Attch 6 - AFOSHSTD 91-501.pdf

BY ORDER OF THE

SECRETARY OF THE AIR FORCE

AIR FORCE OCCUPATIONAL SAFETY

AND HEALTH STANDARD 91-501

7 JULY 2004

Safety

AIR FORCE CONSOLIDATED

OCCUPATIONAL SAFETY STANDARD

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 AFSC/SEGS Certified by: HQ AFSC/SEG (John W. Russell JR) Supersedes AFOSHSTD91-501, 16 September 2002.

Pages: 381

This revision implements Air Force Policy Directive (AFPD) 91-3, Occupational Safety and Health, and furthers consolidation of Air Force Occupational Safety and Health standards. Major Commands (MAJ- COM), direct reporting units (DRU), and field operating agencies (FOA) may supplement this standard when additional or more stringent safety, fire protection, and health criteria is required. Lower-level orga-nizations, installation and above, may also supplement this standard. MAJCOMs will approve these sup-plements. Refer to Air Force Instruction (AFI) 91-301, Air Force Occupational and Environmental Safety, Fire Protection, and Health (AFOSH) Program, for instructions on submitting requests for vari-ance to requirements of this standard. Report conflicts in guidance between this standard, federal stan-dards, or other Air Force directive in writing through MAJCOM, DRU, or FOA ground safety offices to Headquarters Air Force Safety Center, Ground Safety Division, Safety Engineering and Standards Branch (HQ AFSC/SEGS), 9700 G Avenue SE, Suite 222D, Kirtland AFB NM 87117-5670. Records Disposi-tion. Ensure that all records created by this AFOSH Standard are maintained and disposed of IAW AFMAN 37-139, “Records Disposition Schedule.” This standard defines the Air Force’s minimum safety, fire protection, and occupational health standards. Requirements in this publication are mandatory, unless indicated otherwise, and apply to all US Air Force organizations, US Air Force Reserve Command (AFRC) units and all Air National Guard (ANG) personnel, with the exception of state employees. This standard implements parts of Occupational Safety and Health Administration (OSHA) 29 Code of Federal Regulations (CFR), and includes additional requirements not addressed by the OSHA standard. Not included are safety, fire prevention, and occupational health requirements addressed in specific equip-ment technical orders (TO).

No T.O., AFOSH Standard, or Operating Instruction can possibly address every hazard or potential haz-ard that may arise from a specific task or combination of tasks. Where situations exist that are not covered by existing directives, use an Operational Risk Management (ORM) process to assess risk associated with those situations and determine adequate safeguards or procedures to manage the risk. Refer to AFPAM 90-902, Operational Risk Management (ORM) Guidelines and Tools, for guidance on using the ORM process. NOTE: The ORM process may not be used to violate directives or other regulatory guidance.

Normal waiver or variance procedures must be followed in all cases (refer AFI 91-301).

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2 AFOSHSTD91-501 7 JULY 2004

SUMMARY OF CHANGES

This revision incorporates Interim Change IC 2004-01. This interim change (IC 2004-01) corrects admin-istrative errors and clarifies references to standards and other portions of this document. Changed or revised material is indicated by a bar (|).

Chapter 1— INTRODUCTION 11

1.1. Purpose:

1.2. How to Use This Document

1.3. Responsibilities:

1.4. Job Safety Analysis (JSA)

1.5. Occupational Safety and Health Administration (OSHA) Requirements

1.6. National Consensus Standards

Figure 1.1. Job Safety Analysis Guide

Chapter 2— HUMAN FACTORS 17

2.1. Human Factors

2.2. Responsibilities

Chapter 3— PHYSICAL HAZARDS 18

3.1. Hazards

3.2. Responsibilities:

Chapter 4— MANUAL MATERIAL HANDLING AND LIFTING TECHNIQUES 20

4.1. Hazards and Human Factors:

4.2. Manual Handling

4.3. Lifting and Carrying

4.4. Training

4.5. Minimizing Manual Material Handling Hazards:

4.6. Proper Lifting Methods

Figure 4.1. How to Lift Properly

4.7. Carrying Methods

4.8. Carrying Items Up or Down Stairways:

4.9. Manual Material Handling Equipment

4.10. Inspection of Materials

AFOSHSTD91-501 7 JULY 2004 3

4.11. Personal Protective Equipment (PPE)

4.12. Inspection and Maintenance of Manual Handling Equipment (MHE):

4.13. Other Safety Requirements:

Figure 4.2. Manual Material Handling and Lifting Techniques Checklist

Chapter 5— HOUSEKEEPING 30

5.1. Floors and Walking Surfaces

5.2. Scraps and Combustible Waste

5.3. Packing Supplies

5.4. Electric Buffing Machines

5.5. Walls and Ceilings

5.6. Stacking Materials

5.7. Lighting Fixtures

5.8. Trash:

Figure 5.1. Housekeeping Checklist

Chapter 6— FIRE PROTECTION AND PREVENTION 33

6.1. Hazards:

6.2. General Requirements:

Figure 6.1. Fire Protection and Prevention Checklist

Chapter 7— WALKING SURFACES, GUARDING FLOOR AND WALL OPENINGS, FIXED INDUSTRIAL STAIRS, AND PORTABLE AND FIXED LADDERS 43

7.1. General Information

7.2. Hazards and Human Factors associated with Walking and Working Surfaces

7.3. Requirements:

7.4. Fixed Industrial Stairs and Ramps:

7.5. Fixed Ladders

7.6. Portable Ladders:

7.7. Additional Requirements for Stepladders:

Table 7.1. Uniform Combination of Stairway Rise and Tread Dimension

Table 7.2. Ramp Installation Dimension. (NFPA 101, Life Safety Code, Ramps, Classification)

Table 7.3. ANSI Standard on Ladders

4 AFOSHSTD91-501 7 JULY 2004

Table 7.4. Ladders Workload Ratings

Table 7.5. Minimum Overlap for Two-Section Extension Ladders

Figure 7.1. Walking Surfaces, Guarding Floor Openings Wall Opening, Fixed I ndustrial Stairs, and Portable and Fixed Ladders

