Rev. 1/20/04

Any Accident reported by an injured employee, observed by any employee or supervisor, requiring anyone to view or examine the injury shall be reported as an accident. There will be no exceptions regardless of apparent lack of severity.

E.

Accident Investigation Procedure 1. Interview the accident victim at the scene of the accident, if possible. Take good notes! Secure names of witnesses and get an accident report from them. Obtain a written accident report from anyone with any knowledge of the incident, conditions, or other. Obtain a list of workers on the job site the day of the accident. Interview employees who witnessed the accident or were involved. What was the injured person doing at the time of the accident? What work was being done, methods being used, position of equipment, personnel use of personal protective equipment and/or unsafe acts or conditions? Record time, weather, visibility, traffic conditions, location and other related factors. Note type of damage and location. Take notes on physical conditions that may have a bearing on the accident, such as lack of handrails or guarding, poor housekeeping, defective scaffolding, surface or roads conditions, amount of illumination, condition of barricades and warning light, condition of tires, etc. Sketch or Diagram: Measure distances and plot location of vehicles, equipment, barricades, skid marks, equipment, etc. Take pictures before conditions have been disturbed. In the event of a fatality the TKS home office requires 4 sets/copies of the photographs. Check area equipment for defects/problem areas. Determine whether hazards and unsafe practices related to the accident were covered in indoctrination, tool box meetings. These files should be checked to insure training was completed by the accident victim Consider physical or mental deficiencies that may have contributed to the accident: blackout, heart condition, irrational behavior or attempting too much for size and physical strength, etc.
Page 45 of 200 QSP 6.51 Rev. 1/20/04

2.

3.

4.

5. 6.

7.

8.

9. 10.

11.

12. 13.

Obtain a copy of medical records, and Coroners Report, when available. Obtain as much information about the accident victim as possible, including funeral arrangements if applicable. The accident report and all documentation is to be delivered to the TKS Safety Representative within 24 hours of the accident, with a preliminary report due at the TKS office as soon as possible after the accident, with frequent updates. Maintain a copy of all information delivered to TKS in the company files. The TKS Safety Representative will obtain all the available information or that which becomes available in order to prepare a complete accident report file. This is most critical in the event of a fatality.

14.

15.

DO NOT discuss serious accidents with outsiders nor provide an opinion of what happened, how it happened or why it happened. Please discuss this with your supervisor, only. Personal speculation may confuse the issue! F. Doctors Authorization Returning The Injured Employee to Work If the employee has returned to work following time off for an accident - employee must also provide a copy of the Doctor's authorization returning the employee to work. No employee who has left work due to an injury may return to work without a signed doctors return to work authorization. G. Corrective Active Procedure 1. Correct unsafe physical conditions or equipment deficiencies immediately. Check other equipment to make sure it does not have similar defects. Determine the accident cause or causes. Usually accidents occur as the result of a combination of unsafe conditions and unsafe acts. Place additional warning signs, barricades, warning lights if need is indicated, add illumination, etc. Make improvements in maintenance and survey operating procedures or provide the means for better enforcement of existing procedures. Investigate corrective measures taken by TKS and Subcontractors under similar circumstances and incorporate those measures, if applicable. Review project orientation and indoctrination (Subcontractor provided Safety, Skill and Job Training), Tool Box Meetings, and on-the job
Page 46 of 200 QSP 6.51 Rev. 1/20/04

2.

3.

4.

5.

6.

instructions to see if more educational material should be added or improvement can be made in its presentation. 7. Consider the need to transfer employees to new assignments or to terminate employment. Termination should be for cause, such as evidence of flagrant violation of safety rules or repeated violations. Prepare a detailed report on findings and corrective measures to be taken. Institute any follow-up procedures required to insure compliance with changes made.

8. 9.

H.

Accidents in Adjacent Work Areas: If a TKS employee or Subcontractor becomes aware of an accident in any adjacent work area, although not a TKS or Subcontractor work area nor employee; obtain a copy of all relevant information and write a brief report. This may be important in the event of future litigation. Accident reports are required for any TKS employee or Subcontractor employee who is injured at any location on the Owner's property or off the property if work related. Typical Project Team Accident Experience

I.

J.

PROJECT TEAM ACCIDENT EXPERIENCE SAMPLE Project 1989- 1990 1990- 1992 1993 Accident Rate Per Man Hour Man Hours 330,000 510,000 78,000 Lost Time Accidents Accidents 63 108 8 Percent Of Accidents As Lost Time 9.52% 6.48% 0% Fatalities 0 0 0 Lost Time Accident Rate Per Man Hour .0018% .00137% 0%

.019% .021% .010%

6 7 0

Subcontractors will be individually responsible to notify OSHA, federal, state and local authorities in the event of a death and/or multiple injuries (four or more or as required) within forty-eight (48) hours of the time of the accident.

Page 47 of 200 QSP 6.51 Rev. 1/20/04

ACCI DENT REPORT DATE PROJ ECT NAM E LOCATI ON TYPE OF REPORT ( ( ( ( ( ) ) ) ) ) I NJ URY/ I LLNESS ( W ORKMAN) I NJ URY/ I LLNESS ( OTHER) PROPERTY DAMAGE ( J OB SI TE) PROPERTY DAMAGE ( OTHER) VEHI CLE/ EQUI PMENT

I NJURY/ I LLNESS: NAME OF I NJ URED OR I LL EMPLOYER DATE OF I NJ URY OR I LLNESS TRADE TI M E

A. M . P. M .

DESCRI PTI ON OF ACCI DENT

EXTENT OF I NJ URY OR I LLNESS FI RST AI D ADMI NI STERED? Y N I NJ URED REQUI RED OFF- SI TE TREATM ENT Y N

NAME OF HOSPI TAL AND DOCTOR TREATM ENT REQUI RED PROPERTY/ EQUI PMENT/ VEHI CLE: DESCRI PTI ON I F EQUI PMENT OR VEHI CLE, W HO W AS USI NG I T? DESCRI PTI ON OF ACCI DENT

OWNER

EXTENT OF DAM AGE OBSERVATI ONS: I N YOUR OPI NI ON, DI D AN UNSAFE ACT OR CONDI TI ON CAUSE THE ACCI DENT? Y N I F YES, W HAT CORRECTI VE STEPS HAVE YOU TAKEN TO PREVENT SI M I LAR ACCI DENTS?

W I TNESSES OR PERSONS W I TH KNOW LEDGE OF ACCI DENT OTHER THAN THE VI CTI M OTHER COMMENTS

Page 48 of 200 QSP 6.51 Rev. 1/20/04

ACCIDENT SUMMARY

SUBCONTRACTOR: PROJECT: REPORT PERIOD:

(Complete report quarterly for longer projects)
THIS QUARTER YEAR TO DATE PROJECT TO DATE

Through

DATE:

Man Hours Worked OSHA Recorded Cases Lost Time Cases (List Each Below) Days Lost OSHA Recordable Incidence Rate Lost Time Incidence Rate Days Lost Incidence Rage

Number of Cases (days) x 200,000 Incidence Rates = Man Hours Worked Lost Time Case Name / Description Days Lost

Page 49 of 200 QSP 6.51 Rev. 1/20/04

INJURY & ILLNESS REPORT

All work related injuries and illnesses that occur at the Project Site must be reported to the TKS Safety Representative or TKS Project Manager. Company Name Company Address / Phone Number

Date / Time Reported

Social Security No.

Age

Date / Time of Incident

Nature and Extent of Injuries / Illness

Signature State know facts only. DO NOT DRAW CONCLUSIONS. Incident description (State Basic Causes - Who, What, When, Where, Why and How Details)

Corrective Action

Signature TKS Safety Representative Comments

Signature

Page 50 of 200 QSP 6.51 Rev. 1/20/04

X.

FIRE PREVENTION POLICY A. Overview 1. The following is a Fire Prevention Program developed by TKS Industrial Company. These established guidelines will be followed by all TKS employees and Subcontractors through all phases of construction, start-up, debug, facility launch and fine tuning, and warranty. Note that this is only a guideline and is not a training program or manual. It is TKS' intent that proper fire extinguishing equipment be maintained every 3,000 square feet or not more than 100 feet of travel within the building area. This will be duplicated on each floor level. The key to the prevention of loss of life and property damage is appropriate action. Proper action in the first minutes of a fire is worth tons of water ten (10) minutes later. If a fire occurs, notify Plant Security (the telephone number is posted at all phones) and the TKS Safety Representative immediately! If qualified, extinguish fire with a non-combustible fire extinguisher such as sand or an available 20 lbs. ABC chemical fire extinguisher. Shut off the fire fuel supply by removing debris or stored material or shutting off propane or other fuel source.

2.

3.

4.

5.

6.

B.

Fire Prevention 1. Fire extinguishers and fire watch personnel are to be provided at all welding, cutting and burning operations. Fire watch personnel will be trained in the proper classification of fire and the proper utilization of fire extinguishers. Personnel trained as a fire watch will be listed on a training sheet with the employees signature indicating the receipt of training and an understanding of the information. Supervisor's shall instruct their personnel as to the location of the nearest fire alarm, and the method for transmitting an alarm.

2.

3.

4.

Page 51 of 200 QSP 6.51 Rev. 1/20/04

5.

Federal, State, Local, TKS Industrial Company, and Owner safety regulations are to be observed at all times. Water usage from plant fire hydrants, for construction work, is absolutely prohibited. Water may be obtained only from water supply approved by the Owner. Open fires are not permitted on the premises/property. The Plant Security Office shall be notified and approval received before any fire system is taken out of service. Security Personnel shall be notified immediately in the event that fire equipment may be damaged. Storage of any material within ten (10) feet of fire hydrants is strictly prohibited. Work areas will be cleaned on a regular basis to prevent accumulation of material and debris. Waste material shall be removed in accordance with TKS cleaning requirements and the Owner's Policy. No motors or machinery shall be left running during non-working hours except as specifically authorized by TKS. Access aisle will be kept open and free from debris, material, fabrication or anything else that may restrict emergency vehicle access. If building entrance access, access aisles, fire aisles, or passage ways have to be closed for any reason (and they will), TKS is to be notified in advance! All tarps and blankets will be of fire retardant material. Twenty (20) lbs. ABC chemical fire extinguishers are to be placed and maintained on the job in conspicuous locations and at each location where welding, cutting or burning is conducted. These fire extinguishers will not be moved or discharged except for fighting a fire. Anyone discharging an extinguisher as a prank will be subject to immediate dismissal. Fire extinguishers must have a valid inspection certificate. All temporary electric must be properly installed and in accordance with all existing codes and per Owner requirements.

6.

7. 8.

9.

10.

11.

12.

13.

14.

15.

16. 17.

18.

Page 52 of 200 QSP 6.51 Rev. 1/20/04

19. 20.

All portable fuel and solvent containers will be placed on drip pans. All heating equipment will be equipped with necessary safety devices and shall be wired, piped and operated according to all applicable codes, rules and regulations. All portable gas heating appliances are to be inspected, attended by an operator, and protected with a fully charged 15 lbs. carbon dioxide or 20 lbs. dry chemical fire extinguisher provided by the Subcontractor. Tar pots for heating roofing material shall be attended by an operator at all times when in operation. A fully charged 15 lbs. carbon dioxide or 20 lbs. dry chemical extinguisher shall be available at operation. Tar pots shall be located at grade level and fifty (50) feet from all structures and combustible yard storage. Written approval to do hot work shall be obtained through TKS from designated Plant Security Personnel before operations are started. All highly flammable liquids such as gasoline, paint thinner, etc., will be stored in approved safety cans outside of buildings in a safe area approved by the Owner. These storage locations will have a 20 lbs. ABC fire extinguisher. All acids and flammable liquids shall be properly identified and the containers clearly tagged. Before any low flash material (110 F. open cup or less) can be used for any purpose in the plant, Security Personnel are to be contacted for approval. No solid fuel (i.e. coke, etc.) shall be permitted on site. All gas bottles such as propane, oxygen, and acetylene are to be properly supported, stored and tied in a vertical position in areas designated by TKS. All stored bottles shall be capped. All gas bottles in use will be maintained in a vertical position, capped at the end of the working day, and secured to columns or removed from the building. All oxygen and acetylene in use shall be in proper carts. All gas bottles not in use will be removed to the fuel storage area.

21.

22.

23.

24.

25.

26.

27. 28.

29.

30. 31.

Page 53 of 200 QSP 6.51 Rev. 1/20/04

C.

Hot Work Permits and Hot Work Hot Work Permits are plant issued fire or welding permits issued on some new construction projects, and generally required for retrofit projects and work being completed in operating manufacturing facilities. 1. Fire Permit (Welding, Burning, Cutting or Grinding) or Hot Work Permit is to be considered a contractual requirement. Plant Security will issue welding, burning, and/or hot work permits after reviewing the work area. In the event the area has not been adequately prepared, security will not issue a Hot Work Permit and will make recommendations for proper area preparation. Once the Subcontractor has complied, the supervisor may contact security for re-inspection. This procedure will continue until the area is properly prepared and the permit is issued. Generally, Plant Security has many responsibilities, with these inspections scheduled as time permits. Unfortunately, re-inspections may not be possible and at the very least not timely. Be properly prepared for the first inspection. a. When TKS employees are performing the work, the TKS supervisor must complete the TKS Hot Work/Ignition Source Check List daily, and before requesting Plant Security to review the work area and issue the permit.

2.

3.

Under no circumstances will welding, burning, cutting, grinding or other spark generating procedures be permitted without a Plant Security provided Hot Work Permit or Welding Permit issued for that purpose and for specific work. General Safety Rules for Hot work a. Remove ducts on the chamber, fan and stack without hot work or spark producing methods. Do this so interior work is visible to the fire watch personnel. Have water and a fire extinguisher available in case there is a fire. Blank off exhaust ducts to eliminate any chimney effect. Hot work and spark producing methods are strictly prohibited when removing booth exhaust ductwork, exhaust chambers, gas and oil piping, paint piping, and electrical wiring. Post a sign at the work area that states, NO HOTWORK ALLOWED.

4.

b.

Page 54 of 200 QSP 6.51 Rev. 1/20/04

c.

Unscheduled construction work is prohibited. A safety plan, orientation and training must be implemented prior to commencing work. Un-permitted hot work is not allowed. Obtain a hot work permit before commencing work. Dont schedule more demolition work than can be safely accomplished in one shift. Allow time at the end of the shift to make sure the area is safe and secure. Before hot work, check to make sure there are no flammable materials (solvent, paper, wood, cloth and plastic ) in and around work area. Remove all flammable materials before starting work. At least one dedicated fire watch person is required at each work area. Sparks must not enter an area that is not visible to fire watch personnel. If all areas are not visible, additional fire watch personnel must be added. If there is welding between two floors, there will be a need for a fire watch on each floor. If the individual in charge of the fire watch requests work stoppage, do so immediately. Do not resume work until told to do so. Prepare water buckets, fire extinguishers, fire hoses and check if valves are set to open. Whenever possible, wet down the entire work area before starting work. Note: Take all necessary precautions to avoid electrical shock from wetted surfaces.

d.

e.

f.

g.

h.

i.

j. Begin working only after obtaining an authorized signature on the hot work permit. k. Do not place oxygen and/or acetylene cylinders within 35 feet of the hot work area. Check gas hoses daily for leaks. l. When flame cutting, the fire watchmen should continuously keep the area wet to put out any possible flames and to keep the cut material cool. The fire watchman should watch out for flames and/or an outbreak of fire behind or under any equipment. m. Work breaks and lunch periods should be staggered so that work areas are never left unattended. n. Fire inspection at the completion of each shift.
Page 55 of 200 QSP 6.51 Rev. 1/20/04

o. Wet down and check for fire after completing the work. Make it a rule to remove the demolished material from the facility immediately. Inspect demolished material for smoldering or smoke before disposal. p. As for fire inspection after completing the work on booth related equipment and dangerous areas such as ovens where tar is present, a fire watch individual has to stay and check the area for a minimum of two hours. q. For fire inspection at general areas that are not listed above, fire watch personnel must remain in the area for a minimum of 30 minutes after finishing welding, burning and cutting. 5. Booth Modification Mandatory Safety Requirements a. Cleaning Inspection 1. 2. 3. Check and make sure the booth scrubber, tank and exhaust ducts are clean. Check and make sure that all near by solvent lines are properly purged and blanked off. Confirm that all robot / automation equipment solvent and paint hoses have been removed and the connections points have been capped.

b. Temporary blank off plates should be installed on the intake and exhaust ducts. c. Remove flammable materials such as plastic sheets, etc. on the wall inside booth, if any. d. Remove ceiling filters and exhaust filters. e. Dismantle bolts when removing intake ducts and panels. f. Hotwork (the use of any spark producing device) is strictly prohibited for removing exhaust ducts and exhaust chambers. 1. Paint build-up inside exhaust ducts that have been in use for a long time, may be deceiving. The paint build-up may look like thick sheet metal. Keep this in mind and do not us spark producing tools and equipment. Connecting bolts should be dismantled using air tools. Accumulated paint inside the duct should be removed. Cut sheet metal duct using air powered nibblers or shears only.
Page 56 of 200 QSP 6.51 Rev. 1/20/04

2. 3.

6. Demolition Work Safety Requirements a. Keep in mind that paint shop fires are the number one customer plant safety concern. Perform work with the assumption that paint shops are very volatile. Paint shop fires can do tremendous damage to the customers facility and future production. A paint shop fire can cause the following: 1. 2. 3. 4. Personal injuries and possibly death Loss of production Law suits Loss of repeat business

In addition, modification work of an existing line is performed in an environment where accidents can easily happen i.e. falling objects, falling, electric shock, burns, cuts, etc. Each individual should understand and follow all of the required safety rules and regulations and work safe at all times. b. Perform only the work that is scheduled for that particular day. 1. 2. Even though scheduled work is completed, do not perform the next days work. Unscheduled construction work is prohibited. A safety plan, orientation and training must be implemented prior to commencing work.

c.

Hot work / spark producing devices are strictly prohibited in the following areas: 1. 2. 3. 4. 5. 6. Modification work of booth exhaust chamber and exhaust ducts Modification work of exhaust ducts in the phosphate degreasing process Modification work of vertical-run ducts Modification work of paint circulation piping Modification work of gas and oil piping Modification work of a drying oven with accumulated tar. Plasma cutting is permissible only after all tar has been removed. Any and all other areas where there is a strong potential of a fire risk.

7.

Page 57 of 200 QSP 6.51 Rev. 1/20/04

d.

Safety tips for fire prevention: 1. 2. 3. 4. 5. 6. Before hot work, remove flammable materials (solvent, paper, wood, cloth and plastic, etc) from the work area. Before hot work, prepare water buckets, fire extinguishers, fire blankets, and water hoses. Before hot work, get hot work permission from a TKS site manager and report to him after work is completed. Never perform hot work where a HOTWORK PROHIBITED sign is posted. Do not perform hot work, in areas that are not indicated on the Hot Work Permit. After hot work, water thoroughly and make sure the area is safe and free of fire.

e.

Planning the amount of modification work 1. 2. Plan modification work in such a way that it can be completed within that day. Thoroughly saturate with water, and immediately move the demolished sections outside the building. Especially the items removed by flame cutting. This must be done promptly. Emergency information must be clearly posted in the work area at all times. Before commencing work, make sure that there is a way to communicate with the appropriate plant and TKS personnel via telephone, radio, etc.

3.

D.

Temporary Storage Buildings 1. Are to be constructed using only fire retardant materials with all glass being wire glass. As a minimum, any lumber used in these buildings shall meet the American Wood Preserves Associations Standard Cl, C20 and C27, and shall bear certificates of performance or per more stringent standards. All materials shall have a flame spread rating no greater than 25 (ASTM Standard E84) with no evidence of progressive combustion for at least 30 minutes or per more stringent standards. All buildings shall be located at least ten (10) feet from materials which present extraordinary fire hazards.

2.

3.

Page 58 of 200 QSP 6.51 Rev. 1/20/04

4.

Each building shall have at least one (1) 20 lbs. ABC fire extinguisher. Rubbish shall not be permitted to accumulate within, or in the area adjacent to any building. No oily clothes, oily rags, or fuels shall be stored in these buildings. All temporary buildings shall be constructed in such a manner so that a fire shall not cause damage to the permanent construction and installations.

5.

6.

7.

Page 59 of 200 QSP 6.51 Rev. 1/20/04

TKS INDUSTRIAL COMPANY DAILY HOT WORK/IGNITION SOURCE CHECK LIST ATTENTION Daily , and before requesting any cutting, grinding, welding and/or hot work permit from the Owner, the supervisor shall inspect the work area and confirm that precautions have been taken to prevent fire in accordance with NFPA 51B. PRECAUTIONS Yes No Sprinklers in service and sprinkler heads appropriately guarded. Cutting and welding equipment in good repair. Appropriate fire extinguishers, with current inspection certificates attached, in place. Trained fire watch personnel available. Clean blankets or metal shields of the proper type (minimum rating of 1000 degrees F.) available. Appropriate personal protective equipment for the task available. WITHIN 35 FT. OF WORK Floors swept clean of combustibles. Combustible floors wet down, covered with metal or other appropriate shields. No combustible material or flammable liquids. Combustible and flammable liquids protected with covers, guards or metal shields. All wall and floor openings covered with proper shielding material. Covers suspended beneath work to collect sparks.

WORK ON WALLS OR CEILINGS Construction noncombustible and without combustible covering. Combustibles moved away from opposite side of wall. WORK ON ENCLOSED EQUIPMENT (Tanks, containers, ducts, dust collectors, etc.) Equipment cleaned of all combustibles. Containers purged of flammable vapors. FIRE WATCH To be provided during and 30 minutes after operation. Supplied with extinguisher and small hose. Trained in use of equipment, in sounding fire alarm and notifying Owner.

Signed:_________________________________ Date:__________ Time:__________ TKS Job No.______________ (Supervisor)

FINAL CHECK-UP To be made 30 minutes after completion of any operation.

Signed:_________________________________ Date:_________ Time:__________ (Supervisor)

Page 60 of 200 QSP 6.51 Rev. 1/20/04

Page 1/2 TKS Industrial Company Hot Work/Ignition Source Training Introduction: Three things are required for a fire to start and to burn for any period of time: 1. Oxygen 2. Fuel (Combustibles) 3. Ignition source Question: Answer: Question: Answer: What do you look for in a work area to determine if a Hot Work/ Ignition Source Permit is required? Oxygen, fuel and ignition source. How can you see oxygen? You cant, but its in the air that you breathe, so assume that its always present. What should you look for as a source of fuel? Look for anything that is combustible or will burn: Solids such as paper, cardboard, wood, tar, paint, dust, plastic, fabric, rubber, leather, etc. Liquids such as paint, thinners, motor oil, hydraulic oil, gasoline, solvents, etc. Gases such as natural gas, paint fumes, solvent fumes, acetylene, propane, butane, methane (sewer gas), etc. (Remember that a cloud of dust may be as explosive as a cloud of natural gas.) How do you identify a source of ignition? Look for anything that will start a fire such as an open flame from a welders torch, pilot light, cigarette lighter, or gas burner; a spark from a grinder, torch igniter, an electronic igniter for a burner, electrical spark from a motor or other electrical device, or even lightning; extremely high temperatures from molten metal, slag, friction caused by moving parts rubbing together, heating elements, or lights. How far beyond the work area should you look for these three things? Thirty-five (35) feet in all horizontal directions and below the work area if there is a chance that a spark or fire can fall or travel in that direction.

