AFMAN91-203.pdf

BY ORDER OF THE

SECRETARY OF THE AIR FORCE

AIR FORCE MANUAL 91-203

11 DECEMBER 2018

Safety

AIR FORCE OCCUPATIONAL SAFETY,

FIRE, AND HEALTH STANDARDS

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

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

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: HQ AFSEC/SEG

Supersedes: AFI 91-203, 15 June 2012

Certified by: AF/SE

(Maj Gen John T. Rauch)

Pages: 583

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

Occupational Safety and Health Administration (OSHA) 29 Code of Federal Regulations (CFR), and includes additional requirements not addressed by the OSHA standard. 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 standard. Report conflicts in guidance between this standard, federal standards or other Air Force directives through MAJCOM, DRU or

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 requires the collection and/or maintenance of information protected by the Privacy Act of 1974 authorized by 10 United States Code (U.S.C.) 8013, Secretary of the

Air Force, Department of Defense (DoD) 4500.36-R, Management, Acquisition, and Use of Motor

Vehicles, AFPD 24-3, Management, Operations and Use of Transportation Vehicles, and AFI 24-

301, Transportation, Vehicle Operations. 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 http://dpclo.defense.gov/Privacy/SORNs.aspx. 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. The authorities to waive wing/unit-level requirements in this publication are identified with a Tier number (T-0, T-1, T-2, T-3) following the compliance statement. See AFI 33-360, Publications and Forms Management, Table 1.1, for a description of the authorities associated with the Tier numbers. Submit requests for waivers through the chain of http://www.e-publishing.af.mil/ http://dpclo.defense.gov/Privacy/SORNs.aspx

2 AFMAN91-203 11 DECEMBER 2018

command to the appropriate Tier/Waiver approval authority, or alternately, to HQ AFSEC/SEG for variances/exemptions to non-tiered compliance items. This publication may be supplemented at any level, but all direct supplements must be routed to the OPR of this publication for coordination prior to certification and approval. Records Disposition: Ensure all records created as a result of processes prescribed in this publication are maintained IAW AFMAN 33-363, Management of Records, and disposed of in accordance with (IAW) Air Force Records Disposition

Schedule in the Air Force Records Information Management Systems. This standard defines the

Air Force‘s minimum safety, fire protection and occupational health standards. Requirements in this publication are mandatory, unless otherwise indicated. It applies to all Regular Air Force

(RegAF), Air Force Reserve Command (AFRC) and Air National Guard (ANG) military and civilian personnel. Not included are safety, fire prevention and occupational health requirements addressed in specific equipment technical orders (TOs). Portions of this standard may apply to contractors for the protection of AF people and property. Note: MAJCOMs may have more stringent or restrictive requirements than those contained in this standard 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/DRU/FOA safety, health and/or civil engineering organization, as applicable.

Note: With respect to references in this AFI to installation medical treatment facilities, pursuant to 10 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.

SUMMARY OF CHANGES

This document is substantially revised and must be completely reviewed. Major changes include changing this publication to an Air Force Manual, reducing the size of the standard by referring the reader to Occupational Safety and Health Administration (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 29, Mishap Prevention Signs and Tags.

Chapter 1— INTRODUCTION 17

1.1. Objective

1.2. Variances and Exemptions

1.3. How to Use This Document

1.4. Applying Standards

1.5. Job Hazard Analysis (JHA)

1.6. Military-Unique and Nonmilitary-Unique Policy

1.7. Documentation

AFMAN91-203 11 DECEMBER 2018 3

1.8. First Aid and Cardiopulmonary Resuscitation (CPR) Training

1.9. Bloodborne Pathogen Training

1.10. Process Safety Management of Highly Hazardous Chemicals

1.11. Responsibilities

Chapter 2— GENERAL WORK PROCEDURES 22

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. Powered Doors In Facilities Not Used as Hangars

