dafman91-203.pdf

BY ORDER OF THE

SECRETARY OF THE AIR FORCE

DEPARTMENT OF THE AIR FORCE

MANUAL 91-203

25 MARCH 2022

Safety

AIR FORCE OCCUPATIONAL SAFETY,

FIRE, AND HEALTH STANDARDS

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available on the e-Publishing website at www.e-Publishing.af.mil for downloading or ordering.

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: HQ AFSEC/SEG Certified by: AF/SEI

(Colonel Lawrence A. Nixon)

Supersedes: AFMAN 91-203, 11 December 2018 Pages: 350

This manual implements Air Force Policy Directive (AFPD) 91-2, Safety Programs, and parts of

Title 29 Code of Federal Regulations (CFR), Chapter XVII, Occupation Safety and Health

Administration (OSHA), Department of Labor (DoL), This manual defines the Air Force’s minimum safety, fire protection and occupational health standards, including additional requirements not addressed by the OSHA standards. This manual applies to individuals at all levels who are uniformed members or civilian employees of the Regular Air Force, Air Force Reserve

(AFR), the Air National Guard (ANG), the United States (US) Space Force, the Civil Air Patrol, and those who are contractually obligated to comply with Department of the Air Force (DAF) publications. This manual requires the collection and/or maintenance of information protected by the Privacy Act of 1974 authorized by Department of Defense Instruction (DoDI) 5400.11, DoD

Privacy and Civil Liberties Programs. The applicable SORNs F024 AF IL C, Motor Vehicle

Operator’s Records, and F031 AF SP L, Traffic Accident and Violation Reports, are available at https://dpclo.defense.gov/Privacy/SORNs.aspx. Ensure all records generated as a result of processes prescribed in this publication adhere to AFI 33-322, Records Management and

Information Governance Program, and are disposed in accordance with Air Force Records

Disposition Schedule, which is located in the Air Force Records Information Management System.

Refer recommended changes and questions about this publication to the Office of Primary

Responsibility (OPR) using the AF Form 847, Recommendation for Change of Publication; route

AF Forms 847 from the field through the appropriate functional chain of command. Refer to Air

Force Instruction (AFI) 91-202, The US Air Force Mishap Prevention Program, for guidance on submitting requests for variance to requirements of this publication. Report conflicts in guidance between this publication, federal standards or other DAF directives through Major Command http://www.e-publishing.af.mil/ https://dpclo.defense.gov/Privacy/SORNs.aspx

2 DAFMAN 91-203 25 MARCH 2022

(MAJCOM), Field Command (FLDCOM), Direct Reporting Unit (DRU) or Field Operating

Agency (FOA) occupational safety offices to Headquarters Air Force Safety Center, Occupational

Safety Division, Standards and Policy Branch (HQ AFSEC/SEGS), 9700 G Avenue SE, Kirtland

AFB NM 87117-5670. This manual may be supplemented at any level, but to ensure standardization, any organization supplementing this manual must send the implementing publication to AFSEC/SEG for review and coordination before publishing. The authorities to waive wing/delta/unit-level requirements in this publication are identified with a Tier (“T-0, T-1, T-2, T-3”) number following the compliance statement. See DAFI 33-360, Publications and

Forms Management, for a description of the authorities associated to the Tier waiver approval authority. For non-tiered compliance items, the requestor’s commander is the approval authority.

Submit requests for waivers through the chain of command to the appropriate Tier/Waiver approval authority, or alternately, to HQ AFSEC/SEG for variances/exemptions to non-tiered compliance items. The requesting office must send a copy of all approved waivers to the OPR of the Higher Headquarters publication being waived (see DAFI 33-360, paragraph 1.9.4.3.4) within

30 days of approval. Sending an email to the waived publication OPR that includes a completed

AF Form 679, Air Force Publication Compliance Item Waiver Request/Approval, or equivalent, will suffice. Requirements in this publication are mandatory, unless otherwise indicated. Not included are safety, fire prevention and occupational health requirements addressed in specific equipment technical orders (TOs). Compliance with the attachments in this publication is mandatory. The use of the name or mark of any specific manufacturer, commercial product, commodity or service in this publication does not imply endorsement by the DAF.

SUMMARY OF CHANGES

This document is substantially revised and must be completely reviewed. Major changes include reducing the size of the standard by referring the reader to OSHA safety standards and other consensus standards that were previously repeated. Chapters with similar information were combined to reduce redundancy and streamline requirements; a substantial amount of figures and tables were removed, and where appropriate, referenced to the original source; and language for administrative devices, that includes locks and tags not used for hazardous energy control have been moved to Chapter 17. Other changes include implementing required changes to fall protection procedures mandated by the Air Force Audit Agency, clarifying process safety management requirements, eliminating the requirement to use specific National Stock Numbers for specific equipment and personal protective equipment, clarifying fire protection and prevention requirements, and a rewrite of Chapter 9.