Question: Answer:

Question: Answer:

Question: Answer:

Question: Answer:

If fuel, oxygen and a source of ignition are present, can you work in such an area? If the customer agrees that you can work in the area with planning, the proper safety precautions and fire prevention measures in place, you can, and sometimes must, work in such an area.
Page 61 of 200 QSP 6.51 Rev. 1/20/04

Question: Answer:

Page 2/2 How do you know if the customer agrees that you can work in the area? The customer must issue a written permit in order to allow you to work in such an area. This permit may be called a Hot Work Permit, Welding Permit, Cutting Permit, Grinding Permit, Burning Permit, or Hot Work/Ignition Source Permit What other things must be done in order to work in such an area? You must follow all of the customer and TKS Safety Rules and Procedures. These are found in the TKS Safety Manual or the customers safety manual or policy. The TKS Supervisor must complete a Hot Work/Ignition Source Check List daily before performing any work. In addition to these rules, you must follow OSHA and NFPA (National Fire Protection Association) rules as well as the rules of the local fire department. Finally you must follow the recommendations of the manufacturers of the tools or materials that you are using, installing, or demolishing. Is there some way to prevent the need for the hot work permit? Maybe. Can you eliminate all combustibles? If you use a torch, you automatically have combustible gas in place. If the work can be performed without producing a source of ignition the permit may not be required. Is it possible to make connections with fasteners instead of welding, brazing or soldering? If so, you can eliminate the open flame and sparks that are a part of these operations. Can the work be cut with a hand saw instead of a torch? A hand saw may create some heat but it should not be enough to be a source of ignition. Can the work be ground with a hand file instead of a grinder? Again the heat from a hand file is not as great as from a grinder. Plus, the power saw or grinder has an electric motor which can create a spark.

Question: Answer:

Question: Answer:

Can the hot work be removed to an area that is set aside for this particular type of work? This may eliminate the need for the hot work permit.

Page 62 of 200 QSP 6.51 Rev. 1/20/04

TKS INDUSTRIAL COMPANY

Safety Manual Form #27

FIRE BLANKET CHECK-OUT SHEET

SHEET # ______

ATTENTION
To obtain a fire blanket (fiberglass with a 1,000F rating) for use on a particular project, this form must be completely filled out and signed by your supervisor. YES NO
Does each blanket contain a tag and an identification number? Check the condition of each blanket. Is it clean, free of holes and free of any foreign material? A flash test was performed to make sure that the blanket was free of any flammable contaminates? This blanket will be used to shield sparks only. (Do not use this blanket for any other purpose i.e. paint drop cloth, etc.) No Blankets will be issued until all of the above boxes are checked "Yes"

BLANKET TAG NUMBERS

Blankets Logged-Out Tag # / Date
1. 2. 3. 4. 5. 6. 7. 8. 9. 1. 2. 3. 4. 5. 6. 7. 8. 9.

Blankets Logged-In Tag # / Return Date

AUTHORIZED SIGNATURES
Job Name TKS Job # Number of Blankets Required Requested By Issued By Supervisor (OUT) Supervisor (IN / Returned)

Page 63 of 200 QSP 6.51 Rev. 1/20/04

XI.

EMERGENCY PROCEDURE AND EVACUATION PLAN A. Overview 1. This emergency and evacuation plan will be utilized for the entire construction project. All Subcontractors are to review this procedure with their employees prior to their beginning work on this project. The Radio Emergency System will be utilized. These rules for emergency procedure shall be posted at each office telephone, at first aid kits and at every gang box. Also there will be a copy at the safety bulletin board. The efficient manner in which this program will be utilized in an emergency may improve rescue time. A list of all First Aid and CPR certified persons are to be kept on file in case of an emergency. This list of personnel will be provided to the TKS Safety Representative by the Subcontractor. There will be Certified Fist Aid and CPR persons on site in case of an emergency. This system has been established to help direct an ambulance to an injured employee. In case of an emergency, extra persons at the scene of the accident(s), and persons informed by radio, will go to the perimeter road and guide the emergency team to the injured person. If asked by the emergency team, these persons will assist in carrying emergency equipment.

2.

3.

4.

B.

Emergency Radio System 1. Each Subcontractor is to have one TKS Radio Channel for Emergency Radio System Communications. In the event of an emergency, this channel is to be monitored. The emergency will be called into the TKS base unit. TKS will call Plant Security. Plant Security will notify emergency service. Emergency phone numbers are to be posted by phones and in each gang box.

2. 3. 4. 5.

Page 64 of 200 QSP 6.51 Rev. 1/20/04

Be sure aisle ways and access doors are open and clear of any obstructions for emergency equipment access. C. Fire Procedure 1. Fire Emergency a. b. c. d. e. f. g. h. 2. Determine what type of fire you are dealing with to properly extinguish it. Designate a person to report the fire. Designate a person to take charge. Eliminate the fuel source, shut off valves, remove debris, etc. Account for everybody at the fire location. Clear all non-essential personnel from the area. If you are qualified, make an attempt to extinguish the fire with the fire fighting equipment. Start first aid procedures, if needed.

Fire Call a. Give type of fire (chemical, oil, gasoline, etc.). b. Exact location (Column X Column). c. Explain possible hazards (explosion, rapid burning, etc.). d. Explain if people are trapped or if people are injured. e. Give Fire Department entrance gate for project access. f. Meet Fire Department at that entrance. g. Lead them to the location.

D.

Ambulance Call 1. 2. 3. 4. 5. 6. Give type of injury and condition of injured. Exact location (Column X Column) and location of injured (in a building, in a machine, scaffold, on roof, etc.). Explain if injured person(s) is trapped or pinned. Provide ambulance with directions for access including entrance gate. Insure that access and aisles to accident scene are clear for emergency equipment. Meet ambulance at that entrance. Lead them to the accident location.

E.

Roof or Upper Floor Emergencies There will be man baskets installed and maintained on each level of the facility by the Subcontractor working on that level. These will be checked on a daily basis for access, signage and to insure that they are in their designated locations. When a person is injured, the closest crane with accessible reach will move into position and assist the emergency team in lowering the injured person to the ground.

Page 65 of 200 QSP 6.51 Rev. 1/20/04

F.

Emergency Evacuation 1. Purpose Using this procedure as an example, evacuation and shelter should be reviewed with all personnel. 2. Fire a. b. c. d. e. f. 3. Evacuate building by using the nearest exit to your location. Plan to meet at a designated area, at least 100 ft. from the building and off roadways and access walkways. Foreman should check his/her crew to determine that everybody has been accounted for. Do not enter the building under any circumstances until the fire department has announced the building can be entered. Adhere to the evacuation. Do not panic or run, but clear the area quickly.

Tornadoes a. b. c. d. Subcontractor will predetermine tornado shelter location with TKS Project Manager. Evacuate buildings or structure areas using the nearest exit to your location. Plan to meet at a designated area capable of providing protection. Foreman should check his/her crew to determine that everybody has been accounted for.

G.

Emergency Phone Numbers Ambulance / Life Squad service Fire Department service Police Department service TKS Industrial Company Map to Hospital Plant Security will notify emergency

Plant Security will notify emergency

Plant Security will notify emergency

TKS will call Plant Security To be Post At Each Telephone Location

Page 66 of 200 QSP 6.51 Rev. 1/20/04

XII.

LOCKOUT/TAGOUT/BLOCKOUT POLICY A. Purpose This policy establishes a lockout/tagout/blockout procedure for securing machinery and equipment during periods of repair, servicing and/or alteration which could cause injury to personnel or damage the equipment. All employers and employees shall comply with this procedure. B. Responsibility The Subcontractor and all of their personnel involved in an operation which requires a lockout/tagout/blockout are responsible to see that this procedure is followed. C. Definition 1. Lockout/Tagout/Blockout The placement of a lock/tag/blockout on the energy isolating device indicating that the energy isolating device shall not be operated until removal of the lock/tag/blockout in accordance with the stated established procedure. 2. Designated Individual An individual to whom the authority and responsibility to perform a specific assignment has been given by the Subcontractor. 3. Energy Source Any electrical, mechanical, hydraulic, pneumatic, chemical, nuclear, thermal, gravity or other energy sources that could cause injury to personnel. 4. Energy Isolating Device A physical device that prevents the transmission or release of energy, for example, but not limited to the following: A manually-operated electrical circuit breaker, a disconnect switch, manually operated switch, a slide gate,

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a slip blind, line valve, blocks or similar devices with visible indication of the position of the device. 5. Device Specifications a. Locks - Shall be of suitable manufacture, color-coded or otherwise identified for lockout use only. Tags - Standard tags shall be used in all facilities. Multiple Lock Adapter - Locally purchased multiple lock adapters shall be maintained and readily available for use at the desk of the TKS Safety Representative (Lockout Tree).

b. c.

D.

Issuance of Safety Lock 1. All employees shall be instructed in all aspects to the purpose and use of the lockout/tagout procedure by their employer. The standard lockout/tagout/blockout instruction program shall be utilized.

2. E.

Implementation 1. Subcontractors shall instruct all employees in the purpose, use and safety significance of the lockout/tagout procedure. All equipment shutdowns must be coordinated with the Full Service Construction Manager a minimum of 24 hours in advance. The first lock and tag applied and the last lock removed will belong to the TKS Safety Representative. However the Subcontractor will be responsible for Blockout installation and removal. This procedure pertains to all TKS equipment, TKS employees, Subcontractors and Subcontractor employees. Anyone working on electrical and or moving equipment will be required to sign out a lock, multiple lock adapter, and tag at the TKS office. Lockout and lock requires authorization of a TKS Superintendent and the Project Manager. The lock, Multiple Lock Adapter (lockout tree) and tag will be obtained from the TKS safety Representative. The tagout and lock will be recorded in the Tagout Log Book which may be obtained at the desk of the TKS Safety Representative. This book will include the equipment tag number, lock number, equipment location, purpose for lockout, the employee name and signature, employee company name, date signed out, TKS Safety Representative signature, Project
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2.

3.

4.

5.

Construction Manager or Project Manager signature and date tagout and lock were returned to TKS. 6. No lock, other than a TKS provided lock, may be applied to any TKS equipment at any time without specific authorization of the Project Manager or Electrical Superintendent. There will be no exceptions to this policy. Anyone in violation of this policy will be immediately terminated from the project. Private locks with tags may be applied to the multiple lock adapter following the above stated procedure. No lock may be removed from any TKS equipment without the direct authorization of the individual who applied for the tagout and lock or both TKS representatives who approved the tagout. Anyone in violation of this policy will be immediately terminated from the project. In the event of a multiple tagout, the above procedure will apply. Modification of this procedure may be completed only at the discretion of the Project Manager or appropriate members of TKS management. This procedure has been adopted for the Safety and Protection of all personnel.

7.

8. 9.

10.

F.

Sequence of Lockout Procedure 1. When necessary, shut equipment down by the normal stopping procedure, (Depress stop button, open toggle switch, valve, etc.). Open disconnect switch, operate valve, or other energy isolating device so that the energy source(s), (electrical, mechanical, hydraulic, gravity, etc.) are disconnected or isolate from the equipment. Stored energy, such as that in capacitors, hydraulic, air, gas, steam, water pressure, etc., must also be dissipated. Lockout/tagout the energy source(s) with assigned individual device(s). Depending upon the equipment, the Subcontractor is responsible to blockout the equipment and remove the block at the completion of work, with the TKS Safety Representative in attendance. In situations involving more than one person, all employees are required to place their assigned individual lock or tag on the energy isolating device following the stated procedure. Equipment Test - After assuring that no personnel are exposed (as a check on having disconnected the energy sources) operate push button or other normal operating controls to make certain the equipment will not operate.
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2.

3. 4.

5.

CAUTION: Return operating controls to neutral, or off position after test. 6. Where lockout/tagout is not feasible in the case of required, repetitive adjustments or production operations, these shall be accomplished under the Subcontractor's supervision of one designated individual. The equipment is now locked out, or secured. If work on a piece of equipment has not been completed by the end of the shift, and is anticipated to be complete for testing by another shift, the supervisor in charge shall tagout the equipment to allow the removal of all locks except the TKS Safety Representative. The oncoming shift attaches their lock(s) and tags per the above procedure.

7. 8.

G.

Restoring Equipment to Service 1. When the job is complete and equipment is ready for testing or normal service, check the equipment to see that no one is exposed. When equipment is all clear, all locks and blockout shall be removed and the disconnect or the energy isolating devices may be operated to restore energy to equipment. This will be completed under the supervision of the TKS Safety Representative. In the case of required repetitive adjustments or production operations, the designated individual will return the equipment to service when it is clear. The last lock to be removed, with assurance by the responsible subcontractor, will belong to the TKS Safety Representative, who will visually inspect the equipment.

2.

3.

4.

Page 70 of 200 QSP 6.51 Rev. 1/20/04

TKS INDUSTRIAL COMPANY LOCKOUT / TAGOUT / BLOCKOUT LOG BOOK

ITEM NAME OF PERSON LOCKING COMPANY EQUIPMENT LOCKED DATED APPROVED BY OUT THE EQUIPMENT OUT WITH LOCATION LOCKED FOR LOCKOUT LOCK REMOVED DATE TIME APPROVED BY FOR LOCK REMOVAL

Page 71 of 200 QSP 6.51 Rev. 1/20/04

XIII. HAZARDOUS COMMUNICATION PROGRAM All Subcontractors must have a Hazardous Communication Program that meets all applicable government regulations.

OSHA Hazard Communication Program, Material Safety Data Sheets As of March 18, 1989, OSHA Hazard Communication Program has become law, and is in effect, as the employees right to know. This means that all Subcontractors are responsible for informing all of their employees of the possible hazards of any and all applicable materials that they may use on the job.

A.

Employee Training 1. You must teach your employees to read the labels, ask questions, and follow the manufacturer's recommendations for safety precautions and use of personal protective equipment. You must also have available for your employees a Material Safety Data Sheet (M.S.D.S.) for all of the materials you use on the job. A copy of this file is to be maintained in your site office with a second copy maintained in the TKS site office, and a third copy located within 300 feet of the work. Since Hazard Communication is mandatory on all projects, TKS requires a copy of each M.S.D.S. sheet as provided by Subcontractor's material supplier. M.S.D.S. sheets are required for all hazardous materials including: gasoline, paints, acids, epoxies, insulation, metals, sealants, grease, etc. Subcontractor's company name will be on the face of each M.S.D.S. sheet. It is the responsibility of the Subcontractor to obtain Material Safety Data Sheets for all materials supplied by the Subcontractor. The Subcontractor will provide a copy of each M.S.D.S. sheet to the TKS Safety Representative to be maintained in a centralized file by the TKS Safety Representative. This file will be available to all site personnel upon request. Stationary process containers will have signs, placards, process sheets, batch tickets, operating procedures or other written materials in place of labels as long as the chemical content is identified and appropriate hazard noted. In these cases, copies of the original label or M.S.D.S. will be immediately available to employees throughout the work site, either by being posted or maintained by the Subcontractor with a copy provided to the TKS Safety Representative for the centralized file, as discussed above.
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2.

3.

4.

5.

The TKS Safety Representative will review the company labeling system every 30 days for update as needed.

B.

Employee Information Program 1. The Subcontractor's Safety Representative is responsible for the employee information program. He / She will ensure that all elements specified below are carried out. Prior to starting work, each new employee will be informed and will receive information regarding the following: a. b. c. d. Specific chemical hazards; An overview of the requirements contained in the Hazard Communication Standard; Chemicals present in their work place operation; This information will include: 1. 2. 3. Special chemical hazards; Protective/Safety measures the employee will take to prevent overexposure; Measures the company has taken to lessen the hazards include ventilation, respirators, presence of another employee and emergency procedures; Location and availability of your written hazard program; Physical and health effects of the hazardous chemicals; Methods and observation techniques used to determine the presence or release of hazardous chemical in the work area; How to lessen or prevent exposure to these hazardous chemicals through usage of control/work practices, personal protective equipment, and good personal hygiene practices; Steps the company has taken to lessen or prevent exposure to these chemicals; Emergency procedures to follow if personnel are exposed to these chemicals or if there is a chemical spill; How to read labels and review M.S.D.S.'s to obtain appropriate hazard information; Location of M.S.D.S. file and location of hazardous chemical list.

2.

4. 5. 6. 7.

8. 9. 10. 11.

3.

After receiving the information, each employee will sign a form to verify that they received training regarding your written materials, and understood this company's policies on Hazard Communication.
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4.

When a new chemical hazard is introduced onto this project, each involved employee will be given information as outlined above. The Subcontractor's Safety Representative is responsible for ensuring that M.S.D.S. on the new chemical(s) are available, with copies properly filed.

In no event will chemicals be introduced onto the project site without the specific authorization of TKS and the Owner. C. Hazardous Non-Routine Tasks Periodically, employees are required to perform non-routine tasks. Prior to starting work on such projects, each affected employee will be given information by their employer's (Subcontractor's) Safety Representative about hazardous chemicals to which they may be exposed during such activity. D. Informing Subcontractors It is the responsibility of the Subcontractor's Safety Representative to inform lower tier Subcontractors of the following listed items and to insure they're compliance. Availability and location of M.S.D.S. Information Sheets at the project. Hazardous chemicals to which they may be exposed while on the project. Precautions the employees may take to lessen the possibility of exposure by usage of appropriate protective measures. Secure M.S.D.S. sheets for Subcontractors for any hazardous materials introduced by other Subcontractors or lower tier subcontractors. E. Employee Right-To-Know The Subcontractor is responsible to insure every employee has the right to know about the chemicals they are working with in their job area. 1. Beyond the right-to-know personnel must be able to understand any potential health and physical hazards associated with that chemical and have access to appropriate information (M.S.D.S). Each employee must be able to read and understand the M.S.D.S. sheet for each chemical they are using. If questioned by an OSHA inspector, they will be required to explain the information on the M.S.D.S. sheet. Review: It is the responsibility of the Employer/Subcontractor to supply M.S.D.S. sheets to TKS Industrial Company. These M.S.D.S. sheets will be kept on file in the office and will be accessible to all employees. Along with the M.S.D.S. sheets, each Employer/Subcontractor must supply a complete, updated list of all chemicals being brought onsite. No chemical
Page 74 of 200 QSP 6.51 Rev. 1/20/04

2.

3.

may be brought on the premises without prior written approval of the TKS Project Manager. The Employer/Subcontractor will also be required to have copies of the M.S.D.S. sheets in their onsite office and must have a separate copy of the M.S.D.S. sheets within 3 00 feet of the actual place the work is being conducted. 4. The following information about the M.S.D.S. program is provided to help Subcontractors and employees understand why the M.S.D.S. information is important and help meet the legal requirements for Subcontractors and employees. a. Overview of the Program The basic objective of the "The Hazard Communication Program" is to inform and educate all of our employees about the hazardous chemicals that could be encountered in the work place, and the precautionary methods necessary when handling or using these materials. b. The program is divided into four principle responsibilities. 1. Inform employees through the use of labels about hazardous chemicals containers in the work place. Maintain a list of those hazardous chemicals in the work place with a Material Safety Data Sheet (M.S.D.S.) for each chemical. Note: the list of substances and the M.S.D.S. will be readily available for convenient reference by all employees affected. Develop a written "Hazard Communication Program. Note: copies must be available for all employees. Inform and train employees about the hazards in the work place.

2.

3.

4.

Page 75 of 200 QSP 6.51 Rev. 1/20/04

c.

M.S.D.S. General Information 1. M.S.D.S. stands for Material Safety Data Sheets. The M.S.D.S. program is designed so people working with chemicals will have access to information about the substance they are working with and the potential chemical hazards. There are 12 major information areas included in the M.S.D.S. Each manufacturer has options in the form of the finished sheet format. You will not find the information of different manufacturers' M.S.D.S. sheets in the same place, but this information should be presented on all MSDS forms. You must know what each subject area means and be able to explain the meaning and directives included in each section. In every M.S.D.S. you will find the following information: a. Identification Name of the manufacturer, importer, distributor responsible for preparing the M.S.D.S. This section includes the chemical name as it appears on the label, the name and address of the company responsible for preparing the information, a phone number to call in the event of an emergency, and the date the M.S.D.S. was prepared. b. The identity of the material In this section you will find the specific chemical identity, the chemical's common name, the scientific or chemical name, the trade name and abbreviation, the chemical formula, the DOT freight classification, and the CAS number (Chemical Abstract Service Number) which is a unique number assigned to chemicals by the American Chemical Society. c. List of Hazardous Ingredients When more than one ingredient makes up the material, all the ingredients will be listed in the hazardous ingredients section as a percentage of the total mixture. The only exception to this is when the chemical composition is claimed to be a trade
Page 76 of 200 QSP 6.51 Rev. 1/20/04

2.

secret. However, even trade secret information must be disclosed in the event of a medical emergency. d. The physical and chemical characteristics of the material In this section, you will find the following physical characteristics of the chemical with which you are working. 1. 2. 3. 4. 5. 6. 7. 8. 9. Boiling point Vapor pressure Solubility Specific gravity Evaporation rate Appearance Odor Percent volatile Vapor density

Information about appearance and odor aid you in confirming that you are handling the correct material. Labeling mistakes happen, if the material you have looks, smells, or acts differently from the material described, you should immediately report the error to your supervisor. e. Fire and explosion information In this section, you will find the fire hazards of a material, conditions which could result in a fire or explosion, the appropriate extinguishing agents and the approved fire fighting methods. f. The physical hazards of the material (Reactivity Data) This section will tell you the materials with which the chemical is incompatible and the physical conditions which should be avoided, covering: stability, incompatibility with various materials or conditions; hazardous decomposition or by-products; and hazardous polymerization (a chemical reaction where molecules of a chemical

Page 77 of 200 QSP 6.51 Rev. 1/20/04

combined with another material to form a different material). g. Health hazards associated with the chemical This is a very important section. All of the following information will be found here. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Signs and symptoms of overexposure Effects of short-term (acute) exposure Effect of long-term (chronic) exposure Scientific basis for the toxicity data (type of study and results) Principle routes of entry Medical conditions that could be aggravated by over-exposure Whether the chemical is a carcinogen or potential carcinogen Occupational exposure limit information Route of entry refers to the means by which a material enters the body; Injection, Ingestion, Inhalation, Absorption Listing by the National Toxicology Program, the International Agency for Research on Cancer, or by OSHA determines whether a chemical is a carcinogen or potential carcinogen.

h.

