1 Title: Elevated Walking/Working Surfaces (Fall Protection) Site Function: Safety Procedure No.: MC Page: 1 of 16 McIntosh Site Reviewed: 02/2013 Effective: 03/2013 Supersedes: 08/2012 Preparer: B. Turner Owner: M. Ware Approver: T. McAdams EHS Specialist EHS Team Leader Site Manager 1. PURPOSE To establish minimal work practices and requirements which protect workers from falls and other related hazards associated with elevated work, for the BASF McIntosh site personnel, Contractor Employees and Contracted Employees. 2. DEFINITIONS 2.1. Aerial Lift A power platform or a vehicle mounted work platform used to elevate personnel to above ground work locations. This includes articulating boom platforms, vertical towers, and extensible boom platforms Anchorage Point A secure point of attachment for Lifelines, lanyards or deceleration devices Body Harness A fall restraint device component consisting of a harness system designed to spread shock load over the shoulders, thighs and seat area Competent Person One who is capable of identifying existing and predictable hazards in the surroundings or work conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them Fall Protection System A system used to protect personnel from fall hazards. Such systems may include Guardrail Systems, Safety Net Systems, Personal Fall Arrest Systems, Warning Line Systems, Safety Monitoring Systems or covers Guardrail System A barrier erected to prevent personnel from falling to lower levels Floor Openings An opening measuring 12 inches or more in its least dimension, in any floor, platform, pavement, or yard through which a person may fall Floor Hole An opening measuring less than 12 inches but more than 1 inch in its least dimension, in any floor, platform, pavement, or yard through which materials but not persons may fall Lanyard A flexible line or rope, wire rope, or strap which generally has a connector at each end for connecting the Body Harness to a deceleration device, Lifeline, or anchorage.
2 Procedure No.: MC Page: 2 of Leading Edge The edge of a floor, roof or form work for a floor or other walking/working surface, (such as a deck) which changes location as additional floor, roof, decking or form work sections are placed, formed or constructed. A Leading Edge is considered to be an "unprotected side and edge" during periods when it is not actively and continuously under construction Lifeline A component consisting of a flexible line for connection to an anchorage at one end to hang vertically (vertical Lifeline), or for connection to anchorages at both ends to stretch horizontally (horizontal Lifeline), and which serves as a means for connecting other components of a Personal Fall Arrest System to the anchorage Low Pitched Roof A roof having a slope less than or equal to a 4 in 12 vertical to horizontal Lower Level Those areas or surfaces to which an employee can fall. Such areas include but or not limited to ground levels, floors, platforms, ramps, runways, tanks, equipment, or structures Mechanical Equipment All motor or human propelled wheeled equipment used for roof work, except wheelbarrows or mop carts Personal Fall Arrest System A system used to arrest personnel in a fall from a working level. It consists of an anchorage, connectors, a Body Harness, and may include a Lanyard, deceleration device, Lifeline, or suitable combinations of these Qualified person A person who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, successfully demonstrated the ability to solve/resolve problems relating to the subject matter, the work, or the project. For the purposes of this standard, a Qualified Person is a licensed professional (civil and or structural) engineer in the state of Alabama Safety Net System A net placed below workers to catch them in the event a worker falls Safety Monitoring System A safety system in which a Competent Person is responsible for recognizing and warning personnel of fall hazards. The Competent Person shall: Be competent in the recognition of fall hazards. Be capable of warning workers of fall hazard dangers and in detecting unsafe work practices. Be on the same walking/working surface and in visual sighting distance of the employees being monitored. Be close enough to work operations to communicate orally with workers and has no other duties to distract from monitoring function.
