Attachment 6 _APR8715.1 Chapter 14 Shop Safety.pdf
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This document is an Ames Procedural Requirement (APR) establishing shop safety standards for NASA's Ames Research Center (ARC).
The directive applies to ARC personnel and associated facilities, with applicability to contractors only as specified in their contracts or agreements. The document is organized around three main chapters: Responsibilities, General Shop Safety, and Machine Safety. Key responsibilities are distributed among the Occupational Safety, Health, and Medical Service Division (Code QH), which provides safety consulting and oversight; the Ames Health Unit, which provides medical consultation and PPE evaluation; supervisors, who must conduct hazard assessments, ensure personnel training, maintain certifications, and perform visual inspections; and employees, who must obtain training and authorization, inspect equipment before use, report hazards, and use designated PPE. General Shop Safety requirements address hazard assessments through Job Hazard Analyses (JHAs) and Standard Operating Procedures (SOPs) for operations involving potential energy sources, mechanical systems, hazardous materials, and structural hazards. Hand tool requirements mandate appropriate tool selection, proper condition maintenance, and secure storage in tool belts or pouches. Portable powered tools must comply with 29 CFR § 1910.243, with workers requiring training and authorization; battery-operated tools require adherence to manufacturer charging instructions and specific disposal protocols for lithium-ion batteries in non-metallic packaging. Machine Safety encompasses general requirements including 29 CFR § 1910.211 compliance, clearly labeled power disconnects per NFPA 79, red emergency stop buttons, and secure equipment anchoring. Machine operations require thorough inspections, removal of adjusting keys before use, proper work-piece clamping, use of push sticks instead of hands, prohibition on loose clothing and gloves, appropriate PPE including safety glasses and hearing protection, and prohibition on solo operation and operation while under the influence of drugs or alcohol. Machine guarding specifications require guards on gears, pulleys, belts, and shafts to a height of seven feet, with application of Lockout/Tagout (LOTO) controls when guards are removed. Special requirements address magnesium machining, prohibiting moisture use, requiring dry machining only, maintaining magnesium fire extinguishers, and forbidding chip accumulation and vacuum removal. Maintenance and unjamming procedures require machine shutdown and LOTO compliance per APR 8715.1 Chapter 31. Training requirements mandate supervisors provide instruction covering Standard Operating Procedures, safe work practices, PPE selection and use, and manufacturer safety instructions. The directive references applicable standards including 29 CFR § 1910, NFPA 79, NPR 8715.1 Chapters 8 and 13, and ANSI C18.2M Part 2-2021. Compliance is verified through management reviews, self-assessments, internal audits, and Agency triennial audits. The document became effective April 10, 2024, and expires April 10, 2029.
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APR 8715.1 This document is uncontrolled when downloaded or printed.
Verify current version before use at:
https://cdms.nasa.gov/directive/library/ARC
Ames Procedural Requirements
APR 8715.1
Effective Date: __April 10, 2024_______
Expiration Date: __ April 10, 2029______
COMPLIANCE IS MANDATORY
Subject: Chapter 14 – Shop Safety
Responsible Office: Code QH / Occupational Safety, Health, and Medical Service Division
CHANGE LOG
Status
[Baseline /Revision
/Cancelled]
Document Revision
Date of Change
Description
Revision 2 12/14/2018 Changed format to comply with the Ames Quality Management System (AQMS) requirements and added “Document Change Log” and Preface. Removed statement about Union Contract maintaining a list of situations where working alone is prohibited. The applicable policy is APR 8715.1 Chapter 6. Added section 14.2.4 Battery Operated Portable tools. Added several elements to 14.3 Machine Safety.
Revision 3 4/10/24 Moved 14.3.4 Magnesium or other Pyrophoric Material Requirements from Chapter 20 – Fire Protection to this Chapter.
Minor changes to paragraph numbering throughout the document.
Attachment 6 https://cdms.nasa.gov/directive/library/ARC
TABLE OF CONTENTS
PREFACE
P.1 Purpose
P.2 Applicability
P.3 Authority
P.4 Applicable Documents and Forms
P.5 Measurement/Verification
P.6 Cancellation
CHAPTER 14 SHOP SAFETY
14.1 Responsibilities
14.2 General Shop Safety
14.3 Machine Safety
APPENDIX A. ACRONYMS
APPENDIX B. REFERENCES
https://cdms.nasa.gov/directive/library/ARC
PREFACE
P.1 PURPOSE
This chapter provides general shop safety requirements for personnel employed by or working at
Ames Research Center (ARC) not specifically covered in other chapters.
P.2 APPLICABILITY
This directive is applicable to ARC and associated facilities.