Chapter 8— ELECTRICAL SAFETY 67

8.1. Hazards

8.2. Electrical Installation and Equipment

8.3. Receptacles

8.4. Plugs

8.5. Flexible Cords and Extension Cords

8.6. Disconnecting Means, (Circuit Breakers and Disconnect Switches)

8.7. Guarding of Live Parts

8.8. Equipment Grounding:

8.9. Restrictions

8.10. Electrical Installations and Equipment:

8.11. Additional Electrical Equipment Requirements:

8.12. Electronic Equipment

8.13. Emergency Equipment (Electrical Safety Boards)

8.14. Automated External Defibrillator (AED):

8.15. Consult the local CE facility design section whenever specific guidance on lighting is required

8.16. Moisture Guarding

8.17. Undervoltage Protection

8.18. Control Switches

Figure 8.1. Electrical Safety Checklist

Chapter 9— JEWELRY 76

9.1. Finger Rings:

9.2. Other Jewelry

Figure 9.1. Jewelry Safety Checklist

Chapter 10— OFFICE SAFETY 78

10.1. General Information

AFOSHSTD91-501 7 JULY 2004 5

10.2. Hazards and Human Factors:

10.3. Responsibilities

10.4. Basic Office Safety Procedures:

10.5. Office Ergonomics

10.6. Lifting Requirements

10.7. General Office Equipment:

10.8. Working with Video Display Terminals (VDT)

10.9. Elevators:

10.10. Storage:

10.11. Consult the local CE facility design section whenever specific guidance on lighting is required

10.12. Facility managers:

10.13. Pest Control

10.14. Noise:

10.15. Temperature

10.16. Personal Protective Equipment (PPE)

10.17. Training:

Figure 10.1. Office Safety Checklist

Chapter 11— ADVERSE WEATHER 87

11.1. Responsibilities:

11.2. General Lightning Safety for all AF Activities and operations:

Figure 11.1. Adverse Weather Safety Checklist

Chapter 12— HAND TOOL AND PORTABLE POWER TOOLS 90

12.1. Hazards and Human Factors:

12.2. Tool Procurement:

12.3. General Requirements:

12.4. Nonpowered Hand Tools

12.5. Powered Portable Hand Tools

12.6. Personal Protective Clothing and Equipment:

Figure 12.1. Hand and Tools and Portable Tools Safety Checklist

6 AFOSHSTD91-501 7 JULY 2004

Chapter 13— FALL PROTECTION 103

13.1. General Requirements

13.2. Personal Fall Arrest Systems (PFAS)

13.3. For fall protection on aircraft surfaces, see AFOSH Standard 91-100, Aircraft Flight Line – Ground Operation & Activities

Figure 13.1. Fall Protection Checklist

Chapter 14— PERSONAL PROTECTIVE EQUIPMENT (PPE) 111

14.1. AFOSH 48-9, Radio Frequency Radiation (RFR) Safety Program, and AFOSH Standard 48-139, Laser Radiation Protection Program

14.2. Hazards:

14.3. Job Safety Analysis (JSA)

14.4. Responsibilities:

14.5. General Requirements:

14.6. Specific Requirements:

Table 14.1. Rubber Insulating Equipment Voltage Requirements

Table 14.2. Alternating Current (AC) Prooftest Requirements

Table 14.3. Glove Test – Water (NOTE: 1, 2)

Figure 14.1. Personal Protective Equipment (PPE) Checklist

Chapter 15— GROUNDS, LAWN CARE AND MOWING SAFETY 131

15.1. General Information

Figure 15.1. Grounds, Lawn Care and Mowing Safety Checklist

Chapter 16— VEHICLE MOUNTED ELEVATING AND ROTATING WORK

PLATFORMS, MANUALLY PROPELLED AND SELF-PROPELLED

MOBILE WORK PLATFORMS, AND ROLLING (MOBILE)

SCAFFOLDS (TOWERS) 142

16.1. General Information

16.2. Hazards and Human Factors

16.3. General Requirements

16.4. Vehicle-Mounted Elevating and Rotating Work Platforms:

16.5. Manually-Propelled and Self-Propelled Mobile Work Platform and Scaffolds (Towers):

Figure 16.1. Vehicle-Mounted Elevating and Rotating Work Platforms

AFOSHSTD91-501 7 JULY 2004 7

Chapter 17— SCAFFOLDING 159

17.1. General Information

17.2. Hazards and Human Factors

17.3. Requirements:

Table 17.1. Scaffold Grade Planking

Table 17.2. Tube and Coupler Scaffolds – Light Duty

Table 17.3. Tube and Coupler Scaffold – Medium Duty

Table 17.4. Tube and Coupler Scaffold – Heavy Duty

Table 17.5. Outrigger Scaffolds

Table 17.6. Ladder-Type Platforms

Table 17.7. Bricklayers’ Square Scaffolds

Table 17.8. Horse Scaffolds

Figure 17.1. Scaffolding Checklist

Chapter 18— MACHINERY 178

18.1. General Information

18.2. Hazards:

18.3. General Requirements:

18.4. Woodworking Machinery:

18.5. Metal Working Machinery:

18.6. Permanently Installed Grinding Machines:

Table 18.1. OSHA Standards

Figure 18.1. Flange Installation

Figure 18.2. Types 16, 17, 18, 18R, and 19 Cone and Plug Wheels

Figure 18.3. Bench and Floor Stand Grinder Guard Exposure Angles

Figure 18.4. Bench and Floor Stand Grinder Guard Exposure Angles When Contact Below the Horizontal Plane of the Spindle is Required

Figure 18.5. Cylindrical Grinder Guard Exposure Angles

Figure 18.6. Top Grinding Guard Exposure Angles

Figure 18.7. Machinery Checklist

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Chapter 19— EMERGENCY SHOWER AND EYEWASH UNITS 251

19.1. General Information

19.2. Effective Dates

19.3. Responsibilities

19.4. Equipment:

19.5. Acquisition

19.6. Location

19.7. Installation

19.8. Control Valve and Actuating Mechanism:

19.9. Alarms and Lights

19.10. Maintenance and Testing:

19.11. Training

19.12. Water Supply

19.13. Performance Specifications and Installation Requirements for Permanently- Installed Units:

Figure 19.1. Permanent Combination Emergency Shower and Face and Eyewash Unit

Figure 19.2. Self-Contained Non-Pressurized Eye Wash Unit

Figure 19.3. Eyewash Bottle

Figure 19.4. Hand-Held Drench Hose (Permanent)