Chapter 1—INTRODUCTION 14

1.1. Objective

1.2. Roles and Responsibilities

1.3. Variances, Exemptions and Letters of Interpretation

1.4. How to Use This Document

1.5. Applying Standards

1.6. Job Hazard Analysis (JHA)

DAFMAN 91-203 25 MARCH 2022 3

1.7. Military-Unique and Nonmilitary-Unique Policy

1.8. Documentation

1.9. First Aid and Cardiopulmonary Resuscitation (CPR) Training

1.10. Bloodborne Pathogen Training

1.11. Process Safety Management (PSM) of Highly Hazardous Chemicals

Chapter 2—GENERAL WORK PROCEDURES 21

2.1. General Information

2.2. Hazards

2.3. Jewelry

2.4. Housekeeping

2.5. Office Safety

2.6. Ergonomics

2.7. Roll-up Doors

2.8. Receiving/Loading Docks

2.9. Walk-in Refrigerators and Freezers

2.10. Manual Material Handling

2.11. 3D Printers

Chapter 3—WEATHER SAFETY 30

3.1. Responsibilities

3.2. Two-tier Notification System

3.3. General Lightning Safety for all AF Activities and Operations. Note:

Chapter 4—SERVICES OPERATIONS 32

4.1. Purpose

4.2. Laundry

4.3. Lodging

4.4. Food Service Operations

Chapter 5—NONDESTRUCTIVE INSPECTION (NDI) AND OIL ANALYSIS 34

5.1. Scope

5.2. Safety Precautions

5.3. Supervisor Responsibilities

5.4. Nondestructive Inspection Equipment and Fire Protection Systems

4 DAFMAN 91-203 25 MARCH 2022

Chapter 6—FIRE PREVENTION AND PROTECTION 36

6.1. Fire Extinguishers

6.2. General Requirements

Chapter 7—WALKING – WORKING SURFACES 41

7.1. General Requirements

7.2. Stairs and Ramps Requirements. Note

7.3. Fixed Ladders

7.4. Portable Ladders

Table 7.1. Ladders Workload Ratings

7.5. Stepladders

7.6. Emergency Operations

Chapter 8—ELECTRICAL SAFETY 56

8.1. General Information

8.2. Receptacles

8.3. Plugs

8.4. Flexible Cords and Extension Cords

8.5. Disconnecting Means (Circuit Breakers and Disconnect Switches)

8.6. Guarding of Live Parts

8.7. Equipment Grounding

8.8. Restrictions

8.9. Electrical Installations and Equipment

8.10. Additional Electrical Equipment Requirements

8.11. Electronic Equipment

8.12. Emergency Equipment (Electrical Safety)

8.13. Automated External Defibrillator (AED)

8.14. Lighting

8.15. Moisture Guarding

8.16. Under-voltage Protection

8.17. Work on Energized Equipment

Chapter 9—EMERGENCY SHOWER AND EYEWASH UNITS 64

9.1. Scope

9.2. Regulations and Standards

DAFMAN 91-203 25 MARCH 2022 5

9.3. Equipment - Acquisition

9.4. Location and Installation

9.5. Maintenance and Testing

9.6. Training

Chapter 10—GROUNDS, MOWING AND AGRICULTURE TRACTORS 67

10.1. General Information

10.2. Inspection/Maintenance

10.3. Mowing

10.4. Edgers

10.5. Commercial Mowing and Turf Care Equipment

10.6. Tree and Hedge Trimming

10.7. Fertilizers

10.8. Irrigation Systems

10.9. Agricultural Tractors and Implement Attachments

Chapter 11—HAND TOOLS, PORTABLE POWER TOOLS AND MACHINERY 72

11.1. General Requirements

11.2. Tools

11.3. Machinery

Table 11.1. OSHA Standards for Machinery

11.4. Specific Requirements for Machinery

Chapter 12—MATERIAL HANDLING EQUIPMENT (MHE) 79

12.1. Scope

12.2. General Requirements

12.3. Acquisition

12.4. Inspections

12.5. Nuclear-certified Lifting Equipment

12.6. Qualification and Training

12.7. Testing

12.8. Powered Industrial Trucks

12.9. Conveyors

12.10. Manual Hoisting and Pulling Devices

12.11. Hoists

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12.12. Slings

12.13. Mobile and Locomotive Cranes

12.14. Derricks

12.15. Related Hoisting Equipment

12.16. Portable Automotive Lifting Devices and Related Equipment

Table 12.1. Quick Reference Guide for Material Handling Equipment

Table 12.2. Synthetic Web Slings. 1,000 Pounds per Inch of Width – Single Ply (Rated in capacity in pounds)

Table 12.3. Synthetic Web Slings. 1,200 Pounds per Inch of Width – Single Ply (Rated capacity in pounds)

Table 12.4. Synthetic Web Slings. 1,600 Pounds per Inch of Width – Single Ply (Rated capacity in pounds)

Table 12.5. Number of Spacing of Clips for Ropes of Various Sizes. (If manufacturer’s recommendations are not available)

Chapter 13—FALL PROTECTION 101

13.1. Scope

13.2. Hazards and General Information

13.3. Fall Protection Program

13.4. Fall Hazard Survey

13.5. Written Fall Protection and Rescue Procedures

13.6. Fall Protection Plans

13.7. Training

13.8. Equipment Inspections and Maintenance

13.9. Fall Mishap Reporting

Chapter 14—PERSONAL PROTECTIVE EQUIPMENT (PPE) 109

14.1. Scope

14.2. Training

14.3. Hazard Assessment and Equipment Selection

14.4. Proper Care and Maintenance

Chapter 15—TRAINING SYSTEMS 115

15.1. Scope

15.2. General Requirements

15.3. Facility Requirements

DAFMAN 91-203 25 MARCH 2022 7

15.4. Training Systems Requirements

15.5. Requirements of Wheeled Vehicle Egress Assistance Trainers

15.6. Requirements for Aircraft Flight and Similar High Value Training Systems

15.7. Upgrade of Existing Aircraft Flight and Similar High Value Training Systems

Chapter 16—MOBILE ELEVATING WORK PLATFORMS AND SCAFFOLDING 124

16.1. Scope

16.2. Hazards

16.3. Training

16.4. Inspections and Maintenance

16.5. Vehicle-Mounted Elevating and Rotating Work Platforms

16.6. Manually-Propelled and Self-Propelled Mobile Work Platform and Scaffolds

(Towers)

16.7. Scaffolding

Table 16.1. Types of Scaffolding (not all inclusive)

Chapter 17—MISHAP PREVENTION SAFETY SIGNS, TAGS AND LABELING 141

17.1. Scope

Table 17.1. Regulatory Guidance for Mishap Prevention Safety Signs, Tags and Labeling

