Concrete Lab Safety Plan_V1.5_20250703.pdf

TFHRC Concrete Laboratory Safety Plan

Turner-Fairbank Highway Research Center

Concrete Laboratory

Safety Plan

July 2025

Revision 1.5

Record of Revisions Revision Date Description

1.0 28 JAN 2021 Initial release Developed by Michelle Helsel (ESC) and Thomas Russo (SES) Robert Spragg (FHWA)

1.1 5 FEB 2022 Added Section 9.16

1.2 23 JAN 2024 Updated personnel, updated lab safety map, updated emergency evacuation maps

1.3 5 Sept 2024 Updated personnel, added Annex-related safety, added Ch. 10 Unattended (Overnight) Testing

1.4 4 Oct 2024 Updated Laboratory Safety Map (Figure 1) Updated Section 3.1 (Item 10) for staff requirement to review safety plan Added Section 6.5 (Retraining Requirements) Updated Section 8.3 (Fume Hood and Ventilation) Added statement in Section 9.2 regarding the requirement to report equipment damage Added Section 9.17 (Manual Forklift) Updated folder location references

1.5 7 July 2025 Changed title to Section 10 and added Section 10.6

Safety Poster

List of Acronyms TFHRC Turner Fairbanks Highway Research Center

FHWA Federal Highway Administration

FLM Federal Laboratory Manager

HSO Health Safety Officer

RSO Radiation Safety Officer

MSDS Material Safety Data Sheet

SDS Safety Data Sheet

PPE Personal Protective Equipment

SOP Standard Operating Procedure

FG Fairbanks Building Ground Floor

AED Automated External Defibrillator

ANSI American National Standards Institute

UHPC Ultra-High Performance Concrete

ASTM ASTM International Standard

OSHA Occupational Safety and Health Administration

OSHAcademy Occupational Safety and Health Academy courses

LOTO Lock-out, tag out

ABC Fire extinguisher classes A, B, and C

Table of Contents Record of Revisions

Safety Poster

List of Acronyms

Table of Contents

1 Emergency Procedures

2 Scope

3 Policies

4 Personal Protective Equipment (PPE)

5 General Safety Rules

6 Employee Training

7 Safety Audit

8 Chemical Safety

9 Job Hazard Analysis

10 Unattended (Overnight) Testing

1 Emergency Procedures

1.1 Emergency Contact Information

In case of a life-threatening situation call 911 (from mobile phone) or 9911 (from laboratory phone).

Notify security that EMS is enroute.

TFHRC Security Desk:

(202) 493-3003 or X33003

Local Contacts:

Fairfax County Fire (703) 691-0824 Fairfax County Police (703) 691-2131 Poison Control Center (800) 222-1222

Laboratory Address:

Rooms FG-18, FG20, FG22, FG 23 OR Annex Fairbank Building – Ground Floor OR Annex Building Basement / Lab Floor Turner-Fairbank Highway Research Center 6300 Georgetown Pike McLean, Virginia 22101 Last gate on Colonial Farm Road off of Georgetown Pike (VA 193).

Notify safety personnel and laboratory management in the order listed in Table 1 in the event of accident or emergency.

Report All Lab Incidents to Federal Lab Manager, Safety Manager and Contractor Lab Manager

CONTACT INFORMATION FOR THIS LABORATORY

Laboratory: FHWA Concrete Laboratory TFHRC Facilities Manager: Brian Kerr

Building: Fairbank OR Annex Phone Number: (202) 493-3000

Address: Turner-Fairbank Highway Research Center 6300 Georgetown Pike McLean VA 22101

Security Phone Number: (202) 493-3003

Federal Lab Manager: Michelle Cooper

FHWA

Occupational Safety and Health Manager:

Mike David

Office Location: F-209-688 (202) 493-3173

Phone Number: (202) 493-3691 (Office)

(301) 518-2259 (Cell)

Mike.David@dot.gov

Email: Michelle.Cooper@dot.gov Contract Lab Manager: Scott Muzenski

Office Location: F-114

Phone Number: (202) 493-3488 (Office)

(262) 880-0234 (Cell)

Email: Scott.Muzenski.ctr@dot.gov

Instructions

Fire or Gas Leak

• Turn off gas

• Use fire extinguisher if necessary

Medical Emergency/Injury

• If LIFE-THREATENING: call 9-911 (from a TFHRC phone) or 911 (cell phone)

• Not life threatening: call non-emergency phone number (202-493-3003)

Gas Odor (Bio/Chemical)

• Call the Facilities Manager if exposed

Report All Incidents to Federal Lab Manager, Safety Manager and Contract Lab Manager

Table 1: Safety Personnel and Concrete Laboratory Management

No. Role Person Contact

1 Laboratory Manager/ Health Safety Officer (HSO) Scott Muzenski (262) 880-0234

Scott.Muzenski.ctr@dot.gov

2 Federal Laboratory Manager (FLM) Michelle Cooper (202) 493-3691

Michelle.Cooper@dot.gov

3 HRDI-10 Team Leader David Mensching (202) 493-3232 David.Mensching@dot.gov

4 HRDI-40 Team Leader Ben Graybeal Benjamin.Graybeal@dot.gov

1.2 Floor Plan Highlighting Emergency Equipment

Figure 1: Laboratory Safety Map for Fairbank (top) and Annex (bottom)

1.3 Emergency Assembly Areas

Figure 2. Emergency Evacuation Plan

In cases of evacuation, assemble at the locations outlined in Figure 3.