This directive applies to contractors, grant recipients, or parties to agreements only to the extent specified or referenced in the appropriate contracts, grants, or agreements.
In this directive, all mandatory actions (i.e., requirements) are denoted by statements containing the term "shall." The terms "may" or "can" denote discretionary privilege or permission, "should" denotes a good practice and is recommended, but not required, "will" denotes an expected outcome, and "are/is" denotes descriptive material.
In this directive, all document citations are assumed to be the latest version unless otherwise noted.
P.3 AUTHORITY
NPR 8715.1, NASA Safety and Health Programs NPR 8715.3, NASA General Safety Program Requirements
P.4 APPLICABLE DOCUMENTS AND FORMS
Occupational Safety and Health Standards, 29 CFR § 1910 APR 8715.1 Chapter 31, Lockout/Tagout NFPA 79, Electrical Standard for Industrial Machinery (Latest Edition)
P.5 MEASUREMENT/VERIFICATION
Verification of conformance to requirements in this directive are measured through Center and
Responsible Organizational management reviews, self-assessments, and subsequent analysis and reports of conformance to requirements, as well as periodic internal audits.
Verification and measurement for compliance to this directive will be tracked through Agency triennial audit.
P.6 CANCELLATION
APR 8715.1 Chapter 14, Shop Safety, dated December 14, 2018.
https://cdms.nasa.gov/directive/library/ARC
CHAPTER 14 SHOP SAFETY
14.1 Responsibilities
14.1.1 Occupational Safety, Health, and Medical Service Division (Code QH) shall:
a. Provide Safety consulting and/or technical evaluations of the shop work areas at the request of the shop supervisor.
b. Maintain oversight of shop hazard assessment activities, safe work procedures, and employee safety training.
c. Provide specialized safety training at the request of the shop supervisor and maintain training records.
14.1.2 Ames Health Unit shall:
a. Provide medical consultation and examination relative to the government employee’s ability to conduct the shop work assignment, as referred by their supervisor and/or is required.
b. Provide medical consultation and evaluation to government employees for PPE or other occupational health services, such as providing prescription safety glasses to qualified government employees.
14.1.3 Supervisors shall:
a. Complete a workplace hazard assessment to determine if applicable hazards are present, or are likely to be present, for all shop operations. Supervisors can use the following when conducting a hazard assessment of the area: ARC Personal Protective Equipment (PPE) Hazard Assessment Survey form ARC 861; Job Hazard Analysis (JHA); Standard Operating Procedures (SOPs). Sample JHAs can be found on Code Q website https://q.arc.nasa.gov/job-hazard-analysis.
b. Ensure that personnel are trained in shop safety aspects and are qualified to operate authorized equipment.
c. Provide appropriate PPE (e.g., hard hat, safety glasses, hearing protection etc.) for employees and visitors to ARC shop location.
d. Resolve safety issues reported by workers.
e. Maintain documentation of hazard assessments as performed.
f. Maintain documentation of personnel training.
g. Utilize ARC safety resources, such as Code Q website and consultations with Code QH staff, as needed, to fulfill safety responsibilities.
h. Perform periodic visual inspections of work areas to ensure that safety controls are in place, are being used, and are effective.
i. Provide supervision to ensure adherence to safety requirements, special instructions, procedure compliance, and the use of protective devices.
j. Maintain personnel certifications, e.g., Rigging, Welding, Heavy Equipment, per NPR 8715.1, Chapters 8 and 13.
https://cdms.nasa.gov/directive/library/ARC
14.1.4 Employees shall:
a. Get training, skill, and authorization for each tool or machine used.
b. Read and observe the safety requirements delineated in tool and machine manufacturer’s instructions, shop SOPs, JHAs, and this chapter.
c. Report any potential safety hazard to the supervisor.
d. Use, control, and maintain specified PPE.
e. Inspect tools, machines, and guards before each use.
f. Do not use damaged equipment that could pose a hazard.
14.2 General Shop Safety
14.2.1 Hazard Assessment
14.2.1.1 The shops supporting ARC activities contain a few inherent hazards. A variety of controls, both mechanical and administrative, should be applied to shop hazards to either eliminate or minimize the risk to personnel. The requirements of this chapter consist of general operating safety rules and guidelines that complement typical controls applied to mitigate shop hazards. Additional requirements applied to address unique hazards shall be posted in each shop area, contained in the respective training programs, addressed in work procedures, and/or identified through the shop supervisor.
14.2.1.2 Develop a JHA or written procedures (e.g., SOPs) wherever the following hazards exist:
a. Potential energy sources (e.g., electrical power, compressed gasses, hot/cold items, suspended items, large amounts of liquids, and/or flammable materials, etc.).
b. Mechanical systems (e.g., transverse/rotating equipment, power transmission devices, lifting equipment, etc.).
c. Hazardous materials (e.g., paints, lubricants, solvents, castings, stock, alloys, etc.).
d. Structural features (e.g., sharp edges, slip/trip hazards, etc.).