3 Procedure No.: MC Page: 3 of Steep Roof A roof having a slope greater than 4 in 12 vertical to horizontal Suspension Trauma Also known as harness hang syndrome (HHS), is an effect which occurs when the human body is held upright without any movement for a period of time. If the person is strapped into a harness or tied to an upright object they could eventually faint and could lead to a fatality Unprotected Sides and Edges Any side or edge (except at entrances to points of access) of a walking/working surface, e.g., floor, roof, ramp, or runway where there is no wall or Guardrail System at least 39 inches (1.0 m) high Warning Line System A barrier (wire, rope or chain and supporting stanchions) erected on a roof to warn employees that they are approaching an unprotected roof side or edge, and which designates an area in which the roof work may take place without the use of guardrails, Body Harness, or Safety Net systems to protect employees in the area Walking/Working Surfaces Any surface, whether horizontal or vertical, on which a person walks or works, including but not limited to floors, grating, roofs, ramps, bridges, runways, formwork, and concrete reinforcing steel, but does not include fixed ladders, vehicles, or trailers on which personnel must be located to perform their work duties. NOTE: When using stairs, steps, ladders, etc. the 3 points of contact rule should always be followed. Never attempt to climb stairs, ladders or other elevated areas with this 3 point rule compromised. 3. SCOPE This procedure applies to BASF s McIntosh Site. Exceptions: Truck drivers accessing the top of their trailers for inspection / verification purposes only, per DOT requirements, are exempt from the fall protection requirements of this standard. 4. PROCEDURE 4.1. Fall Hazard Assessment All elevated work activities need to be assessed for potential fall hazards. The assessment should include, but is not limited to, whether the elevated working surfaces (ladder, roof, scaffold, etc.) pose a fall hazard and the need for Personal Fall Arrest Systems and anchorage to ensure the worker does not fall and contact the ground or lower obstructions. Sites and/or units are responsible to include the fall hazard assessments in their hazard assessment evaluation or on the Safe Work Permit.
4 Procedure No.: MC Page: 4 of Personal Fall Arrest Systems A Personal Fall Arrest System with continuous attachment shall be used by personnel in work areas that are not protected by Guardrail Systems where there is a danger of falling a distance of 6 feet (1.8 m) or greater. Personal Fall Arrest Systems including Body Harnesses, Lanyards, and associated equipment, must be selected to meet the requirements of 29 CFR Body Harness and Lanyard The primary Personal Fall Arrest System shall be a Body Harness with a shock absorbing Y-lanyard. When a shock absorbing Y-Lanyard is not used, 2 single Lanyards with built-in shock absorbers may be used. When 2 single Lanyards are used, do not secure both Lanyards at the same time except for the time it takes to unhook one Lanyard and attach the other. Lanyards shall be equipped with self-closing and self-locking snap hooks. The Lanyard Anchorage Point must be such that personnel can neither free fall more than 6 feet (1.8 m) or contact any lower level. If a Lanyard may come in contact with hot surfaces, an insulated cover shall be placed on the Lanyard or on the hot surface for protection. When vertical Lifelines are used, each person shall be provided with a separate Lifeline. Attaching Lanyards to sharp edges is prohibited. Before an insulated process line is used as an anchor point, it must be approved by the owner of the insulated line and meet the tie off requirements of attachment A. Unless specifically designed and approved by the manufacturer for such use, a Lanyard shall not be tied back into itself. Writing or marking on Lanyard and Body Harness webbing is prohibited. Lanyards and harnesses shall be of the same manufacturer Anchorage Points Anchorage points used for attachment of personal fall arrest equipment shall be designed and or approved by a Qualified Person. The anchorage shall be capable of supporting 5,000 pounds per worker attached or shall be designed, installed and used as part of a complete Personal Fall Arrest System which maintains a safety factor of at least two, under the supervision of a Qualified Person. Conduit, cable trays, grating, and handrails shall not be used as anchoring points.
5 Procedure No.: MC Page: 5 of Impact Loads Personal Fall Arrest Systems and components subjected to impact loading shall be immediately removed from service and shall not be used again until inspected by a Qualified Person and determined to be undamaged and suitable for reuse. Full Body Harness and Lanyards may not be placed back in service regardless of inspection Suspension Trauma Preventing Suspension Trauma should be part of the elevated work assessment and plans should be in place to ensure prompt rescue when Suspension Trauma straps or similar accessories are not attached to the Body Harness. Note: Safety Step Suspension Straps or Relief Step Devices maybe purchased via the safety supply store Inspections of Personal Fall Arrest Systems Prior to Use Personal Fall Arrest Systems shall be inspected by the user prior to each use for wear, damage and other deterioration. Systems shall be inspected by the user for defects such as cuts, burns, excessive wear, loose splices, defective hardware and distorted thimbles Roof Work Formal Inspections and Documentation Personal Fall Arrest Systems shall be inspected by a Competent Person and documented periodically in accordance with manufacturer s recommendations and or not to exceed an annual frequency. Competent Person can be in-house, trained personnel or can be 3 rd party. Details into the formal inspection program should be in compliance with the manufacturer s recommendations. Removal from Service Defective components shall be immediately removed from service. Personal Fall Arrest Systems and components subject to a fall shall be immediately removed from service. o Body Harnesses and Lanyards shall be removed from service and destroyed. o Retrieval devices and other components that are reusable shall be certified by a qualified manufacturing representative before placing back in service Steep Roof Work Each employee on a steep roof with unprotected sides and edges 6 feet (1.8 m) or more above lower levels shall be protected from falling by Guardrail Systems with toe boards, Safety Net systems, or Personal Fall Arrest Systems.