17.2. Hazards and General Information

17.3. Training

17.4. Sign Requirements

17.5. Safety, Fire Prevention and Health Tag Requirements

17.6. Administrative Devices

17.7. Safety Color Coding, Labeling and Marking for Piping Systems

Chapter 18—HYRDROCARBON FUELS 149

18.1. Scope

18.2. Hazards

18.3. Training

18.4. Personal Protective Equipment (PPE)

18.5. Housekeeping

18.6. Fire Prevention and Protection

18.7. Inspection

18.8. Fuel Storage Systems

18.9. Fuel Servicing Operations

8 DAFMAN 91-203 25 MARCH 2022

18.10. Aircraft Servicing

18.11. Fuel Laboratory Operations

Chapter 19—COMPRESSED GASES 161

19.1. Scope

19.2. General Requirements

19.3. Storage

19.4. Disposal and Shipping

Chapter 20—WELDING, CUTTING AND OTHER HOT WORK 165

20.1. Scope

20.2. Hazards

20.3. Acquisition

20.4. Training and Qualification

20.5. Precautions

20.6. Personnel Protective Equipment (PPE)

20.7. Types of Welding Equipment

20.8. Hot Work Locations

20.9. Contractors

20.10. Hot Work Permit

Table 20.1. How To Fill Out AF Form 592, Hot Work Permit

Chapter 21—HAZARDOUS ENERGY CONTROL 175

21.1. Scope

Table 21.1. Common Hazardous Energy Categories and Corresponding Sources

21.2. Hazardous Energy Control Program

21.3. Training

21.4. Program Self-Inspections

21.5. Authorized Lockout and Tagout Devices

21.6. Hazardous Energy Control Procedures

Figure 21.1. Eight-Step Hazardous Energy Control Procedure Checklist

Figure 21.2. Three-Step Release from Hazardous Energy Control Procedure Checklist

21.7. Hazardous Energy Control Procedures When Establishing An Electrically Safe

Work Condition

21.8. Contractors

DAFMAN 91-203 25 MARCH 2022 9

Chapter 22—FLAMMABLES AND COMBUSTIBLES 182

22.1. Scope

22.2. Hazards

22.3. Training

22.4. Personal Protective Equipment (PPE)

22.5. Housekeeping

22.6. Fire Protection

22.7. Building and Equipment Requirements

22.8. Handling and Dispensing

Table 22.1. Classifications of Flammable and Combustible Liquids

Chapter 23—CONFINED SPACES 194

23.1. Scope

23.2. Definitions

23.3. Hazards

Table 23.1. Common Hazards Involving Confined Spaces (Not all-inclusive)