Figure 19.5. Activating Mechanisms

Figure 19.6. Multiple-Spray Shower and Eyewash

Figure 19.7. Wall-Mounted Permanent Eye and Face Wash

Figure 19.8. Emergency Shower and Eyewash Units Checklist

Chapter 20— SAFETY COLOR CODING, LABELING, AND MARKING FOR PIPING

SYSTEMS 270

20.1. General Information

20.2. Hazards and Human Factors:

20.3. General Requirements:

20.4. Employee Training

20.5. Classification of Material in Piping Systems

Table 20.1. Legend and Color Band Dimensions

Figure 20.1. Exact Identification Always by Name of the Material Contained

AFOSHSTD91-501 7 JULY 2004 9

Table 20.2. Examples of Legend

Table 20.3. Classification of Hazards of Materials and Designation of Colors¹. Reference detailed descriptions in paragraph 20.3.6

Figure 20.2. Safety Color Coding, Labeling, and Marking For Piping Systems Checklist

Chapter 21— HAZARDOUS ENERGY CONTROL (LOCKOUT AND TAGOUT)

AND MISHAP PREVENTION SIGNS AND TAGS. 277

21.1. General Information

21.2. Hazards

21.3. General Requirements:

21.4. Specifications For and Usage of Signs:

21.5. Specifications For and Use of Tags:

21.6. Specifications for and Usage of Lockout and Tagout Devices:

21.7. Sample Lockout or Tagout Procedures:

21.8. Examples of Color Applications

21.9. Examples of Wording for Mishap Prevention Signs

Figure 21.1. Danger Sign

Figure 21.2. Caution Sign

Figure 21.3. Directional Signs

Figure 21.4. Instruction and Identification Signs

Figure 21.5. Standard Biological Hazard Symbol

Figure 21.6. AF Form 979, Danger Tag

Figure 21.7. AF Form 980, Caution Tag

Figure 21.8. AF Form 981, Out of Order Tag

Figure 21.9. AF Form 982, Do Not Start Tag

Figure 21.10. Reverse Side of AF Forms 979 and 982

Figure 21.11. Reverse Side of AF Form 980

Figure 21.12. Reverse Side of AF Form 981

Table 21.1. Standard Criteria & Proportions For Locally Manufactured Signs (Letter Size Versus Legibility Distance)

Table 21.2. Standard Proportions for Danger Signs

Table 21.3. Standard Proportions for Cautions Signs

10 AFOSHSTD91-501 7 JULY 2004

Table 21.4. Standard Proportions for Instruction and Identification Signs

Table 21.5. Standard Proportions for Directional Signs

Table 21.6. Examples of Color Applications

Table 21.7. Examples of Wording For Mishap Prevention Signs

Figure 21.13. DELETED

Figure 21.14. Hazardous Energy Control and Mishap Prevention Signs and Tags Checklist

Chapter 22— FLAMMABLES AND COMBUSTIBLES 306

22.1. General Information

22.2. Human Factors. Human factors fall into two major categories:

22.3. Responsibilities:

22.4. General Requirements:

22.5. Specific Applications:

22.6. Military Exchanges, Commissaries, and Associate Retail Stores

22.7. Small Gasoline Engine Powered Equipment

Table 22.1. Maximum Allowable Size Containers and Portable Tanks

Table 22.2. Storage in Inside Rooms

Table 22.3. Indoor Container Storage

Table 22.4. Indoor Portable Tank Storage

Table 22.5. Outdoor Container Storage

Table 22.6. Outdoor Portable Tank Storage

Table 22.7. Maximum Allowable Size of Containers — General Laboratories

Table 22.8. Maximum Allowable Size of Containers — Health-Related Laboratories

Figure 22.1. CHECKLIST FLAMMABLE AND COMBUSTIBLE LIQUIDS

Attachment 1— GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 338

Attachment 2— IC 2004-1 TO AFOSHSTD 91-501, AIR FORCE CONSOLIDATED

OCCUPATIONAL SAFETY STANDARD 359

AFOSHSTD91-501 7 JULY 2004 11

Chapter 1

INTRODUCTION

1.1. Purpose:

1.1.1. The policy and guidance published by the Department of Labor in the 29 series of the Code of Federal Regulations (CFR) refers to requirements the employer must comply with in order to provide workers a safe and healthy workplace. The Occupational Safety and Health Administration (OSHA) dictates what must be accomplished in the workplace, but not necessarily how it will be accomplished, or by whom.

1.1.2. Basically, this standard assigns responsibilities to individuals or functions, which helps com-manders manage their safety and health programs, ensuring they are in compliance with OSHA. The Air Force Occupational Safety and Health (AFOSH) program provides a uniform program, which Commanders may supplement, when necessary, to ensure a safe and healthful environment is pro-vided in the work place.

1.1.2.1. In addition, AFOSH standards are used to publish requirements necessary to prevent the loss of life or property based on trends or past history. OSHA is concerned only with the safety and health of the worker. In contrast, Air Force Commanders must also be concerned with facility safety and loss reduction, since there is no insurance to replace facilities. AFOSH standards are not only implemented by commanders--functional managers, supervisors, and workers are also involved in this process.

1.1.2.2. A secondary reason for AFOSH standards is that they provide a way to deal with funding and manpower, which are functionally-related and critical to the efficient implementation of each OSHA standard requirement. This is accomplished by proper documentation and justification of requirements for funding and manning programs directed by OSHA.

1.2. How to Use This Document

1.2.1. This document is a consolidation of all material in the 91-series AFOSH standards relating to general operations within the Air Force. References to other AFOSH standards and related Air Force publications, OSHA standards, and national safety consensus standards are provided as appropriate. It is recommended that users search for required information and print in hard copy only the material needed to complete the job at hand. To facilitate electronic word searches, every effort was made to use standard terminology throughout the document. For example, to determine what personal protec-tive equipment is required for a specific job, search for PPE. NOTE: A Glossary of References and Supporting Information (including an explanation abbreviations, acronyms, and terms used) is at Attachment 1.