Figure 3: Emergency Assembly Areas

1.4 First Aid

First Aid is aimed at ensuring that the injured person does not deteriorate while skilled medical assistance is on the way. Do not move the person unless in imminent danger.

In the event of electrical shock: Switch off power before going to the person’s aid.

In case of bleeding: Stop blood flow. Open any shirt collar and pull away from neck. Lay the person in recovery position, on their side with knees bent. Do not provide drinking water.

In case of faints: Lay the person flat. If unable, sit the person in a chair or propped up against a wall.

In case of injury on skin: Heavy exposure to cement dust, wet concrete or associated water requires prompt attention. Quickly remove contaminated clothing, shoes, and leather goods such as watchbands and belts. Quickly and gently blot or brush away excess cement. Immediately wash thoroughly with lukewarm, gently flowing water and non-abrasive pH-neutral soap. Seek medical attention for rashes, burns, irritation, dermatitis and prolonged unprotected exposure to wet cement, cement mixtures or liquids from wet cement. Burns should be treated as caustic burns.

Cement causes skin burns with little warning. Discomfort or pain cannot be relied upon to alert a person to a serious injury. You may not feel pain or the severity of the burn until hours after exposure. Chemical burns must be treated promptly by a doctor. In the event of any complaints or symptoms, avoid further exposure.

In case of injury in eyes: Get medical attention immediately. Call poison control. Rinse continuously with water for several minutes. Immediately flush eyes with plenty of water, occasionally lifting the upper and lower eyelids. Check for and remove any contact lenses.

Continue to rinse for at least 20 minutes. Chemical burns must be treated promptly by a doctor.

If inhaled: Inhalation of large amounts of cement requires immediate medical attention. Call poison control. Remove victim to fresh air and keep at rest in a position comfortable for breathing.

If the individual is not breathing, if breathing is irregular or if respiratory arrest occurs, provide artificial respiration or oxygen by trained personnel. It may be dangerous to the person providing aid to give mouth-to-mouth resuscitation. If unconscious, place in a recovery position and get medical attention immediately. Maintain an open airway. Seek medical help if coughing or other symptoms persist.

If ingested: Rinse mouth. Get medical attention immediately. Call poison control. Have victim rinse mouth thoroughly with water. DO NOT INDUCE VOMITING unless directed to do so by medical personnel. Remove victim to fresh air and keep at rest in position comfortable for breathing. If material has been swallowed and the exposed person is conscious, give small quantities of water to drink. Have victim drink 60 to 240 mL (2 to 8 oz.) of water. Stop giving water if the exposed person feels sick as vomiting may be dangerous. If vomiting occurs, the head should be kept low so that vomit does not enter the lungs. Chemical burns must be treated promptly by a doctor. Never give anything by mouth to an unconscious person. If unconscious, place in recovery position and get medical attention immediately. Maintain an open airway.

1.5 Fire Safety and Evacuation

In the event of an oil fire, do NOT add water.

If you or an article of clothing on your person catches fire, STOP, DROP, and ROLL. Attempt to suffocate the fire by removing access to oxygen.

Immediately pull a fire alarm, which the locations of can be found in Section 1.2 of this Concrete Laboratory Safety Plan.

Call 9-911 in the event of a fire.

Upon the event of a fire or building evacuation, if possible, place a sign on the door handle indicating if all personnel have left that laboratory room. Immediately walk to the nearest building exit and congregate at one of the emergency assembly areas, as shown in Section 1.3 of this Concrete Laboratory Safety Plan.

2 Scope This safety plan is a document that sets standards of conduct, policies, and procedures that manages the conduct of experiments and daily duties in the Concrete Laboratory. The purpose is to establish personnel protection standards and mandatory and consistent safety practices for all Turner-Fairbank Highway Research Center (TFHRC) personnel involved with the Concrete Laboratory. The plan includes methods designed to protect employees from injury and hazards.

This plan also provides contingencies that may arise during use of the laboratories. All TFHRC personnel and contractors who engage in any activities in the laboratory shall be familiar with this plan and comply with its requirements.

3 Policies

3.1 General Policies

1. Federal staff, contractor personnel, and visitors to the Concrete Laboratory must follow TFHRC and FHWA safety requirements.

2. TFHRC has additional regulations and guidelines that must be followed while in the facility.

Therefore, the TFHRC Safety Plan is also applicable to all personnel using the Concrete Lab. Please find the TFHRC Safety Plan at the following link: "R:\Occupancy Emergency Plan\Emergency Evacuation Plan\TFHRC Occupant Emergency plan 2024 (003).doc". The safety plan can also be provided in hardcopy format if requested by laboratory personnel.

3. In the event of an emergency, the Emergency Procedures outlined in Section 1 shall be followed.

4. Anyone seen performing an unsafe practice (or potentially unsafe practice) will be required to stop work until safety requirements can be reviewed and safe work practices employed.

That person will also be required to perform extra safety training and demonstrate that knowledge to the FLM.

5. Unsafe or possibly unsafe practices must be called to the attention of the individual performing unsafe practices, the Contract Laboratory Manager, and the FLM.

6. Accidents or near-miss incidents (where no one is injured, but an event occurs that could have resulted in injuries or damage to equipment) shall be brought to the prompt attention of the FLM. Report accidents and near-miss incidents using the form located at P:\Being Organized\Lab_Safety\Incident or Near Miss Report Form.pdf. A completed form shall be sent to the Contract Laboratory Manager and the FLM, as well as located in the following location: P:\Being Organized\Lab_Safety\Incident or Near Miss Reports.