23.4. Responsibilities

23.5. Written Confined Space Program

23.6. Entry into Immediately Dangerous to Life and Health (IDLH) Conditions

23.7. Master Entry Plan

23.8. Non-permit Confined Space Entry

23.9. MAJCOM/FLDCOM Mandatory Aircraft Confined Spaces

23.10. Training

23.11. Instructions for Completing the AF Form 1024, Confined Spaces Entry Permit

23.12. Contractor Requirements

Chapter 24—AIRCRAFT FLIGHTLINE – GROUND OPERATIONS AND ACTIVITIES 208

24.1. Scope

24.2. Specific Requirements

24.3. Flightline Potentially Hazardous Areas and Operations

24.4. Additional PPE Requirements

24.5. Aircraft Parking Requirements

24.6. Adverse Weather Conditions

Table 24.1. Adverse Weather High Wind Safeguards

24.7. Towing and Taxiing Aircraft

10 DAFMAN 91-203 25 MARCH 2022

24.8. Aircraft Jacking Operations

24.9. Aircraft Engine Operations

24.10. Jet Aircraft Requirements

24.11. Aircraft Cleaning

24.12. Aircraft Tire Mounting and Servicing Operations

24.13. Flightline Vehicle Operations

24.14. Aircraft Hangar Operations

24.15. Aircraft Shop and Flightline Maintenance Operations

24.16. Fall Protection Requirements

24.17. Safety in Flightline Contractor Operations

Chapter 25—CIVIL ENGINEERING 232

25.1. Scope

Table 25.1. Relevant CE-related References

25.2. Supervisory Responsibilities

25.3. Compressed Air

25.4. Shoring and Trenching

25.5. Barricades and Traffic Signs

25.6. Sanitation

25.7. Restrictions

25.8. Equipment Operations and Pavements

25.9. Carpentry and Structural Maintenance

25.10. Protective Coating Maintenance

25.11. Plumbing Maintenance

25.12. Refrigeration and Air Conditioning Maintenance

25.13. Heating Systems and Central Heating Plant Maintenance

25.14. Water and Wastewater Treatment

25.15. Aircraft Arresting Systems

25.16. Miscellaneous

Chapter 26—CRYOGENIC LIQUIDS 241

26.1. Specific Hazards

26.2. General Requirements

26.3. Cryogenic Facility Siting

26.4. Occupational Health

DAFMAN 91-203 25 MARCH 2022 11

26.5. Safety Precautions When Working With LN2, LOX, LH2 and LNG

26.6. Fire Prevention and Protection

26.7. Electrical Safety

26.8. Housekeeping

26.9. Receipt, Storage and Issue of LN2 or LOX

26.10. Common Cryogenic Liquids, Their Properties and Precautions

Chapter 27—INTERIOR SPRAY FINISHING 255

27.1. Scope

27.2. Safety

27.3. Health/Environmental Protection

27.4. Fire Prevention

27.5. Ventilation Systems

27.6. Storage and Handling

27.7. Electrical

27.8. Location of Paint Shops, Dope Shops and Spray-Finishing Operations

27.9. Paint Spray Booths

27.10. Compressed Air Paint Spraying

27.11. Drying Ovens

27.12. Spray Painting of Aircraft

27.13. Painting Radio and Radar Equipment

27.14. Electrostatic Paint Spraying

27.15. Airless Paint Spraying

27.16. Aerosol Cans of Spray Paint

27.17. Powder Coating

27.18. Organic Peroxide Coating

Chapter 28—COMMUNICATION CABLE, ANTENNA AND COMMUNICATION

SYSTEMS 269

28.1. Scope

28.2. General Safety Practices

28.3. Training

28.4. Safety Equipment and Devices

28.5. Tools and Equipment

28.6. High Voltage

12 DAFMAN 91-203 25 MARCH 2022

28.7. Aerial Work

28.8. Ground-Controlled Approach Radars

28.9. Single Phase Portable and Vehicle-Mounted Generators

28.10. Repairs and Adjustments

28.11. Power Distribution Panels

28.12. Radar and Microwave Equipment

28.13. Entering Manholes, Handholes and Unvented Vaults

28.14. Cables

28.15. Special Purpose Vehicles

Chapter 29—BATTERIES – MAINTENANCE, HANDLING AND STORAGE

REQUIREMENTS 281

29.1. Scope

29.2. Safety

29.3. General Facility and Equipment Requirements for Battery Rooms and Areas

29.4. Fire Prevention

29.5. Ventilation Systems

29.6. Storage and Handling

29.7. Electrical

29.8. Installation and Care of Vehicle and Support Equipment Batteries

29.9. Aircraft Battery and Electrical System Specific Requirements

Chapter 30—MOTOR VEHICLE – OPERATIONS AND MAINTENANCE 287

30.1. Scope

Table 30.1. Additional Guidance for Motor Vehicle – O&M

30.2. Specific Hazards

30.3. General Safety

30.4. Occupational Health

30.5. Facility and Equipment Requirements for Vehicle Maintenance Operations

30.6. Fire Prevention

30.7. Ventilation

30.8. Cleaning With Solvents

30.9. Paint Shop

30.10. Air Compressors

30.11. Compressed Gas Cylinders. (Note

DAFMAN 91-203 25 MARCH 2022 13

30.12. Lifting Devices

30.13. Wheel and Tire Maintenance

30.14. Maintenance Operations

Chapter 31—COMPOSITE MATERIALS 311

31.1. Scope

31.2. Specific Responsibilities

31.3. General Requirements

31.4. Specific Applications

31.5. Hazardous Waste Disposal

31.6. Special Mishap Considerations

31.7. Use of Composite Materials in New System Acquisition, and System and Process

Modifications

Chapter 32—PRECISION MEASUREMENT EQUIPMENT LABORATORY 314

32.1. Scope

32.2. Hazards

32.3. Ventilation Systems

32.4. Electrical Safety for PMEL Operations

32.5. Radioactive Material Safety

32.6. Equipment/Component Cleaning

32.7. Tools and Equipment

Attachment 1—GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 321

Attachment 2—SAFETY INSTRUCTIONS TO BE POSTED IN ALL INSTALLATION

FUELS LABORATORIES 350

14 DAFMAN 91-203 25 MARCH 2022

Chapter 1

INTRODUCTION

1.1. Objective.

1.1.1. OSHA safety guidance published in the DoL 29 CFR series provides employees a safe and healthful workplace. OSHA dictates what must be accomplished in the workplace, but in some cases, not necessarily how it will be accomplished, or by whom. Refer to AFSEC

Occupational Safety SharePoint® site for Introduction to OSHA Standards training information located at https://cs2.eis.af.mil/sites/10178/Pages/SEGHomeV2.aspx.

1.1.2. Commanders are responsible for the safety of their facilities and personnel, including the correction of all identified hazards and deficiencies in their workplaces. This publication compliments AFI 91-202, The US Air Force Mishap Prevention Program, and assigns responsibilities to individuals or functions to help commanders manage their safety and health program, ensuring they comply with OSHA and DAF guidance. This publication provides uniform guidance, which safety staffs and commanders may supplement when additional or more stringent safety, fire prevention and health criteria are required.

1.1.3. MAJCOMs/FLDCOMs may have more stringent or restrictive requirements than those contained in this publication or other Air Force Occupational Safety and Health (AFOSH) publications/standards. Therefore, all requests for interpretations or clarifications concerning these publications must be forwarded through the servicing MAJCOM/FLDCOM/DRU/FOA safety, health and/or civil engineering organization, as applicable. Note: With respect to references in this manual to installation medical treatment facilities, pursuant to 10 United

States Code (USC) § 1073c, the Defense Health Agency, a combat support agency, will be responsible for their administration and management; the details of these responsibilities are still being worked and finalized. (T-0)

1.2. Roles and Responsibilities.

1.2.1. All Headquarters Air Force elements shall ensure policies and procedures are consistent with the guidance of this manual.

1.2.2. Headquarters, Air Force Safety Center (AFSEC) shall:

1.2.2.1. Formulate and execute policy. Clarify roles, responsibilities and guidance applicable to all areas of safety.

1.2.2.2. Act as approval authority for safety variances associated with T-1 and above wing/delta-level requirements in this manual.

1.2.3. MAJCOMs, FLDCOMs, DRUs and FOAs shall provide program oversight and supplement safety and health guidance, as necessary, ensure safety training is available to subordinate units. (T-1)

1.2.4. Commanders and Functional Managers shall:

1.2.4.1. Ensure and promote applicable occupational safety and health (OSH) guidance for workplace and operations is available to all personnel. (T-1) https://cs2.eis.af.mil/sites/10178/Pages/SEGHomeV2.aspx

DAFMAN 91-203 25 MARCH 2022 15

1.2.4.2. Ensure and promote compliance with occupational safety, fire prevention and health program requirements in their areas of responsibility. (T-1)

1.2.4.3. Ensure a safe and healthful workplace is provided via a monthly spot-inspection program. (T-1)

1.2.4.4. Provide employees training in job safety, fire prevention and health, as required by:

1.2.4.4.1. OSHA directives. (T-0)

1.2.4.4.2. AFOSH directives. (T-1)

1.2.4.4.3. Air Force Policy Directives (AFPD). (T-1)

1.2.4.4.4. Air Force Instructions (AFI), Air Force Manuals (AFMAN) and any other associated directives. (T-1)

1.2.5. Supervisor. Supervisors will require workers to notify them in advance if they have a medical condition or are taking medications that could interfere with their safe performance of assigned duties. (T-1) Supervisors shall ensure employees are trained, using manufacturer’s instructions or lesson plans, prior to the operation of any type of equipment or accomplishing assigned tasks. (T-1) Supervisors shall routinely evaluate employees on the proper and safe operation of all equipment and associated personal protective equipment (PPE). (T-1) Unsafe behaviors shall be corrected on the spot. (T-1) Supervisors will provide such instruction at time of initial assignment and refresher training, as required. (T-1) If instruction is not available, supervisors shall accomplish a job hazard analysis (JHA). (T-1) Additional supervisor responsibilities can be found in AFI 91-202.

