Attachment D - OSHE Control Manual Chapter 220 (Fall Protection) -- 2022.pdf

NAVSEA

OCCUPATIONAL SAFETY,

HEALTH AND ENVIRONMENT

CONTROL MANUAL

FOR NAVAL SHIPYARDS

Naval Sea Systems Command Environmental Protection, Occupational Safety

And Health Office, NAVSEA 04R 1333 Isaac Hull Avenue, SE

Washington Navy Yard Washington, DC 20376

CHAPTER 220 OSHE CONTROL MANUAL

TABLE OF CONTENTS

SECTION TITLE SHEET

OSHE CONTROL MANUAL 220 Rev C i

220 Fall Protection 220-1

220.1 Discussion 220-1

A. Purpose 220-1 B. Standardization 220-1 C. Scope 220-1 D. Applicability 220-1 E. Background 220-1 F. Effective Implementation Date 220-1

220.2 Appendices 220-1

A. Definitions 220-1 B. Excerpt from Occupational Safety and Health Administration Directive 220-2 Number CPL 02-00-162 (Shipyard Employment “Tool Bag” Directive) C. Example Engineered Anchorage Label 220-2 D. Example Inspection Attributes Record 220-2 E. Fall Hazard Survey and Protection Plan 220-2

220.3 References 220-2

220.4 Overview of Subject Matter and Specific Policy 220-2

A. Definitions 220-2 B. General Requirements 220-3 C. Specific Requirements 220-4 D. Passive Fall Protection Systems and Requirements 220-8 E. Active Fall Protection Systems and Requirements 220-10 F. Accessing Unguarded Roof Tops 220-15 G. Purchasing, Inspection, Storage, Care, and Maintenance of 220-16 Fall Protection Equipment

220.5 Responsibilities 220-18

A. Subject Matter and Program Requirements 220-18 B. Reports, Reporting Requirements, and Records 220-23 C. Training 220-26 220A Appendix A: Definitions 220.A-1 220B Appendix B: Excerpt from OSHA Directive Number CPL 02-00-162 220.B-1 (Shipyard Employment “Tool Bag” Directive) 220C Appendix C: Example Engineered Anchorage Label 220.C-1 220D Appendix D: Example Inspection Attributes Record 220.D-1 220E Appendix E: Fall Hazard Survey and Protection Plan 220.E-1

OSHE CONTROL MANUAL 220 Rev C Sheet 220-1

CHAPTER 220 FALL PROTECTION

220.1 DISCUSSION:

A. Purpose: To provide a compilation of requirements applicable to the Corporate Fall Protection Program.

B. Standardization: This document provides the standardized Fall Protection Safety Policy for Naval Shipyards.

C. Scope: This document applies to evolutions, operations, or tasks that may expose personnel, either shipboard or ashore, who are accessing heights above a solid surface and exposed to fall hazards.

D. Applicability: This program applies to all personnel working at heights and/or utilizing fall protection equipment provided by Naval Shipyards and Intermediate Maintenance Facilities who are accessing heights where there is a possibility of falling:

1. Four feet for general industry work,

2. Five feet for ship repair operations, or

3. From any height onto dangerous equipment, into a hazardous environment, or onto an impalement hazard.

E. Background:

1. Falls from heights are a leading cause of work-related injuries and fatalities. The Naval Shipyards continue to experience serious fall-related mishaps, which lead to reduced readiness and productivity, as well as high medical and compensation costs resulting from these mishaps.

2. Mishaps involving falls are generally complex events, frequently involving a variety of factors. Consequently, preventing falls involves worker engagement, work procedures and fall protection system(s) design.

3. Every Navy command has a duty to protect its workforce by anticipating the need to work at heights and planning the work to protect from all hazards. Effective mishap prevention must be incorporated into the job planning process. All falls are preventable. Careful planning, preparation, and worker participation lay necessary groundwork for an accident-free workplace.

F. Effective Implementation Date.

The effective implementation date is 1 year from the issuance of this chapter.