The allowable levels of exposure to the material Hazardous materials may be used safety if you understand these conditions. 1. The OSHA Permissible Exposure Limits (PEL) is the maximum amount of a chemical a person may be safely exposed to without harm. The American Conference of Governmental Industrial Hygienists Threshold Limit Value (TLV) is the

Page 78 of 200 QSP 6.51 Rev. 1/20/04

concentration of a chemical in the air that can be breathed for five consecutive eight hour workdays by most persons without harmful effects. Other limits may also be recommended, depending on the chemical. 2. TLV stands for the threshold limit value and refers to the airborne concentration of a substance to which workers may be safely exposed without the need for protective equipment. TLV-C, or threshold limit value-ceiling, is the concentration that should not be exceeded even instantaneously. TLV-TWA, or time weighted average, is the average concentration to which a worker may be repeatedly exposed during a normal 8 hour workday without suffering adverse effects. TLV-STEL, or short-term exposure limit, is the concentration to which workers may be safely exposed continuously for a period of 15 minutes or less. If you must work in an area where the concentrations are above the allowable limits, then additional protective equipment will be required. Exposure limits vary from material to material as exposure limits are directly related to the toxicity of the material, so they differ according to the material in question. If you have any questions concerning these

3.

4.

5.

6.

7.

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limits, ask your supervisor for assistance. i. Emergency and First Aid Procedures The emergency and first aid section should be reviewed carefully before work begins with any chemical since procedures vary from material to material. A recommended emergency procedure for one substance could be harmful if used for another. j. The protective equipment and engineering controls required for safe use of the material The information contained in the special protection information section states the personal protective equipment to be used when handling the material, safe handling precautions, engineering control requirements such as ventilation and examples of personal protective equipment. PPE includes, but is not limited to, face shields, respirators, goggles, safety glasses and protective clothing. k. Any special precautions to be taken in handling and storage The special precautions section of the M.S.D.S. contains information on special handling precautions and procedures to take if an accidental leak or spill occurs. Special handling precautions include warnings regarding exposing the material to air, heat, or cold, as well as ventilation requirements. Including waste disposal; spill procedures; respiratory protection; protective clothing and equipment; eye protection; special ventilation requirements; and any special requirements to be taken in handling and storage. l. How to handle spills, leaks and disposal of the material The spill and leak procedures list the cleanup and disposal requirements that must be taken to ensure that the waste material is handled according to regulations.

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d.

Labels 1. All chemicals must be stored in approved containers which are clearly labeled. Unlabeled chemical containers are against the law. Having an unlabeled container is like having medicine bottles with no labels. In case of a chemical accident, everyone must know what the chemical is and where to find the M.S.D.S. sheets in order to take appropriate actions. All containers of hazardous chemicals must be identified with a warning label. The label must contain three pieces of information. a. b. c. The identity of the hazardous chemical. Appropriate hazard warnings. The name and address of the manufacture, importer or responsible party.

2.

3.

As part of our responsibility, we must make sure that all chemicals that we receive comply with the labeling requirements. If the hazardous substance is transferred to a portable container, the portable container must be labeled. Any employee purchasing supplies should request at the time of order placement an M.S.D.S. sheet. Also note the request on the purchase order. Turn in the M.S.D.S. sheets to the TKS office for incorporation into the company file with a copy submitted to TKS.

4.

5.

UNLABELED

CONTAINERS ARE ILLEGAL .

Page 81 of 200 QSP 6.51 Rev. 1/20/04

HAZARD COMMUNICATION PROGRAM

June, 1989

SYMBOLS OF MATERIAL HAZARDS FIRE HAZARD (Red) FIRE 4 (Flash Points) 4-Below 73F 3-Below 100F 2-Below 200F 1-Above 200F 0-Will Not Burn REACTIVITY

HEALTH 2 SPECIAL HAZARD W HEALTH HAZARD (Blue) 4-Deadly 3-Extreme Danger Detonate 2-Hazardous 1-slight Hazard 0-No Hazard

REACTIVITY (Yellow) 4-May Detonate 3-Shock & Heat 2-Violent Chemical Change 1-Unstable if Heated 0-Stable

May

SPECIAL HAZARD (White) W-Use No Water OXY-Oxidizer ACID-Acid ALK-Alkali COR-Corrosive Radioactive The above symbol, extensively used in "Silicon Valley" and numerous other work places, has been developed by the National Fire Protection Association. The N.F.P.A. is primarily concerned with how chemicals will react in a fire. Their four section hazard labeling system provides important information to firefighters and yourself about health, flammability and reactivity of chemical hazards found in the work area in which the symbol is displaced.
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In an emergency, labels are often the first source of information; it is important that we all know how to read the label and understand the information contained therein. Take some time and study the numbering system of the label designations, become familiar with their meanings. 5. Other M.S.D.S. Information a. All sections of the M.S.D.S. must be completed unless trade secrets are involved. Remember- only hazardous materials will have an M.S.D.S. but it is the employers responsibility to first obtain and file an M.S.D.S. If you see a N/A in an M.S.D.S. section, this means that the information is not applicable to the material. The most common hazard to chemical areas are defective storage and handling. The M.S.D.S. will explain safe storage and handling procedures, any protective equipment needed and any special precautions you will need to take. Chemicals may produce toxic vapors, catch on fire, or explode if not stored properly. Remember to store and handle chemicals properly. Changes in temperature or humidity can create problems. Some chemicals will react with other chemical when they are stored together.

b.

c.

Know your M.S.D.S. before emergency occurs. There will not be time during an emergency. M.S.D.S. is for everyone's protection. KNOW YOUR M.S.D.S! Please remember that the information on an M.S.D.S. may be indicated in a different order or format on some sheets or be presented in a different format. All M.S.D.S. should contain all of the above information. The M.S.D.S. are filed in the TKS office in alphabetical order based on the product name.

Page 83 of 200 QSP 6.51 Rev. 1/20/04

MATERIAL SAFETY DATA SHEETS Prepared in accordance with OSHA Standard 29 CFR 1910.1200 GENERAL INFORMATION

Product Line

Trade Name

Company Name and Address (Number, Street, City, State and Zip Code)

Date Issued

Date Revised

Emergency Telephone Number

HAZARDOUS INGREDIENTS

TLV (UNITS)

PHYSICAL DATA

Boiling Point (F) Vapor Pressure

Specific Gravity Percent Volatile Organic By Volume (%) Evaporation Rate (Ether = 1) Product pH

Vapor Density(Air=1) Solubility in Water

Page 84 of 200 QSP 6.51 Rev. 1/20/04

Appearance and Odor ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________ Explosion Hazard Data ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________ Flash Point (Method Used) Flammable Limits LEL UEL

______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________ Extinguishing Media ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________ Physical Fire Fighting Procedures ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________ Unusual Fire and Explosion Hazards ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________
Page 85 of 200 QSP 6.51 Rev. 1/20/04

Health and Emergency Information ______________________________________________________________________________ ______________________________________________________________________________ ______________ Effects of Overexposure ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________

Emergency and first Aid Procedures Eye Contact ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________ Ingestion ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________ Spill or Leak Procedures ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________ Steps to be taken in case material is released or spilled ______________________________________________________________________________ ______________________________________________________________________________

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______________________________________________________________________________ ____________ Waste Disposal Method ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____________________

SPECIAL PROTECTION INFORMATION Respiratory Protection (Specify Type)

Ventilation

Local Exhaust

Mechanical (General)

Protective Gloves

Eye Protection

Other Protective Equipment ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________________

Special Precautions Precautions to be taken in Handling and Storing ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _______________

Page 87 of 200 QSP 6.51 Rev. 1/20/04

Other Precautions ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________

Page 88 of 200 QSP 6.51 Rev. 1/20/04

HAZARD COMMUNICATION INSTRUCTION I have received Hazard Communication Instruction as described in the Hazard Communication Program. The instruction conducted on ___________________________________. (Date)

__________________________ Employee Signature

__________________________ Drivers License Number

__________________________ Company Name

I hereby acknowledge that the above employee has been provided with the Hazard Communication information.

Page 89 of 200 QSP 6.51 Rev. 1/20/04

XIV. CONFINED SPACE ENTRY PROGRAM A. B. C. D. E. Introduction Written Program Confined Space Evaluation And Classification Permit System And Entry Permit Entry Procedures 1. Alternate Entry Procedures (Non-Permit Required) 2. Regular Entry Procedures (Permit Required) Isolation Ventilation And Cleaning Safety Precautions Rescue Duties Of Personnel Training Working With Contractors Confined Space Entry Summary Review Appendix

F. G. H. I. J. K. L. M. N. O.

Page 90 of 200 QSP 6.51 Rev. 1/20/04

A.

Introduction 1. Source This Confined Space Entry Program was written for the Ohio State University and modified by Cecil Smith, Dr. P.H., Chief, Division of Environmental and Occupational Health and Safety, Ohio State University (4123194). It was edited by Richard Carpenter for TKS. 2. Policy TKS Industrial Company (TKS) is firmly committed to providing each of its employees with a safe and healthy work environment. Personnel who are involved in confined space operations face potential dangers from toxic, explosive or asphyxiating atmospheres, as well as engulfment. TKS has established a written Confined Space Entry Program that establishes guidelines for work within confined spaces. 3. Responsibility a. Unless subcontracted, TKS Industrial Company's responsibility is to instruct each employee involved in a confined space entry about the nature of the confined space and regarding the hazards involved, the necessary precautions to be taken, the use of personal protective equipment, emergency equipment, air quality monitoring, the procedure to be followed if an emergency occurs, the Hazard Communication Program, job assignments and responsibilities. If the work is subcontracted, this becomes the responsibility of the Subcontractor.

b.

4.

Continuous Quality Improvement (CQI) It is the intention of TKS to monitor, review and evaluate the safety procedures used during a confined space entry to ensure that adequate safety precautions were followed and to improve procedures for future confined space entries.

B.

Written Program 1. Written Confined Space Entry Program The Program Includes:

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a. b. c. d. e. f. g. h. 2.

Classification of confined spaces. Confined space hazard evaluation. Evaluation forms and entry permits associated with confined space entry. Entry permit system details. Regular and alternate procedures for permit space entry. Duties and training requirements for confined space entry personnel. Work coordination with contractors. Definition of terms related to confined space entry.

Access to the Written Program The written Confined Space Entry Program is available to all employees, Subcontractors, Owners, building trades unions and their authorized representatives upon request. Contact the Contract Manager of TKS to review the written program.

3.

Revision of the Written Program TKS shall be responsible to review the confined space operation and revise the Written Confined Space Program. The document shall be revised whenever a review of entry operations indicates that the permit space program may no longer adequately protect employees. Such revisions shall take place before subsequent entries are authorized. The following circumstances shall require a review of the permit required confined space program: a. b. c. d. e. f. Any unauthorized entry of a permit space. The detection of a permit space hazard not covered by the permit. The detection of a condition prohibited by the permit. The occurrence of an injury or near-miss accident during entry. A change in the use of configuration of a permit space. Employee complaints about the effectiveness of the program.

C.

Confined Space Evaluation and Classification 1. Every confined space shall be evaluated to determine if it is a permit-required confined space. This evaluation shall take place before the Confined Space Entry Permit is completed. The decision tree found in Appendix A shall be used to evaluate the presence of permit and non-permit required confined space. The entry supervisor is responsible to ensure that this evaluation has been performed. A Pre-Entry Confined Space Evaluation Form (Appendix B) shall be completed prior to any confined space entry. This form indicates the
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2.

location, potential hazards, control requirements for an acceptable entry, and other important information needed to properly classify the space as requiring or not requiring a permit for entry. The entry supervisor is responsible to ensure that these forms have been completed. a. The Pre-entry Confined Space Evaluation Form shall be used to document the basis for determining the status of all recognized hazards in a confined space and to insure that they are not present or have been eliminated. This document shall contain the date, the location of the space, and the signature of the person making the determination. The document shall be made available to each employee upon request before entering the space.

3.

A danger sign (Appendix C) shall be posted at all permit spaces, including those locations where access necessitates the use of tools or keys to open. The sign's purpose is to inform employees of the existence, location, and danger posed by permit-required confined spaces. The entry supervisor is responsible to ensure that these warning signs have been posted and are maintained in good condition. Regular confined space entry procedures shall be followed for permit spaces that exhibit single or multiple hazards. Alternate confined space entry procedures shall be followed for permit spaces that only have an atmospheric hazard that can be controlled by ventilation. The specific entry procedures applicable to both types of spaces are described in Section D. All spaces shall be evaluated prior to entry to determine their status as a permit or non-permit confined space using the following procedures: a. If the permit space poses no actual or potential atmospheric hazards and if all other hazards within the space are eliminated (not just controlled) without entry into the space, the permit long as the non-atmospheric hazards remain eliminated space may be reclassified as a non-permit confined space for as If it is necessary to enter the permit space to eliminate hazards, such entry shall be performed under the regular permit space entry procedures. If testing and inspection during this entry demonstrate that the hazards within the permit space have been eliminated, the permit space may be reclassified as a non-permit confined space for as long as the hazards remain eliminated. If hazards arise within a confined space, all employees shall immediately exit the space. The entry supervisor shall then reevaluate the space and determine what measures must be

4.

5.

b.

c.

Page 93 of 200 QSP 6.51 Rev. 1/20/04

instituted to control the hazards(s), as well as to determine the need to reclassify the space as permit-required. d. When there are changes in the use or configuration of a non-permit confined space that might increase the hazards to entrants, the entry supervisor shall reevaluate that space and, if necessary reclassify it as a permit-required confined space.

6.

Employee Responsibility The success of our Confined Space Entry Program depends upon the active participation and cooperation of every employee involved in confined space operations. Employees must observe the danger signs at all permit-required spaces; never enter a confined space without properly certified training and authorization; and faithfully following all instructions on the entry permit.

7.

Confined Space Definition The Confined Space Definition includes but is not limited to the following: a. b. c. d. e. f. Having a limited means of egress. Not designed for continuous employee occupancy. Has less than 19.5% oxygen. Has flammable/combustible/explosive atmospheres present or able to be generated in an area. Toxic atmospheres present or able to be generated or enter into an area. Areas not protected against entry of water, gas, sand, gravel, ore, grain, coal, biological, radiation, corrosive chemicals, or any other substance which could possibly trap, suffocate or harm a person. Poor ventilation. Restricted entry for rescue purposes.

g. h. 8.

Fourteen Rules for Confined Space Entry a. Planning Sessions by Qualified Person (#1) 1. 2. 3. 4. Definite time and date of entry. Work to be accomplished. Designated Personnel. Job Hazard Assessment a. Listing all material stored or to be used in the confined space.

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b.

Research on hazardous properties or combinations or by products.

5.

Method of Operation a. b. c. d. Cleaning Purging Ventilating Safe Work Practices

6.

Backup Safety Procedures a. b. c. First Aid Showers/Decontaminations Rescue Equipment

7. 8.

Pre-Entry session time and date. Commitment for safe work practice. a. b. Testing of Atmosphere (#2) Ventilation (#3) 1. 2. 3. c. Drawing air out of space (Exhaust Air) Blowing air into space (Supply Air) Explosion proof equipment required

Instruction to Personnel (#4) 1. 2. 3. 4. 5. 6. 7. 8. Emergency entry/exit procedures Appropriate personal protective equipment Use of applicable respirators First aid/CPR Lockout/Tagout procedures Rescue plan Applicable safety equipment Rescue drills

d.

Lockout/Tagout/Blockout (#5) 1. 2. 3. Blind flanging of pipes (Blockout) Electrical Lockout Mechanical Lockout/Blockout

e.

Stand-By Personnel and Communication (#6)

Page 95 of 200 QSP 6.51 Rev. 1/20/04

f. g.

Tools and Equipment (#7) Entry Permit Posted at Confined Space Entry Point (#8) Continuous Monitoring Of Atmosphere (#9) Record Keeping (#10) 1. 2. 3. 4. Instruction Survey of Equipment Test results of atmosphere Maintenance of equipment

h. i.

j. k.

Extraction of Equipment (#11) Notification of a Trained and Qualified Emergency Rescue Agency (#12) 1. 2. 3. Pre-confined space coordination meeting Notification when Confined Space Entry Begins Notification when Confined Space Entry Ends

l.

Notification and Authorization of the Owner and TKS (#13) 1. 2. Attendance at planning session Authorization to proceed

m.

Notification Of Plant Safety and Security (#14) 1. 2. When Confined Space Entry Begins When Confined Space Entry Ends

D.

Permit System and Entry Permit 1. Before entry of a permit space is authorized, an entry permit shall be prepared to document that the space is safe to enter. This permit shall be completed using the Pre-entry Confined Space Evaluation Form (Appendix B) as a guide. The entry supervisor is responsible to prepare the entry permit.

Page 96 of 200 QSP 6.51 Rev. 1/20/04

2.

Before entry begins, the entry supervisor shall verify that all necessary precautions have been taken. The entry supervisor must sign the entry permit to authorize entry. The completed permit shall be made available at the time of entry to all authorized entrants, by posting it at the entry portal, so that the entrants can confirm that pre-entry preparations have been completed. The duration of the permit may not exceed the time required to complete the assigned task or job identified on the permit. Additional limitations on the duration of the entry will be described on the permit. The entry supervisor shall terminate entry and cancel the entry permit when: a. the entry operations covered by the entry permit have been completed. a condition that is not allowed under the entry permit arises in or near the permit space (e.g.,loss of ventilation, a facility or area emergency, etc.)

3.

4.

5.

b.

6.

Following completion of the job, exit of entrants and return of space to normal service, the entry supervisor shall debrief personnel involved in the entry and cancel the permit. Any problems encountered during an entry operation shall be noted on the permit so that appropriate revisions to the permit space program can be made. Each canceled entry permit shall be retained for at least one (1) year to facilitate the review of the permit-required confined space program. A copy of the canceled permit is to be sent to the TKS Project Manager.

7.

E.

Entry Procedures 1. Alternate Entry Procedures (Non-Permit Required) a. Alternate procedures for entering a permit space apply when all of the following conditions apply: 1. when the only hazard posed by a permit space is an actual or potential hazardous atmosphere. when continuous forced air ventilation alone is sufficient to maintain the permit space safe for entry. when the work to be performed within the space does not introduce any additional hazards (e.g., work with hazardous
Page 97 of 200 QSP 6.51 Rev. 1/20/04

2.

3.

quantities of flammable or toxic substances and hot work are not permitted). 4. when there is periodic monitoring and inspection data to support (I) and (2). a. The documentation of the above conditions shall be recorded on the Pre-Entry Confined Space Evaluation Form and made available upon request to each employee entering the permit space. If an initial entry of the permit space is necessary to obtain the required monitoring and inspection data, the entry shall be performed under the regular procedures for entering a permit space (including the completion of a Confined Space Entry Permit and the presence of an attendant). If a condition exists which makes it unsafe to remove an entrance cover, the unsafe condition shall be eliminated whenever possible before the cover is removed. When entrance covers are removed, the opening shall be promptly guarded by a railing, temporary cover, or other temporary barrier that will prevent an accidental fall through the opening and that will protect each employee working in the space from being struck by foreign objects entering the space. If the space did not require a danger sign previously, one should be posted as soon as the cover to the space is removed. Atmospheric Testing 1. The entry supervisor is responsible to conduct and record atmospheric tests on the Pre-Entry Confined Space Evaluation Form Atmospheric testing shall be performed without entering and before entrance covers are removed whenever possible. The instrument probe should be carefully inserted into the cover opening to test the air quality before it is removed. If an opening does not exist, the cover should be cracked

b.

c.

d.

e.

2.

Page 98 of 200 QSP 6.51 Rev. 1/20/04

slightly to allow the probe to test the atmosphere. 3. The readings shall be performed over a cross section of the confined space. Atmospheric testing shall be conducted with a calibrated, direct reading instrument for the following conditions in the order given: a. b. c. 5. Oxygen content Flammable gases and vapors Potential toxic air contaminants

4.

The minimum oxygen level shall be 19.5% and the maximum level shall be 23.5%. If oxygen levels are outside this range, the space shall be ventilated until tests show the levels to be in the acceptable range. The maximum lower explosive limit (LEL) is 10%. Whenever possible, the flammable source shall be eliminated and the space ventilated to maintain the LEL below 10%. The monitoring equipment shall be equipped with a functional audible alarm to warn entrants when the 10% LEL is exceeded. Confined spaces that contain a material with a toxic, corrosive, or irritant properties shall be tested for the presence of those atmospheric contaminants. If tests indicate that concentrations are above the permitted levels, the confined space shall be ventilated to reduce those contaminant amounts as low as possible. If ventilation cannot reduce the contaminant concentration below the permitted levels, then the appropriate respiratory protection will be used with ventilation to maintain the exposures as low as possible.

6.

7.

8.

9.

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10.

Physical hazards (such as noise, heat radiation) shall be monitored when applicable and appropriate protective measures will be used for control purposes. The entry supervisor is responsible to complete and record these atmospheric tests on the Pre-Entry Confined Space Evaluation Form.

11.

f.

There shall be no hazardous atmosphere within the space whenever any employee is inside the space. Continuous forced air ventilation shall be used, as follows: 1. An employee may not enter the space until the forced air ventilation has eliminated any hazardous atmosphere. The forced air ventilation shall be so directed as to ventilate the immediate areas where an employee is or will be present within the space and shall continue until all employees have left the space. The air supply for the forced air ventilation shall be from a clean source and may not increase the hazards in the space.

g.

2.

3.

h.

The atmosphere within the space shall be periodically tested as necessary to ensure that the continuous forced air ventilation is preventing the accumulation of a hazardous atmosphere. The entry supervisor is responsible to complete and record these atmospheric tests on the Pre-Entry Confined Space Evaluation Form. If a hazardous atmosphere is detected during entry: 1. All employees shall leave the space immediately. The space shall be evaluated to determine how the hazardous atmosphere developed.

i.

2.

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3.

Measures shall be implemented to protect employees from the hazardous atmosphere before any subsequent entry takes place.

2.

Regular Entry Procedures (Permit Required) a. Regular procedures for entering permit spaces apply under any of the following conditions: 1. 2. When multiple hazards are posted by a permit space. When it is necessary to enter the permit space to control or eliminate the hazards. When the preliminary pre-entry evaluation indicates the need for full permit. a. Before entry of a permit space is authorized, an entry permit shall be prepared to document that the space is safe to enter. This permit shall be completed using the Pre-Entry Confined Space Evaluation Form (Appendix B) as a guide. The entry supervisor is responsible to prepare the entry permit. All pre-entry preparation activities specified on the permit shall be completed before entry is authorized. The preparations include, but are not limited to the following: 1. 2. Isolating the permit space. Depressurizing equipment under positive or negative pressure.

3.

b.

NOTE: Jackets of vessels are to be depressurized. If work is to be performed that could compromise the integrity of the inner jacket wall, the jacket must be drained and free from extremely hot or cold, noxious, poisonous of flammable materials. 3. Lockout, tagout, blockout and tryout all sources of electrical, pneumatic, mechanical, chemical, thermal, or radiation hazards. All the appropriate permits have been secured

Page 101 of 200 QSP 6.51 Rev. 1/20/04

(e.g. hot work, radiation, and lockout/tagout). 4. Purging, inverting, flushing, or ventilating the permit space as necessary to eliminate or control atmospheric hazards. This would include continuous forced air and/or local exhaust. Providing pedestrian, vehicle, or other barriers as necessary to isolate the area and protect entrants from external hazards. All slip and trip hazards are minimized or eliminated. Sharp edges removed or guarded. Appropriate personal protective equipment is available, clean, and in working order. This includes: eye, hand, head, whole body, feet, and respiratory protection. Rescue equipment is available, clean, and in working order. These items would include tripod with mechanical winch or hoist, full body harness, portable explosion proof lighting with ground fault circuit interrupters (GFCI's). Communication equipment or systems are available and functional. This includes radio, voice, visual or hand signals. Emergency and rescue services alerted and available, if needed. Fire protection equipment is available and functional. Atmospheric monitoring instruments available, calibrated and in working order.