2.9. Receiving/Loading Docks

2.10. Walk-in Refrigerators and Freezers

Chapter 3— WEATHER SAFETY 29

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 31

4.1. Purpose

4.2. Laundry

4.3. Lodging

4.4. Food Service Operations

Chapter 5— NONDESTRUCTIVE INSPECTION (NDI) AND OIL ANALYSIS 33

5.1. Scope

5.2. Safety Precautions

5.3. Supervisor Responsibilities

5.4. Nondestructive Inspection Equipment and Fire Protection Systems

4 AFMAN91-203 11 DECEMBER 2018

Chapter 6— FIRE PREVENTION AND PROTECTION 35

6.1. Fire Extinguishers

6.2. General Requirements

Chapter 7— WALKING – WORKING SURFACES 40

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 55

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

8.14. Lighting

8.15. Moisture Guarding

8.16. Under-voltage Protection

8.17. Work on Energized Equipment

AFMAN91-203 11 DECEMBER 2018 5

Chapter 9— EMERGENCY SHOWER AND EYEWASH UNITS 63

9.1. Scope

9.2. OSHA Requirements

9.3. Equipment - Acquisition

9.4. Maintenance and Testing

Chapter 10— GROUNDS, MOWING AND AGRICULTURE TRACTORS 65

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 70

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 77

12.1. General Information

12.2. Special Requirements

12.3. Powered Industrial Trucks

12.4. Conveyors

12.5. Manual Hoisting and Pulling Devices

12.6. Hoists

12.7. Slings

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12.8. Overhead, Gantry, and Underhung Cranes and Monorail Systems

12.9. Mobile and Locomotive Cranes

12.10. Inspection, Maintenance and Testing of Derricks

12.11. Related Hoisting Equipment

12.12. Portable Automotive Lifting Devices and Related Equipment

Table 12.1. Synthetic Web Slings. 1,000 Pounds per Inch of Width – Single Ply (Rated in capacity in pounds)

Table 12.2. Synthetic Web Slings. 1,200 Pounds per Inch of Width – Single Ply (Rated capacity in pounds)

Table 12.3. Synthetic Web Slings. 1,600 Pounds per Inch of Width – Single Ply (Rated capacity in pounds)

Table 12.4. Number of Spacing of Clips for Ropes of Various Sizes. (If manufacturer’s recommendations are not available)

Table 12.5. Testing and Inspection Requirements for Materials Handling and Storage

Equipment

Table 12.6. Additional Testing and Inspection Requirements for Materials Handling and

Equipment Used for Critical and Nuclear Loads

Chapter 13— FALL PROTECTION 154

13.1. Scope

13.2. General Information

13.3. Training

13.4. Fall Protection Equipment

13.5. Inspections and Maintenance

13.6. Operations

13.7. Rescue

Chapter 14— PERSONAL PROTECTIVE EQUIPMENT (PPE) 163

14.1. Scope

14.2. Hazards

14.3. Training

14.4. Personal Protective Equipment (PPE)

14.5. Proper Care and Maintenance

AFMAN91-203 11 DECEMBER 2018 7

Chapter 15— TRAINING SYSTEMS 181

15.1. Scope

15.2. General Requirements

15.3. Facility Requirements

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. .. 190

Chapter 16— MOBILE ELEVATING WORK PLATFORMS 191

16.1. General Information

16.2. Hazards

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)

Chapter 17— SCAFFOLDING 205

17.1. Scope

17.2. Hazards

17.3. General Requirements

17.4. Tube and Coupler Scaffolds

17.5. Tubular Welded Frame Scaffolds

17.6. Masons’ Adjustable Multiple-point Suspension Scaffolds

17.7. Two-Point Suspension Scaffolds (Swinging Scaffolds)

17.8. Stone Setters’ Adjustable Multiple-Point Suspension Scaffolds

17.9. Single-Point Adjustable Suspension Scaffolds

17.10. Boatswains’ Chairs

17.11. Carpenters’ Bracket Scaffolds

17.12. Bricklayers’ Square Scaffolds

17.13. Horse Scaffolds

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17.14. Needle Beam Scaffolds

