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315 West Fourth StreetDavenport, Iowa 52801

(563) 323-62451-800-MANCOMM

(626-2666)Fax: (563) 323-0804

Website: http://www.mancomm.comE-mail: safetyinfo@mancomm.com

Copyright © MCMXCVIII - MMXI

by

All rights reserved. Printed in the U.S.A. This publication is intended for instructional and educational use only. This book is meant to provide a formatted and easy to understand tool for the reader to train and be trained pursuant to OSHA requirements for 10 and 30 hour Construction safety training. While these volumes meet and exceed the OSHA guidelines, please note that they are not an exhaustive overview of every OSHA topic or regulation. It does not alter or determine compliance responsibilities in Title 29, Code of Federal Regulations Parts 1903, 1904, 1910 and 1926 or the Occupational Safety and Health Act of 1970. Except as permitted under applicable law, no part of this publication may, by the person to whom it is first provided or by any other person(s), be repro-duced or distributed in any form or by any means, or stored in any database or other retrieval system, without the prior written permission of the publisher.

This publication is provided as training information in connection with a training course. Although the Federal Regulations published as promulgat-ed are in the public domain, their formatting and sequencing, and other materials contained herein, are subject to copyright law. While best efforts have been made in order to ensure that the information contained herein is as accurate and as complete as possible at the time of printing, the fre-quency of changes to the regulations makes it impossible to guarantee the completeness and accuracy of the following information. Therefore MAN-COMM and its subsidiaries shall under no circumstances be liable for any damages resulting from the use of or reliance upon this publication. In no event does MANCOMM or its subsidiaries express or imply any warranties or assume any liabilities whatsoever arising out of the use or inability to use this material. Furthermore, the mention or appearance of any products, services, companies, organizations, or individuals in no way implies endorsement or denouncement of same by MANCOMM or any of its subsidiaries. This publication is constructed in order to provide accurate in-formation in regard to the material included. It is made with the understanding that the publisher is not involved in providing any accounting, le-gal, or other professional service(s). If legal consultation or other expert advice is required, the services of a professional person should be engaged.

Library of Congress Control Number: 2011934633ISBN: 1-59959-284-3

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Table of ContentsModule Twenty - Steel Erection

Controlling Contractor ...................................................................................................... 2Site Layout ....................................................................................................................... 2Hoisting and Rigging ........................................................................................................ 3Structural Steel Assembly ................................................................................................ 3Column Anchorage........................................................................................................... 4Beams and Columns ........................................................................................................ 4Systems-Engineered Metal Buildings .............................................................................. 5Falling Object Protection .................................................................................................. 5Fall Protection .................................................................................................................. 6Training ............................................................................................................................ 8

Module Twenty-One - Welding and Cutting

Gas Welding and Cutting ............................................................................................... 10Arc Welding .................................................................................................................... 12Fire Prevention ............................................................................................................... 13Welding Accident ............................................................................................................ 14Preservative Coatings .................................................................................................... 14Ventilation....................................................................................................................... 15Personal Protective Equipment ...................................................................................... 16

Module Twenty-Two - Motor Vehicles

Equipment ...................................................................................................................... 18Motor Vehicles on the Worksite ...................................................................................... 18Roadside Construction Safety........................................................................................ 20Flaggers ......................................................................................................................... 24

Module Twenty-Three - Powered Industrial TrucksPowered Industrial Trucks .............................................................................................. 26Fueling and Recharging Operations .............................................................................. 27Trucks and Railroad Cars .............................................................................................. 28Operator Training ........................................................................................................... 29

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Operating Forklifts Safely ............................................................................................... 30Powered Industrial Truck Maintenance .......................................................................... 31

Module Twenty-Four - DOT Placarding

DOT Markings, Placards, and Labels ............................................................................ 34 Module Twenty-Five - Electrical

How Does Electricity Work? ........................................................................................... 36General Requirements ................................................................................................... 36Wiring Design and Protection......................................................................................... 38Grounding connections .................................................................................................. 39Wiring Methods, Components, and Equipment.............................................................. 40Temporary Lighting......................................................................................................... 43GFCI Outlets .................................................................................................................. 44Hazardous (Classified) Locations .................................................................................. 44Safety-Related Work Practices ...................................................................................... 45Arc Flash ........................................................................................................................ 47Use of Flexible Cords and Cables.................................................................................. 49