5.

6.

7. 8.

9.

10.

11.

12.

13.

c.

Evaluate permit space conditions as follows when entry operations are conducted.

Page 102 of 200 QSP 6.51 Rev. 1/20/04

1.

Test conditions in the permit space to determine if acceptable entry conditions exists before entry is authorized. However, if isolation of the space is not feasible because the space is large or is part of a continuous system (such as a sewer), pre-entry testing shall be performed to the extent feasible before entry is authorized. If entry is authorized, entry conditions shall be continuously monitored in the area where authorized entrants are working. (Results should be recorded every 15 minutes or more frequently as conditions necessitate). Test or monitor the permit space as necessary to determine if acceptable entry conditions are being maintained during the course of entry operations. When testing for atmospheric hazards, test first for oxygen, second for combustible gases and vapors, and third for toxic gases and vapors.

2.

3.

d.

At least one (1) attendant is required outside the permit space into which entry is authorized for the duration of entry operations. The permit space shall be evacuated immediately under any of the following conditions: 1. If the entrant or attendant detects a prohibited condition. If the entrant recognizes any warning sign or symptom of exposure to a dangerous situation, (See Appendix D). If the attendant detects the behavioral effects of hazard exposure in an authorized entrant, (See Appendix D). If the attendant detects a situation outside the space that could endanger the authorized entrant(s).

e.

2.

3.

4.

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5. F. Isolation 1.

If the attendant cannot effectively and safely perform all the required duties.

Confined space shall be completely isolated where feasible from all other systems and equipment. However, mechanically introduced fresh air will be an acceptable means to dilute atmospheric hazards. Positive and appropriate preventive measures shall be taken to prevent harmful material from entering the confined space while entrants are inside. Such measures may include disconnecting supply piping and installing blank flanges or caps in the system; or locking valves in the closed position. Line disconnect switches that supply power to mixers, agitators, pumps, motor, etc., shall be tagged and locked with a key type padlock in the "OFF" position. Line fuses in the circuit should be removed where feasible, as an added measure. Such precautions could be a part of the lockout/tagout procedures. Each person in the confined space shall place their own lock on the circuit breaker and shall be in possession of the keys while in that space. Mechanical systems operated by a computer shall be isolated from the computer equipment and controlled manually until completion of the confined space work. Afterwards, the mechanical system can be placed under the control of the computer.

2.

3.

4.

5.

6.

G.

Ventilation and Cleaning 1. Confined space shall be ventilated, preferably by some method of mechanical supply or exhaust system to avoid recirculating contaminated air. All ventilation equipment must be grounded. Chemicals and other contaminant sources shall be removed from the immediate vicinity to prevent introduction into the confined space, especially when ventilating with mechanical equipment. Vehicles and other fuel powered equipment shall not be left running near confined space work or ventilators, unless properly vented or isolated. At no time shall the fuel powered equipment endanger confined space personnel. Oxygen shall never be used for ventilation purposes.
Page 104 of 200 QSP 6.51 Rev. 1/20/04

2. 3.

4.

5.

6.

Confined spaces (e.g. tanks, vessels, hoppers, etc.) shall be emptied and cleaned by hot or cold water flush, steam cleaning, air purge, or other safe suitable. means. Steam lines shall be electrically bonded to the tank to eliminate static electricity and prevent ignition of flammable liquids when steam cleaning. Steam shall not be introduced below the liquid surface of the tanks. Protective clothing and respiratory equipment shall not be used as a substitute for cleaning and ventilation. The ventilation system shall be operated following the cleaning of the confined space.

7.

8. 9.

10.

H.

Safety Precautions 1. Eating, drinking and smoking are prohibited, while entrants are in the confined space. Hand tools shall be clean, in good repair, and selected according to the intended uses. Tools, supplies, and other equipment shall be safety lowered or retrieved from the confined space in an appropriate carrying device to prevent accidents or injuries to the entrants. Ladders shall be secured onto the top and at the bottom, if necessary. Air operated power tools shall be used where possible. Portable electrical tools and cords shall be in good condition and properly grounded, and GFCI protected. Explosion proof equipment and lights shall be used where flammable or combustible atmospheric contaminants are possible. Temporary lights with guards shall be used to prevent contact with the hot bulb. Hot work, lockout/tagout, and radiation permits shall be secured before beginning any of these tasks within the confined space. These permits should be obtained through the shop supervisor.

2.

3.

4. 5. 6.

7.

8.

9.

Page 105 of 200 QSP 6.51 Rev. 1/20/04

10.

Welding or cutting torches are not to be taken into the confined space until ready to be used and shall be removed immediately after use. Gas hoses must be removed from the space and the supply turned off at the cylinder valve, whenever entrants leave the confined space. Compressed gas cylinders, except those associated with self contained breathing apparatus, shall not be taken into the confined space. Where potential exposure to entrants requires the use of respiratory protection or conditions may make rescue difficult, rescue equipment such as a tripod, hoist, body harness, safety belts, and life lines, will be used. The rescue equipment shall be clean, maintained, and in working order.

11.

12.

I.

Rescue 1. At least one member of the rescue service or team must be certified in first aid and in CPR. To facilitate non-entry rescue, retrieval systems or methods shall be used whenever an authorized entrant enters a permit space, unless the retrieval equipment would increase the overall risk of entry or would not contribute to the rescue of the entrant. Retrieval systems shall meet the following requirements: a. Each authorized entrant shall use a full body harness with a retrieval line attached at the center of the entrant's back near shoulder level or above the entrant's head. Wristlets may be used in lieu of the chest or full body harness, if the use of a chest or full body harness is not feasible or creates a greater hazard and that the use of wristlets is the safest and most effective alternative. The other end of the retrieval line shall be attached to a mechanical device or fixed point outside the permit space in such a manner that rescue can begin as soon as the rescuer becomes aware that rescue is necessary. A mechanical device shall be available to retrieve personnel from vertical permit spaces more than 5 feet deep and shall be used where the need for fall protection has been identified.

2.

b.

3.

If in the course of a permit space entry, an attendant becomes aware that an entrant needs assistance in escaping from permit space hazards, the attendant shall: a. b. Summon rescue and other emergency services. Begin non-entry rescue procedures.
Page 106 of 200 QSP 6.51 Rev. 1/20/04

4.

Attendants may enter a permit space to attempt a rescue if it is stipulated in the rescue plan as an alternative and the following conditions have been met. a. b. c. If they have been relieved by another attendant. If they have been trained. If they have been equipped for rescue operations.

5.

If an injured entrant is exposed to a substance for which a Material Safety Data Sheet (MSDS) or other similar written information is required to be kept at the worksite, that MSDS or written information shall be made available to the medical facility testing the exposed entrant.

J.

Duties of Personnel 1. Authorized Entrants Each authorized entrant shall: a. Know the hazards that may be encountered during entry, including information on the mode, signs, symptoms, and consequences of the exposure. Properly use equipment required to safely enter the confined space including equipment for testing and monitoring, ventilating, communication, personal protection, lighting and ingress/egress. Communicate with the attendant as necessary to enable the attendant to monitor entrant status and to alert entrants of the need to evacuate the space. Alert the attendant whenever: 1. The entrant recognizes any warning sign or symptom of exposure to a dangerous situation. The entrant detects a prohibited condition.

b.

c.

d.

2. e.

Exit from the permit space as quickly as possible whenever: 1. An order to evacuate is given by the attendant or the entry supervisor.

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2.

The entrant recognizes any warning sign or symptom of exposure to a dangerous situation. The entrant detects a prohibited condition. An evacuation alarm is activated.

3. 4. 2. Attendants

Each attendant shall: a. Know the hazards that may be faced during entry, including information on the mode, signs, symptoms, and consequences of the exposure. Have read and understood the applicable MSDS (sheets) and be aware of possible behavioral effects of hazardous exposure to authorized entrants. Continuously maintain an accurate count of authorized entrants in the permit space and ensure that the entry permit accurately identifies who is in the permit space. Remain outside the permit space during entry operations until relieved by another attendant. Communicate with authorized entrants as necessary to monitor entrant status and to alert entrants of the need to evacuate the space. Conduct monitoring tests initially and periodically (i.e., every 15 minutes) during the time the entrants are within the permit required confined space. The tests should also be conducted outside the entrance and include measurements for oxygen deficiency, flammable limits, toxic gases, etc. This information is to be recorded on the permit. Monitor activities inside and outside the space to determine if it is safe for entrants to remain in the space and order the authorized entrants to evacuate the permit space immediately under any of the following conditions: 1. 2. If the attendant detects a prohibited condition. If the attendant detects signs and symptoms of hazardous exposure in an authorized entrant.
Page 108 of 200 QSP 6.51 Rev. 1/20/04

b.

c.

d.

e.

f.

g.

3.

If the attendant detects a situation outside the space that could endanger the authorized entrant. If the attendant can not effectively and safety perform all the required duties.

4.

h.

Summon rescue and other emergency services as soon as the attendant determines that authorized entrants may need assistance to escape from permit space hazards. Take the following actions when unauthorized persons approach or enter a permit space while entry is underway: 1. Warn the unauthorized persons that they must stay away from the permit space. Advise the unauthorized persons that they must exit immediately if they have entered the permit space. Inform the authorized entrants and the entry supervisor that unauthorized persons have entered the permit space.

i.

2.

3.

j. k.

Perform non-entry rescues as specified in Section I (Rescue). Perform entry rescues ONLY if trained and equipped for rescue operations and if they have been relieved by a qualified attendant (please review Section I-4 of this manual). 1. Perform no duties that might interfere with the attendant's primary duty to monitor and protect the authorized entrants.

3.

Entry Supervisors Each entry supervisor shall: a. Conduct pre-entry evaluation of the confined space to determine its status as a permit required (PR), non-permit required (NP), or non permit required with ventilation and testing (NPVT). Endorse the Pre-Entry Confined Space Evaluation form upon completion. Know the hazards that may be faced during entry, including information on the mode, signs, symptoms, and consequences of the exposure.

b.

Page 109 of 200 QSP 6.51 Rev. 1/20/04

c.

Insure that appropriate MSDS sheets are available at the confined space and have been reviewed and understood by the authorized entrants and the attendant and other stand-by personnel. Verify that the permit has been filled out correctly, that all tests specified by the permit have been conducted and that all procedures and equipment specified are in place before endorsing the permit and allowing entry to begin. Terminate the entry and cancel the permit when required. Verify that rescue services are available and that the means for summoning them are operable. Remove unauthorized individuals who enter or who attempt to enter the permit space during entry operations. If necessary, contact shop supervisor for advice and security assistance. Determine that entry operations remain consistent with terms of the entry permit and that acceptable entry conditions are maintained, whenever responsibility for a permit space entry operation is transferred and at intervals dictated by the hazards and operations performed. Contact the Division of Environmental and Occupational Health and Safety if necessary about monitoring or entry difficulties for technical support.

d.

e. f.

g.

h.

i.

K.

Training 1. Each employee serving as an authorized entrant, attendant, or entry supervisor during any type of confined space operation shall be trained so that they have he understanding, knowledge, and skills necessary for the safe performance of their duties. This training shall include the following: a. b. The operation of the permit system; The specific duties of each person involved in permit space operations; The hazards of confined spaces including information on the mode, signs, symptoms, and consequences of exposure; The proper use of equipment required during permit space operations including: testing and monitoring equipment, ventilating equipment, communication equipment, personal
Page 110 of 200 QSP 6.51 Rev. 1/20/04

c.

d.

protective equipment, lighting equipment, barriers and shields, ingress/egress equipment, rescue and emergency equipment used for non-entry rescue, and any other equipment necessary for safe entry into and the rescue from permit spaces; e. f. g. h. i. j. 2. The importance of communication between entrant and attendant; The conditions under which the space should be evacuated; The procedures for summoning rescuers; and The procedures to be used for a non-entry rescue. Lockout/tagout/blockout procedures. Hazardous communication program requirements.

Employees who enter permit spaces to perform rescue services shall receive all of the training normally given to authorized entrants, attendants and entry supervisors. In addition, their training shall also include the following: a. The proper use of any personal protective equipment or rescue equipment necessary for making rescues from permit spaces; The specific duties required for rescue personnel; Practice making permit space rescues at least once every 12 months, by means of simulated rescue operations in which they remove dummies, mannequins, or actual persons from the actual or representative permit spaces; Basic first-aid including cardiopulmonary resuscitation (CPR

b. c.

d. 3.

Training shall be provided to each affected employee: a. b. c. Before the employee is first assigned permit space operations duty; Before there is a change in assigned duties; Whenever there is a change in permit space operations that presents a hazard about which an employee has not previously been trained; and Whenever there are deviations from the space permit space entry procedures or there are inadequacies in the employee's knowledge or use of these procedures.
Page 111 of 200 QSP 6.51 Rev. 1/20/04

d.

4.

The training shall document employee proficiency in the duties assigned to authorized entrants, attendants, entry supervisors and rescue service members. Once trained, each employee serving as authorized entrant, attendant, entry supervisor or rescue service member shall be certified. The certification shall contain each employee's name, the signatures or initials of the trainers, and the dates of training. The certificate or certification card shall be available for inspection by employees and their authorized representative upon request.

5.

L.

Working With Subcontractors 1. Subcontractors Working in Confined Spaces a. When a subcontractor is hired to perform work that involves permit space entry, TKS shall: 1. Receive and review a written copy of the Subcontractor's Confined Space Entry Program. Inform the Subcontractor that the workplace contains permit as well as non-permit spaces and that permit space entry is allowed only through compliance with TKS ' and the Owner' s Space Entry Program. Inform the Subcontractor that they must make arrangements for the entry supervisor having responsibility for the confined space to conduct a pre-entry evaluation to determine its status. Notify the Subcontractor of the circumstances, including the hazards identified and the experience with the space, that make the space in question a permit space. Notify the Subcontractor of any precautions or procedures that TKS has implemented for the protection of employees in or near permit spaces where Subcontractor personnel will be working. Debrief the Subcontractor at the conclusion of the entry operations regarding the Permit Space Program regarding any hazards confronted or created in permit spaces during entry operations.

2.

3.

4.

5.

6.

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7.

Coordinate entry operations when employees of more than one Subcontractor are working simultaneously as authorized entrants in a permit space, so that employees of one contractor do not endanger the employees of any other contractor; and Ensure that the Subcontractor and their employees are informed and knowledgeable about all aspects of confined space entry (e.g., hazard recognition, entry operations, atmospheric testing, MSDS, as well as rescue and retrieval). Obtain all available information regarding permit space hazards and entry operations from the Owners.

8.

9.

b.

Each Subcontractor who is retained to perform permit space entry operations shall: 1. Contact or meet with the Project Manager having responsibility or control of the confined space to be entered in order to determine its status. This would include the completion of the Pre-Entry Confined Space Evaluation Form and coordination of the actual entry. Comply with all permit space requirements outlined in this written Confined Space Entry Program. Obtain any available information regarding permit space hazards and entry operations from TKS. Coordinate entry operations with the Owner's contact through TKS; when both the Owner's personnel and Subcontractor personnel will be working in or near permit spaces. Inform TKS and obtain approval for the Permit Space Program that the Subcontractor will follow. Ensure that their employees are trained in all aspects of confined space entry (e.g., hazard recognition, entry operations, atmospheric testing, as well as rescue and retrieval). Inform TKS of any hazards confronted or created in permit spaces, either through a debriefing or during the entry operation.

2.

3.

4.

5.

6.

7.

Page 113 of 200 QSP 6.51 Rev. 1/20/04

8.

Supply all equipment to perform the work including all safety equipment, air quality monitors, etc.

2.

Subcontractors Providing Permit Space Rescue a. When TKS or the Subcontractor arranges to have persons other than their employees perform permit space rescue, the Subcontractor shall: 1. Inform the rescue service of the hazards that may be confronted when called on to perform rescue at the facility; and

3.

Provide the rescue service with access to all permit spaces from which rescue may be necessary so that the rescue service can develop appropriate plans and practice rescue operations.

M.

Confined Space Entry Summary 1. Two major causes for loss of life in confined space situations: a. b. 2. Failure to recognize the hazards in confined spaces. Incorrect rescue attempts.

A confined space consists of: a. b. c. d. Limited entry and exit. Contains known or potential hazards. Has poor natural ventilation. Not designed for continuous human occupancy.

3.

Confined space entry occurs when a persons head or feet pass the plane of the entry. Confined spaces may be classified into two (2) categories: a. b. Open-topped enclosures of depths which restrict the natural flow of air. Enclosures with extremely limited small openings for entry and exit.

4.

5.

Over half of the confined space fatalities are due to improperly executed rescue attempts. Entry permit must be obtained before a confined space may be entered.

6.

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7.

The permit is good for only the time and date it is issued. If the work goes on to the next shift, then a new permit must be obtained. Before a confined space can be entered, it must be washed, cleaned or purged with atmosphere tested. The space must be isolated. a. b. Lockout/Tagout/Blockout All hazardous lines must be disconnected and blanked off.

8.

9.

10.

Ventilation is essential, especially when: a. b. c. There are combustible vapors and gases. Toxic and other contaminants are present. Oxygen excess or deficient atmosphere.

11. 12.

Respiratory protection will be selected by the safety professional. Self-contained breathing apparatus must be worn in areas that are classified as IMMEDIATELY DANGEROUS TO LIFE AND HEALTH (IDLH). Three (3) situations when Self Contained Breathing Apparatus (SCBA) or Air Line respirators must be used: a. b. c. IDLH atmosphere. Unknown contaminant. During emergency entry.

13.

14. 15.

Make sure that your clothing is right for the job. While someone is in the confined space: a. Assign a stand by person (Attendant) to remain at the entrance of the confined space and maintaining communication with the entrants. The standby is the person who is responsible for initiating rescue procedures. Have at least two (2) additional people in the area to assist.

b. c. 16.

Lighting for the confined space must be approved for the atmosphere and potential atmosphere that could exist.

Page 115 of 200 QSP 6.51 Rev. 1/20/04

N.

Review 1. 2. 3. 4. 5. 6. Isolate the confined space. Obtain proper permits before starting work. Perform the environmental tests; air quality monitoring. Make sure stand by personnel/attendant is present. Have a rescue team standing by. If an emergency occurs while you are on stand by, wait for TRAINED RESCUE PERSONNEL TO ARRIVE AND TAKE OVER THE RESCUE ATTEMPT.

O.

Appendix A. B. C. D. E. F. G. Permit Decision Flow Chart Pre-Entry Confined Space Evaluation Form Confined Space Danger Sign Common Signs And Symptoms Of Exposure Confined Space Entry Permit Definitions Confined Space Entry Log

Page 116 of 200 QSP 6.51 Rev. 1/20/04

Appendix A - Permit Decision Flow Chart

Does the workspace contain Permit-Required confined spaces as defined by 1910.148(b)7
YES NO

Consult other applicable OSHA standards

STOP
Inform Employees as required by 1910.148(c)(2)

Will permit spaces be entered?

YES

NO

Prevent employee entry as required by 1910.148(c)(3). Do task from outside space. Task to be done by contractors employees. Inform contractor as required by 1910.148(c)(8)(1),(ii)& (iii). Contractor obtains information required by 1910.148(c)(9)(1) (ii) & (iii) from host

Will contractors enter?

YES

Both contractor & host employees will enter space?

NO YES

NO

Coordinate entry operations as required by 1910.148(c)(8)(iv) & (d)(11) Prevent unauthorized entry

Will host employees enter to perform entry tasks?

YES

NO

Prevent unauthorized entry

STOP

Does space have know or potential hazards?

YES

NO

Non-permit confined space.1910.148 does not apply. Consult other OSHA standards

Can the hazards be eliminated?

NO

YES

Employer may chose to reclassify space to nonpermit confined space using 1910.148(c)(7)

STOP

Can the space be maintained in a constant safe to enter by continous forced air ventilation only?
NO

YES

Space may be entered under 1910.148(c)(5)

STOP
Prepare for entry via permit procedures

Verify acceptable entry conditions (Test results recorded space isolated ifneeded.Rescurers means to summon available,entrance properly equipped.
YES

NO

Permit not valid until contractor meets specifications

Permit issued by authorizing signature. Acceptable entry conditions maintained throughout entry
YES

NO

Entry tasks completed. Permit returned & cancelled

E m e r g ePermit ncy ex i s t valid s ( p runtil ohib ited condition). not conditions E n t r a n c e meet evac u a t e d , e n t r y aborted.(Call permit specifications. rescurers if needed). Permit is void. Reevaluate program to correct/prevent prohibited conditions. Occurence of emergency (usually) is proof of deficient program. No re-entry until program (and permit) is amended. May require new program

Audit permit program & permit based on evaluation of entry by entrants, attendants, testers & preparers, etc.

Page 117 of 200 QSP 6.51 Rev. 1/20/04

APPENDIX B - PRE-ENTRY CONFINED SPACE EVALUATION FORM

GENERAL INFORMATION Location Entry Purpose Date HAZARDOUS STATUS Hazards Expected Yes No Flammable Materials Oxygen Deficiency Corrosive Materials Radiation Heat/Cold Limited Visibility High Pressure Mechanical (Moving Objects) Falling Sharp Objects Exit difficulties Open Flames Other ATMOSPHERIC TESTS Tests Performed Oxygen Flammability Carbon Monoxide Instrument(s) Used CONFINED SPACE CLASSIFICATION [] [] [] Permit Required (PR) - Multiple hazards present SECURE A PERMIT. Non-Permit with Testing and Ventilation (NPTV) - Atmospheric hazard can be controlled by ventilation alone. Non-Permit (NP) - No potential or actual atmospheric hazards present or have been eliminated. Reading % % L.F.L. ppm Tests Performed Hydrogen Sulfide Remarks Test Performed by (Signature) Reading ppm Combustible Dusts Toxic Materials Biological Materials Inclement Weather Slippery/Tripping Surface(s) Inadequate Communication Electrical (Electrocution) Noise Sloping Surface(s) Engulfment/Entrapment Sparks Remarks Hazards Expected Yes No Time Safety Manual Form #7

Page 1 of 3
Page 118 of 200 QSP 6.51 Rev. 1/20/04

PRE-ENTRY CONFINED SPACE EVALUATION FORM

LOCATION ___________________________________ DATE _______________ ENTRY SUPERVISOR ________________________________ PHONE TIME

Mark the appropriate column: Yes No N/A (Not Applicable) 1. Is a "DANGER CONFINED SPACE" sign posted to identify the site as requiring a confined space entry permit to occupy the area? 2. 3. 4. Is a written permit space entry program developed and implemented that complies with Section 1910.14(c)(4)? Is the written program available for inspection by employees and their representatives? Have all ENTRANTS been provided training and acquired the understanding, knowledge and skills necessary for the safe performance of the duties assigned in Section 1910.146 (h)? Have all ATTENDANTS been provided training and acquired the understanding, knowledge and skills necessary for the safe performance of the duties assigned in Section 1910.146 (i)? Have all ENTRY SUPERVISORS been provided training and acquired the understanding, knowledge and skills necessary for the safe performance of the duties assigned in Section 1910.146 (j)? Is the only hazard an actual or potential hazardous atmosphere? Will continuous forced air ventilation alone be sufficient to maintain the permit space safe for entry? Has monitoring and inspection data been developed to eliminate the hazardous atmosphere through forced air ventilation? Has the permit space been isolated? Have steps been taken for purging, inerting, flushing or ventilating the permit space to eliminate or control atmospheric hazards? Is monitoring available to verify that conditions are acceptable for entry throughout the duration of an authorized entry? Are employees trained on how to maintain and properly use testing and monitoring equipment?