7. Prior to testing or conducting an experiment, personnel shall receive training on the hazards or conduct a hazard analysis, review any SDS associated with materials used to conduct the experiment, and review safety procedures including the standard operating procedure and equipment manual (if available).

8. Prior to performing a potentially hazardous activity requiring specific PPE protections, ensure that all personnel within the hazard’s vicinity are aware of the activity and are wearing the proper protections.

9. Cleanliness and good housekeeping are essential practices to ensure a safe laboratory space. All personnel in the concrete laboratory are expected to contribute towards maintaining a clean and orderly laboratory space.

10. All staff are required to review the safety document and acknowledge in writing that they have done so at least every 6 months.

3.2 Radiation Procedures

The primary storage location of the nuclear gauges and the radioactive sources is in Room FG- 23D in the basement level of the Fairbanks building. The room is a large storage closet off the Concrete Testing Laboratory (Room FG-23). Room FG-23D is always locked, with access limited to the RSO and TFHRC Building Emergency Contact. Access is further limited during nonworking hours when the laboratory doors are also locked. Radiation levels in and around FG-23D are surveyed periodically, and a permanently mounted dosimeter records the radiation dose level just outside the door to that room. Signs that are part of the NRC license requirements and which indicate the radiation hazard level are posted on and around the storage area.

Other radioisotope sources at TFHRC, whether in gauges or stand-alone, are special-form sealed sources. Release and dispersal of the radioactive material is unlikely in normal use or in a minor accident.

If the source encapsulation is disrupted, quick action can reduce the consequences of the radioactive material release, minimize contamination, and decrease exposure to workers. The radioisotope source and its container are also described herein as a package. The following steps provide guidance on what to do if a source may have been damaged:

1. Do not touch packages that show signs of leakage.

2. Isolate the packages by roping off an area at least 15 ft (5m) from the package(s) and if possible, put up warning signs.

3. Keep people out of the area.

4. Notify appropriate personnel.

5. Tell anyone who may have come in contact with the damaged package to go to Emergency

Assembly Areas highlighted in Section 1.3 to be checked or advised by radiation safety personnel.

6. Require anyone who handled a potentially leaking or contaminated package to wash his/her hands in a segregated lavatory as a precautionary measure. He/she should be checked or advised by a radiation safety specialist before eating, drinking, and/or smoking and before leaving the premises.

7. Do not immediately clean up the area where the accident has occurred. Get assistance from radiation safety personnel.

The following first aid procedures are recommended in case of an accident involving radioactive materials:

• Medical problems take priority over radiological concerns.

• Use first aid treatment according to the nature of the injury.

• Do not delay care and transport of seriously injured person.

• People exposed to special-form sources are not likely to be contaminated with radioactive material.

• Apply artificial respiration if victim is not breathing.

• Administer oxygen if breathing is difficult.

• Injured people who were in contact with released material should be contained.

Both gauges and stand-alone radioactive sources can stand extensive fire damage without risk of content loss from sealed source capsules. The radioactivity of these sources does not change the flammability or other properties of materials, and the effectiveness of fire control techniques are not affected by the presence of these materials. Most of the radioactive sources in the TFHRC inventory have been designed and evaluated to withstand total engulfment in flames at temperature of 800 degrees Celsius.

4 Personal Protective Equipment (PPE)

4.1 PPE Requirements

1. Appropriate eye, face, head, hand, foot, hearing, and respiratory protection must be worn according to the type of activity being performed (a list of mandatory PPE for each lab equipment is provided on the shared drive).

2. Appropriate eye protection must be worn when working in hazardous surroundings and when there is a possibility that chemicals or particles may become airborne.

3. Closed-toe shoes completely covering the foot shall be worn at all times by personnel in the laboratory. Protective footwear meeting ASTM F2413 shall be used when working in areas where there is a danger of foot injuries due to falling or rolling objects, objects piercing the sole, or when the use of protective footwear will protect the affected employee from an electrical hazard. This might include mixing and molding activities, moving and preparing specimens, and other activities designated by the FLM.

4. A dust mask or respirator is required when working with cement, supplementary cementitious materials, ultra-high performance concrete (UHPC) dry pre-mix materials, dusty aggregates, and in other dusty conditions.

5. Appropriate gloves shall be worn when handling chemicals, steel fibers, ultra-high performance concrete, and concrete materials. Rubber or latex gloves are required when working with fresh concrete, mortar, or paste.

6. Appropriate hearing protection must be worn when working with equipment that can generate loud noises or in environments that are noisy.

7. Personnel must wear appropriate clothes, including shirt, laboratory coats, and full-length pants.

8. Head protection (hard hats) shall be used anytime when there is a possible danger of head injury from impact, from falling or flying objects, or from electrical shock and burns. This includes when using the forklift, crane, or working underneath other equipment.

9. Care should be taken that PPE is worn properly to prevent additional injury or additional safety hazard. For example, loose-fitting long sleeves should be secured to ensure they are not caught by equipment.

10. When working with chemicals, personnel shall follow the recommendations in the chemical’s SDS and those established by the manufacturer/supplier.

4.2 Annual PPE Inventory

An annual inventory of all PPE will be conducted by the Contract Laboratory Manager and HSO during the annual laboratory safety audit to ensure that the lab has adequate quantities of safety equipment. During the inventory, the proper functioning of all PPE equipment will also be verified.