17.15. Plasterers, Decorators and Large Area Scaffolds

17.16. Interior Hung Scaffolds

17.17. Ladder-Jack Scaffolds

17.18. Window-Jack Scaffolds

17.19. Roofing Brackets

17.20. Crawling Boards or Chicken Ladders

17.21. Float or Ship Scaffolds

Chapter 18— HYRDROCARBON FUELS 219

18.1. Scope

18.2. Hazards

18.3. General Requirements

18.4. Fuel Storage Systems

18.5. Fuel Servicing Operations

18.6. Fuel Laboratory Operations

Chapter 19— COMPRESSED GASES 236

19.1. Scope

19.2. General Requirements

19.3. Storage

19.4. Disposal and Shipping

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

SYSTEMS 242

20.1. General Information

20.2. Hazards and Human Factors

20.3. General Requirements

20.4. Worker Training

20.5. Classification of Material in Piping Systems

Chapter 21— HAZARDOUS ENERGY CONTROL 245

21.1. Scope

AFMAN91-203 11 DECEMBER 2018 9

21.2. Hazardous Energy Control Program

21.3. Specifications for Lockout/Tagout (LOTO)

21.4. LOTO Procedures

21.5. Training

21.6. Program Evaluations

21.7. Sample Lockout/Tagout Procedures

21.8. Contractors

Chapter 22— FLAMMABLES AND COMBUSTIBLES 264

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 278

23.1. Scope

23.2. Responsibilities

23.3. General Requirements

23.4. Confined Spaces Classification—Atmospheric Conditions

Table 23.1. Confined Spaces Classification—Atmospheric Conditions

23.5. Specific Requirements

23.6. Emergency and Rescue Procedures

23.7. Training

23.8. Contractor Requirements

23.9. MAJCOM Mandatory Aircraft Confined Spaces

Table 23.2. MAJCOM Mandatory Aircraft Confined Spaces

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23.10. Instructions for Completing the AF Form 1024, Confined Spaces Entry Permit. . 308

Chapter 24— AIRCRAFT FLIGHTLINE – GROUND OPERATIONS AND ACTIVITIES 311

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

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 362

25.1. Scope

25.2. Supervisory Responsibilities

25.3. Occupational Health

25.4. Shop Layout, Equipment, General Walking and Working Surfaces

25.5. Fire Prevention

25.6. Compressed Air

25.7. Jacks and Portable Hoists

25.8. Shoring and Trenching

AFMAN91-203 11 DECEMBER 2018 11

25.9. Barricades and Traffic Signs

25.10. Sanitation

25.11. Restrictions

25.12. Equipment Operations and Pavements

25.13. Carpentry and Structural Maintenance

25.14. Protective Coating Maintenance

25.15. Plumbing Maintenance

25.16. Refrigeration and Air Conditioning Maintenance

25.17. Heating Systems and Central Heating Plant Maintenance

25.18. Water and Wastewater Treatment

25.19. Aircraft Arresting Systems

25.20. Personal Protective Equipment for CE Operations

Figure 25.1. Personal Protective Equipment For CE Operations

Chapter 26— LIQUID NITROGEN (LN2), OXYGEN (LOX) AND CRYOGENS 408

26.1. Specific Hazards

26.2. General Requirements

26.3. Cryogenic Facility Siting

26.4. Occupational Health

26.5. Safety Precautions When Working With LN 2 and LOX

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. Mission-limiting Weather Conditions

26.11. Common Cryogenic Liquids, Their Properties and Precautions

Chapter 27— WELDING, CUTTING AND BRAZING 418

27.1. Hazards and Human Factors

27.2. Acquisition

27.3. Operating Precautions

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27.4. Welding Equipment Precautions

27.5. Facilities

27.6. Installed Equipment

27.7. Clothing and Personal Protective Equipment (PPE)

27.8. Training and Qualification

27.9. Gas Leaks

27.10. Welding Safety

27.11. Purging and Inert

27.12. Vehicle Maintenance Shops

27.13. Portable Gas Welding Units

27.14. Portable Electric Welding Units

27.15. Arc-Welding

27.16. Resistance Welding

27.17. Welding in Confined Spaces

27.18. Hazards Associated with Fluxes, Coverings, Filler Metals and Base Metals.

Note:

Table 27.1. Selection of Proper Shade Number for Welding Operations

Table 27.2. How To Fill Out AF Form 592, Hot Work Permit

Chapter 28— INTERIOR SPRAY FINISHING 440

28.1. Scope

28.2. Safety

28.3. Health/Environmental Protection

28.4. Fire Prevention

28.5. Ventilation Systems

28.6. Storage and Handling

28.7. Electrical

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

28.9. Paint Spray Booths

28.10. Compressed Air Paint Spraying

AFMAN91-203 11 DECEMBER 2018 13

28.11. Drying Ovens

28.12. Spray Painting of Aircraft

28.13. Painting Radio and Radar Equipment

28.14. Electrostatic Paint Spraying

28.15. Airless Paint Spraying

28.16. Aerosol Cans of Spray Paint

28.17. Powder Coating

28.18. Organic Peroxide Coating

Chapter 29— MISHAP PREVENTION SIGNS AND TAGS 454

29.1. Scope

29.2. Specific Information

29.3. Requirements

29.4. AF Form 1118 and AF Form 979

29.5. Specifications For and Use of Safety, Fire Prevention and Health Tags

29.6. General Requirements for Use of Tags

29.7. Specific Requirements For Use of Tags

29.8. Administrative Devices

Table 29.1. Standard Criteria & Proportions for Locally Manufactured Signs (Letter Size vs.