Module Twenty-Six - Lockout/Tagout

Lockout/Tagout General Information .............................................................................. 54Training .......................................................................................................................... 57General Lockout/Tagout Suggested Procedures ........................................................... 58Special Requirements .................................................................................................... 62Outside Personnel (Contractors).................................................................................... 63

Module Twenty-Seven - Signs / Tags

Classification of Signs .................................................................................................... 66Accident Prevention Tags ............................................................................................... 67

Module Twenty-Eight - HazCom 2

Hazard Communications ................................................................................................ 70HazCom Program .......................................................................................................... 71Identify Responsible Staff .............................................................................................. 71Develop a List of Hazardous Chemicals ........................................................................ 72List of Hazardous Chemicals Workshop ........................................................................ 72Material Safety Data Sheets Procedures ...................................................................... 72Identify Chemical Hazards Workshop ............................................................................ 73Labeling Procedures ...................................................................................................... 74Container Labeling Workshop ........................................................................................ 74Employee Training Requirements .................................................................................. 75

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Module Twenty-Nine - Hazardous Waste Operations and Emergency Response (HAZWOPER)HAZWOPER .................................................................................................................. 78Emergency Response .................................................................................................... 78

Module Thirty - Ergonomics

Ergonomics and the General Duty Clause ..................................................................... 81Musculoskeletal Disorders (MSDs) ................................................................................ 83Conclusion ..................................................................................................................... 84

Module Thirty-One - Safety and Health Programs

General Guidelines ........................................................................................................ 85Design Standards........................................................................................................... 86Performance Standards ................................................................................................. 86Major Elements .............................................................................................................. 87Recommended Actions .................................................................................................. 88Safety & Health Program Checklist ................................................................................ 90

Module Thirty-Two - Assesing Safety and Health Programs

Introduction .................................................................................................................... 91Conclusion ................................................................................................................... 100

Module Thirty-Three - Industrial Hygiene

Industrial Hygiene ........................................................................................................ 101Worksite Analysis ......................................................................................................... 102

Module Thirty-Four - Recordkeeping

Reporting...................................................................................................................... 108Recordkeeping ............................................................................................................. 108Step 1: Are You Required to Maintain a 300 Log? ....................................................... 109Step 2: Is This Person Recordable? .............................................................................110Step 3: Is This Case Work-Related? .............................................................................110Step 4: Is This a New Case? .........................................................................................112Step 5: Is This Case Recordable? ................................................................................112Step 7: How to Update This Case (When Required) ....................................................118Step 8: How to Complete, Display, and Retain Records ...............................................118Employee Involvement ..................................................................................................119

Module Thirty-Five - Medical Records

Medical and Exposure Records .................................................................................. 122Preservation of Records............................................................................................... 124Access to Records ....................................................................................................... 125

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Module Thirty-Six - Inspections, Citations, and PenaltiesReasons for Inspections............................................................................................... 128Employer Rights ........................................................................................................... 128Inspection Preparation ................................................................................................. 128The Inspection ............................................................................................................. 130If Citations Are Issued .................................................................................................. 132Appeal Process ............................................................................................................ 132Compliance Duties Owed to Each Worker ................................................................... 133

Module Thirty-Seven - Bloodborne Pathogens

Bloodborne Pathogens................................................................................................. 136Exposure Control Plan ................................................................................................. 137Engineering and Work Practice Controls ..................................................................... 137Personal Protective Equipment .................................................................................... 138Housekeeping .............................................................................................................. 138Hepatitis B Vaccination ................................................................................................ 139Exposure Incident ........................................................................................................ 139Communicate Hazards to Employees .......................................................................... 140Records ........................................................................................................................ 141

Module Thirty-Eight - Open Forum .................................................................................. 143 Photography Credits ......................................................................................................... 145 Index ................................................................................................................................. 147

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Steel Erection

1

Module Twenty

Steel Erection

§1926.750

.752(a); .755(b)(2); .759(b); .760(e)

§1926.754(e)(3)(iii); .760(c)(3)

§1926.752(a), (b), (d); .755(b)(2); Subpart R Appendix G (c)(4)(ii)

§1926.753(d)(1)(iv); .760(b)(2); .760(c)(4);

.761

Scope

Management Controls

Alerts (postings, signs, markings)

Records and Procedures

Training

Steel Erection

Subpart R

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Controlling Contractor

The Controlling Contractor is a prime contractor, general contractor, construction manager, or any other legal entity which has the overall responsibility for the construction of the project —its planning, quality, and completion.