1.2.6. DAF personnel (military and civilian) shall:

1.2.6.1. Comply with OSH guidance. (T-0)

1.2.6.2. Promptly report unsafe working conditions/activities including any safety, fire and health hazards and deficiencies to the supervisor. (T-1)

1.2.6.3. Promptly report injuries and illnesses to the supervisor, e.g., occupational illness and on-duty injury to DoD military and civilian personnel, and off-duty injury to DoD military personnel. (T-1)

1.2.6.4. Comply with PPE requirements, including its use, inspection and care; ensure required guards, interlocks and enclosures are properly used. (T-1)

1.2.6.5. Notify supervisors in advance if they have a medical condition or are taking medications that could interfere with their safe performance of assigned duties. (T-1)

1.3. Variances, Exemptions and Letters of Interpretation.

1.3.1. The affected work center shall process a request for variance or exemption when it is impossible to meet AFOSH guidance due to operational needs, mission impact or technical reasons. (T-1) When requesting a variance or exemption, the work center leadership must identify and implement interim control measures to reduce the degree of risk associated with the hazard in order to protect personnel, equipment and/or property. (T-1) The process for requesting a variance or exemption is provided in AFI 91-202.

16 DAFMAN 91-203 25 MARCH 2022

1.3.2. Air Force letters of interpretation (LOIs) are written in response to AFOSH-related inquiries submitted from DAF personnel or units regarding specific aspects of or terminology in this manual or with OSHA standards and guidance, and applicable adopted national consensus safety guidance. AFSEC/SEG is responsible for responding to and providing clarification to meet the operational needs of the DAF. LOIs provide this response and are intended to clarify the application of established standards, policy or procedure, but they may not, in themselves, establish or revise DAF policy or procedure. The LOI specifically cites the source policy or procedure document being interpreted and include the time duration of the

LOI.

1.4. How to Use This Document.

1.4.1. This publication incorporates appropriate parts of the 29 CFR §§ 1910 and 1926 standards that relate to Air Force/Space Force operations. References to other Air Force publications and national consensus standards are provided as appropriate. Air Force/Space

Force activities must comply with OSHA requirements at all times, unless the military-unique exemption applies in accordance with Department of Defense Instruction (DoDI) 6055.01, DoD Safety and Occupational Health (SOH) Program, and AFI 91-202. (T-0)

1.4.2. This publication is intended for use by fire, safety and health professionals, commanders, functional managers, supervisors and employees. It provides AFOSH requirements that shall provide equal or greater protection than applicable federal regulatory standards. (T-1) The information in this publication is for the protection of employees, Air

Force/Space Force property and equipment, and to ensure compliance with Federal law. Note:

This publication does not apply to state employees or ANG members not in federal status.

Note: This publication may contain criteria not fully compatible with host-nation safety criteria. In case of conflict, safety offices shall facilitate coordinated concerns through their hierarchy for resolution.

1.5. Applying Standards. Air Force and Space Force personnel must comply with all applicable safety guidance during Air Force/Space Force operations. (T-1) If, or when, there is conflicting guidance, use the guidance that provides the most protection for the employee until conflict resolution is attained.

1.5.1. Compliance.

1.5.1.1. This Air Force standard contains both horizontal and vertical fire, safety and health standards/requirements within the various chapters. Generally, horizontal standards/requirements apply across all industries/activities; whereas, vertical standards/requirements apply to a specific industry/activity, e.g., construction or telecommunications. There are occupational safety and health mandates contained within one chapter of this publication which could be interpreted as vertical; however, because safety rules are established based upon hazards and not just tasks, the mandate may, in fact, be applied horizontally across several occupations. Example: Confined space requirements in Chapter 23 – primarily a General Industry application, but may apply to applicable portions of aircraft maintenance tasks. For this reason, broad guidance cannot be codified to address all situations. If there is doubt, contact the local safety office for guidance. Resolve locally, when possible, using risk management techniques focused on the hazard and hazard mitigation.

DAFMAN 91-203 25 MARCH 2022 17

1.5.1.2. When AFOSH guidance or other established safety criteria does not cover a situation, use non-Air Force standards to include, but not limited to, national consensus standards, professional safety and health standards, and other Federal agency standards.

1.5.2. OSHA Requirements. DAF safety officials cannot grant exemptions to OSHA standards, only the Department of Labor has the authority to grant exemptions to OSHA standards. Refer to AFI 91-202 for additional guidance.

1.5.3. National Consensus Standards. National consensus standards referenced in this document have been adopted, in whole or in part, for DAF use and list the standard, part/document number, part/document title and date of standard, as applicable, e.g., American

Society of Mechanical Engineers (ASME) B30.9, Slings, and National Fire Protection

Association (NFPA) 70, National Electrical Code. Personnel needing access to American

National Standards Institute (ANSI) and/or other national consensus standards can contact the installation occupational safety office for guidance and assistance.

1.5.4. Joint Base Safety Standard Compliance. DAF personnel at Joint Bases will follow safety requirements outlined in the approved support agreement(s) developed in accordance with DoDI 4000.19, Support Agreements, and AFI 25-201, Intra-Service, Intra-Agency, and

Inter-Agency Support Agreements Procedures. (T-1) When there is conflicting guidance, use the guidance that provides the most protection. Further conflicts in safety program requirements will first be coordinated through senior leadership at the local level for resolution.

(T-1) If resolution at the local level cannot be obtained, the unit will refer conflicts to

AFSEC/SEG through the appropriate MAJCOM/FLDCOM/FOA/DRU safety office for cross-service resolution. (T-1)

1.6. Job Hazard Analysis (JHA). JHAs are conducted on all work processes, where appropriate, to identify potential fire, safety or health hazards, determine appropriate training and personal protective equipment (PPE), and include preventative measures in procedures to mitigate the hazards. Refer to AFI 91-202 for additional guidance.

1.7. Military-Unique and Nonmilitary-Unique Policy. The DAF shall apply AFOSH, OSHA, DoD and other non-DoD regulatory safety and health standards and guidance to military-unique workplaces, operations, equipment and systems in whole or in part, insofar as practicable. (T-0)

DAF directive guidance is to comply with AFOSH, OSHA, DoD and other non-DoD regulatory safety and health standards and guidance as provided under federal law and in accordance with

DoD policy with respect to military-unique and nonmilitary-unique workplaces, operations, equipment and systems. (T-0)

1.7.1. Military-Unique. The term military-unique refers to military and civilian workplaces, operations, equipment and systems unique to the national defense mission. This includes combat and operation, testing and maintenance of military-unique equipment and systems, such as military weapons, military-unique aircraft, early warning systems, military space systems, ordnance and tactical vehicles. It also includes operations such as peacekeeping missions; field maneuvers; combat training; aerospace operations; military flight and missile operations; military-unique research, development, test and evaluation activities; and actions required under national defense contingency conditions.