Legibility Distance)

Table 29.2. Standard Proportions for Danger Signs

Table 29.3. Standard Proportions for Caution Signs

Table 29.4. Standard Proportions for Instruction and Identification Signs

Table 29.5. Standard Proportions for Directional Signs

Table 29.6. Examples of Color Applications

Table 29.7. Examples of Wording for Mishap Prevention Signs

Chapter 30— COMMUNICATION CABLE, ANTENNA AND COMMUNICATION

SYSTEMS 467

30.1. General Information

30.2. Specific Hazards

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30.3. General Safety Practices

30.4. Training

30.5. Safety Equipment and Devices

30.6. Tools and Equipment

30.7. High Voltage

30.8. Rubber Insulating Floor Matting

30.9. Aerial Work

30.10. Antenna Supports (Towers and Poles)

30.11. Single Phase Portable and Vehicle-Mounted Generators

30.12. Repairs and Adjustments

30.13. Power Distribution Panels

30.14. Cathode Ray Tubes

30.15. Radar and Microwave Equipment

30.16. Entering Manholes and Unvented Vaults

30.17. Cables

30.18. Special Purpose Vehicles

30.19. Ground Controlled Approach Radars

Chapter 31— BATTERIES – MAINTENANCE, HANDLING AND STORAGE

REQUIREMENTS 493

31.1. General Information

31.2. Safety

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

31.4. Fire Prevention

31.5. Ventilation Systems

31.6. Storage and Handling

31.7. Electrical

31.8. Installation and Care of Vehicle and Support Equipment Batteries

31.9. Aircraft Battery and Electrical System Specific Requirements

AFMAN91-203 11 DECEMBER 2018 15

Chapter 32— MOTOR VEHICLE – OPERATIONS AND MAINTENANCE 502

32.1. Specific Hazards

32.2. General Safety

32.3. Occupational Health

32.4. Facility and Equipment Requirements for Vehicle Maintenance Operations

32.5. Fire Prevention

32.6. Ventilation

32.7. Hazardous Materials Storage and Handling

32.8. Electrical

32.9. Cleaning With Solvents

32.10. Paint Shop

32.11. Air Compressors

32.12. Compressed Gas Cylinders

32.13. Lifting Devices

32.14. Wheel and Tire Maintenance

32.15. Maintenance Operations

Chapter 33— COMPOSITE MATERIALS 534

33.1. Scope

33.2. Specific Responsibilities

33.3. General Requirements

33.4. Specific Applications

33.5. Hazardous Waste Disposal

33.6. Special Mishap Considerations

33.7. Use of Composite Materials in New System Acquisition, and System and

Process Modifications

Chapter 34— PRECISION MEASUREMENT EQUIPMENT LABORATORY 538

34.1. General Information

34.2. Specific Hazards

34.3. Supervisor Responsibilities

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34.4. Ventilation Systems

34.5. Electrical Safety for PMEL Operations

34.6. Radioactive Material Safety

34.7. Cathode Ray Tubes

34.8. Equipment/Component Cleaning

34.9. Tools and Equipment

Attachment 1— GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 550

AFMAN91-203 11 DECEMBER 2018 17

Chapter 1

INTRODUCTION

1.1. Objective.

1.1.1. Occupational Safety and Health Administration (OSHA) safety guidance published in the Department of Labor (DoL) 29 series Code of Federal Regulations (CFR) 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 hazards and deficiencies in their workplaces. This standard 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 Air Force guidance. This standard provides uniform guidance, which safety staffs and commanders may supplement when additional or more stringent safety, fire prevention and health criteria are required.

1.2. Variances and Exemptions. The effected 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.

1.3. How to Use This Document.

1.3.1. This standard incorporates appropriate parts of the 29 CFRs 1910 and 1926 standards that relate to Air Force operations. References to other Air Force publications and national consensus standards are provided as appropriate. Air Force activities must comply with OSHA requirements at all times, unless the military-unique exemption applies IAW DoDI 6055.01, DoD Safety and Occupational Health Program, and AFI 91-202. (T-1)

1.3.2. This standard is intended for use by fire, safety and health professionals, commanders, functional managers, supervisors and employees. The information in this standard is for the protection of employees, Air Force property and equipment, and to ensure compliance with

Federal law. Note 1: This standard does not apply to state employees. Note 2: This standard 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.

