CFR 1926.450 - SUBPART L SCAFFOLDS CFR 1926.450 - SUBPART L SCAFFOLDS.
Subpart N 1910.178 Powered Industrial Truckswiagribusiness.org/safety/PIV_Bauer.pdf · Subpart N...
Transcript of Subpart N 1910.178 Powered Industrial Truckswiagribusiness.org/safety/PIV_Bauer.pdf · Subpart N...
7/1/2015
1
1
Subpart N 1910.178 Powered Industrial Trucks
Mary Bauer CIH, CSP Compliance Assistance Specialist
Eau Claire, WI 54701
715-832-9019
WABA
July 15, 2015
Wisconsin Dells, WI
MY BACKGROUND
Mary Bauer
30 years w/ OSHA
IH/ Safety
CIH: Certified Industrial Hygienist
CSP: Certified Safety Professional
1000 + Inspections
NUMBER OF SERIOUS VIOLATIONS – FY 2014
29
CFR
19
10
SU
BPA
RTS
MATERIALS HANDLING & STORAGE [1910.176 – 184]
3
SUB
PAR
T N
257
305
339
418
590
178(q)(7)
178(p)(1)
178(l)(6)
178(l)(4)(iii)
178(l)(1)(i)POWERED INDUSTRIAL TRUCKS – COMPETENCY TRAINING
POWERED INDUSTRIAL TRUCKS – REFRESHER TRAINING IN RELEVANT TOPICS
POWERED INDUSTRIAL TRUCKS – CERTIFICATION OF TRAINING
POWERED INDUSTRIAL TRUCKS – SAFE OPERATING CONDITION
POWERED INDUSTRIAL TRUCKS – EXAMINATION FOR DEFECTS
7/1/2015
2
4
Definition - Powered Industrial Truck
American Society of Mechanical Engineers
(ASME B56.1 Formerly ANSI B56.1 standard)
“Mobile, powered truck used to carry, push, pull, lift, stack, or
tier material”
WHAT IS NOT A CRANE (NOT INCLUDED IN
THE CONSTRUCTION CRANE STANDARD)?
Tow trucks*
Vehicle mounted
work platforms
Self-propelled
elevating work
platforms
Stacker cranes
5
FORKLIFTS ARE NOT CRANES OR JACKS!
7/1/2015
3
8
Class I - Electric Motor Rider Trucks
9
Class I - Electric Motor Rider Trucks
• Counterbalanced
Rider Type, Stand-Up
7/1/2015
4
10
Class III - Electric Motor Hand or Hand/Rider Trucks
• Low lift platform
• Low lift walkie pallet
• Reach type outrigger
• High lift straddle
• High lift counterbalanced
• Low lift walkie/rider pallet
11
Class III - Electric Motor Hand or Hand/Rider Trucks
12
Class III - Hand & Hand/Rider Trucks
7/1/2015
5
13
Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires
Fork, counterbalanced (cushion/solid tires)
14
Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires
15
Class V - Internal Combustion Engine Trucks - Pneumatic Tires
Fork, counterbalanced (pneumatic tires)
7/1/2015
6
16
Class V - Internal Combustion Engine Trucks (Pneumatic Tires)
17
Class VI - Electric & Internal Combustion Engine Tractors
Sit-down rider
18
Class VII - Rough Terrain Forklift Trucks
Straight-mast forklift Extended-reach forklift
All rough terrain forklift trucks
7/1/2015
7
19
Rough Terrain Straight Mast Forklifts
20
Rough Terrain Extended-Reach
Forklifts
Modifications and additions
which affect capacity and safe
operation shall not be
performed by the customer or
user without manufacturer’s
prior written approval. Capacity,
operation, and maintenance
instruction plates, tags, or
decals shall be changed
accordingly.
21
1910.178(a)(4) Modifications
Must get manufacturer’s
approval for modification
7/1/2015
8
Do not load
the ends of
the forks
If the truck is equipped with
front-end attachments other
than factory installed
attachments, the user shall
request that the truck be
marked to identify the
attachments and show the
approximate weight of the
truck and attachment
combination at maximum
elevation with load laterally
centered.