1.2.2. AFOSH standards are intended for use, not only by installation ground safety officials and commanders, but by functional managers, supervisors, and workers, at all levels. Therefore, the infor-mation in this standard is derived from many sources and includes non-Air Force and Air Force direc-tives. This information is included in order to provide policy, guidance, and implementation in a single, simple to use and understood document for the protection of worker health and compliance with Federal Law. This consolidated standard applies to all US Air Force organizations, including all

12 AFOSHSTD91-501 7 JULY 2004

US Air Force Reserve and Air National Guard personnel. In addition, as it refers to ANG Air Techni-cian during their daily operations as well as when deployed as a federal military force.

1.3. Responsibilities: Also see specific responsibilities listed in all chapters and those listed in AFI 91-301, Air Force Occupational and Environmental Safety, Fire Protection, and Health (AFOSH) Pro-gram.

1.3.1. Air Staff. All Air Staff elements will ensure policies and procedures are consistent with the spirit and intent of this standard.

1.3.2. Air Force Safety Center (HQ AFSC). Will:

1.3.2.1. Provide professional advice and guidance applicable to all areas in the realm of safety.

1.3.2.2. Act as approval authority for safety variances. NOTE: Requests for variances shall be processed through MAJCOM, Direct Reporting Units (DRU), or Field Operating Agencies (FOA) ground safety offices.

1.3.3. Major Commands (MAJCOM), (DRU), and (FOA). will provide program oversight and sup-plements, as necessary.

1.3.4. Commanders or Functional Managers and Supervisors:

1.3.4.1. Ensure that applicable Occupational Safety and Health (OSH) guidance for workplace and operations are available to all personnel.

1.3.4.2. Ensure compliance with occupational safety, fire prevention, and health program require-ments in their areas of responsibility

1.3.4.3. Ensure AFOSH program requirements are part of the measurement of subordinate employees’ performance in all activities.

1.3.4.4. Ensure pertinent OSHA documents and AFOSH standards are available at installation ground safety offices.

1.3.4.5. Provide a safe and healthful workplace and conduct self-inspections for hazards or defi-ciencies.

1.3.4.6. Provide training for employees in job safety, fire prevention, and health as required by OSHA and AFOSH directives, Air Force Policy Directives (AFPD), Air Force Instructions (AFI), Air Force Manuals (AFMAN), and any other associated directives.

1.3.4.7. Provide PPE and ensure compliance with program requirements (refer to Chapter 14).

1.3.5. Supervisors. Supervisors must recognize potential mishap factors in the workplace. Supervi-sors shall not require personnel to work in environments and conditions that are hazardous to their safety or health without first providing adequate engineering and administrative controls or personal protective equipment (PPE). Supervisors will:

1.3.5.1. Ensure safe working conditions.

1.3.5.2. Provide necessary protective equipment.

1.3.5.3. Ensure required guards and protective equipment are provided, used, and properly main-tained.

AFOSHSTD91-501 7 JULY 2004 13

1.3.5.4. Ensure tools and equipment are properly maintained and used.

1.3.5.5. Plan the workload and assign employees only to jobs they are qualified to perform.

1.3.5.6. Ensure the employees understand the work to be done, the hazards that may be encoun-tered, and the proper procedure for doing the work safely.

1.3.5.7. Take immediate action to correct any violation of safety rules observed or reported to them.

1.3.5.8. Ensure workers exposed or potentially exposed to hazardous chemicals or materials are trained on the hazards of those chemicals and materials per AFOSH Standard 161-21, Hazard Communication. Information should be retrieved from the Material Safety Data Sheet (MSDS) for each chemical or material used, however for selection of PPE the installation BEE will be con-sulted.

1.3.5.9. Conduct Job Safety Analysis (JSA) of job tasks whenever required to ensure a safe work environment. NOTE: A JSA shall be accomplished when new equipment is installed, equipment is relocated, or new procedures are implemented in critical or hazardous operations. The JSA pro-cess overlaps on the Bioenvironmental Engineering (BE) efforts to link tasks to hazards and iden-tifying Occupational Health (OH) personal protective equipment (PPE) requirements. The JSA should be conducted with involvement from BE to avoid duplication of effort and to ensure proper awareness of process changes. Refer to paragraph 1.4. of this standard and AFI 91-202, The US Air Force Mishap Prevention Program and AFI 91-301, Air Force Occupational and Environmen-tal Safety, Fire Protection, and Health (AFOSH) Program.

1.3.6. Air Force Personnel (military and civilian). Will:

1.3.6.1. Comply with OSH guidance.

1.3.6.2. Promptly report safety, fire, and health hazards and deficiencies to the supervisor.

1.3.6.3. Promptly report injuries and illnesses to the supervisor.

1.3.6.4. Comply with PPE requirements, including its use, inspection, and care.

1.3.6.5. Give due consideration to personal safety and the safety of fellow workers while perform-ing assigned tasks.

1.4. Job Safety Analysis (JSA). Supervisor’s outlines (lesson plans) may be modified to include this requirement. The prescribing directives for conducting JSAs are AFIs 91-202 and 91-301. General requirements for PPE is also located in OSHA 29 CFR 1910.132, Personal Protective Equipment-Gen-eral Requirements. See Figure 1.1. for a sample JSA.

1.4.1. Documentation. Each workcenter must conduct and document JSAs where appropriate. JSAs will include the following data:

1.4.1.1. Work procedure evaluated.

1.4.1.2. Name and signature of person certifying the JSA has been performed.

1.4.2. Training. Training will include discussion on any personal protective equipment (PPE) require-ments identified in Bioenvironmental Engineering (BE) and Safety surveys. At a minimum, training should reemphasize these requirements and must include:

14 AFOSHSTD91-501 7 JULY 2004

1.4.2.1. When PPE is necessary;

1.4.2.2. How to don, take off, adjust, and wear PPE;

1.4.2.3. Limitations of PPE;

1.4.2.4. Care, maintenance, useful life, and disposal of PPE; and

1.4.2.5. An opportunity for each employee to demonstrate understanding of training and ability to use PPE properly (hands-on training prior to work).