Site Layout

The Controlling Contractor must make sure that the following are provided and maintained:

› Adequate access roads into and through the site for the safe delivery and movement of derricks, cranes, trucks, other necessary equipment, and the material to be erected and means and methods for pedestrian and vehicular control. Exception: This requirement does not apply to roads outside of the construction site.

› A firm, properly graded, drained area, readily accessible to the work with adequate space for the safe storage of materials and the safe operation of the erector's equipment.

Before steel erection may begin, the Controlling Contractor must provide the steel erector with written notification that:

› The concrete in the footings, piers, and walls has sufficient strength to support the loads imposed during steel erection.

› The mortar in the masonry piers has sufficient strength to support the loads imposed during steel erection.

› Any repairs or modifications to anchor bolts were properly conducted.

§1926.751

§1926.752(c)

§1926.752(a)

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Steel Erection

3

Hoisting and Rigging

Cranes

All safety precautions regarding cranes, such as inspections and operations, must be followed when using cranes in steel erection.

Multiple Lifts (aka Christmas Treeing)

Multiple lifts are only allowed: › According to manufacturer’s instructions. › If a multiple lift rigging assembly is used. › A maximum of five members per lift. › To lift beams and other structural members. › If all employees involved in the lift have been trained to do so.

Structural Steel AssemblyStructural stability must be maintained at all times.

Shear connectors

Shear connectors must not be attached so that they stick up from the top flanges of beams, joists, or beam attachments until after the metal decking (or other walking/working surface) has been installed.

Shear connectors may not be installed from within a controlled decking zone.

§1926.753(c), (e)

§1926.754(a)

§1926.754(c)(1)-(2)

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Column Anchorage

All columns must be anchored by a minimum of four anchor rods/bolts.

Anchorage must be designed to resist a minimum eccentric gravity load on the column of 300 pounds.

Columns must be evaluated by a competent person to determine whether they need to be guyed or braced.

Repair, replacement, or field modification to anchor rods: › Must not happen without the approval of the project structural engineer.

› The Controlling Contractor must provide written notification to the steel erector of adequacy of anchor bolts modified/repaired in the field.

Beams and Columns

During the final placing of solid web structural members, the load must not be released from the hoisting line until the members are secured with at least two bolts, per connection, of the same size and strength as shown in the construction documents.

The bolts must be drawn up wrench-tight or secured by an equivalent connection as specified by the project structural engineer of record.

Double Connections

When making a double connection at or near a column, the first member must remain connected to a supporting member by at least one connection bolt at all times unless a connection seat or equivalent connection device is supplied with the members to secure the first member.

§1926.755

§1926.756(a)

§1926.756(c)(1)

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Steel Erection

5

Open Web Steel Joists

Minimize the risk of collapse of lightweight steel joists by:

› Specifying erection bridging and method of attachment.

› Requiring erection bridging to be anchored to terminus point.

› Specifying method of placing loads on steel joists.

Systems-Engineered Metal BuildingsEach structural column shall be anchored by at least four anchor rods/anchor bolts.

Rigid frames shall have 50 percent of their bolts or the number of bolts specified by the manufacturer (whichever is greater) installed and tightened on both sides of the web adjacent to each flange before the hoisting equipment is released.

Construction loads must not be placed on any structural steel framework unless such framework is safely bolted, welded, or otherwise adequately secured.

Falling Object Protection

Struck-by Hazard

All materials, equipment, and tools that are not in use while aloft shall be secured against accidental displacement.

The Controlling Contractor shall bar other construction processes below steel erection unless overhead protection for the employees below is provided.