6 Procedure No.: MC Page: 6 of Low-pitched and Flat Roof Work Personnel engaged in roofing work on a low-pitched roof with Unprotected Sides and Edges 6 feet (1.8 m) or more above lower levels shall be protected from falling by any of the following: Guardrail System with toe boards, Safety Net systems, Personal Fall Arrest Systems, Combination of Warning Line System and Guardrail Systems, Warning Line System and Safety Net system, Warning Line System and Personal Fall Arrest System, or Warning Line System and Safety Monitoring System. Or, on flat roofs 50 ft. (15.2 m) or less in width, the use of a Safety Monitoring System without a Warning Line System is permitted. Exception: Employees engaged in servicing and maintenance of roof mounted equipment may do so without fall protection provided the following: o The roof is flat, and o Walkways and equipment being serviced are 6 feet (1.8 m) or more from the roof edge, and o Employees are trained and instructed to stay within the clearly marked walkway Leading Edge Work Employees working on the same level where Leading Edge work is taking place, whether engaged in the Leading Edge work or not, must be protected by a Guardrail System, Safety Net system or Personal Fall Arrest System Roof Skylights Skylights shall be guarded by a standard skylight screen or a fixed standard railing on all exposed sides Warning Line System When used must be erected around all sides of the roof work area. The wire, rope or chain shall be rigged and supported in such a way that its lowest point (including sag) is not less than 34 inches (.9 m) from the walking working surface and its highest point no more than 39 inches (1.0 m)from the walking working surface. The warning line stanchion supports must be able to withstand at least 16 pounds of force, 30 inches (.76 m) above the roof surface without tipping. Minimal tensile strength of the rope, wire or chain must be 500 pounds after being attached to the stanchion. The line shall be attached at each stanchion in such a way that pulling on one section of the line between stanchions will not result in slack being taken up in adjacent sections before the stanchion tips over. If Mechanical Equipment is not being used, the warning line must not be less than 6 feet (1.8 m) from the roof edge.
7 Procedure No.: MC Page: 7 of 13 If Mechanical Equipment is being used, the warning line must not be less than 6 feet (1.8 m) from the roof edge which is parallel to the direction of Mechanical Equipment operation and no less than 10 feet (3.1 m) from the roof edge which is perpendicular to the direction of the Mechanical Equipment operation Safety Nets If Safety Nets are used, manufacturer s recommendations (i.e. installation, maintenance, inspection requirements, etc.) shall be followed and the manufacturer s written recommendations must be kept at the job site and made available for review upon request. In addition the requirements of (c) must be followed Working from Portable Ladders Work from portable ladders shall be assessed to identify and eliminate fall hazards. If the Portable Ladder cannot be repositioned to stay within 1 ft. (0.3 M) of the side rails, other working surfaces such as a platform ladder, scaffold, etc. should be considered to eliminate the fall potential. NOTE: For safe use of portable ladder requirements reference BC , Portable Ladders Working from Scaffolds Personnel accessing incomplete scaffolds (missing or inadequate mid rails and/or top rails or Floor Openings in the scaffold deck) are required to use appropriate Personal Fall Arrest Systems while working on the scaffold deck. Note: Scaffolds may be used as an Anchorage Point only if the scaffold provider has documentation showing that the scaffold meets the requirements of an Anchorage Point Steel Erection Employees engaged in steel erection activities shall comply with the requirements of this procedure except that when compliance with the maximum 6-foot free-fall distance is not practicable. In such cases, appropriate engineering and administrative controls and/or Personal Fall Arrest Systems shall be utilized as necessary to limit the free-fall distance to as close to 6 feet (1.8 m) as possible. Additional requirements relating to steel erection are found in 29 CFR 1926 Subpart R- Steel Erection Rig Hoisted Personnel Platforms Rig hoisted personnel platform use is permissible when other elevated working surfaces would be more hazardous or is not possible because of structural design or worksite conditions. When use is allowed, the platform and lift shall comply with 29 CFR Hoisting Personnel and with McIntosh Procedure MC Aerial Lifts Personnel occupying aerial lifts are required to wear a Body Harness and be anchored to the designated anchor point in the basket at all times. If an aerial lift is not equipment with a manufactured Anchorage Point, appropriate measures shall be taken with the manufacturer to have one installed before using the aerial lift.