1.4.2.6. Retraining is required when:

1.4.2.6.1. Employee exhibits a lack of understanding or skill with the required PPE;

1.4.2.6.2. Changes in the workplace render previous training obsolete; or

1.4.2.6.3. Changes in the types of PPE used render previous training obsolete.

1.4.2.7. Supervisor must verify affected employees have received and understand required train-ing through written certification that contains:

1.4.2.7.1. Name of each employee trained;

1.4.2.7.2. Dates of training; and

1.4.2.7.3. Subject of certification.

NOTE: This should be documented IAW AFI 91-301 (i.e.: respirator, fire extinguisher, personal protec-tive eye equipment).

1.5. Occupational Safety and Health Administration (OSHA) Requirements

1.5.1. Air Force safety officials at all levels are prohibited from providing waivers for material in this standard derived from OSHA rules (refer to AFI 91-301, paragraph 6.2.). Air Force Safety Center or higher-headquarters officials may establish more stringent requirements than those established by OSHA, when supported by AF mishap analysis, inspection reports, etc. When appropriate, OSHA ref-erences are provided.

1.5.2. Some non-OSHA requirements cannot be waived without the specific permission of HQ AFSC/SEG, HQ AFMOA/SG, or HQ AFCESA/CES/CEX, whichever is appropriate. In those instances, a statement indicating who to contact is included.

1.6. National Consensus Standards . Select committees of federal, industrial, and private sector person-nel develop these standards under the sponsorship of one of the national standards-setting organizations.

Examples are: American National Standards Institute (ANSI), National Fire Protection Association (NFPA), and the American Society of Mechanical Engineers (ASME). National consensus standards are not directive, unless adopted by a regulatory federal agency or the Air Force. NOTE: National consensus standards referenced in this document, have been adopted for Air Force use.

AFOSHSTD91-501 7 JULY 2004 15

Figure 1.1. Job Safety Analysis Guide.

F1.1. Sequence of Basic Steps. Break the task down into its basic steps. For example, what is done first, what is done next, and so on. You can do this by: (1) observing the task, (2) discussing it with workers, (3) using your experience and knowledge of the task, or (4) a combination of all three. Record the steps in the task in their normal order of occurrence. Describe what is done; not the details or how it is done. Three or four words are normally enough to describe each step in the task.

F1.2. Potential Mishap Causes or Hazards. For each task step, ask yourself what mishap could happen to workers performing the task and what the probability would be of the mishap occurring. Get the answers by: (1) observing the task, (2) discussing the task with workers, and (or) (3) using “lessons learned” from other mishaps. Ask the questions:

F1.2.1. Can workers be struck by or contacted by anything?

F1.2.2. Can they strike against or come in contact with any item which can cause injury?

F1.2.3. Can they be caught in or between anything?

F1.2.4. Can they fall?

F1.2.5. Can they overexert?

F1.2.6. Are they required to do repetitive lifting or heavy lifting?

F1.2.7. Are they exposed to potential hazards such as chemical substances, physical agents (including noise, ergonomic, and thermal stress), ionizing and non-ionizing radiation, or biological exposures?

F1.3. Recommended Safe Task Procedure. For each identified potential mishap cause or hazard, con-sider the following questions:

F1.3.1. How should the workers perform the task step to avoid the mishap or eliminate the potential haz-ard?

F1.3.2. What can be done to eliminate or mitigate the hazard by redesigning the work area or equipment?

JOB: DATE:

WORKCENTER: SUPERVISOR:

TITLE OF WORKER WHO PERFORMS TASK:

REQUIRED PERSONAL PROTECTIVE EQUIPMENT (PPE):

ANALYSIS BY: REVIEWED BY:

16 AFOSHSTD91-501 7 JULY 2004

F1.3.3. How can the procedure be modified to eliminate the hazard? NOTE: Be sure to describe in detail the precautions workers must take and ensure that these steps are placed in the task procedure or checklist.

Take special care that important steps or details are not inadvertently omitted from the task. Ensure that the guidance is clear and specific and easily understood by workers. Also, include the requirements in paragraph 1.3.5.9. in the JSA.

AFOSHSTD91-501 7 JULY 2004 17

Chapter 2

HUMAN FACTORS

2.1. Human Factors. Human factors encompass two major categories. These are attitudinal and physical factors that may affect worker performance:

2.1.1. Unhealthy emotions, job or domestic pressures, distractions, job knowledge, hurrying or feel-ing rushed can contribute to an unsafe attitude and negatively impact worker performance.

2.1.2. Physical factors such as fatigue, physical strength, reactions to over-the-counter and prescrip-tions medications, and the influence of alcohol and illegal drugs may contribute to behavior that leads to a mishap. Examples include workers:

2.1.2.1. Ignoring directions from supervisors and workleaders.

2.1.2.2. Failing to use personal protective equipment (PPE) or proper tools.

2.1.2.3. Performing a task while distracted by personal problems or interpersonal situations.

2.1.2.4. Not following established procedures or taking unauthorized shortcuts to save time.

2.1.2.5. Performing job tasks while taking prescribed medications that may cause drowsiness.

2.1.2.6. Performing job tasks while under the influence of alcohol or illegal drugs.

2.1.2.7. Using equipment when not properly trained or qualified.

2.1.2.8. Being unaware of the hazardous properties of flammable and combustible liquids or materials and there proper control. (OSHA 29 CFR 1910.1200, Hazard Communication).

2.2. Responsibilities. Managers, supervisors, and workers must be aware of human factors such as fatigue, worry, anger, inattention, illness, or improper attitudes than can lead to worker error and may result in injury. Engineers, functional managers, and supervisors can in some cases mitigate the effects of human factors in the work place by considering personnel exposure and work processes when placing machinery and equipment in the workplace.