23
1910.178(a)(5)
ID - Attachments
Show Weight Combo
Max Elevation
The user shall see that all nameplates and markings are in place and are maintained in a legible condition.
24
1910.178(a)(6)
7/1/2015
9
As used in this section, the term, "approved
truck" or "approved industrial truck" means a
truck that is listed or approved for fire safety
purposes for the intended use by a nationally
recognized testing laboratory, using nationally
recognized testing standards. Refer to
1910.155(c)(3)(iv)(A) for definition of nationally
recognized testing laboratory.
25
1910.178(a)(7)
(1) High Lift Rider trucks
shall be fitted with an
overhead guard
manufactured in
accordance with
paragraph (a) (2) of this
section, unless operating
conditions do not permit.
26
1910.178(e) Safety guards
Lacks Overhead
Guard
(1) Battery charging installations
shall be located in areas
designated for that purpose.
(2) Facilities shall be provided for
flushing and neutralizing spilled
electrolyte, for fire protection, for
protecting charging apparatus from
damage by trucks, and for
adequate ventilation for dispersal
of fumes from gassing batteries.
27
1910.178(g) Changing and charging storage batteries
Battery Charging
7/1/2015
10
Designated Battery Charging Area 1910.178(g)(2)
Adequate Ventilation
1910.178(g)(2)(10)&(11) Fire Protection
1910.157(c) Safety Showers
Eye Wash
1910.178(g)(8) Brake Set
Properly Positioned
Where general
lighting is less than 2
lumens per square
foot, auxiliary
directional lighting
shall be provided on
the truck.
29
1910.178(h)(2) - Lighting
1 candle source = 12.57 lumens
(1) Concentration levels of carbon monoxide
gas created by powered industrial truck
operations shall not exceed the levels
specified in 1910.1000.
30
1910.178(i) Control of noxious gases and fumes
50 PPM
7/1/2015
11
ACUTE EXPOSURE
Headache
Nausea
Weakness
Irritability
Chest Pain
Unconsciousness
CHRONIC EXPOSURE
Headache
Dizziness
Anorexia
Ataxia
Confusion
FORKLIFT EXHAUST TEST
Not Required by
Federal OSHA but
indicator of
problems.
MN State Law
Often tested by
service companies
< 1%
7/1/2015
12
(1) The brakes of highway trucks shall
be set and wheel chocks placed under
the rear wheels to prevent the trucks
from rolling while they are boarded with
powered industrial trucks.
(2) Wheel stops or other recognized
positive protection shall be provided to
prevent railroad cars from moving during
loading or unloading operations.
A safe distance shall be maintained
from the edge of ramps or platforms
while on any elevated dock, or platform
or freight car. Trucks shall not be used
for opening or closing freight doors.
34
(k) Trucks and railroad cars
Wheel chocks
(3) Fixed jacks may be
necessary to support a
semitrailer and prevent
upending during the
loading or unloading when
the trailer is not coupled
to a tractor.
35
(k) Trucks and railroad cars
Jacks - Prevent upending
(4) Positive protection
shall be provided to
prevent railroad cars
from being moved
while dockboards or
bridge plates are in
position.
36
(k) Trucks and railroad cars
Prevent movement of rail cars
7/1/2015
13
1910.178(n)(11) Dockboard or bridgeplates, shall be properly secured before they are driven
over. Dockboard or bridgeplates shall be driven over carefully and slowly and their rated
capacity never exceeded.
1910.178(k)
Fixed Jacks
1910.178(k)(1)
Wheel Chocks
1910.30(a)
1910.178(j)
1910.178(n)(11)
Dockboard/Bridge Plates
Maintenance of dock plates and levelers can be hazardous – A safety bar (lockout device) may be needed. Access to dock door area should be restricted (e.g., cones, guard rails or other barrier).
Best Safety Practice: Have a place for drivers to wait. No “Live Loading”
7/1/2015
14
Trailer “Deadlining” with a lockout device Lock is applied to emergency brake, and must be removed before airline can be connected Prevents driver from pulling away before employees are clear Dock supervisor or forklift operator has custody of key
(3) Unauthorized
personnel shall not be
permitted to ride on
powered industrial trucks.
A safe place to ride shall
be provided where riding
of trucks is authorized.