Any PPE that does not function properly or that is nearing or past expiration shall be brought to the attention of all users, safety officers, and the Contract Laboratory Manager. Non-functioning or expiring PPE shall be replaced following the established procurement procedures.

5 General Safety Rules

1. Store and stack materials so that they will not fall over. Check shelves to make sure they are not overloaded and are properly anchored to prevent collapse.

2. No items shall be stored on top of ovens or on top of other equipment not intended for storage.

3. Personnel shall not wear loose fitting clothing or accoutrements (badges, jewelry, etc.), and shall secure badges when operating mixers or other equipment that can catch the badge and cause strangulation.

4. Keep work areas and equipment clean and free of debris.

5. All containers must be labeled with its contents, including aggregates, cementitious materials, chemicals, powders, liquids, and water. Where possible, do not put labels on lids

– mark the outside of the container and include a label inside as well, if appropriate.

6. Do not place any part of your body in an area where it may be crushed by moving parts, including but not limited to areas adjacent to hydraulic equipment, lifting equipment, pallet jacks, and automated machinery.

7. Equipment shall be locked out or blocked open before personnel work in an equipment crush zone or pinch point.

8. If equipment breaks or if you notice any defects in the equipment you are using, immediately inform the Contract Laboratory Manager.

9. Do not operate any equipment or conduct any physical work if you are under the influence of mood altering substances (drugs, alcohol, etc.).

10. Inform the Contract Laboratory Manager before starting work in the laboratory if you have a medical or physical condition that makes it unusually hazardous or impossible to perform certain tasks. This information will be kept confidential.

11. Inform the Contract Laboratory Manager before starting work in the laboratory if you are taking prescription medication(s) that may impair your judgment, impair your ability to safely perform your work, or be a safety hazard. Provide a note from the doctor stating what physical activities you can and cannot perform. This information will be kept confidential.

12. Electrical cords must be protected and removed from aisle/walkways. Dispose of cut or broken electrical cords. Use a properly rated electrical cord for the equipment you are using. An underrated electrical cord is a safety and fire hazard.

13. Promptly cleanup all spills. Properly dispose and cleanup the spilled material according to SDS. Spill kits are provided within the lab as shown in Figure 1.

6 Employee Training

6.1 Required Training Courses

All personnel working in the Concrete Laboratory shall complete and pass courses on the following topics:

• Introduction to Occupational Safety and Health (OSHAcademy Course 600)

• Essentials of Occupational Safety and Health (OSHAcademy 601)

• Hazard Communication Program (OSHAcademy 705)

Additional courses for specific job duties include:

• Electrical Safety for Employee Basics (OSHAcademy Course 115)

• Personal Protective Equipment (OSHAcademy Course 709)

• Hand and Power Tool Safety (OSHAcademy Course 810)

• Crane and Derrick Safety I (OSHAcademy Course 820)

6.2 Forklift

All personnel using a forklift shall obtain certifications before operating. Under direction of TFHRC Facility Management, the FLM will identify the required training.

6.3 Equipment Standard Operating Procedures

Proper operation and maintenance of equipment is expected of all personnel using the Concrete Laboratory, and is fundamental to the safe and continued operation of the research laboratory and the government-owned equipment therein. The proper operation protocols, safety considerations, and common hazards that an operator should be aware of are specific to each equipment. These details are located in each equipment’s Standard Operating Procedure (SOP).

Before operating equipment, personnel shall read the SOPs and safety procedures regarding the equipment of interest. The equipment SOPs and safety procedures are located here: P:\Being Organized\SOPs.

Before operating certain equipment, personnel shall also be properly trained by the designated expert for the equipment of interest. The expert identified for each piece of equipment and the specific equipment requiring in-person training are outlined in the list of laboratory equipment (available at: "P:\Being Organized\SOPs\SOPs.xlsx").

After completing an in-person training provided by the identified equipment expert, the OSHA Training Form (located at: "P:\Being Organized\Lab_Safety\Training Documents\OSHA Training Form.docx") the training record shall be reported in the Equipment Training Record (available at:

P:\Being Organized\Lab_Safety\Training Documents\Training Records).

6.4 Bi-Annual Laboratory Safety Meetings

All personnel working regularly in the Concrete Laboratory and those designated by the FLM shall attend two lab safety meetings each year, one every six months. The bi-annual laboratory safety meetings will be scheduled by the FLM. Prior to the meeting, personnel shall review this safety plan, locations of all emergency and safety equipment, potential hazards, emergency procedures, and emergency contacts. During the meeting, personnel can bring any specific concerns they have with regards to safety for discussion in the group. Following the meeting, personnel shall sign a form provided by the FLM indicating that they reviewed and understand the content of this safety plan. Participation by personnel not working in the concrete laboratory full-time shall be at the discretion of the FLM.

Additional laboratory safety meetings will be held at the discretion of the Contract Laboratory Manager and FLM following safety incidences or near misses. The fall bi-annual meeting shall present conclusions from the annual safety audit.

6.5 Retraining requirements

Occasionally, retraining of equipment may be necessary. In general, hands-on training of equipment should occur on a 2 year interval. Refer to the SOP list at: "P:\Being Organized\SOPs\SOPs.xlsx" for a list of training intervals.

Additionally, when staff are away from work for an extended period of time, they may lose knowledge of proper procedures or tasks. In such a case, staff should be monitored to see if they are performing tasks appropriately after returning from time away and then retrained if necessary.