18 AFOSHSTD91-501 7 JULY 2004

Chapter 3

PHYSICAL HAZARDS

3.1. Hazards.

3.1.1. Hazards should be engineered out, substitute a less hazardous material or less hazardous pro-cess, isolated operations, provide work-around procedures, provide administrative controls, whenever possible before considering the use of PPE. The use of protective equipment is considered to be the least preferred method of controlling hazards and should not be relied on alone to provide protection against hazards. Protective equipment should be used in conjunction with guards, engineering con-trols, and sound manufacturing practices. When PPE will be used to protect workers from physical hazards consider that eye, face, and body injuries may be caused by exposure to chemicals, by mate-rials being thrown from a machine, and when air pressure or similar energy source propels substances at sufficient velocity to be injurious. Other eye and face injuries may occur when harmful liquids are sprayed, squirted, splattered, dropped, or applied. When PPE is required, the proper protective devices must be matched to the hazards identified. This is accomplished by reviewing the JSA and material safety data sheets (MSDS) for the task being accomplished, (refer to Chapter 14), or contact the installation ground safety or bioenvironmental engineering staffs for assistance. Eyewash units, eye/ face units, deluge showers, and other similar devices are emergency equipment and are not substitutes for protection devices (refer to Chapter 19).

3.1.2. Examples of physical hazards follow:

3.1.2.1. Use of soaps and solvents can cause surfaces to become slippery and create the potential for slips and falls. Soaps and solvents can also cause health problems such as dermatitis, eye irri-tation, and other medical problems if the solvents become inhaled.

3.1.2.2. Certain cleaning solvents may ignite if applied to hot surfaces or when heated, causing fires and (or) injuries to workers.

3.1.2.3. Pressure cleaners and steam cleaners operate at pressures in excess of 100 pounds per square inch (psi) and temperatures near 200 degrees Fahrenheit (F). Improper use can result in severe personal injury.

3.1.2.4. Hazards are present when working in areas where flying or falling objects may be present.

3.2. Responsibilities:

3.2.1. The supervisor shall assess the workplace to determine if hazards are present, or are likely to be present, that could necessitate the use of PPE. If such conditions exist the supervisor shall conduct a JSA to determine the best method of controlling the risk and, if necessary, the appropriate PPE required for a particular task. (Refer to OSHA 29 CFR 1910.132.)

3.2.2. The supervisor shall develop a Job Safety Outline (lesson plan) which contains all the job safety training the workers will require (JSAs may be incorporated into the Job Safety Outline).

3.2.3. When the worker receives job safety training, the supervisor will document the training IAW AFI 91-301. The supervisor may maintain these three documents together or as separate documents.

See AFI 91-202, The US Air Force Mishap Prevention Program and AFI 91-301, AF Occupational &

AFOSHSTD91-501 7 JULY 2004 19

Environment Safety, Fire Protection and Health (AFOSH) Program for information on the JSA, and Job Safety Outline. NOTE: A JSA is not required whenever existing guidance covers all safety requirements of an operation or process. Examples are: TO 00-25-172, Ground Servicing of Aircraft and Static Grounding/Bonding, and TO 1-1-3, Inspection and Repair of Aircraft Integral Tanks and Fuel Cells.

20 AFOSHSTD91-501 7 JULY 2004

Chapter 4

MANUAL MATERIAL HANDLING AND LIFTING TECHNIQUES

4.1. Hazards and Human Factors:

4.1.1. Strains, sprains, hernias, fractures, bruises, and lacerations may result from poor manual mate-rial handling and lifting practices. The greater sizes and quantities of equipment and materials being used throughout the Air Force in recent years has contributed to an increase in injuries associated with manual material handling and lifting operations. Lifting, carrying, dropping, and lowering are the common physical acts responsible for these injuries. Sprains account for approximately 30 percent of the lost time injuries in the Air Force. Many strains are the direct result of improper lifting techniques, lifting with no assistance, or failure to use required and available manual material handling equip-ment.

4.2. Manual Handling. Influencing factors when manually lifting materials include the size, shape, and weight of the object to be lifted (and distance to be moved). Proper lifting techniques are as important as the weight of the object to be lifted. Heavy weights or awkward positions may require mechanical assis-tance or team lifting to be used (Refer to paragraph 4.6.3.).

4.3. Lifting and Carrying. There are several variables, which influence the ability of people to manu-ally handle and lift materials. Physical capabilities of individuals and variables in the work environment need consideration. Proper consideration and knowledge of limitations and the use of correct lifting and carrying techniques will reduce the possibility of injury.

4.3.1. Physical characteristics include factors such as strength, mobility, fatigue, and motor functions of the individual.

4.3.2. Psychological considerations might be the motivation, emotional state, job satisfaction, and attitude of the individual toward work.

4.3.3. Pre-existing worker injuries may also bear consideration.

4.3.4. Task variables might include the weight, size, shape, distribution, degree of shift (of the load in the container), and the location of the center of gravity (CG) of the load to be handled.

4.3.5. Workplace layout and the degree of movement required, obstacles, distances moved, and direc-tion of movement must be factored.

4.3.6. Level of demand to include frequency of lift, duration of lifting task, accelerations and veloci-ties of lift, shift duration, degree of precision, and relative proportion of muscles involved in the lift shall be considered.

4.3.7. Environmental variables can have an impact, consider heat and cold stress, noise and vibration, lighting, toxic agents, traction, stability of the work platform, and atmospheric contaminants that could affect the task.

4.4. Training. Supervisors must train personnel who regularly perform manual lifting duties. Supervi-sors will ensure their personnel receive thorough instructions on the proper techniques to use and what PPE is required. In addition, personnel will be instructed in the use of available manual lifting devices and the procedures for performing routine or high risk manual handling activities. To the new worker, hand

AFOSHSTD91-501 7 JULY 2004 21

trucks and wheelbarrows look deceptively easy to use. Supervisors will instruct workers on their use.

Seeking improvements in the methods used for accomplishing the work and eliminating manual material handling hazards; and an understanding of the stresses involved during manual handling which cause injuries are important and should also be addressed during training. This training should include both ver-bal and written materials that explain how to do the task correctly with practice and proper motions.

Training will be documented on the IAW AFI 91-301, or other authorized methods (refer to AFI 91-301).