Yes

No

N/A

5.

6.

7. 8. 9. 10. 11. 12. 13.

Page 2 of 3

Page 119 of 200 QSP 6.51 Rev. 1/20/04

PRE-ENTRY CONFINED SPACE EVALUATION FORM (continued)

Mark the appropriate column: Yes No N/A (Not Applicable) 14. Is ventilating equipment needed to obtain acceptable entry? 15. 16. 17. 18. 19. 20. Is communication equipment necessary and available for use between attendant and entrant? Are the entrants provided with personal protective equipment to be adequately protected insofar as feasible engineering and work practice controls allow? Has adequate lighting equipment been supplied to allow a safe work area and allow a quick exit in an emergency? Has the area been secured with barriers and shields from pedestrian, vehicle or other barriers to protect the entrants from external hazards? Is the confined space provided with equipment, such as ladders, needed for safe ingress and egress by authorized entrants? Is there other training, equipment or services needed to provide safe confined space entry?

Yes

No

N/A

SAFETY EQUIPMENT CHECKLIST

Safety Harness with attached Life Lines Respirator and type ____________________ Hard Hat Eye Protection Hand Protection Ear Protection Food Protection Protective Clothing Ventilator Resuscitator Communications Equipment Gas Tester with Alarms Other (specify)

EVALUATOR (Entry Supervisor)

Name Signature
Page 120 of 200 QSP 6.51 Rev. 1/20/04

Page 3 of 3

Appendix C - Confined Space Danger Sign

Page 121 of 200 QSP 6.51 Rev. 1/20/04

Appendix D - Common Signs and Symptoms of Exposure Irritation of eyes, nose and throat Tearing Changes in complexion or skin color Breathing difficulties Coughing Coordination difficulties Confusion Incoherent speech Dizziness, nausea, light-headed Clammy skin Weak or strong rapid pulse Heat rash Fatigue and/or weakness Sneezing Tightness in the chest Drooling Diarrhea Slurred speech Irritability Headaches Profuse sweating Fainting Convulsions Unconsciousness, coma

Page 122 of 200 QSP 6.51 Rev. 1/20/04

Appendix E - Confined Space Entry Permit

Safety Manual Form #9
GENERAL INFORMATION Location Entry Purpose ADDITIONAL PERMITS REQUIRED Yes Hot Work Lockout/Tagout Line Breaking Other (Explain) EMERGENCY SERVICES Name: HAZARD EXPECTED Yes Mechanical Electrical Engulfment Configuration (Entrapment) CONTROL MEASURES Yes Isolation (Chemical, Utility, Outlets, etc.) Lockout/Tagout/Tryout Line Disconnected Line Blanked/Capped Other (Explain) PROTECTIVE EQUIPMENT Yes Thermal Protection Safety Shoes/Boots Fire Extinguisher Non-sparking Tools Explosion Proof Lighting Other (Explain) ATMOSPHERIC TESTING Acceptable Contaminant Level Oxygen 19.5 - 23.5% Explosive (Gas/Vapor) <10% LEL Hydrogen Sulfide 10 ppm Carbon Monoxide 35 ppm No Ear Muffs/Plugs Respirators Face/Eyes Head Tripod Mechanical Winch Yes No Gloves Coveralls Safety Harness Life Line Gnd Fit Int Yes No No Area Secured/Posted Ventilation (Dilut./Local Exh.) Guarding Inerting/Purging Yes No Telephone/Radio: No Portable Radio/Phone Hand Signals Unaided Voice Other (Explain) Entry Supervisor Entrant(s) COMMUNICATIONS Yes No Attendant(s) Date:_______________ Subcontractor:_______________

No Atmospheric Oxygen Deficiency Explosive Carbon Monoxide Hydrogen Sulfide

Yes

No Other (i.e., Radiation, Noise, Heat, Toxics)

Yes

No

Time

ENTRY AUTHORIZATION/CANCELLATION Authorization Name Signature Cancellation Date Time

Instrument(s) Used

Tester (Initials)

Name Signature

Date Time

* Pre-entry Confined Space Evaluation Form Attached_______

* Confined Space Entry Log Required_______ * MSDS sheets at Confined Space Entry locations_______ * Entrance & Attendants Training including Hazardous Communications_______ Note: File Permit in Department and Forward Copy to EOHS

Page 123 of 200 QSP 6.51 Rev. 1/20/04

Appendix F - Definitions Acceptable Entry Condition The condition that must exist in a permit space to allow entry and to ensure that employees involved with a permit-required confined space entry can safely enter into and work within the space. Attendant An individual stationed outside one or more permit spaces who monitors the authorized entrants and who performs all attendants duties assigned in the permit space program. Authorized Entrant An employee who is authorized to enter a permit space. Blanking or Blinding The absolute closure of a pipe, line, or duct by the fastening of a solid plate that completely covers the bore and that is capable of withstanding the maximum pressure of the pipe, line, or duct with no leakage beyond the plate. Confined Space A space that: (1) Is large enough and so configured that an employee can bodily enter and perform assigned work; and (2) Has limited or restricted means for entry or exit (for example, tanks, vessels, silos, storage bins, hoppers, vaults, and pits are spaces that may have limited means of entry.); and (3) Is not designed for continuous employee occupancy. Double Block and Bleed The closure of a line, duct, or pipe by closing and locking or tagging two in-line valves and by opening and locking or tagging a drain or vent valve in the line between the two closed valves. Emergency Any occurrence (including any failure of hazard control or monitoring equipment) or event internal or external to the permit space that could endanger entrants. Engulfment The surrounding and effective capture of a person by a liquid or finely divided (flowable) solid substance that can be aspirated to cause death by filling or plugging the respiratory system or that can exert enough force on the body to cause death by strangulation, constriction, or crushing.

Page 124 of 200 QSP 6.51 Rev. 1/20/04

Entry The action by which a person passes through an opening into a permit-required confined space. Entry includes ensuing work activities in that space and is considered to have occurred as soon as any part of the entrants body breaks the plane of an opening into the space. Entry Permit The written or printed document that is provided by the employer to allow and control entry into a permit space. Entry Supervisor The person (such as the employer, foreman, or crew chief) responsible for determining if acceptable entry conditions are present at a permit space where entry is planned, for authorizing entry and overseeing entry operations, and for terminating entry. Hazardous Atmosphere An atmosphere that may expose employees to the risk of death, incapacitation, impairment of ability to self-rescue (that is, escape unaided from a permit space), injury, or acute illness from one or more of the following causes: (1) Flammable gas, vapor, or mist in excess of 10 percent of its lower explosive limit (LEL); (2) Airborne combustible dust at a concentration that meets or exceeds its LEL; (3) Atmospheric oxygen concentration below 19.5 percent or above 23.5 percent; (4) Atmospheric concentrations of any substance that could exceed an existing Federal standard or consensus standards as enforceable by Occupational Safety and Health Administration (OSHA). This would include the permissible exposure limits (PELs) identified in the Z-Tables of Title 29 Code of Federal Regulations, Part 1910.1000 (29 CFR 1910.1000); (5) Any other atmospheric condition that is immediately dangerous to life or health. Hot Work Permit The employers written authorization to perform operations (e.g., riveting, welding, cutting, burning, and heating) capable of providing a source of ignition. Immediately Dangerous to Life or Health (IDLH) Any conditions that pose an immediate or delayed threat to life or that would cause irreversible adverse health effects or that would interfere with an individuals ability to escape unaided from a permit space.

Page 125 of 200 QSP 6.51 Rev. 1/20/04

Inerting The displacement of the atmosphere in a permit space by a noncombustible gas (such as nitrogen) to such an extent that the resulting atmosphere is noncombustible. Isolation The process by which a permit space is removed from service and completely protected against the release of energy and material into the space by such means as: blanking or blinding; misaligning or removing sections of lines, pipes, or ducts; a double block and bleed system; lockout or tagout of all sources of energy; or blocking or disconnecting all mechanical linkages. Line Breaking The intentional opening of a pipe, line, or duct that is or has been carrying flammable, corrosive, or toxic material, an inert gas, or any fluid at a volume, pressure, or temperature capable of causing injury. Non-Permit Confined Space A confined space that does not contain or, with respect to atmospheric hazards, have the potential to contain any hazard capable of causing death or serious physical harm. Oxygen Deficient Atmosphere An atmosphere containing more than 23.5 percent oxygen by volume. Oxygen Enriched Atmosphere An atmosphere containing more than 23.5 percent oxygen by volume. Permit-Required Confined Space (Permit Space) A confined space that has one or more of the following characteristics: (1) Contains or has a potential to contain a hazardous atmosphere; (2) Contains a material that has the potential for engulfing an entrant; (3) Has an internal configuration such that an entrant could be trapped or asphyxiated by inwardly converging walls or by a floor which slopes downward and tapers to a smaller cross-section; or (4) Contains any other recognized serious safety or health hazard. Permit-Required Confined Space Program (Permit Space Program) The employers overall program for controlling, and, where appropriate, for protecting employees from, permit space hazards and for regulating employee entry into permit spaces. Permit System The employers written procedure for preparing and issuing permits for entry and for returning the permit space to service following termination of entry.

Page 126 of 200 QSP 6.51 Rev. 1/20/04

Prohibited Condition Any condition in a permit space that is not allowed by the permit during the period when entry is authorized. Rescue Service The personnel designated to rescue employees from permit spaces. Retrieval System The equipment (including a retrieval line, chest or full-body harness, wristlets, if appropriate, and a lifting device or anchor( used for non-entry rescue of persons from permit spaces. Testing The process by which the hazards that may confront entrants of a permit space are identified and evaluated. Testing includes specifying the tests that are to be performed in the permit space.

Page 127 of 200 QSP 6.51 Rev. 1/20/04

Appendix G - Confined Space Entry Log

Safety Manual Form #6

C O N F INED SPACE ENTRY LOG

DATE: TIM E :

Location of Space or Vessel:

Purpose for Entering Space or Vessel:

Employees Performing W ork: Company Employees NAME TIM E IN TIM E O U T NAME Non-Company Employees TIM E IN TIM E O U T

PRECAUTIONS Employee Qualified? Safety Observer? Space/Vessel Clean? Space Vessel Atmosphere Safe for Entry? Periodic/Continuous Monitoring Required? Lines to Vessel Blanked or Disconnected? Lockout Devices? Safety Lights? Communication Devices?

YES

NO

PROTECTIVE EQUIPMENT Belt/Harness/Life Line? Breathing Apparatus? W a rning Signs? Protective Gear? Fire Equipment? Forced Ventilation? Rescue Gear on Hand? Miscellaneous Equipment?

YES

NO

* * * *

Pre-entry Confined Space Evaluation Form Attached___ Confined Space Entry Log Required___ MSDS sheets at Confined Space Entry locations___ Entrance & Attendants Training including Hazardous Communications___

Name of Safety Observer: Miscellaneous Precautions?

Issued by:_______________

Date:

Section Manager

Page 1 of 2
Page 128 of 200 QSP 6.51 Rev. 1/20/04

CONFINED SPACE ENTRY LOG

PERMISSIBLE GAS
1. Oxygen %

YES

NO

INSTRUMENT USED

ACTUAL READING

TESTED BY

ENTRY LEVEL
19.5% TO 23.5%

2. 3. 4. 5. 6. 7. 8. 9. 10. Calibrated direct-reading instruments used to test confined space atmosphere:

Name Make Serial No. Last Calibration Date Name Make Serial No. Last Calibration Date

RESCUE AND EMERGENCY SERVICES 1. Contacts in the event of an emergency include name and telephone number. A. C.

B.

D.

2. Rescue services available for this confined space entry. employee 3. Rescue Equipment available: Oxygen Resuscitator - Inhalator First Aid Equipment De-Fibrillator Additional rescue equipment available Page 2 of 2
Page 129 of 200 QSP 6.51 Rev. 1/20/04

outside rescue service

Chest/full body harness Retrieval line properly installed W ristlets when it is the safest and most effective alternative

XV.

HOUSEKEEPING/AREA CLEANING

A clean project promotes safety and improves quality and production efficiency. A. Overview 1. It is the intention of TKS to monitor and review each Subcontractor's work area, storage area and laydown area cleaning in order to maintain a clean and safe project site. TKS expects each Subcontractor to conduct a broom clean" policy while on this project. Each Subcontractor shall be responsible for removing all trash generated by their work. This trash must be removed from work areas on a daily basis and deposited into dumpsters provided by the subcontractor. Trash will not be permitted to accumulate during any portion of any shift. All areas will be kept broom swept clean on new construction projects and dust mop clean on all retrofit and modification projects in existing production facilities.

2.

B.

Area Cleaning 1. Subcontractor Cleaning Requirement All areas are to be kept broom swept clean with debris removed immediately. This is a cleaning daily requirement. If instructed to clean the area, TKS expects the Subcontractor to clean the area immediately. The Subcontractor may file a written protest, but the area must be cleaned as directed by TKS. The project will be maintained to a high degree of cleanliness. Upon verbal notice, TKS reserves the right to clean the Subcontractor's area and backcharge the Subcontractor for costs incurred. 2. General Area Cleaning Requirement(Composite Cleaning Crew Ratio by hours worked 1:10) The subcontractor will include in his bid 1(one) hour of clean up labor for every 10 (ten) hours of work performed on site. However, composite cleaning crew contribution does not limit the Subcontractor's obligation to maintain laborers to clean equipment, work and break areas as specified in XV.B1 above.

Page 130 of 200 QSP 6.51 Rev. 1/20/04

C.

Other Requirements 1. Each Subcontractor will be responsible for supplying and maintaining trash barrels with lids at their work areas. These containers are to be emptied at the end of each shift or as they are filled. Each Subcontractor with designated storage, laydown and break areas shall maintain these areas in an organized, trash free condition. A Company sign identifying the subcontractor must be visible. Clean up problem areas will be identified as a normal part of safety tours/safety survey. Proper clean up is an integral part of maintaining a safe site. The sample Fuel Storage Area Policy will be followed. (See XXVII) Oil soaked rags and paint and cleaning debris will be disposed of in containers specified for that use. Cigarette butt cans filled with sand and spittoons will be utilized in break areas which are authorized smoking areas. No paint, thinner or solvents will be stored in the construction facility.

2.

3.

4. 5.

6.

7.

Page 131 of 200 QSP 6.51 Rev. 1/20/04

XVI. BUILDING PROTECTION: Owner's Property Protection A. Responsibility It is the responsibility of TKS and each Subcontractor to protect the property, building and equipment of the Owner and other contractors working in the same areas where our work is in progress. B. Property Damage Accidents may occur involving property damage. However, we must make every effort to prevent these accidents. Recognizing that some damage may occur, we must make every effort to protect these potential areas of damage. When damage occurs it must be reported, investigated for cause to determine future prevention and corrected/repaired immediately. 1. Prevention of Building and Equipment Damage a. Job Hazard Analysis for the identification of some areas of potential building damage. Employee training to make employees aware of the hazards, proper protective measures and reporting of damage.

b.

2.

Protection From Damage a. Physical protection of the building and equipment: 1. 2. 3. 4. 5. 6. 7. 8. b. Tarpaulins, Temporary walls, Plywood barriers and enclosures, Barricades, Guardrails, Isolation of work areas, Predetermined fabrication area locations, Sand boxes (filled with oil dry or other substances) for pipe threading machines, Tag lines attached to material being hoisted etc.

Areas for Protection Any area of the building, piece of equipment or anything that might be damaged. 1. 2. 3. Roof (plywood floor) Siding (temporary wall) Floor
Page 132 of 200 QSP 6.51 Rev. 1/20/04

a. b.

wood damage under loads of materials or equipment pipe machines in sand boxes to prevent oil spots and dangers from employee slips and falls.

3.

Repair of Damage a. All damage needs to be reported immediately, investigated and repaired as soon as practical. Repair will be coordinated with the Owner. These areas of damage will be returned to original condition depending upon Owner requirements.

b.

C.

Reporting Damage 1. Damage will be reported on an Incident Form (See the Forms Section of this manual). The issue is not that damage may occur, but most important that damage be prevented through proper protection and be properly repaired once the extent of damage is known. Unreported damage may pose a serious safety hazard to personnel and at the very least may cause further deterioration of the facility or equipment from the affects of additional work and/or weather.

2.

3.

D.

Investigation 1. The purpose for the investigation of property damage is to determine the extent of damage to be certain of repair requirements and to determine the need for any long lead purchased equipment items. The second purpose of the investigation is to determine the facts surrounding the accident in order to prevent similar or other accidents and/or damage in the future. Obviously responsibility for the accident will be placed, but any reputable contractor would not want to deliberately leave unrepaired damage. If it is determined that a Subcontractor would prefer not to determine the extent of damage and correct these problems, he will not remain on the TKS list of acceptable Subcontractors for future work.

2.

3.

Page 133 of 200 QSP 6.51 Rev. 1/20/04

INCIDENT REPORT 1. Date/Time of Incident: 2. Name of Person(s) Involved:

3. Employed By (Company/Subcontractor): 4. Name of Supervisor: 5. Incident Description:

6. Completed By:

7. Corrective Action: (To be completed by Company/Subcontractor Supervisor)

8.
Name Date

9. Return To: Safety Department

Page 134 of 200 QSP 6.51 Rev. 1/20/04

XVII. SITE SECURITY PROGRAM 1. TKS will assist, as required, Plant Security with the enforcement of site security to protect the facility's equipment from theft, vandalism and Owner's loss of property. Depending upon Owner requirements, entry to the site may require construction badges, stickers attached to hard hats, temporary or permanent drive-in" passes, a visitor's pass, etc., as specified in the contract. Plant security will enforce plant rules and notify the Project Manager of any violations. A daily report of all safety activities and work in progress will be logged by the TKS Safety Representative and be reviewed with the Project Manager, Security Manager or Plant Safety Representative on a daily basis. All Subcontractors will post signs with Company name on their office trailers, operating equipment, vehicles and stored materials. All Subcontractors will have on file with the Project Manager, a list of emergency telephone numbers where supervisors or owners can be reached after working hours in case of an emergency. A plan view of the site showing the location of the Plant Security Office will be included with each contract document. The site may be enclosed by a fence. Each person entering the construction site must have completed the Project and Safety Orientation Program. If the TKS/Owner provided Project Safety Orientation is required, the TKS Safety Representative will issue numbered stickers to all personnel, which will be used for project identification and project access. The TKS Safety Representative will maintain a log of the personnel and hard hat sticker or badge numbers issued. This list will be updated on a daily basis and be provided to Plant Security. Any person not displaying the sticker on their hard hat will be referred to the TKS Safety Representative. Temporary "drive-in" passes may be issued by Plant Security for vehicles which are required to be "on-site" on a regular basis. A drive-in pass must be requested in writing by the Subcontractor. TKS will issue and log all drive-in passes on an as-needed basis. Drive-in passes must be displayed on the vehicles dashboard at all times.
Page 135 of 200 QSP 6.51 Rev. 1/20/04

2.

3.

4.

5.

6.

7.

8. 9.

10.

11.

12. 13.

Temporary "drive-in" passes will be issued by the guard for deliveries. All materials or equipment leaving the job site must be checked out through Plant Security. Security will record the name, license number, company, date, time and material leaving the site. This information will be supplied to the Project Manager on a daily basis. A material gate pass may be required for any item of materials, equipment or tools to leave the Owner's property.

Equipment and Tool Lists may be required by the contract for any material, equipment or tools brought onto the construction site that may later be removed from the site.

Page 136 of 200 QSP 6.51 Rev. 1/20/04

TKS INDUSTRIAL COMPANY Site Equipment List Customer Name: Location: Customer Job No.: ITEM 1 2 3 4 DESCRIPTION Trailer Carts Automobile Office Equipment Telephone Base Radio Hand Radio Computer Printer Typewriter Fax Desk Desk Chair Table Table Chair Bookcase Bookcase Locker Locker Locker Xerox Copier Blue Line copier Drawing Cabinet Copy Board Utilities Electric Hook-Up Plumbing Hook-Up Waste Hook-Up Electric Bill Phone Bill Water Bill Waste Bill Accounts UPS Federal Express Office Supplies SIZE QUANTITY Date: TKS Job No.: By: INITIAL MONTHLY MONTHLY

Page 137 of 200 QSP 6.51 Rev. 1/20/04

TOOL

LIST

24 HOUR NOTICE IS REQUIRED BEFORE CHECKING OUT COMPANY TOOLS. COMPANY NAME/SUPERVISOR EMPLOYEE NAME DATE COMPANY TOOL PERSONNEL TOOLS
DESCRIPTION OF ITEM AMOUNT BROUGHT IN AMOUNT REMOVED SERIAL #

/ /

/ / / / / / / / / / / / /

Page 138 of 200 QSP 6.51 Rev. 1/20/04

XVIII. DRUG POLICY TKS INDUSTRIAL COMPANY DRUG AND ALCOHOL POLICY Previous Revision 2-3-95 Revised 9-16-96

The following general guideline is presented for compliance with TKS Industrial Company Drug and Alcohol Policy. A. Drug and Alcohol Policy 1. The possession or drinking of alcoholic beverages at any time while on the job site property or reporting to the job site property while under the influence of alcohol is prohibited and is cause for immediate termination. The possession, use, distribution and/or sale of drugs is prohibited on the job site property and is cause for immediate termination. In these instances, Local or State Law Enforcement officials will be notified.

2.

B.

Purpose 1. Abuse of illegal drugs and alcohol may have a serious adverse effect on an employees job performance and on our work environment. Employees who work under the influence of illegal drugs or alcohol are not fit for work. Such employees often disrupt normal production and pose safety risks to themselves and to fellow employees.

C.

Policy 1. TKS Industrial Company (hereinafter TKS) has the legal right, responsibility and obligation to try to provide a safe work environment and maintain a drug-free workplace. Therefore, TKS expects all its employees and all subcontractor employees to refrain from being under the influence of illegal drugs and expects its employees to refrain from using, possessing, selling, purchasing, receiving or distributing illegal drugs or alcohol while on the job or on company premises, and to refrain from off-the-job abuse of illegal drugs and alcohol which affects job performance or threatens the property or safety of TKS or other employees. TKS has adopted this drug and alcohol policy in order to better maintain a safe and efficient workplace and to ensure a drug and alcohol-free working environment.

2.

Page 139 of 200 QSP 6.51 Rev. 1/20/04

3.

Definitions: The following definitions apply for the purposes of this policy: Drug: Any chemical substance that may produce physical, mental, emotional or behavioral change in the user. Illegal drug: a. b. c. Drugs which are not legally obtainable. Drugs which are legally obtainable but have been obtained illegally. Drugs which are not used for the purpose for which they are prescribed, intended or manufactured.