Repetitive tasks occurring over a long period of time may result in an increased likelihood of mistakes. Therefore, staff should be occasionally monitored when performed repetitive tasks over a long period of time and retrained if necessary.

7 Safety Audit The Contract Laboratory Manager and HSO shall conduct an annual safety audit. The audit shall evaluate compliance with the Concrete Laboratory Safety Plan and identify safety concerns regarding equipment, training, materials, records, and operating procedures. The audit shall ensure the SDS system is up-to-date.

The audit shall be conducted with findings presented to the FLM in writing at least one month prior to the fall Bi-Annual Safety Meeting.

8 Chemical Safety

8.1 Incident Response

Emergency chemical spills are spills greater than 2 liters, involve a highly toxic or reactive compound, present an immediate fire or environmental hazard, or require additional PPE (e.g., respirator) and specialized training to properly cleanup. In the event of an emergency chemical spill:

• Cease all activities and immediately evacuate the affected area. Notify all personnel in the area of the spill and encourage them to also evacuate.

• If chemical exposure has occurred to the skin or eyes, the affected personnel shall be taken to the nearest safety shower and eyewash station.

Non-emergency chemical spills are spills less than 2 liters, do not involve a highly toxic or reactive material, and do not present a significant fire or environmental hazard. These spills can be cleaned up by properly trained laboratory personnel using conventional laboratory PPE and the laboratory spill kit. When a non-emergency spill occurs in the laboratory:

• Isolate the area surrounding the spill,

• Notify other laboratory personnel of the spill,

• Absorb and collect the spill material using pads or another absorbent material such as oil dry or kitty litter.

• Decontaminate the spill area using an appropriate solvent. Soap and water is often the most effective.

8.2 Chemical Hazards

Chemical hazards of primary concern in the Concrete Laboratory include but are not limited to:

corrosive liquids and solids, solvents, flammables, hazardous gases, and cryogenic hazards.

Before handling any chemical, personnel shall read and understand the following guidelines:

• Exercise appropriate care when storing, handling, or disposing of all chemicals and other materials. Follow this Safety Plan and ask Laboratory Management if there are any questions.

• Review the SDS when starting to work with a chemical and review the SDS periodically if there is continued use of a chemical.

• Know where clean-up kits and emergency equipment are located (Refer to Figure 1).

• Wear the appropriate PPE outlined in the SDS and by the manufacturer when handling and using chemicals.

• Store chemicals properly, using either manufacturer guidelines or following the SDS.

8.3 Fume Hood and Ventilation

Personnel shall follow and understand the below guidelines while working within the fume hood.

• Laboratory fume hoods during use shall be operated with a minimum average 100 ft/min face velocity at full open sash or sash stop position.

• When determining the minimum flow rate through the fume hood, the sash stop position may not be lower than 18 inches above the work surface.

• When operating the fume hood, the sash should be positioned to maximize the protection to the user.

• When not using the fume hood, the sash should be lowered to the lowest possible position.

8.4 Chemical and Materials Check-in and Disposal

Upon the arrival of a chemical, the chemical shall be labelled in accordance with the Concrete Laboratory Safety Plan. Chemicals and materials shall be added to the material inventory database located in the shared drive at: P:\Being Organized\Materials_Inventories, and the SDS shall be provided in accordance with this Safety Plan.

When disposing of a chemical, do not pour into any sink drains, environmental drains, or outside of the building. Create a list of all chemicals needing disposal and gather all corresponding SDS records and label information. The Contract Laboratory Manager or designee shall coordinate disposal of the chemicals.

8.5 Labeling

Each container of a material or chemical received from a manufacturer must include a label with appropriate identification and hazards of that chemical. The name and address of the chemical manufacturer or distributor must also be on the label. If a container arrives without the manufacturer's label, an appropriate label must be affixed to it. If a chemical’s label is removed, the container shall be immediately re-labelled.

When chemicals or materials are transferred to a secondary container, that container shall be properly labeled regardless of appearance.

Proper labeling on any container in the laboratory shall indicate:

• Date filled;

• Common chemical name of the chemical or material in the container;

• Name of primary user;

• Hazard risks based on the globally harmonized system (GHS) pictograms;

• Other information such as concentration, hazard identification, and/or date of purchase.

Labels shall be maintained with legible writing. If it is not practical to label the container, for example size or temperature concerns, the personnel overseeing the experiment shall discuss concerns with the Contract Laboratory Manager or the FLM.

8.6 Safety Data Sheet (SDS)

SDS in accordance with the Hazard Communication Standard shall be readily available for chemicals and materials used in the laboratory. The SDS for chemicals and material brought into the laboratory shall be added to the Concrete Laboratory’s SDS Digital Repository ("P:\Being Organized\Lab_Safety\SDS") and shall be provided to the Contract Laboratory Manager or designee for inclusion into the physical SDS binders.

SDS binders are located in the titration room (F-G22). Individual SDS shall be arranged in alphabetical order within the binders.

9 Job Hazard Analysis

9.1 Proper Use of PPE

PPE training will be conducted by a proficient member of the staff. PPE that is used in the laboratory should have its purpose and proper use explained, including but not limited to: gloves, coats, glasses/face shields, foot wear, and respirators/dust masks. This training will be performed when an employee is newly hired, has an accident that could have been mitigated with proper PPE or new PPE, at the discretion of the Contract Laboratory Manager, and as requested by laboratory personnel. PPE training records shall be kept by the Contract Laboratory Manager and

HSO.