Information to assist the supervisor in establishing a program may be found in this chapter and in the National Safety Council (NSC) Accident Prevention Manual for Industrial Operations, Engineering, and Technology. When necessary, the supervisor should contact the installation ground safety staff for assis-tance in developing the program and to review the NSC publication. The supervisor shall consider having personnel evaluated for physical fitness for duty when job tasks require continuous manual lifting. When required, physical profile changes will be evaluated for possible reassignment actions to prevent recurring injuries to personnel.

4.5. Minimizing Manual Material Handling Hazards:

4.5.1. Engineering Controls. A preferred method of minimizing the risk of manual lifting is the use of engineering controls such as employing mechanical assists to decrease the force, the repetition, dis-tance of travel, and frequency of the manual handling activities. Some examples might include employing scissor tables, elevators, conveyors, and gravity chutes.

4.5.2. Administrative Controls. Job rotation schedules and mandatory work-rest cycles can be useful to reduce mishap potential, but do not eliminate the hazard and are not as reliable as engineering con-trols.

4.5.3. Work Design Principles. Conduct a job safety analysis (refer Figure 1.1.) to identify potential hazards, and when practical, arrange tasks and select workstations using the following principles:

4.5.3.1. Place objects to be lifted at the approximate height of the knuckles when the arms dangle at side of the body.

4.5.3.2. Limit stack height to shoulder level. If items must be stacked higher, provide step-up access to eliminate lifting above shoulder level.

4.5.3.3. Use grips, handles, and other devices to provide better control of items.

4.5.3.4. Slide materials instead of lifting, whenever possible.

4.5.3.5. Use gravity assist in moving materials.

4.5.3.6. Ensure adequate maneuvering space to eliminate the need to twist the body.

4.5.3.7. Consider team lifting when items are known to weigh more than 25 pounds. (Refer to paragraph 4.6.3.)

4.6. Proper Lifting Methods. No single technique for preventing injury during lifting and material han-dling has been discovered despite numerous research efforts. The best prevention strategy is to ensure workstations are properly designed, loads are manageable in both size and weight distribution, the fre-quency and duration of lifting are not excessively stressful, and workers can demonstrate a knowledge of proper techniques for material handling. There are three basic methods of lifting, that is, straight back-bent knees, free style, and kinetic. Each has advantages and limitations (refer to Figure 4.1.).

22 AFOSHSTD91-501 7 JULY 2004

4.6.1. The kinetic method is the most widely accepted and taught because it provides more stability for the worker while reducing load on the back muscles and intervertebral disks. Instructions how to lift properly follow:

4.6.1.1. Before an object is lifted, it should be inspected to make certain no grease or slippery sub-stance will cause the object to slip. Also inspect the objects for slivers, sharp edges, and rough or slippery surfaces before attempting to lift.

4.6.1.2. Position feet correctly. Place far enough apart for balance with one foot to the rear of the object and the other foot slightly ahead of the other and to the side of the object.

4.6.1.3. Crouch close to the load. Crouching is preferred to squatting. Stay close to the load to minimize strain on the back muscles.

4.6.1.4. Always keep the back as straight as possible. It may not be possible to keep the back in the vertical plane but avoid arching the back. Bend from the hips and not from the middle of the back.

Figure 4.1. How to Lift Properly.

4.6.1.5. Pick up materials with a full palm grip. Do not attempt to pick up items using a fingertip grip. Gloves ( Leather or Leather-palmed) shall be worn when lifting objects which have sharp or burred edges or splintered surfaces.

4.6.1.6. With the arms, slide the object towards the body putting it in motion (kinetic energy). At the same time, lift the object with the legs and bring the back to a vertical position. Keep the object close to the body; avoid twisting while lifting.

4.6.2. Setting the Object Down. Use the same motion as when lifting, but reverse it to set an object down. Lower the load by bending the legs and crouching with the back straight. Take care when releasing the load to prevent injury to fingers, hands, or feet.

AFOSHSTD91-501 7 JULY 2004 23

4.6.3. Team Lifting. When its required to move heavy or unusual shaped items manually, always seek and obtain assistance When it is not practical to use mechanical equipment assign additional workers to the task. When two or more people are required to move or carry an object, adjust the load so each person carries an equal part. If possible use workers similar in size and train them in team-lifting.

Workers need to understand that if one worker lifts too soon, shifts the load, or lowers improperly, that person or their partner(s) may be overloaded and strained. Test lifts should be made before pro-ceeding. The key to lifts using two or more personnel is to make every move in unison. Assign one person to give orders to ensure the necessary coordination for movement. The supervisor and workers are responsible for assessing all available methods to safely handle materials described above and using mechanical assistance whenever possible.

4.7. Carrying Methods. Acceptable carrying methods differ, based upon the type of material, distance, and number of workers. Workers should be instructed during initial training in each procedure--for exam-ple, neck, shoulder, side, tray, two-person, and under-arm carry methods, etc. (see definition for “carrying methods” in Attachment 1). Points to remember:

4.7.1. Use appropriate PPE as determined for each task, such as gloves, to protect the hands and pro-tective footwear, as required by paragraph 14.5.10., to protect the feet.

4.7.2. Keep fingers away from pinch and shear points.

4.7.3. Do not carry a load that obstructs the view of the direction of travel. Make sure that the path of travel is clear.

4.7.4. Do not turn at the waist to change direction or to put an object down. Turn the whole body and crouch down to lower the object.

4.8. Carrying Items Up or Down Stairways:

4.8.1. Adhere to the guidance provided by the supervisor.

4.8.2. Try to reduce the bulk or size of the object carried to allow for maximum visibility.

4.8.3. Use assistance when required and available.

4.8.4. Use mechanical material handling equipment whenever loads are too heavy or bulky to be lifted or carried efficiently or safely by hand. Forklifts, hand trucks, rollers, conveyors, or cranes (when properly used) simplify materials handling and greatly reduce the hazards of handling supplies and equipment.

4.9. Manual Material Handling Equipment. This equipment will be used whenever loads are too heavy or bulky to be lifted or carried efficiently or safely by hand. Hand trucks, dollies , two-wheeled hand trucks and wheelbarrows (when properly used) simplify materials handling and greatly reduce the hazards of handling supplies and equipment.