14.2.2 Hand tools
14.2.2.1 Use the appropriate tool for the job. Makeshift arrangements such as the use of a screwdriver as a chisel, a pair of pliers as a wrench, a wrench as a hammer, or overloading a wrench by using a pipe extension (cheater bar) on the handle shall not be employed.
14.2.2.2 Use only tools that are in good condition and free from damaged, broken, splintered, or defective parts. Be sure that hammer heads are secure and tight on handles.
14.2.2.3 Mushroomed heads on cold chisels, punches, hammers, etc. are to be ground down to avoid injury from flying particles or handling.
14.2.2.4 Use suitable shields to cover the dangerous parts of sharp-edged or pointed tools.
14.2.2.5 Standard tool belts, grunt bags, pouches, boxes, or similar should be used for carrying tools.
14.2.3 Portable Powered Tools
14.2.3.1 Tools shall be guarded in accordance with 29 CFR § 1910.243.
14.2.3.2 Workers shall be trained, qualified, and authorized for tools utilized.
https://cdms.nasa.gov/directive/library/ARC
14.2.3.3 Tools and usage shall comply with 29 CFR § 1910.241, et seq.
14.2.3.4 Provide JHAs for portable powered tools and identify specific PPE requirements.
14.2.3.5 JHAs shall be readily available where tools are used.
14.2.3.6 Inspect portable power tool cord for any signs of damage. If damaged, remove and secure tool from use, repair by a qualified electrician (i.e., competent person) or replace as warranted.
14.2.3.7 Battery Operated Portable Tools
14.2.3.8 Avoid overcharging; follow manufacturer’s charging instructions.
14.2.3.9 When disposing of a lithium-ion battery, each cell or battery must be placed in an individual, non-metallic package that completely encloses the cell or battery. Mark package with shop contact information and process in accordance with Ames Hazardous Waste protocols.
14.2.3.10 If you suspect battery damage has occurred, do not use. Contact the Hazardous Waste group and dispose of accordingly.
14.3 Machine Safety
14.3.1 General Machine Safety
14.3.1.1 Prevent injuries such as debris in the eye, cuts, and caught/crush entrapment through diligent compliance with 29 CFR §1910.211, et seq. and written SOPs.
14.3.1.2 Disconnecting means shall be in accordance with NFPA 79.
14.3.1.3 The main power disconnect to the machine shall be clearly labeled and the operator familiar with its location.
14.3.1.4 Noisy equipment shall be identified with noise hazard warning labels.
14.3.1.5 Decals or placards with similar statements shall be affixed to power tools and machines that produce hazardous noise levels. Signs and decals shall have wording in black letters on a yellow background.
14.3.1.6 Emergency stop buttons shall be colored RED.
14.3.1.7 Manually operated valves and switches controlling the operation of equipment and machines shall be clearly identified and readily accessible.
14.3.1.8 Equipment and machinery shall be securely placed and anchored, to prevent moving.
14.3.1.9 Lamps used for general illumination of machine operation shall be protected from accidental contact or breakage.
14.3.2 Machine Operations
14.3.2.1 The following safety rules shall be observed at all times when operating machinery:
a. Operate machines in accordance with manufacturer’s recommendations.
b. Prior to use, inspect machine tools thoroughly, remove adjusting keys, chucks, and wrenches.
c. Never attempt to operate any machine tool until you fully understand how it works and know how to stop it quickly.
https://cdms.nasa.gov/directive/library/ARC
d. Be familiar with the hazards and controls in the JHA for the machine.
e. Review and update the JHA when the machine is moved to a new location or modified from its original design function.
f. Always secure the work piece to the machine with an appropriate clamping device
g. The power shut-off switch or emergency stop shall be within reach of the operator's position at each machine.
h. Follow machine feed rates; don’t force materials into or pull them through faster than the machine can process them.
i. Use push sticks, not your hands, to feed stock materials.
j. Do not operate any machine tool without proper lighting.
k. Foot-operated switches shall be guarded or arranged to prevent accidental actuation by personnel or falling objects.
l. Never reach into an operating machine.
m. Know where your hands are at all times.
n. Always stop the machine before cleaning it or taking measurements of the workpiece.
o. Know which machines are operated manually and which could start automatically by computer control.
p. Review the Safety Data Sheet (SDS) for stock being machined.
q. Never wear loose or torn clothing, secure long hair. These items can become caught in revolving machine parts.
r. Gloves should never be worn when operating machinery except when absolutely necessary.
s. Use appropriate PPE; safety glasses, goggles, face shield, hearing protection, nonslip shoes, toe reinforcement, respirator or otherwise as stated in the JHA or posted in the shop.
t. Sufficient clearance shall be provided around and between machines to allow for safe operations, set up and servicing, material handling, and waste removal.
u. Clean up with dustpan and brush or compressed air with appropriate OSHA nozzle
v. Do not leave a manual machine running unattended.
w. Do not work alone when operating machine tools.
x. Do not operate any machine tool while under the influence of drugs, alcohol, or any medication that could cause drowsiness.