§1926.758

§1926.759

§1926.757

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AArc Flash 47Arc Welding

Grounding 12Training 12

Assessing Safety and Health Programs 91Documentation 92Employee Interviews 92Site Conditions and Root Causes of Hazards 93

BBeams and Columns 4Bloodborne Pathogens 135

Communicate Hazards to Employees 140Definition 136Engineering and Work Practice Controls 137Exposure Control Plan 137Exposure Incident 139Hepatitis B 136Housekeeping 138Personal Protective Equipment 138Records 141

DDOT Placarding 33

EElectrical 35

Approach Distances 46Arc Flash 47Extension Cords 50Flexible Cords and Cables 49

General Requirements 36GFCI Outlets 44Hazardous (Classified) Locations 44Power Strips 51Switchboards and panelboards 41Switches 41Temporary Lighting 43Wiring Design and Protection 38

Employer Rights 128Ergonomics 81

General Duty Clause 81Musculoskeletal Disorders (MSD) 83Solutions 84

Extension Cords 50

FFlexible Cords and Cables 49

Splices 50

GGFCI Outlets 44

HHazard Communications (HazCom) 69

Employee Training Requirements 75Labeling Procedures 74List of Hazardous Chemicals Workshop 72Material Safety Data Sheets Procedures 72Program 71"Right to Know" 70

Hazardous Waste Operations and Emergency Response (HAZWOPER) 77Emergency Response 78

Documentation 79Emergency Responders 78Plan 78Refresher Training 79

Index

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IIndustrial Hygiene 101

Worksite Analysis 102Air Contaminants 103Biological Hazards 103Chemical Hazards 103Ergonomic Hazards 104Physical Hazards 104

Inspections, Citations, and Penalties 127Appeal Process 132

Citation appeal procedures 133Notice of Contest 132Review Commission 133

Complaints/referrals 128Employer Rights 128Fatality/catastrophe 128If Citations are Issued 132

post citation 132Imminent danger 128Inspection Procedures 129Programmed inspections 128The Inspection 130

Closing Conference 131Opening Conference 130Walkthrough Inspection 131

Violations and Penalties 133

LLockout/Tagout 53

Electrical written program 55General Requirements 54Special Requirements 63Stored Energy 60Training 57

MMedical Records 121

Access to Records 125Definitions 123Preservation of Records 124Purpose 122Scope 122

Motor Vehicles 17Equipment 18General Requirements 18

Brakes 18Lights 18

Roadside Construction Safety 20

PPowered Industrial Trucks 25

Fueling and Recharging Operations 27Changing and charging storage batteries 27Eye/Face Wash and Shower Units 28Fuel handling and storage 27

Maintenance 31Modifications and Attachments 26Operating Forklifts Safely 30

Traveling with Trucks 30Truck operations 30

Operator Training 29Certification 29Refresher training 29Training 29

Safety guards 27Trucks and Railroad Cars 28

RRecordkeeping 108Recordkeeping and Reporting 107

Employee Involvement 119Quick Start Guide

STEP 1: Are you Required to Maintain a 300 Log? 109

Step 2: Is this Person Recordable? 110Step 3: Is this Case Work-Related? 110Step 4: Is this a New Case? 112Step 5: Is this Case Recordable? 112Step 7: How to Update this Case (When

Required) 118Step 8: How to Complete, Display, and Retain

Records 118Recordkeeping 108Reporting 108

Reporting 108Roadside Construction Safety 20

SSafety and Health Program 85

Design Standards 86General Guidelines 85Major Elements 87

Employee involvement 87Hazard prevention and control 87Management commitment 87Safety and health training 87Worksite analysis 87

Performance Standards 86Recommended Actions 88Safety & Health Program Checklist 90

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Signs / Tags 65Accident Prevention Tags 67Classification of Signs 66

Steel Erection 1Beams and Columns 4Column Anchorage 4Controlling Contractor 2Hoisting and Rigging 3Open Web Steel Joists 5Site Layout 2Structural Steel Assembly 3Systems-Engineered Metal Buildings 5

Stored Energy 60

TTraining

Arc Welding 12Lockout/Tagout 57

VViolations and Penalties 133

WWelding and Cutting 9

Arc WeldingGrounding 12Training 12

Gas Welding and Cutting 10Cylinders 10

Personal Protective Equipment 16Preservative Coatings 14Ventilation 15

Working Clearances 37