4.9.1. Hand Trucks, Dollies and Wheelbarrows. Hand trucks, dollies, wheel barrows or other manual devices shall be used to lift and (or) carry bulky or heavy items whenever possible.

4.9.1.1. Hand trucks. Tip the load to be lifted forward slightly so the tongue of the truck goes under the load.

4.9.1.1.1. Make sure the tongue of the truck is all the way under the load prior to movement.

24 AFOSHSTD91-501 7 JULY 2004

4.9.1.1.2. Keep the center of gravity of the load as low as possible. Place heavy objects on the bottom of the load. Keep feet clear of the wheels.

4.9.1.1.3. The center of gravity of the load on both the hand truck and wheelbarrow will be kept as low as possible. The weight should be forward so it will be carried by the axle, not the handles. If loaded correctly, the hand truck should carry the load—the operator need only bal-ance and push.

4.9.1.1.4. Place the load so it will not slip, shift, or fall. Load only to a height that will allow a clear view ahead. For added safety, strap or chain bulky or dangerous cargo (such as cylinders or drums) to the hand truck’s frame.

4.9.1.1.5. Avoid walking backward with a hand truck if possible. This eliminates the need for a worker to look over their shoulder to see clearly.

4.9.1.1.6. Never brake a hand truck by putting your foot on its wheel; keep your feet clear of the wheels at all times.

4.9.1.1.7. When going down an incline, keep the hand truck ahead of you. When going up, pull the hand truck behind you.

4.9.1.1.8. Move the truck at a safe speed. Do not run. Keep the truck constantly under control.

4.9.1.1.9. Secure and store unused trucks in a designated area where they don't create a hazard or traffic obstruction.

4.9.1.1.10. When a hand truck is loaded in a horizontal position, proper lifting procedures dis-cussed in (paragraph 4.6.) will be used to prevent operator injury.

4.9.1.2. The same basic principles listed in paragraphs 4.9.1.1.1. through 4.9.1.1.10. shall apply to dollies and wheelbarrows.

4.9.1.3. Two-wheeled hand trucks and wheelbarrows are designed in a variety of shapes and sizes for both general and special purposes. Preference will be given to procuring hand trucks and wheelbarrows equipped with knuckle guards.

4.9.2. Multi-Wheel Trucks. As with two-wheeled equipment, multi-wheeled trucks and dollies vary greatly in design and use. Most mishaps occur due to improper parking causing the worker to fall over the equipment or improper loading of material which causes the cart to tip. Extra emphasis will be placed on worker training in these two areas, along with frequent observation of work practices to immediately correct unsafe acts. In addition:

4.9.2.1. When loading, arrange the cargo so items won’t fall.

4.9.2.2. If the truck has no drawbar, push it. Keep your hands behind the cart.

4.9.2.3. If the truck has a drawbar, pull it, so you’ll be able to see better. Stand to one side, to keep the truck from running onto your ankles.

4.9.2.4. If there are floor markings, stay within their boundaries.

4.9.2.5. When storing the truck, lock or block its wheels.

4.9.2.6. Don’t misuse the truck.

4.9.2.7. Don’t ride on a truck designed for a walking operator.

AFOSHSTD91-501 7 JULY 2004 25

4.9.2.8. Don’t carry other people.

4.9.2.9. Don’t carry more than the truck’s maximum load capacity.

4.9.2.10. Ensure the weight of the truck, plus its load, is less than maximum posted floor loads.

4.9.2.11. Make sure you have enough clearance in aisles and other tight areas.

4.9.2.12. Remember that the inertia, or momentum, of a truck can make it hard to change its speed or direction.

4.9.2.13. Watch out for pedestrians--always give them the right-of-way.

4.9.2.14. Don’t block aisles, doorways, or material another worker may need.

4.9.3. Lever-Operated Hoists:

4.9.3.1. Acquisition. Lever-operated hoists shall meet the requirements and specifications of rec-ognized industry standards.

4.9.3.1.1. Capacity of all lever-operated devices shall be permanently and conspicuously marked in an easily visible place on the hoist.

4.9.3.1.2. Only ratchet and pawl and load brake hoists, which include a means to prevent a suspended load from self-lowering, will be procured. Lowering under load shall be by opera-tion of the hoist lever.

4.9.3.2. Inspections. Daily or prior to each use, lever-operated hoists shall be inspected for:

4.9.3.2.1. Loose or worn parts, nuts, bolts, etc.;

4.9.3.2.2. Cracked or broken welds or parts;

4.9.3.2.3. Deformed or damaged hooks

4.9.3.2.4. Bent or deformed pawls.

4.9.3.3. Annual inspection shall include:

4.9.3.3.1. Complete inspection of all wire rope, chain, and fittings or attachments.

4.9.3.3.2. Inspection of brakes, pawls, or other holding features.

4.9.3.3.3. Inspection of the chain length. Chains that have elongated more than one fourth of an inch in 12 inches shall be removed from service.

4.9.3.4. Identification Tags. Identification tags shall be attached to all hoists and shall include the following information: date of inspection; date of proof test; capacity of hoist; and identification number of hoist.

4.9.3.5. Maintenance and Testing:

4.9.3.5.1. All new hoists will have the manufacturer’s certification indicating that all proof-testing has been accomplished. All hoists which have had load-suspension parts altered, replaced, or repaired will be proof-tested before use. These tests will be performed at no less than 100 percent or more than 125 percent of the rated capacity. Underhung hoists that are not an integral part of a supporting structure for lateral movement, such as an overhead crane, must have manufacturer’s certification indicating the proof test was accomplished with a test

26 AFOSHSTD91-501 7 JULY 2004

load of at least 125% of rated capacity ) Reference ANSI/ASME B30.16). A record of all tests will be maintained by the user.

4.9.3.5.2. Maintenance and lubrication will be performed according to the manufacturer’s instruction or applicable TO.

4.9.3.6. Safe Operations:

4.9.3.6.1. Lever-operated hoists shall only be used in a direct pull. Where indirect pulls are permitted by design of the hoist, a sheave or pulley of adequate size shall be used.

4.9.3.6.2. Hoist cable, rope, and chain shall not be wrapped around the load. Use only slings or other approved lifting devices.