OSHE CONTROL MANUAL 220 Rev C Sheet 220-2

220.2 APPENDICES:

A. Definitions.

B. Excerpt from OSHA Directive Number CPL 02-00-162 (Shipyard Employment “Tool Bag” Directive).

C. Example Engineered Anchorage Label.

D. Example Inspection Attributes Record.

E. Fall Hazard Survey and Protection Plan

220.3 REFERENCES:

A. OPNAV M-5100.23, Navy Safety and Occupational Health Program Manual, (Latest Revision).

B. OSHA Directive Number CPL 02-00-162 (Shipyard Employment “Tool Bag” Directive).

C. NAVFAC P-307, Management of Weight Handling Equipment.

D. 29 Code of Federal Regulations (CFR) 1910, Occupational and Health Standards for General Industry.

E. American National Standards Institute (ANSI)/American Society of Safety Professionals (ASSP) Z359 Fall Protection Code.

F. NAVSEAINST 4700.17, Preparation and Submission of Trouble Reports.

G. 29 Code of Federal Regulations (CFR) 1915, Occupational and Health Standards for Shipyard Employment.

H. Naval Ships Technical Manual (NSTM) Chapter 600, Hull Outfitting Equipment (Latest Revision).

I. Department of the Navy Fall Protection Guide (Latest Revision).

J. OPNAVINST 3500.39D Operational Risk Management (Latest Revision).

K. OSHE Control Manual 130, OSHE Deficiency Reporting System.

220.4 OVERVIEW OF SUBJECT MATTER AND SPECIFIC POLICY:

OSHE CONTROL MANUAL 220 Rev C Sheet 220-3

A. Definitions: To implement the requirements of this chapter effectively, numerous terms and definitions must be understood. For convenience, they are listed in Appendix A, Definitions.

B. General Requirements:

1. Due to the nature of work performed in Naval Shipyards and Intermediate Maintenance Facilities, workers at times will be required to perform their duties at elevated locations.

Personnel exposed to fall hazards must be appropriately trained in accordance with this chapter.

Fall hazards must be mitigated in accordance with this chapter.

2. Workers weighing less than 130 and over 310 pounds, as well as those with known back problems or heart conditions, are at a greater risk of personal injury from fall protection equipment in the event fall arrest occurs. These individuals must self-identify to their supervisor and the Fall Protection Program Manager prior to entering into the Fall Protection Program.

More information on this topic is discussed within section 220.4.E.1 of this manual.

a. Currently, there is no fall protection equipment approved for use by pregnant workers.

Pregnant workers must not don personal fall protection equipment.

3. Personnel must report, through their chain of command, when fall protection equipment is impacted. Personnel must be medically evaluated in the event fall arrest occurs.

4. The Hierarchy of Fall Protection per reference (E), or preferred order of control measures, for an identified fall hazard is:

a. Hazard Elimination: Changing the task, process, controls or other means to remove the need for an employee to be exposed to a fall hazard (e.g., bring the job to the ground).

b. Passive Fall Protection System: Use of a physical barrier that isolates the worker from the fall hazard, which does not require the wearing or use of personal fall protection equipment (e.g., guardrail systems, covers, safety nets, etc.).

c. Fall Restraint System: Restrict the worker’s movements so the worker’s center of mass cannot reach beyond the fall hazard by utilizing a combination of anchorage, anchorage connectors, connecting means and full body harness.

d. Fall Arrest System: The collection of equipment components that are configured to arrest a free fall by utilizing a combination of anchorage, anchorage connectors, connecting means (energy absorbing lanyard, SRD, etc.) and full body harness.

e. Administrative Controls: Within the fall protection plan; detail the infeasibility of the above listed fall protection mitigation measures, introduce new work practices that reduce the risk of falling, and outline how to perform work tasks as safely as possible without a secondary system (e.g., erecting warning lines or designated areas, restricting access to certain areas, or posting warning signs).

OSHE CONTROL MANUAL 220 Rev C Sheet 220-4

NOTE

Control measures are not mutually exclusive. There may be situations when more than one control measure should be used to reduce the risk of a fall.

5. Where fall hazards exist, workers must maintain a primary and secondary fall protection system at all times. If the primary fall protection system fails, the secondary fall protection system will protect the worker.