Legal drug: Prescription drugs and over-the-counter drugs legally obtained and used for the purpose for which they are prescribed or manufactured. Alcohol or alcoholic beverage: Any consumable beverage that has an alcoholic content.

Reasonable cause means:

A belief or suspicion that illegal drug or alcohol use is influencing an employees behavior, appearance, job performance, attendance, or fitness for work, or that the employee is using, possessing, selling, purchasing, receiving or distributing illegal drugs or alcohol while on the job or while on Company premises or on premises on which TKS is performing work.

On the job:

On Company premises or on a premises or job site on which TKS is performing work. This scheduled and nonscheduled working hours on the property or site of TKS work.

D.

Procedure 1. Use of Drugs or Alcohol While on the Job or While on Company Premises Employees who are under the influence of, or who use, possess, sell purchase, receive or distribute illegal drugs or alcohol while on the job or while on company premises or on premises on which TKS is performing work are subject to immediate discharge. Local or State law enforcement officials may be summoned as required at the discretion of the TKS Project Manager or other Project team member.
Page 140 of 200 QSP 6.51 Rev. 1/20/04

E.

Drug and Alcohol Testing 1. Coverage: At its discretion TKS may require all employees (TKS and Subcontractors) to be drug and alcohol tested. Depending upon owner requirement, a testing center representative will collect a urine sample necessary for drug and alcohol testing. All employees must sign any required consent-to-testing and release-of-medical information forms, and cooperate fully with procedures for collecting and securing urine samples, including random samples. In order to gain access to the job site, all TKS employees (TKS and Subcontractors) must have successfully passed a drug and alcohol screening test within the last 6 months. In addition, TKS and its subcontractors will conduct drug or alcohol testing under other circumstances, including random testing. Where additional testing is required under such TKS will notify affected employees of the requirements and the provisions of this policy will be followed to the extent applicable. Employees who are requested by TKS to have additional drug testing due to random sampling or based on reasonable cause will be asked to submit to a drug and/or alcohol test. Employees required to submit to a drug and/or alcohol test who refuse to consent to testing, sign the appropriate forms and/or comply with all sample collection and chain-of custody procedures including random sampling are subject to immediate discharge. When TKS has such reasonable cause, it will request that employee submit to a search of: a) any vehicle brought onto or parked upon property, (b) the employees personal effects and/or any package, briefcase, lunch box, thermos bottle, purse, athletic bag or other personal property brought onto company premises; (c) the employees locker, and/or (d) the employees work stations, including desk, tool chests, file cabinets, etc. Employees who refuse a request by the company to conduct a search under this rule are subject to immediate discharge. TKS and/or its subcontractors may contact Local or State Law Enforcement when it has reasonable cause to believe illegal drug or alcohol use is influencing an employees behavior, job performance, appearance, attendance, or fitness for duty, or that the employee is using, possessing, selling, purchasing, receiving or distributing illegal drugs or alcohol while on the job or while on company premises or on premises on which TKS is
Page 141 of 200 QSP 6.51 Rev. 1/20/04

2.

3.

4.

5.

6.

7.

8.

working, or is otherwise abusing illegal drugs or alcohol off-the-job in a manner which affects job performance or threatens the property, safety of TKS or other employees. F. Legal Drug Use 1. Prescription Drug Use TKS does not prohibit employees from using prescription drugs while on the job or on company premises, provided: (a) the prescription drugs are prescribed for medical reasons by a licensed medical practitioner; and (b) the employees use of prescription drugs does not adversely affect job performance or threaten the property, safety of TKS or other employees. A doctors work authorization will be required for the employee to work on a TKS Project while taking this medication. Any employee who is using prescription drugs or over-the-counter medication must notify his employer (the Subcontractor) and the TKS Project Manager or his designated representative and inform them of the medication and show physician approval and altered work status. 2. Over-the-Counter Drug Use TKS prohibits employees from abusing over-the-counter drugs while on the job or on company premises where such use: (a) adversely affects the employees job performance; or (b) threatens the property, safety of TKS personnel or other employees. TKS personnel may require submission to a drug and/or alcohol test and/or apply the disciplinary procedures of this policy to any employee who abuses over-the-counter drugs in a manner which violates either (a) or (b) of this paragraph. See the second paragraph of item F.1. G. Treatment/Employee Assistance Program (EAP) 1. TKS recognizes illegal drug and alcohol abuse as a health problem for which there is proven effective treatment, but which can result in devastating employment-related and personal when unattended. TKS and/or its subcontractor is willing to assist any employee who desires to overcome a drug or alcohol problem. TKS employees who feel they have developed an addiction to, dependence on, or other recurring problem with illegal drugs or alcohol should seek confidential assistance by calling the TKS Industrial Company provided Employee Assistance Program (EAP). Phone number is 1-800-854-1446. All voluntary inquiries to EAP will be held in confidence. However, employees who commit a violation of this policy may not then voluntarily
Page 142 of 200 QSP 6.51 Rev. 1/20/04

2.

submit to EAP (or other employee assistance programs) in order to avoid the discipline imposed under this policy. 3. Employees referred by TKS and/or its subcontractor to EAP who are found to have any addiction to, dependence on, or recurring problem with illegal drugs or alcohol are required -as a condition of continued employment - to successfully complete any outpatient or inpatient treatment and rehabilitation program, and any and all follow-up care, including random drug and/or alcohol testing, established for them and/or to which they are referred by EAP. Any employee who refuses referral to a treatment program, rejects treatment, fails to abide by all aspects of his or her treatment program, including random drug and/or alcohol testing, or leaves his or her treatment program prior to successful completion or treatment and rehabilitation and any and all follow-up care, is subject to disciplinary action up to and including immediate discharge following management review of the facts.

Page 143 of 200 QSP 6.51 Rev. 1/20/04

XIX. HELICOPTER LIFT POLICY It is the intent of TKS to monitor and review the safety procedures for construction helicopter lifts to ensure the safety of all employees. It is the responsibility of the Subcontractor who requests the use of a construction helicopter to utilize and enforce the following safety precautions. In addition, the safety of all employees, whether directly or indirectly involved with the lift, in the flight path area, or at staging area will be the responsibility of the Subcontractor utilizing the service of the helicopter lift equipment, whether the individuals affected are the Subcontractor's employees or not. A. Helicopter Lifts 1. Tentative Lift Schedule: The tentative helicopter lift schedule is required for submission with the Subcontractors construction schedule to TKS. Construction Lift Time Available: Helicopter lifts must be scheduled with TKS approval, with lift limited to after hours, weekends or holidays. Lift dates and alternate days are to be reserved as early in the project as possible, but no later than 30 days prior to the lift. Special FAA Requirements: The Subcontractor will contact the FAA to determine if any special procedures are required in the lifting area. This information will be submitted to TKS with the tentative construction lift schedule, which will be provided at the Pre-mobilization Meeting. Preflight Orientation: One week prior to the first lift (each Subcontractor involved and lifting for the first time on this project) will attend a pre-flight safety orientation at the TKS office. a. Safety gear will be discussed, including the use of tag lines, hard hats with chin straps, goggles, tie-off lines/safety straps, etc. Safety procedures will be discussed, including specific pre-lift instructions and work assignments. Staging areas will be identified, if not previously discussed. The lifting company and the type of helicopter to be used will be identified. A copy of the flight plan filed with the FAA will be given to TKS.
Page 144 of 200 QSP 6.51 Rev. 1/20/04

2.

3.

4.

5.

b.

c. d.

e.

6.

At the Subcontractor Construction Meeting (prior to each lift) all items pertaining to the lift will be discussed with colored site drawings showing the lift area, staging area, helicopter refueling area, flight path and alternate flight path. a. The number of lifts, equipment and material being lifted will be identified. The lift time will be stated including estimated duration. Personnel assignments will be discussed. How many people at each location and who is responsible for each crew. The number of radios and those personnel who will utilize radios during the lift are to be identified. A preflight form is to be provided to TKS at this meeting.

b. c.

d.

e. 7.

One day before the helicopter lift all areas affected by the lift will be walked toured by TKS, Subcontractors, Owner, Helicopter Pilot and Signalmen. The Day of the Helicopter lift: a. When lifting through any building opening, a minimum of 2 people will be on the roof to guide material. This does not include the signalman from the helicopter company. A final walk through by TKS and the Subcontractor of the staging area, unloading area, refueling area, and the flight path will be conducted. These areas must be clear of all debris such as loose tar paper, plywood, sheet metal, tarpaulins, insulation and all other object that would move in a strong wind possibly injuring someone or be sucked through the rotor wing causing the helicopter to lose lift. Any other large and/or lightweight objects must be properly secured in the staging, unloading and flight path areas. The Subcontractor is responsible to clear all lift affected areas of the Owner's facility. TKS and Plant Security may assist with this process. The Subcontractor will be responsible for vehicular traffic control including barricades, flagmen and radio communication.

8.

b.

c.

Page 145 of 200 QSP 6.51 Rev. 1/20/04

d.

TKS and Plant Security will be provided with operable radios with the frequency being utilized by the Subcontractor and helicopter crew.

B.

Safety Procedures For Helicopter Lifts 1. The Subcontractor shall furnish to the Project Manager a written description of the helicopter work and plan of operation as specified above. The Subcontractor shall not use a helicopter until a plan for the helicopter's use has been approved by TKS. The Subcontractor shall furnish an insurance certificate as evidence to the Project Manager that such operations are covered by personal injury and property damage insurance in the amount specified in the contract documents. Helicopter service shall be provided by a carrier experienced in the operation of helicopters who has at least the equivalent of two (2) years experience in performing construction lifting operations. The ground crews and all personnel in the staging and construction areas (drop zone) must be required to wear proper protective equipment: a. b. c. d. 6. Hard hat with chin straps. Safety glasses and dust goggles. Gloves - preferably rubber for the prevention of shock from electricity, which can be created by certain atmospheric conditions. Ear plugs (where required).

2.

3.

4.

5.

Units to be lifted are to be placed in the staging area at least ten (10) feet apart. The units should be at least 100 feet from obstacles such as trees, electrical lines, light standards, etc. A minimum amount of men shall be required to install or remove equipment and material. The helicopter flight path and 200 feet either side shall be kept clear of people and traffic. Traffic will be controlled with road blocks by the Subcontractor's personnel. Tag lines shall be used to insure safe handling of the loads and all lifting equipment shall be inspected prior to the lift. The Subcontractor in charge of the helicopter lift will be responsible for all communications and safety required for the lift.
Page 146 of 200 QSP 6.51 Rev. 1/20/04

7.

8.

9.

10.

11.

As discussed previously, on the morning of the lift a meeting will be scheduled to brief the construction crew, Fire and Security personnel, and the Project Manager of the helicopter lift flight path, safety procedures and work assignments. Notice of any safety meeting will be given to the TKS Safety Representative 48 hours prior to the meeting. The Owner Representatives, TKS, Project Manager, Project Construction Manager, TKS Safety Representative or Superintendent may stop the lift at any time for procedural or safety issues without cost impact to TKS Industrial Company or the Owner.

12.

Page 147 of 200 QSP 6.51 Rev. 1/20/04

PROPOSED HELICOPTER LIFTS Contractor: Date Submitted: Date of Lift: Alternate Date of Lift: Times of Scheduled Lifts: Pre-Lift Meeting Date & Time: Equipment to be Lifted: Route of Lift (From ground area to roof area):

Alternate Route Because of Wind Direction:

Type of Helicopter to be Used: Experienced Signalman @ Loading Site: Experienced Signalman @ Unloading Site: Cargo Hooks Equipped with Emergency Mechanical/Electrical Release: Has Signal System Been Reviewed by Pilot and Ground Crew: HELICOPTER GROUND CREW Has Ground Crew Read OSHA Helicopter Rules: Has Lifting Equipment Been Inspected and Approved: Safety Hats W/Chin Straps: Safety Goggles (NOT Glasses): Hearing Protection, All Crew: No Loose Clothing, Gloves, All Crew: Has Briefing Meeting for Each Days Operation Occurred: Has all hook-up, un-hook, and support personnel been advised, by the pilot, of the potential danger zones, and the pre-determined safety zone around the helicopter: Has lifting and receiving area been cleared of loose objects or secured: Yes No Yes No Yes No Yes Yes Yes Yes Yes No No No No No Yes No Yes No Yes No Yes Yes No No

Page 148 of 200 QSP 6.51 Rev. 1/20/04

XX.

PAINTING SAFETY Painting and coating applications present potentially hazardous conditions for the painters and other personnel in the work area. Many painters who have worked in the profession for years are unaware of some of the potential health risks and physical dangers. The purpose of this program is to set a minimum level of understanding. All painters should also view the video presentation on Painting Operations as part of the Subcontractor's training or orientation program. A. Purpose All painters will have a basic understanding of safety and health standards associated with their job task. B. Objectives 1. Each painter must be able to: a. b. c. Identify hazardous ingredients in paint. Explain the potential health hazards associated with painting. Explain routes of entry and over exposure to paints and how they can be prevented. Identify potential physical hazards associated with painting. Describe the personal protective equipment (PPE) needed for various paints and the care of this equipment. Have a basic understanding of the first aid requirements associated with the painting profession.

d. e.

f.

2.

Each painter should have an understanding of the following information: a. Paints are made up of three (3) basic parts. Pigments give color to the paint, binders cause paint to stick to surfaces and solvents evaporate to leave the pigments and binders behind.

Page 149 of 200 QSP 6.51 Rev. 1/20/04

b.

c.

Some pigments, binders and solvents contain hazardous materials. Pigments may contain lead, zinc, chromium, titanium dioxide, and other heavy metals. Binders may contain alkyd, urethane, and epoxy resin. Besides water, solvents may be naphtha, ether, xylene, alcohol, mineral spirits and other highly volatile substances. Paints may become a health hazard if any of the hazardous materials in paint come in contact with the body or enter the body. These materials may enter the body (route of entry) through the skin or eyes, through breathing the vapors or by swallowing the paint product (ingestion, inhalation, injection, absorption). There are two (2) types of health effects caused by paint materials, acute and chronic. 1. Acute reactions take place immediately or soon after exposure, such as eye and skin irritation, irritation to respiratory tract, headache, dizziness, mental disorientation or unconsciousness. Chronic effects may be delayed skin rashes or dermatitis, liver, lung or kidney damage. Acute reactions are usually short lived, but chronic effects may be long lasting or permanent, taking months or years to develop.

d.

2.

e.

Health care professionals have set occupational exposure limits for working safely with potentially hazardous materials. A very important value is the TLV-TWA or Threshold Limit Value - Time Weighted Average. This information can be found on the MSDS sheet for each paint and gives guidelines on the amount of acceptable exposure for an eight (8) hour day. MSDS - Material Safety Data Sheets contain very important information about each paint product. Before working with each paint product you should read the specific MSDS sheets for that product. The Subcontractor is responsible to provide each employee with MSDS training. Some of the physical hazards associated with painting operations are fire and explosion potential; slips, trips, and falls; ladder and scaffolding problems; and mechanical lift operations. Many paints and solvents are classified as flammable and fire is a danger. Paints and thinner should never be stored onsite unless in approved flammable cabinets. Rags soaked in solvents are potential fire hazards.

f.

g.

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h.

Static electricity is a potential fire hazard when working with paint thinner and solvents. When pouring fluids from one container to another, make sure the container is grounded and bonded. When working with painting materials make sure appropriate safety practices are followed. Use special storage and handling equipment, bond and ground containers, provide proper ventilation, use personal protective equipment and follow proper personal hygiene. Paint containers should be stored in cabinets or rooms specially designed for flammable liquid storage. Storage areas should be cool, dry, well ventilated areas away from heat and flames. Some painting operations may require the use of personal protective equipment, such as gloves, aprons, safety goggles and barrier creams. Under certain conditions, respirator or hearing protection may also be necessary. Ask your supervisor and check the MSDS to determine if respiration or hearing protection is recommended for the painting operation at your work site. Because it is impossible to predict when an emergency will occur, take the time to learn your company's emergency procedures now, and consult the Emergency and First Aid section of the MSDS for the specific substances you use. If you encounter an unconscious victim and have reason to believe that the cause may be inhalation of toxic vapors, call for help immediately. Do not attempt a rescue unless you are qualified to do so, are wearing proper protective equipment, and have a standby observer. In this case, move the victim to fresh air and give artificial resuscitation until medical help arrives. If your eyes have been splashed, they must be flushed with running water for at least fifteen (15) minutes. Splashes to the skin with a solvent based paint should be wiped off with a dry cloth and then washed with soap and water. If a paint is ingested, do not induce vomiting, see a Doctor immediately. If a fire occurs, sound the alarm and follow the stated fire policy and procedures.

i.

j.

k.

l.

m.

n.

o.

p.

Page 151 of 200 QSP 6.51 Rev. 1/20/04

q.

Skin contact with many paints can result in: 1. 2. 3. Irritation Chapping Dermatitis

r.

Eye contact with paints can cause: 1. 2. Irritation Blindness

s.

Inhalation of paints can result in: 1. 2. 3. 4. 5. 6. 7. Respiratory Irritation Muscular Weakness Headache Fatigue Dizziness Nausea Death

t.

Ingestion of paints can result in: 1. 2. 3. 4. Damage to mucous membranes Nausea Cramps Diarrhea

u.

Appropriate work practices: 1. 2. 3. 4. 5. 6. Bonding and grounding Ventilation Special storage requirements Proper personal protective equipment Proper hygiene Never dump paints down the drain

v.

Emergency Procedures: 1. 2. Consult Material Safety Data Sheets Only attempt a rescue if you are qualified and you have the proper rescue equipment.

Page 152 of 200 QSP 6.51 Rev. 1/20/04

XXI. PERSONAL PROTECTIVE EQUIPMENT (PPE) A. General 1. It is TKS' intention to require Subcontractors, tradesmen and employees to wear appropriate Personal Protective Equipment at all times on construction projects from design through start up specifically and at all other times, generally. This includes: a. b. c. d. e. f. g. Proper Clothing Proper Foot Protection - OSHA 1926.96 Respiratory Protection - OSHA 1926.103 (see 1910.134) Head Protection - OSHA 1926.100 Hearing Protection - OSHA 1926.101 (see 1926.52) Eye and Face Protection - OSHA 1926.102 Fall Protection - OSHA 1926.500 through 1926.503 Subpart M Appendix A-E.

2.

Each Subcontractor shall enforce the wearing of hard hats. These hard hats must meet the ANSI Z89.1-1969 regulations. This construction project will be a hard hat project throughout its entirety (construction through start up). Violators will be removed from the project. Hard hats meeting ANSI Z892-1971 are required for high voltage, shock & burn hazards. OSHA sites the following reasons for the wearing of hard hats, to prevent head injuries from: a. b. c. d. Falling Objects Flying Objects Electrical Shock Bump Hazards

3.

NOTE: Hats are also required by TKS as an employer identifier. Subcontractor logos are required on all hard hats. 4. All personnel shall wear shirts, long trousers and safety shoes at all times. No shorts, tennis shoes, etc., will be permitted. All personnel will wear safety glasses with side shields unless instructed otherwise by the Project Manager.

5.

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6.

Shirts must be worn at all times. Shirts with buttons or zippers must kept buttoned or closed. T-shirts will be required as a minimum during hot weather. Employees grinding or chipping concrete must wear proper respirators and eye protection. Dust from grinding concrete is a suspected "carcinogen".

7.

B.

Personal Protective Equipment (As required in the TKS Fabrication Facility) 1. WELDING Hazard-Major Exposure Hazard Inhalation Eye Clothing Control Measures: Ventilation - Use enough ventilation. Local exhaust at the arc, or both to keep the fumes and gases from the worker's breathing zone and the general area. Train the welder to keep his head out of the fumes. Respiratory Protection - Use respirable fume respirator or air supplied respirator when welding in confined space or general work area when local exhaust or ventilation does not keep exposure below TLV. Eye Protection - Wear helmet or use face shield with filter lens shade number 12 or darker. Shield others by providing screens and flash goggles. Protective Clothing - Wear hand, head, and body protection which help to prevent injury from radiation, sparks and electrical shock. At a minimum this includes welder's gloves and a protective face shield, and may include arm protectors, aprons, hats, shoulder protection, as well as dark substantial clothing. Train the welder not to permit electrically live parts or electrodes to contact skin, clothing or gloves if they are wet. Insulate from work and ground.

Page 154 of 200 QSP 6.51 Rev. 1/20/04

Selection of Shade Number For Welding Filters Welding Operation Shielded Metal-Arc Welding, up to 5/32 in. (4 mm) electrodes Shielded Metal-Arc Welding, 3/16 to 1/4 in. (4.8 to 6.4 mm) electrodes Shielded Metal-Arc Welding, over 1/4 in. (6.4 mm) electrodes Gas Metal-Arc Welding (Nonferrous) Gas Metal-Arc Welding (Ferrous) Gas Tungsten-Arc Welding Atomic Hydrogen Welding Carbon Arc Welding 2. P A I N T/S O L V E N T S Hazard-Inhalation Eye Skin Contact Control Measures: Respiratory Protection - Use NIOSH approved chemical cartridge respirator to remove solid airborne particles of over spray and organic vapors during spray application. In Confined Areas: Use NIOSH approved supplied-air respirators or hoods. Eye Protection - Use safety eye wear designed to protect against splash of liquids. Other Protective Equipment - Use impervious gloves and/or clothing to prevent skin contact Ventilation - Provide general dilution or local exhaust ventilation in volume and pattern to keep TLV of hazardous ingredients below acceptable limits. Suggested Shade Number* 10

12

14 11 12 12 12 14

Page 155 of 200 QSP 6.51 Rev. 1/20/04

3.

INSULATION Hazard-Inhalation Eye Skin Contact Control Measures Summary - Protective equipment should be provided as necessary to prevent irritation to the throat, eyes and skin, and to keep exposures below the applicable exposure guidelines. Goggles - Safety glasses with side shields are recommended to keep dust and fibers out of the eyes. Gloves - Leather or cotton gloves should be worn to prevent skin contact and irritation. Barrier creams may also be used to reduce skin contact and irritation. Respirator - Use a NIOSH approved dust/mist respirator to protect against nuisance duct and fibers. (Examples of NIOSH approved disposable dust/mist respirators for this type of exposure are the 3M 9900 and Moldex 2200 respirators.) Operations such as sawing, blowing, tear out, and spraying may generate airborne fiber concentrations requiring a higher level of respiratory protection. For exposures exceeding 10 fibers per cubic centimeter, a NIOSH approved, half-mask respirator with High Efficiency Particulate Air (HEPA) filter cartridge should be used Ventilation - Local exhaust ventilation should be provided at areas of cutting to remove airborne dust and fibers. General dilution ventilation should be provided as necessary to keep airborne dust and fibers below the applicable exposure limits and guidelines. The need for ventilation systems should be evaluated by a professional industrial hygienist, while the design of specific ventilation systems should be conducted by a professional engineer. Other - Loose fitting, long sleeved clothing should be worn to protect skin from irritation. Exposed skin areas should be washed with soap and warm water after handling or working with fiber glass. Clothing should be washed separately from other clothes, and the washer should be rinsed thoroughly (run empty for a complete wash cycle). This will reduce the chances of fiber glass being transferred to other clothing.