1.4. Applying Standards. Air Force personnel must comply with all applicable safety guidance during Air 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.

1.4.1. Compliance.

1.4.1.1. 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 https://cs2.eis.af.mil/sites/10178/Pages/SEGHomeV2.aspx

18 AFMAN91-203 11 DECEMBER 2018

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 standard 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 your local safety office for guidance.

Resolve locally, when possible, using risk management techniques focused on the hazard and hazard mitigation.

1.4.1.2. 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.

1.4.2. Occupational Safety and Health Administration (OSHA) Requirements. Air Force 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.

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

Society of Mechanical Engineers B30.9, Slings, and National Fire Protection Association 70, National Electrical Code. Personnel needing access to American National Standards Institute and/or other national consensus standards can contact the installation Occupational Safety office for guidance and assistance.

1.4.4. Joint Base Safety Standard Compliance. Air Force personnel at Joint Bases will follow safety requirements outlined in the approved support agreement(s) developed IAW DoDI

4000.19, Support Agreements. (T-1) 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/FOA/DRU safety office for cross-service resolution. (T-1)

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

1.6. Military-Unique and Nonmilitary-Unique Policy. The Air Force 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 IAW DoD policy with respect to military-unique and nonmilitary-unique workplaces, operations, equipment and systems. Refer to AFI 91-202 for additional guidance.

1.7. Documentation. This standard 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, AFMAN91-203 11 DECEMBER 2018 19 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 standard offers an optional alternative to paper forms, MAJCOMs, NAFs, local procedures, Technical Orders (TOs) and other Air Force guidance may continue to require use of these forms. Check the prescribing directive(s) before discontinuing use of any forms.

1.8. First Aid and Cardiopulmonary Resuscitation (CPR) Training. Initial first aid and CPR training shall be accomplished prior to assigning an individual duties where first aid and CPR are requirements of the position. (T-1) All employees requiring CPR training will receive refresher training before current CPR certification expires. (T-1) Whether by the local Medical Group, the

American Red Cross or other appropriate organization, CPR training shall be provided for unit instructors, who, in turn, will train unit personnel. (T-1) If CPR training is not provided by the host medical facility, instructor training shall be obtained from an approved source, e.g., American Red

Cross, American Heart Association, military network, etc. (T-1) Training will also include Public

Access Defibrillator training IAW AFI 44-177, Public Access Defibrillator Program. (T-1) Note

1: Self-aid and buddy care 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 2: Remote location is defined as emergency care that is more than three to four minutes from the workplace.

1.9. 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 IAW 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, self-aid buddy care (SABC). For workplaces with employees that meet this job description, supervisors shall establish a written exposure control plan and conduct training IAW 29 CFR

1910.1030. (T-0)

1.10. Process Safety Management of Highly Hazardous Chemicals.

1.10.1. The Air Force 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) Process safety management also applies to explosives and pyrotechnics, which are defined in AFMAN 91-201, Explosives Safety Standards.

1.10.2. 29 CFR 1910.119, Appendix A, List of Highly Hazardous Chemicals, Toxics and

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

1.11. Responsibilities.

20 AFMAN91-203 11 DECEMBER 2018

1.11.1. Air Staff. All Air Staff elements shall ensure policies and procedures are consistent with the guidance of this manual.

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

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

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

1.11.3. Major Commands (MAJCOMs), 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)

1.11.4. Commanders and Functional Managers shall:

1.11.4.1. Ensure and promote applicable occupational safety and health (OSH) guidance for workplace and operations is available to all personnel. (T-1)

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

1.11.4.3. Provide a safe and healthful workplace by conducting monthly spot-inspections for hazards or deficiencies. (T-1)

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

1.11.4.4.1. OSHA directives. (T-0)

1.11.4.4.2. AFOSH directives. (T-1)

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

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

1.11.5. Supervisor’s Responsibilities. Supervisor responsibilities can be found in AFI 91-202.

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 manual/instructions or lesson plans, prior to the operation of any type of equipment or accomplishing assigned tasks. (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 JHA.