41
1910.178(m) Truck operations
A SAFE PLACE TO RIDE
IS REQUIRED
(i) When a powered industrial truck is left
unattended, load engaging means shall be
fully lowered, controls shall be neutralized,
power shall be shut off, and brakes set.
Wheels shall be blocked if the truck is
parked on an incline.
(ii) A powered industrial truck is
unattended when the operator is 25 ft. or
more away from the vehicle which remains
in his view, or whenever the operator
leaves the vehicle and it is not in his view.
(iii) When the operator of an industrial
truck is dismounted and within 25 ft. of
the truck still in his view, the load
engaging means shall be fully lowered,
controls neutralized, and the brakes set to
prevent movement.
42
1910.178(m)(5) Truck Operations
Unattended Truck
(ii) A powered industrial
truck is unattended when
the operator is 25 ft. or
more away from the
vehicle which remains in
his view, or whenever the
operator leaves the
vehicle and it is not in his
view.
7/1/2015
15
An overhead guard shall be
used as protection against
falling objects.
NOTE:An overhead guard is
intended to offer protection from the
impact of small packages, boxes,
bagged material, etc.,
representative of the job
application, but not to withstand the
impact of a falling capacity load.
43
1910.178(m)(9) Overhead Safety Guard
Whenever a truck is equipped with
vertical only, or vertical and horizontal
controls elevatable with the lifting
carriage or forks for lifting personnel,
the following additional precautions
shall be taken for the protection of
personnel being elevated.
(i) Use of a safety platform firmly
secured to the lifting carriage and/or
forks.
(ii) Means shall be provided whereby
personnel on the platform can shut off
power to the truck.
(iii) Such protection from falling objects
as indicated necessary by the
operating conditions shall be provided.
44
1910.178(m)(12) Lifting Personnel
45
What do the standards require???
7/1/2015
16
46
1910.178(m)(12) Elevatable platform
Approved work basket
Safety Chains
Level Surface
Barricade
Section 5(a)(1) - ANSI B-56.1
PERSONNEL ELEVATING PLATFORMS
Good Platform must
include guardrails
Secure the platform to
the forklift.
Screen at forklift side
PERSONNEL ELEVATING PLATFORMS
OSHA 5(a)(1) Violations
ANSI/ITSDF B56.1-2005:
No screen (scissor point)
Cannot be secured to forks
or backrest
7/1/2015
17
(3)Other trucks traveling in the same direction at intersections,
blind spots, or other dangerous locations shall not be passed.
(4) The driver shall be required to slow down and sound the horn at
cross aisles and other locations where vision is obstructed. If the
load being carried obstructs forward view, the driver shall be
required to travel with the load trailing.
(5) Railroad tracks shall be crossed diagonally wherever possible.
Parking closer than 8 feet from the center of railroad tracks is
prohibited.
(6) The driver shall be required to look in the direction of, and keep
a clear view of the path of travel.
(9) Stunt driving and horseplay shall not be permitted.
49
1910.178(n)Traveling
50
(1) Only stable or safely
arranged loads shall be
handled. Caution shall be
exercised when handling off-
center loads which cannot be
centered.
(2) Only loads within the rated
capacity of the truck shall be
handled.
(3) The long or high (including
multiple-tiered) loads which
may affect capacity shall be
adjusted.
51
1910.178(o) Loading
7/1/2015
18
(1) If at any time a
powered industrial truck
is found to be in need of
repair, defective, or in any
way unsafe, the truck
shall be taken out of
service until it has been
restored to safe operating
condition.
52
1910.178(p) Operation of the truck
Take out of service
Industrial trucks shall be
examined before being placed in
service, and shall not be placed
in service if the examination
shows any condition adversely
affecting the safety of the
vehicle. Such examination shall
be made at least daily.
Where industrial trucks are used
on a round-the-clock basis, they
shall be examined after each
shift.
Defects when found shall be
immediately reported and
corrected.
53
1910.178(q)(7) Examination of Trucks
Examination
INSPECTIONS
Per manufacturer’s guidelines.
At least daily before use.
Check all working components and safety device.
Address all leakage of fluids.
Search for defective hydraulic/pneumatic hoses.