Page 156 of 200 QSP 6.51 Rev. 1/20/04

4.

LUBRICANTS Hazard-Inhalation Skin Contact Eye Contact Ingestion Control Measures Ventilation - Sufficient to keep solvent vapor less than TLV. Respiratory Protection - Advised when concentrations exceed TLV. Protective Gloves - Advised to prevent possible skin irritation. Eye Protection - Approved eye protection to safeguard against potential eye contact, irritation or injury. Other Protective Equipment - None required.

5.

ADHESIVES (Aerosol or Brushed) Hazard-Eye Skin Inhalation Control Measures: Respiratory Protection - If workplace exposure limit(s) of product or any component is exceeded, a NIOSH/MSHA approved air supplied respirator is advised in absence of proper environmental control. OSHA regulations also permit other NIOSH/MSHA respirators (negative pressure type) under specified conditions (see your safety equipment supplier). Engineering or administrative controls should be implemented to reduce exposure. Ventilation - Provide sufficient mechanical (general and/or local exhaust) ventilation to maintain exposure below TLV(s). Protective Gloves - Wear resistant gloves such as: Neoprene Eye Protection - Chemical splash goggles in compliance with OSHA regulations are advised; however, OSHA regulations also permit other type safety glasses. (consult your safety equipment supplier

Page 157 of 200 QSP 6.51 Rev. 1/20/04

6.

CAULKING Hazard-Eye Skin Inhalation Ingestion Control Measures Respiratory Protection - The use of respiratory protection depends on the vapor concentration above the time-weighted TLV; use a NIOSH approved cartridge respirator or gas mask. Ventilation - General mechanical ventilation may be sufficient to keep product vapor concentrations within time-weighted TLV ranges. If general ventilation proves inadequate to maintain safe vapor concentrations, supplemental local exhaust may be required. Other special precautions such as respiratory masks or environmental devises may be required in extreme cases. Protective Gloves - The use of impermeable gloves is advised to prevent skin irritation in sensitive individuals. Eye Protection - Safety glasses, chemical goggles and/or face shields are recommended to safeguard against potential eye contact, irritation or injury.

7.

GRINDING/CUTTING WITH TORCH/PLASMA CUTTING Hazard-Inhalation Eye Clothing Skin Control Measures Ventilation - (confined area) Use fans, blowers, etc. to keep air moving through unit to prevent breathing fumes. Respiratory - Since all metals emit fumes when ground on, torched, plasma cut, in confined area should use a respirator (Ref. # 9920 3M/with yellow button) Eye Protection - Face shield or goggles, or safety glasses with side shields should be worn when grinding to prevent injury from fragments. In confined area torch cutting, plasma cutting full face shield should be worn. Supervisor to determine these areas. Burning goggles, should be used when torch cutting or plasma cutting
Page 158 of 200 QSP 6.51 Rev. 1/20/04

Recommend Shades For Cutting Goggles (SAMPLE ONLY) Torch Soldering 2 Torch Brazing 3 or 4 Light Cutting, up to 1 in. (25 mm) 3 or 4 Medium Cutting, I to 6 in. (26 to 150 mm) 4 or 5 Heavy Cutting, over 6 in. (150 mm) 5 or 6 Gas Welding (Light), up to 1/8 in. (3.2 mm) 4 or 5 Gas Welding (medium), 1/8 to 1/2 in. (3.2 to 12.7 mm) 5 or 6 Gas Welding (Heavy), over l/2 in. (12.7 mm) 6 or 8 Protective Clothing - Hand, body protection to prevent sparks, or molten metal from burning skin. Clothing must be fire retardant, or leather apron, sleeve for arm protection. 8. MATERIAL HANDLING Hazard-Hands Feet Eyes Back Head Control Measures Eye Protection - Safety glasses with side shields to be worn. So that fragments of metal, dirt, wood chips or banding, can not be blown into eyes. Hands - Leather work gloves should be worn when handling sheared steel, structural shapes, due to burns, and sharp edges. (Leather gloves or rubber gloves should not be worn when operating a Rotobrush, Mag drill or Hand drill) Feet Safety shoes are to be worn at all times to protect feet. Head - When handling material or working over top of a fellow worker, hard hats will be worn to protect against injury. (Supervisor will determine when hard hats should be worn.) Back - (rules for lifting) There are no comprehensive and sure-fire rules for "safe" lifting. Manual materials handling is a very complex combination of moving body segments, changing joint angles, tightening muscles, and loading the spinal column. The following DO's and DO NOT's apply, however:

Page 159 of 200 QSP 6.51 Rev. 1/20/04

DO design out manual lifting and lowering in the task and workplace. If it nevertheless must be done by a worker, perform it between knuckle and shoulder height. DO be in good physical shape. If you are not accustomed to lifting and vigorous exercise, do not attempt to do difficult lifting or lowering tasks. DO think before acting. Place material conveniently within reach. Have handling aids available. Make sure sufficient space is cleared. DO get a good grip on the load. Test the weight before trying to move it. If it is too bulky or heavy, get a mechanical lifting aid or somebody else to help, or both. DO get the load close to the body. Place the feet close to the load. Stand in a stable position with the feet pointing in the direction of movement. Lift mostly by straightening the legs. DO NOT twist the back or bend sideways. DO NOT lift or lower awkwardly. DO NOT hesitate to get mechanical help or help from another person. DO NOT lift or lower with the arms extended. DO NOT continue heaving when the load is too heavy. 9. DEFINITIONS Breathing Zone - Imaginary globe of two foot radius surrounding the head. Chronic Toxicity - Adverse (chronic) effects resulting from repeated doses of or exposures to a substance over a relatively prolonged period of time. Fume - Airborne particle formed by the evaporation of solid materials e.g. mineral fume omitted during welding usually less than one micron in diameter. Inhalation - The breathing in of a substance in the form of gas. Vapor fume mist or dirt. P.P.E - Personal Protective Equipment includes items such as gloves, goggles, respirators and protective clothing.

Page 160 of 200 QSP 6.51 Rev. 1/20/04

TLV - Threshold Limit Valve, a term used by ACGIH to express airborne concentration of a material to which nearly all persons can be exposed day after day without adverse effects. ACGIH - American Conference Of Governmental Industrial Hygienists which develops and publishes recommended occupational exposure limits for hundreds of chemical substances and physical agents.

Page 161 of 200 QSP 6.51 Rev. 1/20/04

XXII. EQUIPMENT INSPECTION PROGRAM The safe operation and maintenance of equipment being used on this project will be required. 1. Equipment Inspection Equipment being delivered to the job site must be checked by the Subcontractor intending to use this equipment to ensure that the equipment is in proper working condition. 2. Equipment Training It will also be the responsibility of the Subcontractor to instruct their employees in the proper usage and safety procedures for this equipment. Employees must be instructed on the proper use of each different type of equipment utilized. 3. Equipment Utilization a. At a time prior to building or area enclosure, all equipment will be converted to propane, have catalytic converter installed or be traded for electric type of equipment. TKS intends to monitor the air quality within the building to maintain a safe working environment. All equipment must have diapers installed to prevent oil and grease leakage. Oil and grease leaks will be covered with oil dry and cleaned as soon as possible. Boom type equipment must have boom protection installed. All equipment must have the "Emergency Stop" maintained in proper working order. A back up alarm will be required on all moving equipment, such as trucks, forklifts, manlifts, and etc. Daily survey of safety equipment must be conducted with problems noted and repaired if needed. Cranes, forklifts and manlifts will require a formal weekly inspection. These inspections must be logged and filed.
Page 162 of 200 QSP 6.51 Rev. 1/20/04

b.

c.

d. e.

f.

g.

h.

i.

Hand signals for material handling equipment must be posted in an area where it is readily available to all employees. Weight load limit will be posted on all floor levels except slab on grade. All employees who will operate equipment must be instructed on proper safety procedures.

j.

k.

Subcontractors are required to maintain ALL equipment in a good state of repair.

Page 163 of 200 QSP 6.51 Rev. 1/20/04

ANNUAL CRANE INSPECTION Equipment Type: Make / Model: Boom Length: Job Site Location: A. Inspection (Check if OK: Detail Exceptions Below) 1. General: Capacity Chart Controls Marked Operator's Manual Proximity Signs Signal Charts Signal Horn Back-up Alarms Tailwing Protection Fire Extinguisher Boom Angle Indicator Load Moment Device 2. Machinery: Controls Operational Brakes, Clutches Drum Guards Drum rotation Indicator Power Boom Hoist Boom Hoist Pawl Boom Hoist Kickout Power Load Lowering Brake Locks Safety Brakes Check Valves 3. Attachments: Boom Boom Stops Point Sheaves Sheave Guards Jib Jib Stops Hook & Block Jib Hook 4. Exceptions: Reeving Wire Ropes Rope Sockets Cable Clamps Pendants Outriggers / Controls Tire / Tracks Counterweight Swing Mechanism / Circle Swing Brakes Travel Mechanism / Chains Travel Brakes Hydraulic Leaks Air Leaks Pressure Settings Carbody / Carrier Revolving Frame Gantry Turntable Mounting OK Telescoping Length Indicator Load Indicator Cab Safety Glass Ladder / Hand Holds Levels Exhaust Pipes Machinery Guards Fuel Filler (Location) Appearance / Housekeeping Instrument Check OK Serial #: Jib Length: Crane Location: Hours: Equipment #:

(R.O.)

Inspector Signature: Customer Authorized Signature:

Page 164 of 200 QSP 6.51 Rev. 1/20/04

CRANE INSPECTION COMPANY JOB SITE NAME JOB SITE LOCATION OPERATOR'S NAME (Last) REFERENC E (First) (Middle) INTERNAL EQUIPMENT MODEL EQUIPMENT SERIAL # OPERATOR'S SS #

ITEMS TO BE INSPECTED AND INSPECTION MAINTENANCE CODE

INSPECTION INTERVAL: 10 HOUR CHECK LIST (DAILY)

(MONTH) _______________ DAY OF INSPECTION _______________ (YEAR) _______________ 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Lubricate Operations Manual Lights & Horn Back-up Alarm Gauges Swing Brake Boom Angle Indicator Load Moment Indicator Anti-two Block Elec. & Hyd. Brakes and Air System Outrigger Float Pads Tire Condition and Pressure Antifreeze and Coolants Crankcase and Auto Transmission Air Compressor Oil Level Hourmeter Hydraulic Reservoir Hydraulic Oil Filter Wire Rope Hoists Boom and Attachments 1 2, 3, 19 7, 19 3, 5, 7 3, 7 3, 7, 19 3, 7, 19 3, 17, 19 3, 5, 7, 13 1, 16 4, 9, 10 4 4 4, 8 3, 5, 19 4 6, 12 20 1, 6, 7, 9 1, 6, 7, 9 D D D D D D D D D D D D D D D D D D D D D D 1 2 3 4 5 6 7 8 9 10 11

INSPECTOR'S INITIALS INSPECTION COPIES: (S) - SATISFACTORY (U) UNSATISFACTORY (NA) NON APPLICABLE

Page 165 of 200 QSP 6.51 Rev. 1/20/04

DAILY CRANE INSPECTION A. Daily visual inspections by the operator or other qualified person shall be made of: 1. All functional mechanisms for maladjustments interfering with proper operation. 2. All limit switches shall be checked without a load on the hook. 3. Lines, tanks, valves, pumps, and other parts of air or hydraulic systems for deterioration or leakage. 4. Hooks for deformation and cracks and fully functional safety clips. 5. Hoist or load attachment chains including end connections for excessive wear, twist, distorted or stretched links interfering with proper function. 6. Excessive wear, broken wires, stretch, kinking or twisting of ropes and rope slings, including end connections. ANY DEFECT AFFECTING SAFE OPERATIONS SHALL BE CORRECTED BEFORE FURTHER OPERATION.

MONTH

CONTRACTOR CONTRACTOR

DATE

NAME

DATE

NAME

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Page 166 of 200 QSP 6.51 Rev. 1/20/04

WEEKLY CRANE INSPECTION CONTRACTOR: EQUIPMENT OR ID NO.: A. GENERAL REQUIREMENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. B. Capacity Chart Limitation Notices Control Markings Proximity Sign Signal Chart Signal Horn Back-up Alarm Fire Extinguisher Drum Rotation Ind. Angle Indicator Load Indicator Cab or Guard Safety Glass Hand Hole 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Levels Exhaust Pipes Sheave Guards Drum Guards Power Load Lowering Power Boom Hoist Boom Hoist Holding Valve Boom Hoist Kickout Main Winch Brake Aux. Winch Brake Telescope Holding Valve Swing Brake Service Brakes Parking Brake DATE: MILEAGE: HOURS:

EXAMINATION - ATTACHMENT 1. 2. 3. 4. 5. 6. Hook Block Jib Hook Rope Sockets Cable Clamps Boom Boom Wear Pads 7. 8. 9. 10. 11. Point Sheaves Extension Assembly Jib Assembly Anti-Two Blocking Wire Rope and Sling

C.

EXAMINATION - MAIN MACHINE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Control Valves Main Winch Auxiliary Winch Winch Brakes Swing Mechanism Boom Cylinders Boom Mounting Frame Telescope Cylinders Hydraulic Leaks Air Leaks Hydraulic Oil Levels 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Hydraulic Pumps Hydraulic Swivel Hydraulic Hoses Revolving Frame Counterweight Swing Circle Chassis Outriggers Travel Brakes Tires Lubrication

D.

Comments:

Authorized Signature:

Date:______________

XXIII. A.

SLIPS, TRIPS AND FALLS PREVENTION POLICY Purpose

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It is the intent of TKS to ensure that each Subcontractor creating a fall hazard will install properly constructed guardrails, handrails or covers per OSHA and other federal, state and local standards. B. Responsibility It is the Subcontractor's responsibility to ensure that measures are taken to eliminate or rectify conditions that may result in slips, trips, or falls. TKS may monitor and review the initial installation and will also, during safety tours, note any fall hazards and lack of proper protection 1. Handrail a. A standard railing consists of a top rail, mid rail, and a toe board. The top rail shall be at a height of 42 inches. A complete railing structure shall be capable of withstanding a force load of 200 lb. in any direction. All handrails around floor openings must have a sign stating, Do Not Remove". Any Subcontractor employee not reinstalling the existing temporary or permanent handrail will be subject to immediate dismissal.

b.

c.

d.

2.

Floor Hole a. A floor hole cover must be constructed of a minimum 3/4 inch plywood of extra strength and must be secured against accidental displacement and a painted sign stating, "Danger Hole Below". The protection around the floor perimeter is acceptable to use 1/2inch wire rope. During the steel erection, one 1/2-inch wire rope at 42-inch height will be acceptable. After steel erection and before final installation of specific material, two (2) 1/2-inch wire ropes must be used for protection of employees. Top rail 42 inches from floor or platform. Mid rail 21 inches from floor to platform. A toe board at least 4 inches wide (4 inches high).

b.

3.

Housekeeping a. All areas are to be kept clean with trash and debris removed immediately to prevent tripping and loss of traction hazards.

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b.

All areas are to be inspected for the presence of grease, oil, water etc. to eliminate slip hazards. Each Subcontractor is required to maintain a bag of oil dry, at all times.

C.

Preventing Slips, Trips, and Falls 1. Falls are one of the easiest work injuries to prevent. Causes of Falls: a. b. 2. Loss of footing Loss of traction

Precautions to prevent falls on stairs. a. b. c. Pay attention Use handrails Step deliberately

3.

Precautions to prevent trips. a. b. c. Pay attention to where you are going Keep your eyes on the path ahead Step deliberately

4.

Precautions to prevent slips on slick surfaces. a. b. Take small steps Do not make sudden turns

5.

Facility Equipment. a. Inspect equipment before using.

6.

Deliberate Acts. a. b. c. d. Unless there is an emergency, take your time. Avoid horse play. Avoid short cuts, use designated walking areas. Do not climb or stand on surfaces designed for other purposes (Example: tables, chairs, conveyors).

7.

Ways to prevent potential fall situations. a. Look for potential fall situations and eliminate them whenever possible.
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b. c. d. e. 8. 9.

Check floor surfaces to see if they are greasy or cluttered. Always face direction that you are working. Practice good house keeping. Erect temporary handrail on all elevated surfaces.

Ladders used for temporary construction work will be tied off to a structure. Employees working at an elevation from which a fall may occur are to be tied off with a safety belt and 6 foot lanyard utilized and/or an accompanying safety net, if required by OSHA or other federal, state or local requirements.

Page 170 of 200 QSP 6.51 Rev. 1/20/04

XXIV. LADDERS SAFETY SCAFFOLDS AND SAFETY NET SAFETY A. Ladder

Most serious ladder injuries are the result of falls of less than seven (7) feet. 1. Three (3) Types of Ladders: a. b. c. 2. Straight Ladder Extension Ladder Stepladder

Ladder Inspection - Before using a ladder, please complete the following inspection: a. Extension and Straight Ladders 1. Make sure the rungs are in good condition. Check for cracks in welds, separation in metal or fiberglass. Check rungs on wood ladders for splitting or cracking. If a pull rope is present, make sure it is firmly attached and not frayed. Make sure foot pads are intact, bolts secure and not eroded. Make sure the brackets are firmly attached, in line with the rungs and free to move automatically into place. Have extra rope to tie off the ladder. Leveling blocks should be at least two feet square. Never use the top three (3) rungs of the ladder. If you have to use the top three (3) rungs, then you need a bigger ladder. The top three (3) rungs should extend above the platform or work areas. The base of the ladder must be set back a safe distance from the vertical approximately one fourth (1/4) of the working length of the ladder. The rule of thumb for setting straight
Page 171 of 200 QSP 6.51 Rev. 1/20/04

2.

3. 4.

5. 6. 7.

8.

9.

and extension ladders is for every four (4) feet of vertical height, the base of the ladder should be set back one (1) foot from the face of the work area. b. Stepladders Read all stepladder safety warnings attached to the ladder. 1. 2. Check all stepladders for stability. Stepladders must be fully opened to permit the spreader to lock. Make sure spreaders will lock into place. Never use the top two (2) steps on any stepladder.

3. 4. 3. Ladder Safety

Various types of ladders are available on the job site for your use. There is no excuse for using a make shift means of access to a work area. Use the right ladder for the job. a. Broken or damaged ladders must not be used. Repair or remove broken ladders immediately. Ladders to be repaired must be tagged "DO NOT USE" and be removed from the job site. Do not splice together short ladders to make a longer ladder. All straight and extension ladders must be tied off at the top. Ladders should not be placed against movable objects. The areas around the top and base of the ladders must be free of tripping hazards such as loose materials, trash and electrical cords. Ladders which project into passageways or doorways, where they could be struck by personnel, moving equipment or materials being handled must be protected by barricades or guards. You must face the ladder at all times when ascending or descending. Be sure that your shoes are free of mud, grease, or other substances which could cause a slip or fall.

b. c. d. e.

f.

g.

h.

Page 172 of 200 QSP 6.51 Rev. 1/20/04

i. j.

Do not carry materials up a ladder. Use a hand line. Always move the ladder to avoid over-reaching. As a rule of thumb; if your belt buckle passes the ladder rail while you are reaching laterally, you are over reaching, DO NOT overreach. Move the ladder to the work area. Metal ladders shall not be used for electrical work or in areas where they could contact energized wiring. The use of metal ladders is restricted to special applications where the heavier wooden ladders are not practical. Be careful of electrical wires or other hazards when moving or positioning ladders. Ladders should not be used for other than the intended purpose. Ladders are not pick boards.

k.

l.

4.

Scaffolds and Ladders a. Scaffolds shall be erected on firm foundations, leveled with screw jacks, and secured to the adjoining structure at regular intervals. Damaged or bent scaffold parts shall be removed from service. Scaffold decks shall be fully planked. All planks shall be free of cracks, saw cuts and large knots. Scaffolds over 10 above the floor shall be equipped with standard guardrails and toe boards. Swinging or suspended scaffolds shall be provided with separately anchored vertical life lines for each individual on the scaffold. The anchorage for suspended scaffolds shall be capable of supporting 4 times the maximum rated load (including men, tools, guardrails, material, etc.). All scaffolds shall be inspected daily for defects or damage. Repairs shall be made before work loads are imposed on the scaffold. Scaffolds and ladders are to be maintained and used in accordance with the manufacturers instructions.

b. c.

d.

e.

f.

g.

Page 173 of 200 QSP 6.51 Rev. 1/20/04

5.

Safety Nets a. Before they are put into use, all nets must be inspected by a competent person. If a net has been in storage, the test strands must be sent to the manufacturer for analysis before the net is used. Nets are to be erected according to the manufacturers standards. Nets, anchorage points, cables, hooks, and ties should be inspected regularly for damage or deterioration.

b. c.

Page 174 of 200 QSP 6.51 Rev. 1/20/04

XXV. JOB SITE INSPECTION CATEGORIES 1. Accident Prevention Organization a. b. c. 2. Schedule for posting safety material. Hard hat requirements. Safety Meetings scheduled.

Housekeeping and Sanitation a. b. c. d. e. f. g. h. i. j. k. General neatness of working areas Regular disposal of waste and trash Passageways and walkways clear. Adequate lighting. Projecting nails removed. Oil and grease removed. Waste containers provided and used. Sanitary facilities adequate and clear. Drinking water tested and approved. Adequate supply of water. Drinking cups or sterilized bubblers.

3.

First Aid a. b. c. d. e. f. First aid station. First aid supplies. First aid instruction on the job. Telephone numbers and locations of nearby physicians. Telephone number and location of nearest hospital. Injuries reported promptly to proper persons.

4.

Fire Prevention a. b. c. d. e. f. Fire instructions to personnel. Fire extinguishers identified, checked and lighted. Telephone number of fire department posted. Hydrants clear, access to public roads open. Good housekeeping. NO SMOKING posted and enforced where needed.

Page 175 of 200 QSP 6.51 Rev. 1/20/04

5.

Electrical Installations a. b. c. d. e. Adequate wiring, well insulated. Fuses/circuit breakers provided. Fire hazards checked. Electrical dangers posted. Proper fire extinguishers provided.

6.

Hand Tools a. b. c. d. Proper tool being used for each job. Neat storage, safely carrying. Inspection and maintenance. Damaged tools repaired or replaced promptly.

7.

Power Tools a. b. c. d. e. f. g. h. i. Good housekeeping where tools are used. Tools and cords in good condition. Proper grounding. Proper instruction in use. All mechanical safeguards in use. Tools neatly stored when not in use. Right tool being used for the job at hand. Wiring properly installed. Enough men used to handle material.

8.

Power Actuated Tools a. b. c. d. e. f. g. h. Local laws and ordinances complied with. All operators qualified. Tools and charges protected from unauthorized use. Competent instruction and supervision. Tools checked and in good working order. Tools not used on any but recommended materials. Safety goggles or face shields used. Flying hazard checked by backing up, removal of personnel or use of captive stud tools.

9.

Ladders a. b. c. d. e. Stock ladders inspected and in good condition. Stock ladders not spliced. Properly secured, top and bottom. Side rails on fixed ladders extend above top landing. Built-up ladders constructed of sound materials.
Page 176 of 200 QSP 6.51 Rev. 1/20/04

f. g. h. i. 10.