(T-1)

1.11.6. Air Force Personnel (military and civilian) shall:

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

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

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

AFMAN91-203 11 DECEMBER 2018 21

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

22 AFMAN91-203 11 DECEMBER 2018

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. IAW AFI 91-202, the 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, Air Force guidance and National Fire Protection Association

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 includes:

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

1910.196, Ionizing Radiation, and AFI 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. Noise issues are common to industrial and outside work areas such as flightlines and transportation/logistics maintenance areas, but noise in an office area or from an outside source can present problems. 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. 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, Flammables and

Combustibles, of this standard.

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)

2.3.1. Finger Rings. Rings (any material type) shall not be worn by personnel engaged in work in industrial areas, performing maintenance on aircraft, vehicles, equipment or machinery. (T-

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

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

AFMAN91-203 11 DECEMBER 2018 23

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. (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. (T-0)

2.3.1.6. Performing work on or around high temperature equipment. (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, etc., 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. Clean up spills as soon as possible and post warnings until cleanup is complete. This includes sidewalks, parking lots etc. Facility managers shall ensure potholes are filled and uneven surfaces corrected. (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)

24 AFMAN91-203 11 DECEMBER 2018

2.4.1.2. Place telephone and electrical cords 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, loosed or curled mats, 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. Combustible Materials and Waste. Refer to AFI 32-7042, Waste Management, for approved hazardous waste disposal procedures and guidance. Safety Data Sheets required for each hazardous chemical, IAW 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. Use or storage of flammable or combustible 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 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.

2.4.5. Stacking Materials. Refer to 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 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 manufacturer‘s instructions, regardless of height.

2.4.6. Lighting Fixtures. 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. Garbage cans within a food handling environment shall be washed and sanitized monthly with hot soapy water. (T-1) All other garbage cans shall be cleaned as needed. (T-1)

Exterior garbage cans shall be securely covered when not actually being filled or emptied. (T-

1)

AFMAN91-203 11 DECEMBER 2018 25

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. Material shall not be placed 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. Aisles and passageways shall be kept clear of tripping hazards. (T-0)

2.4.8.3. Nails shall be removed from loose lumber or the points turned down. (T-0)

2.4.8.4. Tools and supplies shall be properly stored. (T-0)

2.4.8.5. Disconnect switches, distribution panels and alarm supply boxes shall not be blocked by any obstruction that would prevent ready access. (T-0)

2.4.8.6. Wire reels shall be stacked with strips of wood between reels. (T-0)

2.4.8.7. Noncombustible materials shall be neatly kept in designated cabinets with their contents plainly marked. (T-1)

2.4.8.8. Compressed Air. If using compressed air for cleaning equipment, keep the air pressure as low as practical, but limit air pressure to less than 30 psi. Follow TO, manufacturer’s data 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. (T-0)

2.4.8.9. Machinery and equipment shall be kept clean of excess grease, oil and excessive dust. (T-1) Pressure gauges and visual displays shall be kept clean, visible and serviceable at all times. (T-1) Drip pans and wheeled or stationary containers shall be cleaned and emptied at the end of each shift. (T-2)

2.4.8.10. All work surfaces and floors shall be kept free of any visible accumulation of dust or any other foreign particles, as practicable. (T-0)

2.5. Office Safety.

2.5.1. General Office Equipment.

2.5.1.1. Chairs.

2.5.1.1.1. Inspect chairs regularly for broken casters or other defects. New or replacement caster chairs shall have at least five (5) legs. (T-1) Note: Five (5) or more legged caster chairs are more stable and ergonomically sound than four (4) legged caster chairs.

2.5.1.1.2. Do not stand on a chair to change a light bulb, retrieve overhead items or when hanging pictures/decorations, etc. Use stepstools or ladders to access anything above shoulder level.

2.5.1.1.3. Do not tilt back, lean sideways or reach behind to lift objects while seated in a chair.

26 AFMAN91-203 11 DECEMBER 2018

2.5.1.2. File Cabinets.

2.5.1.2.1. Store heavy material in bottom drawers and load cabinets from the bottom up.

2.5.1.2.2. Close drawers when not in use.

2.5.1.2.3. Do not climb on open file drawers.

2.5.1.3. Office Shelving/Bookcases. Store heaviest objects/books on lower-level shelves.

2.5.2. Electrical Equipment.

2.5.2.1. Appliance, electrical equipment and other office machines shall comply with 29

CFR 1910.334, Use of Equipment. (T-0)

2.5.2.2. Keep access to fuse or circuit breaker boxes or electrical controls clear and unobstructed with panel doors closed to prevent electrical flashover if a malfunction occurs. Refer to National Fire Protection Association 70, National Electrical Code, and

Chapter 8, Electrical Safety, for additional guidance on fuse and circuit breakers in the office area.