9.2 Proper and Regular Maintenance

Proper maintenance of equipment is expected of all personnel using the Concrete Laboratory, and is fundamental to the safe and continued operation of our research lab. Personnel using Concrete Laboratory equipment should be aware of the proper maintenance protocols for regular equipment use, and should contact the equipment expert in the event of equipment malfunctions.

Maintenance details are located in each equipment’s Standard Operating Procedure (SOP).

In the event of an equipment malfunction and no injury, immediately turn off the equipment.

Employ lockout, tagout procedures. If possible, disconnect the power from the equipment. Notify personnel of the equipment malfunction, specifically the equipment expert. Place a sign on the equipment stating not to use the equipment without contacting the equipment expert and receiving approval. The equipment damage should also be reported to the Equipment Damage Log located at: "P:\Being Organized\Lab_Equipment\EquipmentDamageLog.xlsx".

9.3 Hydraulic Systems

Modern hydraulic systems, systems that use fluid to move and do work, are capable of producing enormous amounts of force with startling speeds. Fingers, hands, and the whole body can be injured from hydraulics. Know the machine you are using and what safeguards it has to keep the operator safe.

• Do not allow someone who is untrained, unexperienced, or uneducated of the dangers to operate any hydraulic machine.

• DO NOT disable any of the safety components or features, including but not limited to:

limit detectors, safety doors/screens, and proximity switches.

• Inspect power supply cables and hydraulic fluid lines often to ensure they are not worn.

• Know what a machine will do if it loses power or hydraulic pressure, gravity can/often will cause parts of the machine to move.

• Be aware of what your test specimen may do when using a hydraulic press.

9.4 Chemical Reactions

Cement-based materials, when combined with water, can result in a material with a very high pH that can lead to caustic burns, irritation, and dermatitis. Cement causes skin burns with little warning. Discomfort or pain cannot be relied upon to alert a person to a serious injury. Proper PPE and safety procedures should be utilizing when handling fresh cement.

9.5 Risk of Puncture and Cuts

Many materials used in the concrete laboratory and equipment used to prepare specimens are sharp and pointed. This puts concrete laboratory staff at an increased risk of puncture or cuts.

Proper use of PPE and extreme care should be taken when handling Ultra-High Performance Concrete (UHPC) and demolding concrete specimens.

9.6 Lockout/Tag Out

Lockout, tag out (LOTO) is a system in which any machinery or equipment that is undergoing maintenance or not functioning safely or properly is shut down. The equipment is powered off, the power sources are disconnected, and at least one person places a physical lock on the powering mechanism of the machine. The lock is placed on a switch, valve, or other energy-isolating device such that access to turn the machine on is physically impossible without having the key or combination to remove the lock. If a lock cannot be placed on the device, a tag is placed instead to explain the reason for the shut down and hazards currently existing because of the machine’s current status. Any energy stored in the machine must then be released (e.g., releasing pressure) and verified (e.g., checking pressure gage reading equals zero).

LOTO keeps everyone safe by preventing reactivation or re-energization of equipment when that equipment is not operating properly or is undergoing maintenance. Machinery not locked out could be turned on by an unknowing individual, causing bodily harm to the person working on the machine. Re-energization of equipment can lead to an electrical discharge injury or spark a fire. The large mixers, thermotron, ovens, presses, saws, and grinders should be locked and tagged out when undergoing maintenance.

• When preparing to LOTO, notify all people in the area of work and those who may operate the equipment.

• Before performing the LOTO procedures, ALWAYS ensure that residual or stored energy within the equipment is removed or dissipated prior to continuing with LOTO. These activities include, but are not limited to discharging capacitors, releasing spring energy, and bleeding fluid lines. If it is not safe to perform these actions, install physical barriers or contact professionals. Contact all workers who may come in contact with this equipment to notify them about the equipment’s current status.

• If possible, multiple people should lock out the equipment to prevent removal and activation until the equipment is safe to properly use.

• Know what source(s) you need to isolate: Electrical, Hydraulic/Pneumatic, Mechanical, Gravitational, or Chemical. Some equipment may require locking multiple sources to undergo LOTO.

9.7 Crane

Safe use of a crane can prevent harm to yourself and others. Know the dangers of load swing, load type, and operational limits. Inspect your equipment, load, and path. Make sure those around you know when you are lifting and where you intend to go. Do not allow untrained employees to use this equipment. Know the dangers of load balancing and influences of swing. Take caution to avoid pinch/crush points.

1. Before use, ensure the crane is suitable for the planned hoisting task. Confirm it has appropriate travel, lift, and capacity.

2. Visually and physically inspect the crane before use. Check for damage, wear, and proper operation of all functions.

3. Confirm the load weight. Check the capacity of all equipment including the hardware, rope, and slings. Do not exceed the rated capacities.

4. Select the correct sling for each lift. Inspect slings and other rigging hardware before use for wear, stretch, or other damage. Do not use damaged or defective slings. Use softeners around sharp corners. Do not splice broken slings.

5. Warn all people in the load lift area before starting the lift. Ensure that the path of the load is clear of people and obstructions. Do not lift loads over anyone. Center the crane hoist over the load before hoisting to prevent swinging of the load.

6. Slide the sling fully onto the hoisting hook and ensure the safety latch is closed. Do not load the hook tip or hammer a sling into place.

7. Secure unused sling legs. Do not drag slings or leave loose materials on a load being hoisted.

8. Keep hands and fingers from being trapped when slack is taken out of a sling. Step away before the lift is started.

9. Move the load and controls smoothly. Minimize load swing.

10. Walk ahead of the load during travel and warn people to keep clear. Use a tagline to prevent rotation or other uncontrolled motion. Raise the load only as high as necessary to clear objects. Do not ride on the hook or load.