1.7.2. Nonmilitary-Unique. The term nonmilitary-unique refers to military and civilian workplaces, operations, equipment and systems comparable generally to those of the private

18 DAFMAN 91-203 25 MARCH 2022

sector. Examples include facilities involved and work performed in the repair and overhaul of weapons, aircraft or vehicles (except for equipment trials); construction; supply services; civil engineer or public works; medical services; and office work. DAF shall comply with AFOSH, OSHA, DoD and other non-DoD regulatory safety and health standards and guidance with respect to nonmilitary-unique workplaces, operations, equipment and systems, regardless of whether work is performed by military or civilian personnel.

1.8. Documentation. This publication specifies use of Air Force Technical Order (AFTO) Form

95, Significant Historical Data, AFTO Form 244, Industrial/Support Equipment Record, or other appropriate inspection, maintenance and general purpose forms for documenting maintenance and inspection actions. With expanding use of automated systems for tracking these activities, requiring specific paper forms may impede use of more efficient automated processes. Therefore, use of automated systems for documenting inspections, maintenance and other activities is acceptable in place of specified AFTO Forms 95 and 244 or other appropriate inspection, maintenance and general purpose forms if they contain the same information called for by the designated form. Electronic signatures or other unique personal identifiers (not initials) are acceptable. While this publication offers an optional alternative to paper forms, MAJCOMs, FLDCOMs, Numbered Air Forces (NAFs), local procedures, Technical Orders (TOs) and other

DAF guidance may continue to require use of these forms. Check the prescribing directive(s) before discontinuing use of any forms.

1.9. First Aid and Cardiopulmonary Resuscitation (CPR) Training. Initial first aid/CPR training shall be accomplished prior to assigning an individual duties where first aid/CPR are requirements of the position. (T-1) All employees requiring CPR training will receive refresher training before current CPR certification expires. (T-1) Unit CPR instructors may be trained by the local medical group or trained directly by the American Red Cross or American Heart

Association. Unit CPR instructors will, in turn, train unit personnel. (T-1) If CPR training is not provided by the host medical facility, any instructor receiving training directly from the American

Red Cross or American Heart Association will be required to maintain the requirements and pay the costs related to maintaining a certification. (T-1) The unit CPR instructor will ensure training includes public access defibrillator training in accordance with AFI 44-177, Public Access

Defibrillator Program. (T-1) Note: Self-aid and buddy care (SABC) may be used to fulfill first aid training requirements; however, it does not cover CPR. Employees performing duties with risk of severe cuts, burns or electrocution, or perform duties in remote locations away from emergency responders will have a plan for immediate medical response pending definitive transfer and care.

(T-0) Note: Remote location is defined as emergency care that is more than three to four minutes from the workplace.

1.10. Bloodborne Pathogen Training. Any person with routine duties where tasks and procedures involve reasonably anticipated exposure to blood or other potentially infectious materials (e.g., individual responsible for rendering medical assistance as part of their duties) must be trained and enrolled in the Bloodborne Pathogen Program in accordance with 29 CFR §

1910.1030, Bloodborne Pathogen, and AFI 44-108, Infection Prevention and Control Program.

(T-0) A person may be required to receive separate first responder training outside of bloodborne pathogen, e.g., First Aid, CPR, SABC. For workplaces with employees that meet this job description, supervisors shall establish a written exposure control plan and conduct training in accordance with 29 CFR § 1910.1030. (T-0)

DAFMAN 91-203 25 MARCH 2022 19

1.11. Process Safety Management (PSM) of Highly Hazardous Chemicals.

1.11.1. The DAF implements 29 CFR § 1910.119, Process Safety Management of Highly

Hazardous Chemicals, requirements to prevent or minimize consequences of catastrophic releases of toxic, reactive, flammable or explosive chemicals. The criteria in 29 CFR §

1910.119 shall be used in its entirety for program implementation and application unless otherwise specified. (T-0) PSM may also apply to explosives and pyrotechnics. Refer to 29

CFR § 1910.119, AFI 91-202 and Defense Explosives Safety Regulation (DESR)

6055.09_AFMAN 91-201, Explosives Safety Standards, for additional guidance. Note: Also refer to MIL-STD-882E, Department of Defense Standard Practice: System Safety, Task 108, Hazardous Materials Management Plans, which is the DoD’s standard governing risk assessment and safety data requirements for hazardous materials management.

1.11.2. 29 CFR § 1910.119, Appendix A, List of Highly Hazardous Chemicals, Toxics and

Reactives, contains a list of chemicals used in the DAF, whether the chemical is in a mixture or a byproduct of a chemical process and/or reaction.

1.11.3. Responsibilities.

1.11.3.1. The installation Occupational Safety (SEG) office shall:

1.11.3.1.1. Serve as the focal point for coordinating and implementing PSM procedures, to include leading the PSM team if one is required. (T-1)

1.11.3.1.2. With the assistance of the Hazardous Material Management Process Team, conduct and document an assessment of the installation’s chemical quantities on-hand that are listed in 29 CFR § 1910.119, Appendix A. (T-0)

1.11.3.1.2.1. If the chemicals on the installation do not exceed the threshold quantities listed in 29 CFR § 1910.119, Appendix A, the installation SEG will document the assessment and note that, in accordance with 29 CFR § 1910.119, Appendix A, threshold quantities, a PSM program is not required. (T-1) In this case, a reassessment will be accomplished and documented at a minimum of every three years from the initial assessment or sooner when new chemicals or increased quantities of chemicals listed in 29 CFR § 1910.119, Appendix A, are introduced to the installation. (T-1)

1.11.3.1.2.2. If the chemicals on the installation exceed the threshold quantities listed in 29 CFR § 1910.119, Appendix A, the safety office will advise the installation commander a formal PSM program and PSM team led by the installation safety office is required by this manual. (T-0)

1.11.3.1.3. Ensure copies of OSHA-required PSM documentation are maintained in the installation safety office for OSHA’s review for the life of the process. (T-0)

1.11.3.1.4. Assess installation operations and advise NAF/SE, FLDCOM/SE and

MAJCOM/SE of the number and type of operations that fall under the PSM program.