6. Personnel must not work at heights, work near unguarded edges, or work in an isolated area alone. Whenever possible, employees should work in pairs (buddy system). This is to ensure the Rescue Plan can be carried out as quickly as possible.

7. All unguarded edges must be evaluated and hazards mitigated in accordance with this chapter.

8. Fall protection requirements must be considered and used regardless of the time duration of the work. For example; if a 2-minute job requires 15 minutes to establish fall protection, then personnel must spend the required 15 minutes to establish their fall protection.

9. Fall Protection equipment must be turned into the tool room;

a. For inspection per section 220.4.G.2. (Inspection),

b. Once it has been impacted or shows signs of impact loading, or

c. When it fails pre-use/post-use inspection.

C. Specific Requirements:

1. Walking/Working Surfaces.

a. When personnel will be on a surface with unprotected sides or edges 4 feet (5 feet for ship repair operations) or greater above a lower level, they must be protected with Fall Protection Systems in accordance with this chapter.

b. Personnel exposed to fall hazards on walking-working surfaces at any height above dangerous equipment, impalement hazards, or hazardous environments must be protected with Fall Protection Systems in accordance with this chapter.

c. When any portion of a guardrail system, gate, or safety chain is removed and personnel are exposed to an unguarded edge, personnel must be protected from falling with Fall Protection Systems in accordance with this chapter.

d. When guardrail systems are used around holes that serve as points of access (e.g., ladderways, hatches, etc.), the guardrail system opening:

OSHE CONTROL MANUAL 220 Rev C Sheet 220-5

(1) Must possess a self-closing gate that slides or swings away from the hole, and meets the requirements of section 220.4.D.1 (Guardrail Systems), or

(2) Must offset to prevent personnel from walking or falling into the hole.

e. Reference B provides to Occupational Safety and Health Administration (OSHA) employees and interested parties’ guidance concerning the application of occupational safety and health standards in shipyard employment. Appendix B, Excerpt from OSHA Directive Number CPL 02-00-162 (Shipyard Employment “Tool Bag” Directive), provides guidance concerning the applicability of 29 CFR 1910.28, 1910.29, and 1910.140 for fall protection on vessels and on shore.

2. Edges over/near water. When working at the unguarded edge of a pier, quay wall, or flooded dry-dock 5 feet or more above a solid surface (e.g., camel or barge), fall prevention/protection methods must be in place.

a. Personal floatation devices (PFDs) must be worn when working with 6 feet of deck edges of vessels afloat and other surfaces above water (e.g., piers, camels, barges, floating cranes, etc.)

where guardrails or an equivalent form of fall protection is not provided to prevent a fall into the water.

3. Aerial Work Platforms (AWP).

a. When working in an AWP, a Fall Restraint System is the safest and preferred method of protecting the occupants. If an adjustable energy absorbing lanyard cannot be configured in a Fall Restraint System, then an energy absorbing lanyard must be configured for Fall Arrest to prevent contact with the nearest lower obstruction.

(1) Self-retracting devices are prohibited from use while working from an AWP.

b. Personnel must stand on the floor of the platform only, must not sit or climb on railings, and must not use planks, ladders, or other devices positioned on railings.

c. When working inside the platform, personnel must not anchor outside of the platform.

d. When exiting/entering the basket at heights, personnel must maintain 100% fall protection. Entry and exit requirements must be outlined in a Fall Protection Plan in accordance with section 220.5.B.2. (Fall Protection Plans).

e. Personnel must follow procedures outlined in reference A. For procedures not addressed within reference A, personnel must follow Original Equipment Manufacturer (OEM) instructions.

(1) When an AWP provides an anchor point, it must be used in accordance with the

OEM instructions or as outlined in this chapter, whichever is more stringent.

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WARNING

DO NOT tie off to guardrails!

f. When work will take a platform over water, personal floatation devices must be worn by the occupants in addition to their personal fall protection system in accordance with the following:

(1) Where the distance from the working surface to the water is 25 feet or more, personal fall restraint or arrest is required. Personal floatation devices are not required.

(2) Where the distance from the working surface to the water surface is less than 25 feet and the water depth is less than 10 feet, or hazards (i.e., machinery, barges, camels, or other structures) are present, personal fall restraint or arrest is required. Personal floatation devices are not required.