8 Procedure No.: MC Page: 8 of 13 Anchoring to an adjacent pole, structure or equipment while working from an aerial lift shall is prohibited. The anchor point shall be in a location in the basket that will not allow the occupant to be thrown out of the basket. Personnel working in aerial lifts shall not stand on the rails of the basket Covering for Floor Holes, roofs and other elevated walking/working surfaces Holes in floors, roofs and other Walking/Working Surfaces shall be covered to provide personnel protection. Covers shall be capable of supporting, without failure, the weight of the employee, equipment and materials that may be imposed on the cover at any one time. Covers shall be secured when installed to prevent accidental displacement. All covers, except cast iron manhole covers or steel grates used on streets or roadways, must be marked with the word "HOLE" or "COVER" to provide warning of the hazard Maintenance and Repair of Elevated Walking/Working Surfaces The employer shall ensure through regular and periodic inspections and maintenance that Walking/Working surfaces are in a safe condition for employee use. All hazardous conditions shall be corrected, repaired or guarded to prevent employee exposure until repairs are made. Guarding may be in the form of an adequate cover or Guardrail System capable of withstanding a force of 200 lb (909.7 kg) applied within 2 inches (5 cm) of the top edge. Where the structural integrity of the Walking Working Surface is compromised, a Qualified Person must perform or supervise the maintenance or repair of that surface. When removing grating and creating a Floor Opening with a potential to fall 6 feet (1.8m) or greater, workers shall be protected from falling through the opening. Temporary Floor Openings shall have standard railing or shall be constantly attended by someone. Grating shall not be walked on until it has been fastened in place. If the Floor Opening is 4 feet (1.2m) or greater and remains open, it shall be barricaded with adequate guardrails.
9 Procedure No.: MC Page: 9 of Protection from Falling objects During roof work, materials and equipment shall not be stored within 6 feet (1.8m) of the roof edge unless barriers are erected at the edge, and materials piled or stacked near the edge must be stable and self-supporting. Erect toe boards, screens or Guardrail Systems to prevent objects from falling through Floor Holes or off the working surface from higher levels. When toe boards are used as protection from falling objects, they must be erected along the edges of the overhead walking or working surface for a distance sufficient to protect persons working below. When tools, equipment or materials are piled higher than the top edge of a toe board, paneling or screening must be erected from the scaffold deck or toe board to the top of a Guardrail System s top rail or mid rail, for a distance sufficient to protect personnel below. Barricading at the ground level shall be erected to prevent personnel from walking or working under elevated work areas. Barricading may include barricade tape with warning tags, orange mesh fencing, or any other type material capable of keeping personnel away from elevated work areas Training All BASF McIntosh personnel, Contract Employees and Contractor employees who might be exposed to fall hazards shall be trained such that each of these employees will be able to recognize the hazards of falling and the procedures to be followed to minimize these hazards. Contractor training is the responsibility of the contract company Training shall include as necessary: The requirements of this standard; Types of fall hazards in the workplace. The correct procedures for erecting, maintaining, disassembling, and inspecting the Fall Protection Systems to be used; The use and operation of Guardrail Systems, Personal Fall Arrest Systems, Safety Net systems (when applicable), Warning Line Systems, Safety Monitoring Systems, Controlled Access Zones, and any other protection which may be used; The role of each employee in the safety monitoring system when this system is used; The limitations on the use of Mechanical Equipment during the performance of roofing work on Low Pitched roofs; The correct procedures for the handling and storage of equipment and materials and the erection of overhead protection; and The role of employees in fall protection plans Retraining must be conducted when: There is reason to believe that any affected employee who has already been trained does not have the understanding and skill required to be able to