Rungs not over 12 inches on center. Stepladders fully open when in use. Metal ladders not used around electrical hazards. Proper maintenance and storage.

Scaffolding a. b. c. d. e. f. g. h. i. j. k. l. Erection under proper supervision. All structural members adequate for use. All connections adequate. Safe tie-in to structure. Ladders and working areas free of debris, snow, ice, grease. Proper footings provided. Passersby protected from falling objects. Supports plumb, adequate cross-bracing provided. Guard rails and toe boards in place. Scaffold machines in good working order. Ropes and cables in good condition. Frequent inspection.

11.

Hoists, Cranes and Derricks a. b. c. d. e. f. g. h. i. Inspect cables and sheaves. Check slings and chains, hooks and eyes. Equipment firmly supported. Outriggers used if needed. Power lines inactivated, removed or at a safe distance. Proper loading for capacity at lifting radius. All equipment properly lubricated and maintained. Signalmen where needed. Signals understood and observed.

12.

Heavy Equipment a. b. c. d. e. f. Regular inspection and maintenance. Lubrication, brakes, warning signals operative. Lights, brakes, warning signals operative. Wheels choked when necessary. Haul roads well maintained and laid out properly. Protection when equipment is not in use.

13.

Motor Vehicles a. b. c. Regular inspection and maintenance. Qualified operators. Local and state vehicle laws and regulations observed.
Page 177 of 200 QSP 6.51 Rev. 1/20/04

d. e. f. 14.

Brakes, lights, warning devices operative. Weight limits and load sizes controlled. Personnel carried in a safe manner.

Conveyors and Cableways a. b. c. d. e. Proper inspection and maintenance. Good housekeeping. Screens and other protection where needed. Adequate inspection, maintenance ladders and walkways. Lighting.

15.

Marine Equipment a. b. c. d. e. f. g. h. i. j. Waterways rules and regulations observed. Life jackets provided and used. Life preservers provided. Fire protection. Engine and machinery room safety maintained. Floating pipelines, walkways, and handrails. Handrails aboard vessels. Deck clear, free of oil and grease. Lights. Cable.

16.

Equipment Maintenance a. b. c. Planned maintenance and inspection program. Adequate equipment records. Proper oils, fuels, lubricants used.

17.

Garages and Repair Shops a. b. c. Fire hazards identified and controlled. Dispensing of fuels and lubricants. Good housekeeping.

18.

Barricades a. b. c. d. Floor openings planked over or barricaded. Roadways and sidewalks effectively protected. Adequate lighting provided. Traffic properly controlled.

Page 178 of 200 QSP 6.51 Rev. 1/20/04

19.

Handling and Storage of Materials a. b. c. d. e. f. g. h. i. j. Neat storage area, clear passageways. Materials neatly stacked. Stacks on firm footings, not too high. Proper number of men for each operation. Men picking up loads correctly. Materials protected from heat and moisture. Protection against falling into hoppers and bins. Dust protection observed. Extinguishers and other fire protection. Traffic routing and control.

20.

Excavation and Shoring a. b. c. d. e. f. g. h. i. j. Shoring of adjacent structures. Shoring and sheathing as needed for soil and depth. Public roads and sidewalks supported and protected. Materials not too close to edge of excavations. Lighting at night. Water controlled. Equipment at safe distance from edge. Ladders or stairs provided where needed. Equipment ramps adequate, slope not too great. Frequent inspection.

21.

Pipelines a. b. c. Shoring and bracing as needed. Equipment in working order. Proper access to deep trenches.

22.

Demolition a. b. c. d. e. f. g. Operations planned ahead. Shoring of adjacent structures. Material chutes. Sidewalk and other public protection. Clear operating space for trucks and other vehicles. Adequate access ladders or stairs. Regular supervision.

23.

Pile Driving a. Proper storage procedures.

Page 179 of 200 QSP 6.51 Rev. 1/20/04

b. c. d. e. f. 24. Shafts a. b. c. d. e. f. g. 25. Boilers a. b. c. 26.

Unloading only by property instructed workers. Steam lines, slings, etc., in operating condition. Pile driving rigs properly supported. Ladders on frames. Care observed by top man.

Ladders, stairs adequate and safe. Top of shaft barricaded, toe-boards provided. Adequate lighting. Ventilation. Inspection and maintenance of elevators and hoists. Signals being used. Shoring and bracing.

State and local regulations and codes observed. Pressure gauges checked and operating. Equipment in good working order.

Pressure Vessels a. b. c. Gauges operating and checked regularly. Equipment in sound working condition. Connections properly made.

27.

Explosives a. b. c. d. e. f. g. h. i. j. k. l. m. n. Qualified operators. Proper transport vehicles. Local laws and regulations observed. Storage magazines constructed per regulations or as recommended. Experienced personnel handling explosives at all times. Cases opened with wooden tools only. No Smoking posted and enforced where appropriate. Continuity check tested before each shot. All personnel familiar with signals and signals properly used at all times. Inspection after each shot. Proper protection and accounting for all explosives at all times. Proper disposition of wrappings, waste and scrap. Advise residents nearby of blasting cap danger. Check radio frequency hazards.

Page 180 of 200 QSP 6.51 Rev. 1/20/04

28.

Flammable Gases and Liquids a. b. c. d. e. f. All containers clearly identified. Proper storage practices observed. Fire hazard checks. Proper storage temperatures and protection. Proper types and number of fire extinguishers nearby. Carts for moving cylinders.

29.

Welding and Cutting a. b. c. d. e. f. g. h. i. j. k. Qualified operators. Screens and shields. Goggles, gloves, clothing. Equipment in good operating condition. Electrical equipment grounded. Power cables protected and in good repair. Fire extinguishers of proper type nearby. Inspection for fire hazards. Flammable materials protected or removed. Gas cylinders chained upright. Gas lines protected and in good condition.

30.

Steel Erection a. b. c. d. e. f. g. Safety nets. Hard hats, safety shoes, gloves. Taglines. Fire hazards at rivet forge and welding operations controlled. Floor opening covered and barricaded. Ladders, stairs or other access provided. Hoisting apparatus checked.

31.

Concrete Construction a. b. c. d. e. f. g. h. i. j. Forms properly installed and braced. Adequate shoring, plumbed and crossbraced. Shoring remains in place until strength is attained. Proper curing period and procedures. Check heating devices. Mixing and transport equipment supported and traffic planned and routed. Adequate runways. Protection from cement and concrete burns. Hard hats, safety shoes, shirts covering skin. Nails and stripped form material removed from area.
Page 181 of 200 QSP 6.51 Rev. 1/20/04

32.

Masonry a. b. c. Proper scaffolding. Masonry saws properly equipped and dust protection provided. Safe hoisting equipment.

33.

Roads and Parking Lots a. b. c. d. e. f. g. h. Laws and ordinances observed. Competent flagmen properly dressed, instructed and posted. Adequate warning signs and markers. Equipment not blocking right of way. Traffic control through construction site. Adequate marking and maintenance of detour routes. Dust control. Adequate lighting.

Page 182 of 200 QSP 6.51 Rev. 1/20/04

SAFETY EVALUATION CHECKLIST CONTRACTOR: PROJECT: DATE: EVALUATED BY:

Routine tours of a Subcontractor's work can identify unsafe practices that can cause accidents. The following safety related items can be evaluated by observing conditions on a walk through inspection. Where warranted , the appropriate Owner's representative should occasionally walk through the area and check the Subcontractor's practices against the items on the following list that apply to the job, or other items that may be appropriate. Problem areas should be discussed with the Subcontractor promptly. Checklists are working documents only and not official records of the job. They should be destroyed upon job completion. YES Is a copy of the Subcontractor's Safety Manual on site? 1. Does the Subcontractor conduct new employee orientation A. 2. 3. 4. Are Safety Handbooks Issued to Employees? NO

Does the Subcontractor hold weekly Safety Meetings? Is the Subcontractor Safety Performance monitored? Are Safety Education Posters displayed? A. Is the Accident Record (OSHA Log) posted?

5. 6.

Are emergency telephone numbers prominently displayed? Are First Aid Kits available? A. Are trained First Aid personnel available?

7.

Are nearby medical facilities available? A. B. Have prior arrangements for service been made? Are EMS Units available and familiar with site?

Page 183 of 200 QSP 6.51 Rev. 1/20/04

YES 8. 9. Are hard hats used? Is hearing, eye, respiratory or other special protective equipment used?

NO

EXCAVATING AND TRENCHING 10. Are underground utilities researched and located? 11. Are excavated materials kept back from edges of excavations? 12. Are excavations shored, braced, or sloped? 13. Are access ladders, barricades, bridges maintained in good condition? 14. Does the Subcontractor inspect excavations daily? HEAVY EQUIPMENT 15. Are all vehicles equipped with back-up alarms? 16. Are seat belts provided on equipment? 17. Is equipment inspected and serviced? FIRE PROTECTION 18. Are fire department numbers prominently posted? 19. Are building exits clearly marked? 20. Is fuel stored with: Containment Dikes No Smoking Signs Posted Proper Fire Extinguishers Proper Housekeeping 21. Are flammable liquids stored outside of buildings? 22. Are flammable liquids stored in approved cans? 23. Are battery charging operations safety conducted? 24. Is flammable rubbish removed from buildings daily? 25. Are the required number and type of extinguishers distributed and maintained?

Page 184 of 200 QSP 6.51 Rev. 1/20/04

YES ` ELECTRI CAL EQUI PMENT 26. Ar e wor n or dam aged cor ds used? 27. Ar e swi t ches guar ded and cl ear l y i dent i f i ed? 28. I s pr oper gr oundi ng and G. F. I . i m pl em ent ed? 29. Ar e el ect r i cal hazar ds post ed and guar ded? 30. I s a l ockout / t agout pr ocedur e i n use? W ELDI NG AND CUTTI NG 31. Ar e oxygen and acet y l ene bot t l es st or ed separ at el y? 32. Ar e bot t l es secur ed i n upr i ght posi t i ons? 33. Ar . e caps i n pl ace when bot t l es ar e m oved? 34. Ar e gauges and hoses i nspect ed per i odi cal l y ? 35. Ar e f i r e wat ches m ai nt ai ned dur i ng oper at i ons? 36. Ar e f i r e ext i ngui sher s wi t hi n 30' of oper at i ons? HOUSEKEEPI NG 37. Ar e m at er i al s s t acked saf el y? 38. Ar e wor k ar eas cl eaned on a t i m el y basi s ? 39. Ar e st ai r s , guar dr ai l s , bar r i cades, and cover i ngs i nspect ed and kept i n good condi t i on? 40. Ar e f i r e depar t m ent num ber s pr om i nent l y post ed? HAND, POW ER AND POW DER ACTUATED TOOLS 41. Ar e hand t ool s i nspect ed and m ai nt ai ned? 42. Ar e power t ool s guar ded and gr ounded? 43. Ar e user s t r ai ned on power act uat ed t ool s ? COMMENTS:

NO

Page 185 of 200 QSP 6.51 Rev. 1/20/04

JOB SITE INSPECTION Job Site: Week Ending: Mon Tue Wed Thu Fri

A = Acceptable NA = Not Acceptable X = Correction Necessary 1. First Aid Supplies - Convenient, Adequate 2. Excavating/Trenching - Shoring, Underground Lines 3. Employee Practices - Lifting, Safety Rules 4. Floor Openings - Barricaded, Covered, Perimeter Floor Protection 5. Housekeeping - Debris, Fall & Fire Hazards 6. Ladders, Safety Feet, Lashed, Sound Base Out 1/4 Length of Ladder 7. Material Hoist - Gates, Signals, Signs, No Riding 8. Overhead Protection - Falling Objects, Entrances, Openings, Sidewalks 9. Personal Protective Equipment - Hard Hats, Goggles, Footwear 10. Scaffolding - Locks, Guardrails, Toe Boards, Planks Secured Tied to Building 11. Shaftway Protection Barricades, Guardrails 12. Stairways - Guardrails, Tread Fillers, Clean 13. Storage of Materials - Neat, Lashed, Nails in Scrap Lumber Bent Over or Removed 14. Temporary Lighting - Stair, Closed Areas, Condition 15. Tools, Equipment - Guard, Grounded, Condition 16. Attach additional entries (if necessary) I have personally inspected the above items. Those marked "X" have been corrected with the following exceptions:

Reviewed & Approved

Inspector

Date

Page 186 of 200 QSP 6.51 Rev. 1/20/04

XXVI.

TEMPORARY HANDRAIL DESIGN

Page 187 of 200 QSP 6.51 Rev. 1/20/04

XXVII.

FUEL STORAGE AREA

Page 188 of 200 QSP 6.51 Rev. 1/20/04

Fuel Storage Area 1. All fuel storage tanks are to be within a dikes area of sufficient size to retain the total capacity of the tanks. All fuel storage tanks will be stored in an area designated by the Project Manager. Two or more tanks grouped together will not exceed 2,200 gallons without a five foot separation between tanks. A twelve foot wide drive will be maintained for access and egress and for the approach of emergency fire equipment. Fuel storage area must be maintained free of weeds, paper, debris, and other combustibles. The following signs must be posted on each tank: a. b. c. d. 7. 8. 9. Contractor's name Type of fuel No smoking Danger/Flammable

2.

3.

4.

5.

6.

All engines must be shut down while refueling. 20 lbs. ABC type fire extinguisher must be placed at each fuel storage tank. Each group of tanks shall have a 12 in. high earth dike to contain spills, in addition, two layers of four mill poly to be placed under each group of tanks and covered with a six inch layer of soil to contain spillage and to reduce contaminated soil. Gravity flow tanks are prohibited without self-closing valves. Emergency venting must be installed on all tanks as per the NFPA #30 1977. All fueling operations, while in progress, must be electrically bonded. All tanks must be grounded. All federal, state and local regulations will also be followed. GASOLINE & PROPANE STORAGE

10. 11.

12. 13. 14.

Page 189 of 200 QSP 6.51 Rev. 1/20/04

XXVIII.

CRANE SIGNALS

Page 190 of 200 QSP 6.51 Rev. 1/20/04

XXIX.

Sample CRANE REACH CAPACITY

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XXX. SUGGESTED TOOL BOX SAFETY MEETING TOPICS The Subcontractor is required to conduct weekly Tool Box Safety Meetings. At these meetings a safety topic will be selected for discussion. Handouts should be provided for stimulation of interest in the topic and for later reflection. 1. 2. 3. 4. 5. 6. TKS Safety Manual - Components Personal Protective Equipment Report to work rested and physically to fit to perform your job. Wear clothing suitable for weather conditions and work responsibilities. Wear approved safety footwear suitable for your tradein good condition. Use gloves, aprons or other suitable skin protection when handling rough materials, chemicals, hot or cold objects. Replace these items if worn. Jewelry (rings, bracelets, neck chains, etc.) should not be worn. Special safety equipment is provided for your protection: Use when required, keep in good condition and report loss or damage immediately. In or near construction areas, locate gas, power and water sources before starting work. Contact utility companies. Know location and proper use of fire extinguishing equipment and how to give fire alarm. Flammable liquid containers should be clearly labeled and stored in a protected, separate area Flammable liquids should be used only in small amounts and in approved metal safety cans. Do not block building aisles, traffic lanes, fire exits, or fire equipment. Maintain safe access ways to work areas. Avoid shortcuts. Use ramps, stairs, walkways, ladders, etc.
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7. 8.

9.

10.

11.

12.

13. 14. 15.

16. 17.

Properly brace or shore up excavations side wall if not sloped. Place excavation spoil far enough away from excavations to avoid load strain on walls. Remove surface rocks that may fall in. Termination: If you commit an unsafe act, you will receive a warning on the first offense. A written warning will be issued on the second safety offense. Termination on the third offense. However, a serious safety infractions or fraudulent claim of an injury will immediately result in termination. General Foreman and Foremen have been held accountable by regulating authorities for injuries occurring to personnel under their supervision. Have just one ( 1 ) person give commands when team - lifting big loads. Intoxicants and non-prescribed drugs are NOT PERMITTED on the project site - cause for disciplinary action. The use of prescription drugs is to be reported to your supervisor for job assignment safety considerations. Rely on your supervisor's knowledge and experience if you do not understand any rule or work operation. Work with care and good judgment at all times to avoid accidents - whether or not a specific rule is contained in this manual. Give your wholehearted support to safety activities. Preventing your accident depends mostly on YOU! Examples and safety rules cannot cover every conceivable situation. You must pause and use common sense to reach a decision about actions that may result in an accident to yourself or someone else. If we seriously consider the consequences of our actions, few of our actions would result in accidents. Compressed gas bottles. Dangers of compressed air. Accident procedure. Ladder safety. Scaffold Safety.
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18.

19.

20. 21.

22.

23.

24.

25.

26.

27. 28. 29. 30. 31.

TKS Industrial Company Project Weekly Tool Box Meeting Report

TKS / Subcontractor: Superintendent or Foreman: Subject of Meeting:

Date: Project Number:

Location:

Attendance:

(Names)

Badge #

Company Name

Remarks:

(Unsafe conditions and suggestions offered by employees or other supervisors for correction of hazardous conditions).

Distribution:

Original to Project: Copy for Project:

Safety Supervisor Site File

Note:

OSHA Safety and Health Regulations for Construction Paragraph 1926.20 and 1926.21 required, in part, that employers establish accident prevention program conditions. Since OSHA compliance officers will look for evidence that employers have provided training for employees, the above report can be used to document and record your employee training efforts).

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XXXI.

SAFETY MANUAL FORMS

Form # QSF #671 QSF #670 QSF #170 QSF #177 QSF #659 QSF #700 QSF #703 QSF #701 QSF #698 QSF #676 QSF #557 QSF #662 QSF #693 QSF #694 QSF #695 QSF #692 QSF #691 QSF #696 QSF #705 QSF #706 QSF #689 QSF #673 QSF #680 QSF #660 QSF #685 QSF #169

Description Accident Investigation Report Accident Summary Daily Hot Work Checklist Hot Work / Ignition Source Training Lockout / Tag Out / Blockout Log Confined Space Entry Log Confined Space Evaluation Form Confined Space Entry Permit Confined Space Tag Subcontractor Incident Report Project Site Equipment List Tool List Annual Crane Inspection Crane Inspection Daily Crane Inspection Weekly Crane Inspection Safety Evaluation Checklist Daily Job Site Inspection Report Weekly Tool Box Meeting Report Training Verification Form (Sign In Sheet) Safety Violation Form Subcontractor Injury / Illness Report Material Safety Data Sheets Proposed Helicopter Lifts Hazard Communication Instruction Fire Blanket Check-out Sheet

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XXXII.

ACKNOWLEDGEMENT LETTER TKS INDUSTRIAL COMPANY SAFETY TRAINING & ACKNOWLEDGMENT LETTER

This letter is my acknowledgement that I, ____________________________, have received the following safety Orientation Training. Safety Orientation provided by: _______________. Reviewed Safety Video I have read and understand the TKS Safety Manual Revision _________ dated _______________. _______________________________ on

I understand and agree that if I violate any safety rule, I will be removed immediately from the project and will not be able to return.

__________________________ Date

_____________________________ Badge Number

_______________________________________________ Name _______________________________________________ Address __________________________ Union Local Number _____________________________ Company Name

Check One Below __________ I am certified in First Aid / CPR __________ I am not certified in First Aid / CPR

__________________________ Date of Certification If you are currently certified in First Aid / CPR, you will receive a Red Cross Sticker for your hard hat.
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XXXIII. A. B.

INDEX Alphabetical Index Resource Information Availability

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A. B.

Alphabetical Index Resource Information Availability It is the responsibility of all TKS employees to be familiar with the provisions of this safety manual and to know and understand the mandatory safety and health requirements and regulations as presented in the material listed in this section. 1. TKS Manuals & Other Resource Material available for review, include: a. b. c. d. e. f. g. Contract Document, (September, 1994) Field Manual for Construction Management, (April, 1995) Materials for Technical Education at TKS (April, 1991), (Compiled for Beginners), Quality Assurance Manual, QAM-1, (August 14, 1992) Confined Space Entry Program Manual, Employee Handbook, (January, 1993) Project Reports: 1. 2. 3. h. Honda East Liberty Project, HAM EXII, (1990) Ford Twin Cities Retrofit Project, (1992) Honda de Mexico, Bumper Line Project, (1993)

Project Photograph Albums: 1. Yamaha Phase I, 1987, - Parts Line including Pretreatment with Phosphate, E-Coat, and Top Coat Booths, Ovens, Air Supply Units, Sludge System, and Utilities. Yamaha Phase 2, 1988, - Paint Line, with Color & Clear Coat Booths, Ovens, Air Supply Units, Sludge System, Utilities and etc. Kubota. 1988, - Paint Line with Shotblast. Honda East Liberty Plant. HAM EXII, 1990 - Automobile Paint Line with Base Coat & Color Coat Booths, Miscellaneous Booths, Ovens, Air Supply Units and Sludge System. Nissan IV. 1991, - Automobile Paint Line (basically all aspects of the Paint Department and Project Construction Management). Ford Michigan Truck. 1993, - Automobile Paint Line. Ford Twin Cities Retrofit Project. 1992, - Paint Line Retrofit including Booths, Air Supply Units, Ovens, Robotics & Conveyor. Honda De Mexico Facia. 1993, - Bumper Paint Line. Tomasco Mulciber. 1993 - E-Coat System.
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2.

3. 4.

5.

6. 7.

8. 9.

2.

Resources Available for review in the TKS Shop Office include: a. b. c. Construction Regulatory Guide, 29CFR 1926 Regulations and Index, JJ Keller (updated Bi-Annually). 1910 OSHA Guide, Plant Safety Regulations & Index, JJ Keller (updated Bi-Annually) Hazardous Waste Management Guide, Identification, Monitoring, Treatment and Disposal, (Regulations, Compliance, and Management Guidelines), JJ Keller (updated Bi-Annually). Hazardous Waste Guide: for generators, transporters and TSD's, JJ Keller, (updated Bi-Annually).

d.

3.

Resources Available for review in the TKS Library include: a. b. c. d. Ohio Basic Building Code (Based on BOCA) manual, (updated every 3 years). Michigan Department of Labor Occupational, Safety & Health Standards Act (MIOSHA). Uniform Building Code, updated every 3 years. Southern Building Code Congress International, Inc. (SBCCI). 1. 2. 3. 4. 5. 6. e. f. g. h. i. j. k. l. m. n. o. Standard Building Code Standard Existing Building Code Standard Fire Protection Code Standard Mechanical Code Standard Plumbing Code Standard Gas Code

Illinois State Plumbing Code. National Electrical Code, (updated every 2 years). National Electrical Manufacturers Association Standards (NEMMA). Underwriter Laboratories Directories. National Fire Codes (NFPA). Fire Protection Handbook (NFPA). Thomas Register for products and services availability, company profiles, and specifications & product information. Engineering Manuals. Vendors and Suppliers Catalogs. Computer Software. Other Reference Books.

4.

Safety Questions may be researched upon your request, please see the Contracts Manager.

C.

Safety Program Flow Sheet

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END OF SECTION

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