Look for quickfix signs (not acceptable) i.e. electrical tape, rags tied on hoses…
7/1/2015
19
INSPECTIONS
Why is this inspection form weak?
56
RESTRAINTS OR SEAT BELTS
“OSHA's enforcement policy on the use of seat
belts on powered industrial trucks is that
employers are obligated to require operators of
powered industrial trucks that are equipped
with operator restraint devices, including seat
belts, to use the devices.”
Enforcement of the Use of Seat Belts on Powered
Industrial Trucks in General Industry October 9,
1996:
SEATBELTS
Must be worn when
equipped.
Prevent the operator from
being pinned by the truck or
overhead guard.
Must install if retrofit is
available Click for rollover video
7/1/2015
20
INSPECTION
Labels
Ensure that
capacities for
attachments
are listed
INSPECTION
Load Backrest
Extension is damaged
INSPECTION
How much wear is
acceptable?
7/1/2015
21
FORKLIFT INSPECTIONS
Overhead guard
improperly welded
FORKLIFT INSPECTION
Broken Fiberglass
Housing is a Laceration
Hazard
INSPECTION
Leaking Hydraulic Fluid
Can lead to:
Low pressure
Air bubbles
Erratic operation
Slippery surfaces
7/1/2015
22
LP TANK ORIENTATION: PRESSURE RELIEF VALVE AT
THE 12:00 POSITION
Slot/Hole Correctly Placed on Locator Pin
Slot/Hole not Place on Locator Pin
If the valve operates, the vapor will
come out and not the liquid
65
1910.178(l) Operator training.
(i) The employer
shall ensure that
each powered
industrial truck
operator is
competent to
operate a powered
industrial truck
safely
66
1910.178(l)(1) Safe operation.
7/1/2015
23
Prior to permitting an
employee to operate a
powered industrial truck
(except for training
purposes), the employer
shall ensure that each
operator has successfully
completed the training
required by this
paragraph (l), except as
permitted by paragraph
(l)(5).
67
1910.178(l)(1)(ii) Prior to permitting employee to operate PIT
Ensure successful
completion of training
(i) Trainees may operate a powered
industrial truck only:
(A) Under the direct
supervision of persons who
have the knowledge, training,
and experience to train
operators and evaluate their
competence
(B) Where such operation does
not endanger the trainee or
other employees.
68
1910.178(l)(2) Training program implementation.
Trainees may operate under direct supervision
Combination - formal
instruction (e.g., lecture,
discussion
interactive computer learning
video tape
written material)
Practical training
demonstrations performed by
the trainer and practical
exercises performed by the
trainee), and evaluation of the
operator's performance in the
workplace.
69
1910.178(l)(2)(ii) Training shall consist of:
Combination of ways to train
7/1/2015
24
All operator training
and evaluation shall be
conducted by persons
who have the
knowledge, training,
and experience to train
powered industrial
truck operators and
evaluate their
competence.
70
1910.178(l)(2)(iii) Trainer
An evaluation of each powered industrial truck operator's performance shall be
conducted at least once every three years.
71
1910.178(l)(4)(iii) Evaluation
If an operator has previously received training in
a topic specified in paragraph (l)(3) of this
section, and such training is appropriate to the
truck and working conditions encountered,
additional training in that topic is not required if
the operator has been evaluated and found
competent to operate the truck safely.
72
1910.178(l)(5) Duplication of training
7/1/2015
25
The employer shall certify that
each operator has been
trained and evaluated as
required by this paragraph (l).
The certification shall include
the name of the operator, the
date of the training, the date of
the evaluation, and the identity
of the person(s) performing
the training or evaluation.
73
1910.178(l)(6) Certification.
74
Certification • The employer shall certify that each
operator has been trained and
evaluated as required by the standard.
• Certification shall include:
– Name of operator
– Date of training
– Date of evaluation
– Identity of person(s) performing the
training or evaluation
75
Training Program Content
• Operators shall receive initial training in
the following topics, except in topics
which the employer can demonstrate are
not applicable to safe operation in the
employer’s workplace.