11. Set loads down on blocking, never directly on a sling. Do not pull or push loads out from under the hoist.

12. Do not leave the load or crane unattended while the load is suspended.

13. Where crane operation by other personnel must be restricted, employ lockout and tag out procedures.

14. Store slings off the floor in a clean, dry location on hooks or racks. Do not leave slings, accessories, or blocking lying on the floor.

15. Emergency response preparedness is a necessity when operating an overhead crane.

Operators and workers should plan for situations such as electrical or mechanical failure.

16. When performing maintenance, follow lock-out/tag-out procedures.

17. Operators and workers shall wear fitted clothing, secure hair, and secure jewelry when working near cranes. Workers should never ride on the load or rigging of the crane.

18. Operators must know the load capacity of their crane, loads that exceed the limits of the crane shall not be moved. The load rigging requirements need special attention. Loads that cannot be safely rigged shall not be lifted.

9.8 Confined Space

Confined spaces are areas that have limited ingress, egress, and movement space. Few confined spaces are located in the Concrete Laboratory and they present a unique hazard. Confined spaces include the concrete waste pits, service tunnel to the mixing room pit, and the storage tunnel/chemical waste storage area.

• Alert others to your intent to enter a confined space prior to entering and again once you have exited the space. Personnel should not enter a confined space without having someone nearby to check on you while in the confined space.

• Avoid confined spaces under hot conditions. Higher temperatures in confined spaces can lead to rapid heatstroke or exhaustion.

• If entering a confined space where chemical vapors or gases are present, check the oxygen level before entering.

9.9 Hand Tool Safety

Tool safety is a hazard often overlooked. Damaged tools can fail catastrophically, causing bodily harm, shocks, or burning in some cases. Having quality tools and using them properly can prevent injury.

• Regularly inspect tools for wear and damage. Replace tools if needed.

• Ensure all tools are maintained for longevity and safe use. Regularly perform maintenance such as sharpening, grinding, or replacing worn bits.

• Dress for the tools you intend to use. Avoid loose fitting clothes or articles of jewelry. Wear the appropriate protective equipment.

• Use the right tool for the job. DO NOT use a wrench as a hammer or a screwdriver as a chisel.

• Do not carry power tools by the cord.

• Secure your work in a vice or a clamp if possible.

• Keep extra tools handy in case the first tool does not work.

9.10 Proper Use of Fire Extinguisher

Fire safety equipment must be easily accessible to the laboratory and include a fire extinguisher (type ABC) available within 50 feet of all laboratory spaces. The fire safety equipment may include fire blanket or automatic extinguishing systems. Fire extinguishing systems shall be inspected during the annual safety audit.

A type ABC fire extinguisher is a dry chemical extinguisher that can be used on class A, B, and C fires. Class A fires are fueled by wood, trash, and paper. Class B fires are fueled by liquids and gasses. Class C is for fires fueled by electrical sources that are still being supplied power.

9.11 Chemical Spills

Treat all, known and especially unknown, chemicals as dangerous to one’s health. Proper handling of chemicals can help prevent spills and protect the well-being of all. Reducing the volume of the chemical to only what is necessary, labelling containers correctly, providing SDS, maintaining good housekeeping, and having consistency in storage are a few ways to prevent and control chemical spills.

Know the location of spill controls (ie. rags for chemical clean up or secondary containers), inert materials to help clean up spills (ie. sand, kitty litter, etc.), and drainage outlets that chemicals should not enter.

Ensure chemicals are stored in their proper locations. Acids and other liquid chemicals should be stored within a primary and secondary container.

9.12 Compressed Gas

Mishandling of compressed gas cylinders can lead to injuries of the surrounding workers and damage or destruction of equipment. Due to the very high internal pressure of the gas (approximately 2500 psi when the tank is full), dropping or tipping over a tank can cause cracks to form in the container, which can lead to shrapnel-laden explosions. Therefore, any personnel handling compressed gas tanks must be properly trained and be knowledgeable about the risks of mishandling the tanks. The following list constitutes a set of guidelines for all personnel handling compressed gas tanks.

Moving

• When moving a cylinder from a cart to a station, the tanks shall be moved by tilting and rolling them on their bottom edges. They shall not be intentionally dropped, struck, or permitted to strike each other violently.

• When moving large gas cylinders (>27 inches), an approved gas cylinder cart should be used.

• A cylinder should never be moved or transported without the protective cap.

Storing

• Do not store a compressed gas cylinder close to salt, corrosives, chemicals, combustibles, or fumes.

• Store compressed gas cylinders in an adequately protected, dry, and well-ventilated area so to prevent damage and tampering of the cylinder.

• Store compressed gas cylinders away from exits and egress routes.

• When a tank is not secured to a cart in transit, it must be secured to wall or appropriate stand by using a strap or a chain.

• Replace the regulator with a safety cap when the cylinder is not in use.

Using

• Ensure that you have the correct regulator for the gas cylinder you are using.

• Frequently inspect gas cylinder connections and fittings for deterioration and damage.

• Do not use a leaking, corroded, or damaged cylinder.

• When stopping a leak between the cylinder and regulator, always close the valve before tightening the union nut.

• Do not try to refill a tank or mix gases inside a tank.

• Ensure you know the proper safety procedures and usage guidelines for the gas type.