2.5.2.3. Appliances such as refrigerators and coffee makers shall not be plugged into modular office furniture unless the furniture electrical system is rated and certified by Civil

Engineering for general appliance use. (T-0) Note: Modular office furniture electrical systems are normally designed only to provide power to office equipment, e.g., personal computers, monitors, printers, etc. Refer to 29 CFR 1910, Subpart S, Electrical, for additional guidance.

2.5.2.4. Only qualified electricians, using approved materials shall install or perform electrical work IAW National Fire Protection Association 70. (T-0) Refer to Chapter 8 for additional information.

2.5.3. Items that could present hazards, such as knives or razors, shall not be left unprotected in desk drawers, storage cabinets, on top of counters or desktops. (T-1)

2.5.4. Lighting. Consult the local Civil Engineering facility design section when specific guidance on lighting is required. Fluorescent light bulbs contain toxic materials and shall be managed IAW local hazardous waste disposal criteria. (T-0) Supervisors shall ensure any stroboscopic effect with moving machinery is eliminated when using fluorescent lighting fixtures. (T-1) Work area lighting shall be installed to eliminate glare and harsh shadows. (T-

1) Supplementary or additional lighting shall be provided where general lighting is not sufficient. (T-1)

2.5.5. Heating, ventilation and air conditioning systems shall be maintained and inspected

IAW American National Standards Institute/American Society of Heating, Refrigerating and

Air Conditioning Engineers 62.1, Ventilation for Acceptable Indoor Air Quality. (T-1) Filters shall be changed as needed. (T-1) Do not cover air vents or obstruct air flow from registers.

(T-1) Do not place furniture, equipment or materials where they interfere with air movement or thermostats. (T-1)

2.5.6. Elevators.

AFMAN91-203 11 DECEMBER 2018 27

2.5.6.1. Elevators shall be inspected annually by a certified inspector. (T-0) Elevator inspection certification shall be posted in the cab of the elevator in view of all passengers or retained by the building manager and a permanent sign posted in the cab that identifies the location of the elevator certification. (T-0)

2.5.6.2. Elevators shall stop level with the floor when the doors open to prevent a tripping hazard. (T-0) Report elevator malfunctions immediately to the unit facility manager.

Employees shall not try to stop elevators by placing a hand or foot in closing doors. (T-0)

Employees shall not use elevators during emergency evacuation. (T-0)

2.5.6.3. Refer to American Society of Mechanical Engineers A17.1, Safety Code for

Elevators and Escalators, and American Society of Mechanical Engineers A17.2, Guide for Inspection of Elevators, Escalators and Moving-Walkways, for additional guidance on elevators.

2.6. Ergonomics. Ergonomics attempt to fit the job to the person, rather than forcing the person to fit the job. Adapting the job to the employee helps reduce stress and eliminates many potential injuries and disorders from overuse of muscles, poor posture and repetitive motion. Ergonomic hazards occur when the body may not be positioned correctly for a work task or working conditions put a strain on the body. They may include sore muscles, improperly adjusted workstations and/or chairs, poor posture, frequent lifting, vibration, repetitive motion or awkward movement. Contact the installation BE for questions relating to ergonomics or to have an ergonomic assessment completed. Refer to OSHA website:

https://www.osha.gov/SLTC/ergonomics/controlhazards.html and the U.S. Army Public

Health Center website:

https://phc.amedd.army.mil/topics/workplacehealth/ergo/Pages/default.aspx for additional guidance.

2.7. Roll-up Doors. Roll-up doors shall be maintained in good operating condition with door tracks free of debris and obstructions to allow smooth operation. (T-1) Operators shall conduct a visual inspection of door path and track-way and correct any discrepancies before operating door.

(T-1) Individuals shall remain clear of door path while door is in motion. (T-1) Auxiliary service roll-up doors, to include tow vehicle exit doors, shall meet the following requirements:

2.7.1. Be able to open a minimum of 8 feet or 70 percent of maximum opening height. (T-1)

2.7.2. Powered roll-up doors equipped with one touch open or close buttons shall have a crush sensor on the bottom of the door installed and operational.