14.3.3 Machine Guarding
14.3.3.1 These rules shall be observed for all machines that have exposed moving, rotating, or cutting parts:
a. Learn about the machines you use. Know where the moving, rotating, and cutting parts are located.
https://cdms.nasa.gov/directive/library/ARC
b. Gears, pulleys, belts, couplings, ends of shafts having keyways, and other revolving or reciprocating parts shall be guarded to a height of 7 feet above the floor. The guards should be removed only when repairing or adjusting the machine and must be replaced before operating.
c. Apply LOTO controls when machine guard is removed.
d. Recessed or safety setscrews should be used in collars and on all revolving or reciprocating members of the machine tool or its equipment.
e. Ensure that all guards and interlock safety devices are installed and properly positioned.
f. Review the machine’s JHA to determine if all appropriate guarding is in place.
g. Install additional point-of-operation guarding when needed for planned work.
h. Supervisor or designee verifies appropriate use of guards during machine operations.
14.3.4 Magnesium
14.3.4.1 The following precautions shall be observed when using magnesium, pyrophoric, and toxic materials:
a. Provide a written Job Hazard Analysis (JHA) for work tasks described in this paragraph.
b. Any deviations from these procedures may be made only with supervisory approval.
c. Machine magnesium DRY; never use moisture. On occasion, some oils are permitted. Check with the supervisor.
d. While machining magnesium, keep a magnesium fire extinguisher in the immediate area for instant use; review directions on the extinguisher before beginning machining operation.
e. Accumulation of magnesium chips on or around machines is forbidden; clean accumulation often and place in a special container marked MAGNESIUM; keep the container in an open area.
f. Blowing chips with air is forbidden. This practice may produce a future fire-hazard potential.
g. Never use a vacuum cleaner for chip removal from the machine.
h. Deliver the container with chips to a supervisor at the end of the shift for proper disposal.
14.3.5 Maintenance and Unjamming
14.3.5.1 Before performing maintenance or clearing a jam, turn the machine off and wait until the parts have stopped motion.
14.3.5.2 Use proper LOTO procedures specified in chapter 31.
14.3.5.3 Follow manufacturers instruction for lubrication of a machine. Injury to the operator and damage to the machine may result from improper procedures.
14.3.6 Training
14.3.6.1 Supervisors shall provide training on job tasks for proper installation, adjustment, operation and maintenance from machine supplier, on-the-job training, and supplemental sources. At a minimum training shall include.
a. Standard Operating Procedures for all laboratory operations.
b. Safe work practices and techniques.
https://cdms.nasa.gov/directive/library/ARC
c. The selection and use of designated PPE.
d. Manufacturer's instructions for safely using tools and equipment.
https://cdms.nasa.gov/directive/library/ARC
APPENDIX A. ACRONYMS
AQMS
APR
Ames Quality Management System Ames Procedural Requirement
ARC Ames Research Center
CFR Code of Federal Regulations JHA Job Hazard Analysis LOTO Lockout/Tagout
NASA National Aeronautics and Space Agency NPR NASA Procedural Requirement
PPE Personal Protective Equipment SOP Standard Operating Procedure https://cdms.nasa.gov/directive/library/ARC
APPENDIX B. REFERENCES
B1. Supervisors Safety Manual, 10th Edition, 1992, National Safety Council, Chicago, Illinois 60611.
B2. Accident Prevention Manual for Industrial Operations, 10th Edition, 1992, National Safety Council, 444 North Michigan Avenue, Chicago, Illinois 60611.
B3. 29 CFR 1910 Subpart O, Machinery and Machine Guarding B4. 29 CFR 1910 Subpart P, Hand and Portable Powered Tools
B5. 29 CFR 1926 Subpart K, Electrical. 1926.441, Batteries and Battery Charging B6. NPR 8715.3D, NASA General Safety Program Requirements
B7. ANSI C18.2M Part 2-2021, Portable Rechargeable Cells and Batteries – Safety Standard, dated March 17, 2021 B8. NFPA 79, Electrical Standard for Industrial Machinery (Latest Edition)
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