(T-1)

1.11.3.2. The Installation PSM Program Team, when required, shall:

1.11.3.2.1. Include representatives from the installation occupational safety office, Bioenvironmental Engineering (BE), HMP Program OPR (also called the installation

20 DAFMAN 91-203 25 MARCH 2022

Hazardous Material Management Process team lead), Civil Engineer (CE), Environmental Management office, Fire & Emergency Services (F&ES) Flight, Emergency Management Flight and all highly hazardous chemical users, as defined in

29 CFR § 1910.119. (T-1)

1.11.3.2.2. Develop and coordinate the installation plan for employee participation.

(T-0)

1.11.3.2.3. Meet as necessary to conduct and review process hazard analyses (PHA). (T-1)

Note: The PSM Program Team is not necessarily the same team that performs the

PHA in 29 CFR § 1910.119(e). These PHAs will be performed by internal staff members, through a contract, or a combination of both. (T-0)

DAFMAN 91-203 25 MARCH 2022 21

Chapter 2

GENERAL WORK PROCEDURES

2.1. General Information. This chapter provides general work procedures for a safe and healthful workplace, to include the wearing of jewelry, workplace safety, ergonomics and housekeeping. In accordance with AFI 91-202, the supervisor will ensure job safety training outline will evaluate and identify PPE requirements. (T-1) All facilities shall comply with DoD standards, UFC 3-600-01, Fire Protection Engineering for Facilities, DAF guidance and NFPA

101, Life Safety Code. (T-0)

2.2. Hazards. Physical hazards are the most common workplace hazards. Hazards can include working from heights; slips, trips and falls; falling objects; spills; faulty equipment; and noise hazards. Other examples of workplace hazards include:

2.2.1. Radiation. Ionizing and non-ionizing are the two basic types of radiation. 29 CFR §

1910.1096, Ionizing Radiation, and AFMAN 48-148, Ionizing Radiation Protection, list requirements for working in an area with ionizing radiation. Non-ionizing radiation includes most radio frequency energy sources, light sources and lasers. Protection levels and requirements are outlined in AFI 48-139, Laser and Optical Radiation Protection Program, and AFI 48-109, Electromagnetic Field Radiation (EMFR) Occupational and Environmental

Health Program.

2.2.2. Noise. Noise can cause hearing loss and/or prevent hearing of warning signals.

Hazardous noise issues are common to industrial and outside work areas such as flightlines and maintenance areas, but should be uncommon in administrative work areas. Concerns with workplace noise levels, should be evaluated. The installation Bioenvironmental Engineer (BE), or joint base equivalent, conducts occupational environmental hazard risk assessments, then recommends appropriate engineering controls, administrative actions or PPE. Refer to AFI 48-

127, Occupational Noise and Hearing Conservation Program, and 29 CFR § 1910.95, Hearing

Conversation Program, for additional guidance.

2.2.3. Thermal Exposure. Refer to AFI 48-151, Thermal Injury Prevention Program, for guidance and information on thermal injuries and their prevention/treatment.

2.2.4. Inhalation. Inhalation of hazardous materials can cause acute (irritation, allergic reaction and/or damage the lungs and respiratory tract) and/or chronic (permanent damage, disease and cancer) health effects. Inhalation hazards need to be evaluated by BE to determine if respiratory protection is required. Refer to 29 CFR § 1910.134, Respiratory Protection, and

AFI 48-137, Respiratory Protection Program, for guidance and information.

2.2.5. Chemical. Chemical hazards may exist in everyday products such as cleaning supplies, pesticides and paints. It may also include vapors and fumes from welding and brazing, solvents, and flammable or combustible liquids. Refer to 29 CFR § 1910.1200, Hazard Communication, AFI 90-821, Hazard Communication (HAZCOM) Program, and Chapter 22 of this publication.

2.3. Jewelry. Jewelry, such as rings, watches, bracelets and necklaces, that presents a potential for catching, snagging, pulling or tearing shall be evaluated, controlled and restricted from wear if it presents a hazard to the employee or operation. (T-1)

22 DAFMAN 91-203 25 MARCH 2022

2.3.1. Finger Rings. Personnel engaged in work in industrial areas, performing maintenance on aircraft, vehicles, equipment or machinery will not wear rings of any material type. (T-0)

Personnel will comply with established safety precautions to prevent personal injury. (T-0)

Rings shall not be worn while performing the following activities (this list is not all-inclusive):

2.3.1.1. Climbing, ascending or descending activities where personnel could fall or jump from elevated surfaces. (T-0) This includes personnel working on elevated surfaces, e.g., ladders, scaffolds, platforms, roofs, or high reach vehicles, e.g., refuelers, wreckers, sweepers, dump trucks and stake bed trucks.

2.3.1.2. Materials handling operations, e.g., warehousing, parts handling, operating equipment, packing and crating, and attaching/detaching equipment to tow vehicles. (T-0)

2.3.1.3. Any type of work where personnel are exposed to moving machinery, rotating or revolving parts, or activities that could result in their hands being caught by a moving part and injured. (T-0)

2.3.1.4. Performing work or inspection on or near energized electrical parts where contact could result in injury or damage to equipment. (T-0) Articles such as jewelry, earrings, rings, hair fasteners, bracelets, key chains or metallic ID (dog) tags with metal chains shall also be removed and metal framed eyeglasses shall be secured by a band or cord to prevent them from falling into energized electrical circuits or machinery. (T-0) Note: This prohibition includes conductive jewelry such as necklaces, bracelets, watches, etc. These items will permit inadvertent electrical current transfer to the worker.

2.3.1.5. Performing maintenance or inspections on aircraft or ground support equipment, including civil engineering-type or transportation-type maintenance where such activity could result in injury. (T-0)

2.3.1.6. Performing work on or around high temperature equipment where contact with these surfaces could result in injury. (T-0)

2.3.2. Eyewear. Metal eyeglasses shall be secured by a band or cord to prevent them from falling into energized electrical circuits or moving industrial machinery. (T-1) Note: It‘s best practice to wear nonmetallic eyeglasses and neck lanyards (e.g., ID cardholders) with a breakaway safety band, lanyard or cord to prevent them from falling into energized electrical circuits or moving industrial machinery.