Disposal

• Do not refill a compressed gas cylinder. Refilling compressed gas tanks should always be performed by third parties.

• Tanks in the loading dock must be secured to a cart or a wall using a chain/strap and have the protective cap in place. Tanks may only be in the loading dock for pickup and/or replacement with a full tank.

• When a cart is used as a compressed gas tank station, use the wheel breaks to lock the tank station into position.

9.13 Liquefied Gas

Liquefied gas tanks typically store both liquid and gas phases. While tanks for liquefied gas are designed to minimize the heat exchange between inside the tank and the surrounding environment, the heat exchange still occurs. The transfer of heat causes the liquefied gas to evaporate and turn into gas form. The transformation into gas causes a volume expansion, which causes the tank to expel some gas in order to release internal pressure. This mechanism leads to a progressive loss of liquid, whether the tank is used or not. Therefore, liquefied gas has a shorter storage life than compressed gas. To maintain the gas in its liquid form, gases are typically cooled to sub-zero (Celsius) temperatures.

If proper precautions are not taken, the cooled gas can injure the user or damage the surrounding equipment. The released liquefied gas can rapidly freeze skin tissue and eye fluid, resulting in cold burns, frostbite, and permanent damage.

Other dangers associated with liquefied gases include rapid expansion in the event of vaporization. In the case of liquefied nitrogen, the rapid vaporization and expansion due to rapid release from a tank can reduce the percent (%) of oxygen in the surrounding atmosphere. Thus vaporization can cause oxygen deficiency, which may result in nearby personnel unconsciousness.

Before handling liquefied gas, personnel should be trained and introduced to the risks and good practices related to the handling of liquefied gas tanks. The following list constitutes a set of guidelines, which should be read by any personnel that may handle compressed gas tanks.

• Do not operate or handle a liquefied gas tank without the proper PPE.

• Do not operate a tank which is clearly deteriorated. Signs of deterioration indicators can include: Corrosion or damage on the cylinder/tank surface, broken or inaccurate gauges, frequent venting of gas through the pressure release device, frost formation on the valve handles or tank body.

• If you observe deterioration signs on a tank, contact the Contract Laboratory Manager and the personnel in charge of the equipment.

• Liquefied gas tanks should be stored in well-ventilated areas.

• Use only approved containers to store liquefied gas.

• Only store liquid nitrogen in containers with loose fitting lids. Never seal liquid nitrogen in a container. The pressure in a tightly sealed container will increase as the liquid boils and may explode after a short time. This does not apply to tanks due to the presence of safety valves, which release gas in case of a pressure buildup.

• If using a cryogenic transfer hose, make sure that the hose is properly connected to the tank before opening the “liquid” valve on the tank.

• Do not try to force-open any of the valves with a wrench or any other tool. If a valve must be opened and is not opening properly, report the issue to the Contract Laboratory Manager and the personnel in charge of the equipment. Tools should not be used to open a valve.

• Operate the liquefied gas tank away from personnel who are not wearing PPE.

9.14 Laser

While lasers may be uncommon in the lab, steps still need to be taken to protect yourself and others. Some of the laser sources in the laboratory include laser pointers, laser-guided infrared thermometers, and laser scanners. Lasers present a hazard mainly to the eyes. Even the weakest of lasers can have lasting effects if prolonged exposure occurs.

• Do not point lasers directly into anyone’s eyes.

• If one must view a laser, use optical aids that are rated for the laser class.

• If possible, view lasers remotely.

• Respect all barriers and protections in place.

• Know the risks and heed all warnings.

9.15 Radiation Safety

The concrete laboratory has radiation sources within its immediate vicinity. Personnel shall take appropriate precautions to ensure safety when near the radiation sources. See Section 3.2 of this Concrete Laboratory Safety Plan.

9.16 Floor Gaps

Gaps or voids in the floor or any standing work surface must not exceed 2 inches in both width and length. Holes or gaps exceeding 2 inches in width and length can present tripping hazards or opportunities for injury and can lead to equipment instability. Holes or gaps exceeding this dimension in both width and length must be immediately cordoned, work stopped within the area, and brought to the attention of the Contract Laboratory Manager for proper remediation.

Special attention shall be paid during cleaning of waste pits, and grates shall be replaced by staff in such a way that gaps and holes do not exceed 2 inches in width and length.

9.17 Manual Forklift

The manual forklift can be used to lift or transport heavy items within the lab. Never use the manual forklift without proper training. The weight of the objects being lifted should always be cross-checked with the capacity of the manual forklift. Additionally, the placement of the object on the forks may require a multiplication factor to be applied to the weight of the object being lifted.

• Always check the manual forklift for wear or damage prior to use.

• Always be sure to lock the wheels of the manual forklift prior to lifting.

• Always be sure to lock the height of the forks prior to placing an object on them, removing and object, or transporting an object.

10 Unattended (Off-Hours) Testing Some concrete related testing needs to be performed for extended periods of time; therefore, it is required to leave tests unattended and continuing overnight and/or through weekends. Special precautions should be considered for such testing. In addition, certain activities require chemicals that shall remain within a functioning fume hood or ventilated area at all times to ensure personnel safety from strong fumes. In the event that equipment begins to malfunction, the equipment shall be turned off and inspected prior to commencing testing or unattended usage.

Table 2 provides a summary of the testing that commonly occurs for extended periods of time and is left unattended.

Table 2. Summary of Unattended Testing Performed in the Concrete Laboratory…