– Truck-related topics
– Workplace-related topics
– The requirements of the standard
7/1/2015
26
76
Training Program Content (continued)
– Operating instructions, warnings and precautions
– Differences from automobile
– Controls and instrumentation
– Engine or motor operation
– Steering and maneuvering
– Visibility
Truck-related topics
– Fork and attachment adaptation, operation, use
– Vehicle capacity and stability
– Vehicle inspection and maintenance that the operator will be required to perform
– Refueling/Charging/ Recharging batteries
– Operating limitations
– Other instructions, etc.
77
Training Program Content (continued)
– Surface conditions
– Composition and stability of loads
– Load manipulation, stacking, unstacking
– Pedestrian traffic
– Narrow aisles and restricted areas
– Operating in hazardous (classified) locations
– Operating on ramps and sloped surfaces
– Potentially hazardous environmental conditions
– Operating in closed environments or other areas where poor ventilation or maintenance could cause carbon monoxide or diesel exhaust buildup
Workplace-related topics
78
Training Program Content (continued)
• The requirements of the
OSHA standard on powered
industrial trucks must also be
included in the initial operator
training program.
7/1/2015
27
79
Refresher Training and Evaluation
• Refresher training, including an evaluation of
the effectiveness of that training, shall be
conducted to ensure that the operator has the
knowledge and skills needed to operate the
powered industrial truck safely.
• Refresher training required when:
– Unsafe operation
– Accident or near-miss
– Evaluation indicates need
– Different type of equipment introduced
– Workplace condition changes
80
Refresher Training and Evaluation (continued)
• An evaluation of each powered
industrial truck operator’s
performance must be
conducted:
–After initial training,
–After refresher training, and
–At least once every three years
81
Avoidance of Duplicative Training
• If an operator has previously
received training in a topic specified
in this section, and the training is
appropriate to the truck and working
conditions encountered, additional
training in that topic is not required
if the operator has been evaluated
and found competent to operate the
truck safely.
7/1/2015
28
82
Unique Characteristics of Powered Industrial Trucks
• Each type of powered industrial
truck has its own unique
characteristics and some inherent
hazards.
• To be effective, training must
address the unique characteristics
of the type of vehicle the employee
is being trained to operate.
SKID STEER
MUSTANG
PIN ON EACH SIDE-INSTALL INSIDE CAB
7/1/2015
29
EMERGENCY RESPONSE
What is the response
if the drum contains
flammable or toxic
liquid?
WAREHOUSING - STORAGE AREA
Pallet Racking
Damage
Design
Compatible Parts
Anchorage
Weight Rating
ANSI Standard
OSHA ENFORCEMENT
87
Effective Powered Industrial Truck Operator Training Program
• Four major areas of concern must be
addressed:
– The general hazards that apply to the
operation of all or most powered industrial
trucks;
– The hazards associated with the operation of
particular types of trucks;
– The hazards of workplaces generally; and,
– The hazards of the particular workplace
where the vehicle operates.
7/1/2015
30
WAGE & HOUR REFERRAL
No one under 18 allowed on a PIT
“Order 7 of Hazardous Occupations” prohibits employees
under 18 years of age from operating forklifts, employers must
make certain that workers under 18 years of age are not
permitted to use PIT’s.
SUMMARY
All Operators Must Be Trained
OSHA Standards are “Minimum” Training
Best Practices Include:
Written Test, Inspection Records, Evaluations
Frequent Observations
Focus on Highest Risk Areas: Kaizen Events
Human Performance Factors
QUESTIONS QUESTIONS
7/1/2015
31
DISCLAIMER
This information has been developed by an OSHA Compliance Assistance Specialist and is intended to assist employers, workers, and others as they strive to improve workplace health and safety. While we attempt to thoroughly address specific topics or hazards, it is not possible to include discussion of everything necessary to ensure a healthy and safe working environment in a presentation of this nature. Thus, this information must be understood as a tool for addressing workplace hazards, rather than an exhaustive statement of an employer’s legal obligations, which are defined by statute, regulations, and standards. Likewise, to the extent that this information references practices or procedures that may enhance health or safety, but which are not required by a statute, regulation, or standard, it cannot, and does not, create additional legal obligations. Finally, over time, OSHA may modify rules and interpretations in light of new technology, information, or circumstances; to keep apprised of such developments, or to review information on a wide range of occupational safety and health topics, you can visit OSHA’s website at www.osha.gov.