2.3.3. Medic-Alert. Personnel that require identification for medical issues are permitted to don non-dangling/non-hazardous medical alert items, e.g., clasps, medical cards in hard hats, identification badge holders, to warn co-workers of potential medical issues. Supervisors shall ensure such items do not create hazards during worker’s assigned tasks. (T-0)

2.3.4. These restrictions do not apply to administrative and support personnel assigned office duties or visiting these areas, but not performing industrial work.

2.4. Housekeeping.

2.4.1. Floors and Walking Surfaces. Keep areas where personnel walk and work free of potential tripping and slipping hazards such as tools, electrical cords, air lines and packaging materials.

DAFMAN 91-203 25 MARCH 2022 23

Clean up spills as soon as possible and post warnings until cleanup is complete. This includes sidewalks, parking lots etc. Facility managers shall promptly report potholes and uneven surfaces to CE. (T-0)

2.4.1.1. Facility managers will ensure removal of snow and ice from all facilities walkways, sidewalks, handicap ramps and work areas expediently where they may create a hazard or interfere with the work. (T-0) If ice cannot be readily removed, sand or other approved materials shall be applied. (T-1) Snow and icicles above walkways shall be removed by the unit or a work request shall be submitted for areas that cannot be reached.

(T-1)

2.4.1.2. The supervisor will ensure telephone and electrical cords are placed where they do not pose tripping hazards. If placement in foot-traffic areas is unavoidable, cords and cables shall be properly protected by molded housings, bridges or other covers approved for such use to prevent tripping. (T-0)

2.4.1.3. Briefcases, wastebaskets, etc., shall be placed under desks, against a wall or otherwise out of the way. (T-1)

2.4.1.4. Repair or replace stair and floor defects, such as loose tiles, broken steps, torn carpeting, loose or curled mats, and worn, frayed or damaged anti-slip material on stairs or inadequate lighting.

2.4.1.5. Do not position a step stool or ladder in front of a door if the door can swing and contact the stool, ladder or individual using it. Station a guard at the door if a step stool or ladder must be placed in a doorway. (T-1)

2.4.2. Hazardous Materials and Waste. Refer to AFMAN 32-7002, Environmental

Compliance and Pollution Prevention, for approved hazardous waste disposal procedures and guidance. Safety Data Sheets required for each hazardous chemical, in accordance with AFI

90-821, can assist with the proper identification of waste prior to being removed for disposal, especially for wastes generated as a result of unused and/or expired hazardous chemicals. The supervisor will ensure use or storage of flammable liquids shall be kept to a minimum and not exceed the maximum allowable quantities specified in Chapter 22. (T-1)

2.4.3. Packing Supplies and Recycled Materials. Non-soiled excelsior (fine wood shavings), straw, shredded paper, recyclable cardboard, recyclable paper and other packing/recyclable materials shall be stored in an isolated fire-resistant area and/or container. (T-0). Small supplies of packing materials, which are kept in shops for immediate use, shall be stored in metal or noncombustible covered containers. (T-1) Remove hazardous material markings and/or placards, protruding nails, brads and staples from crates, cases, packing boxes, casks, boards and lumber to prevent injury to personnel.

2.4.4. Electric Buffing Machines. Supervisors shall ensure electric buffing machines are equipped with under-voltage/overvoltage sensing and cutoff controls. (T-1)

2.4.5. Stacking Materials. Refer to Air Force Joint Manual (AFJMAN) 23-210, Joint Service

Manual (JSM) For Storage and Materials Handling, for guidance on stacking materials. When materials are stacked to a height less than 15 feet, maintain an 18-inch clearance below ceiling sprinkler deflectors. If the stack is over 15 feet in height, increase the clearance to 36 inches

(when only joists, rafters, beams and roof trusses exist, without a ceiling constructed below, a

24 DAFMAN 91-203 25 MARCH 2022

36 inches clearance will also be required. (T-1) Position all stacks of materials to ensure an

18-inch clearance around light or heating fixtures, or follow the manufacturer‘s instructions, regardless of height.

2.4.6. Lighting Fixtures. The supervisor will ensure tubular light fixtures (fluorescent/light-emitting diode) without self-locking tubes shall have shields, clamps or other devices installed to keep the tubes from falling out of the fixture. (T-1)

2.4.7. Waste disposal containers in food handling environments shall be equipped with disposable liner material and emptied not less frequently than once each working day, unless unused. Containers shall be maintained in a clean and sanitary condition and sanitized at least once monthly. (T-1) All other waste containers shall be cleaned, as needed. (T-1) Exterior garbage cans shall be securely covered when not actually being filled or emptied. (T-1)

2.4.8. General Safe Practices. All areas, shops, yards, buildings and mobile equipment facilities/areas shall be maintained in a clean and orderly condition. (T-0) Supervisors and employees are responsible for good housekeeping in or around the work area they are supervising or working.

2.4.8.1. Do not place material where it creates a hazard for employees or visitors, by falling, being a trip hazard or causing the collapse of structures. (T-0)

2.4.8.2. Keep aisles and passageways clear of tripping hazards. (T-0)

2.4.8.3. Remove nails from loose lumber or the points turned down. (T-0)

2.4.8.4. Properly store tools and supplies. (T-0)

2.4.8.5. Do not block, obstruct or disconnect switches, distribution panels and alarm supply boxes preventing ready access. (T-0)

2.4.8.6. Stack wire reels with strips of wood between reels. (T-0)

2.4.8.7. Keep noncombustible materials neat and plainly marked, and in designated cabinets. (T-1)

2.4.8.8. Compressed Air. Compressed air shall not be used for cleaning purposes except where reduced to less than 30 psi, and only with effective chip guarding and PPE. (T-0)

Follow TO, manufacturer’s instruction or local procedures as applicable. Ensure the nozzle discharge tip is a diffuser type. Compressed air shall not be used to blow chips or other debris from an employee’s body or clothing. Screens, barriers or protective cones attached to air nozzles shall be used to prevent flying chips and particles from striking the eyes and skin of the operator.