10 Procedure No.: MC Page: 10 of RESPONSIBILITIES recognize fall hazards and the procedures to be followed to minimize these hazards. Changes in the workplace or types of Fall Protection Systems/equipment that make previous training obsolete McIntosh Site Manager / Vice President The McIntosh Site Manager or Business Supervisor of each facility has the primary responsibility for the implementation of this procedure McIntosh Site Environmental, Health and Safety (EHS) Team Leader The EHS has the primary responsibility for the initiation, re-issuance, administration, and/or interpretation of this procedure. 6. RELATED DOCUMENTS 29 CFR Guarding floor and wall openings and holes 29 CFR 1926 Subpart M, Fall Protection standard 29 CFR 1910 Subpart D, Walking and Working Surfaces 29 CFR 1910 Subpart F, Powered Platforms, Manlifts, Vehicle mounted platforms 29 CFR , Duty for Fall Protection 29 CFR , Fall Protection Systems criteria and practices 29 CFR , Training Requirements ANSI Z Safety Requirements for Personal Fall Arrest Systems, Subsystems and Components
11 Procedure No.: MC Page: 11 of 13 ATTACHMENT A Typical tie-off attachments for one worker MAXIMUM ALLOWABLE SPANS FOR BEAMS USED AS FALL PROTECTION BEAMS Depth MAXIMUM DEPTH WIDTH ALLOWABLE SPAN (in) (in) (ft) Width CHANNELS Depth DEPTH (in.) MAXIMUM ALLOWABLE SPAN (ft)
12 Procedure No.: MC Page: 12 of 13 TEES Depth Width MAXIMUM DEPTH WIDTH ALLOWABLE SPAN (in) (in) (ft) BEAM TABLES ARE BASED ON THE FOLLOWING: 1. Personnel use shock-absorbing Lanyards (meeting ANSI Z359.1) which limit the load distributed to the Body Harness to 900 lbs. 2. One worker is tied to a beam within a given span at any time. 3. Table is not for Lifeline (cable) anchorage. 4. Spans > 20 ft. shall not be approved by a Qualified Person. IF ANY OF THE ABOVE CONDITIONS CANNOT BE MET, ALTERNATIVE ANCHORAGE POINTS AND FALL PROTECTION SYSTEMS MUST BE APPROVED BY A QUALIFIED PERSON. MAXIMUM ALLOWABLE SPANS FOR PIPES USED AS FALL PROTECTION PIPES NOMINAL PIPE DIAMETER (in) MAXIMUM ALLOWABLE SPAN (ft) Nominal Pipe Diameter < 3 not allowed PIPE TABLE IS BASED ON THE FOLLOWING: 1. Personnel use shock-absorbing Lanyards (meeting ANSI Z359.1) which limit the load distributed to the Body Harness to 900 lbs. 2. One worker is tied to a pipe within a given span at any time. 3. Carbon steel pipes. 4. Continuously welded pipe i.e. no flanges or fittings within the tie-off span. 5. Nominal pipe diameter based on un-insulated lines. 6. Table is not for Lifeline (cable) anchorage. 7. Spans > 20 ft. shall not be approved by a Qualified Person. IF ANY OF THE ABOVE CONDITIONS CANNOT BE MET, ALTERNATIVE ANCHORAGE POINTS AND FALL PROTECTION SYSTEMS MUST BE APPROVED BY A QUALIFIED PERSON.
13 Procedure No.: MC Page: 13 of 13 Required Clearance Illustration
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WSH Regulations and Case Studies WSH Forum for Pest Management 20 Feb 14 Mr. Teo Han Ping Head, Programme Management, Occupational Safety & Health Division, Ministry of Manpower A Great Workforce A Great
Fall protection for the real world The Protecta Product Range Anchorages Anchor Straps/Round Straps Anchor Strap with Interlocking Rings (rated to 22kN): AM500/100AU - 1.0m AM500/150AU - 1.5m Webbing Round
Personal commitments you can live and work by: I anticipate possible dangers in any given operation and make every effort to analyze and avoid them before starting work, including immediately communicating