(3) In situations outside of the above scenarios, occupants may disconnect their personal fall protection from the anchor point when the platform is over water. As the operator is trained in both the capabilities of the AWP and as an Authorized Person of fall protection, they, with their supervisor, are in the best position to make this risk decision. This decision will depend on the unit in use, operator experience, height above water, depth of water, wind conditions, and structures that potentially create a tunneling effect of wind.

g. Additional requirements within Chapter 34 of Reference A (OPNAV M-5100.23, Aerial

Work Platform Safety) must be followed as applicable.

4. Crane-Suspended Personnel Platform. The lifting of personnel by crane must only be accomplished in accordance with Reference C (NAVFAC P-307).

5. Fixed Ladders General Requirements.

a. The use of ladders with broken or missing rungs or steps, broken or split side rails, or other faulty or defective construction is prohibited. When ladders with such defects are discovered, they shall be reported to Code 106 immediately.

b. Any ladder with structural or other defects must be immediately tagged “Dangerous: Do

Not Use” or other similar language, and removed from service.

c. Inspection of metal ladders must include checking for corrosion of interiors of open end, hollow rungs.

d. Ladder surfaces must be free of puncture and laceration hazards.

e. All personnel must face the ladder when climbing.

OSHE CONTROL MANUAL 220 Rev C Sheet 220-7

f. All personnel must maintain three points of contact on the ladder while climbing (i.e., one hand, two feet; one foot, two hands).

g. Personnel must not carry any object or load (e.g., tool bag) that could cause them to lose balance and fall while climbing up or down the ladder.

h. Regardless of fixed ladder length or height, if a fixed ladder possesses a fall arrest system (e.g., SRD or climbing ladder safety system), then this fall arrest system must be utilized when climbing.

i. Personnel performing work at any height from a fixed ladder must utilize a fall arrest system in conjunction with a fall protection work positioning system.

j. Additional fixed ladder requirements pertaining to their design can be found within

Reference D (29 CFR 1910.23).

6. Fixed Ladders (non-shipboard).

a. Fall protection is required on fixed ladders that extend over 20 feet in height. Each fixed ladder over 20 feet must be equipped with a personal fall arrest system or ladder safety system.

(1) The 20 feet is measured from the initial walking-working surface where the ladder begins to the next walking-working surface/platform/landing where the ladder ends. The distance of the ladder extension rails above the next walking-working surface is excluded from this measurement.

b. For fixed ladders equipped with safety cages that were installed before November 19, 2018 and extend more than 20 feet, cages may remain on the ladder; however, they are not recommended as the mitigation measure for a fall.

NOTE

If a fixed ladder starts at a landing that is greater than 20 feet above a lower level, fall protection must be provided regardless of the length of the ladder. For example; if a ladder section begins at a landing and the climber could fall greater than 20’ past the landing, but the length of that ladder is less than 20’, fall protection must be provided.

c. Additional fixed ladder requirements pertaining to fixed ladder fall protection can be found in Reference D (29 CFR 1910.28 and 1910.29).

7. Fixed Ladders (shipboard)

a. In-hull bulkhead ladders (i.e., half-moons, D-hole cutouts) are not recognized as a safe walking-working surface and must not be used without utilizing a Personal Fall Arrest System.

OSHE CONTROL MANUAL 220 Rev C Sheet 220-8

8. Portable Ladders.

a. Personnel must face the ladder and keep their center of mass within the confines of the side rails when performing work from a portable ladder.

b. Personnel performing work from a portable ladder near guardrails with a fall hazard beyond the base of the ladder must utilize a secondary fall protection system. Tie-off to the portable ladder is prohibited.

(1) A personal fall arrest system must be used when personnel are working from a portable ladder near guardrails, such that personnel could fall over the guardrails.

c. Personnel must set up all straight or extension ladders with a 4:1 ratio and lashed, blocked, or otherwise secured to prevent accidental displacement.

d. Neither the top of a stepladder nor the step below the top of a stepladder may be used as a step or used to stand on while performing work.

e. The top two steps of a portable ladder must not be used.

f. Portable ladders used to gain access to an upper landing surface must extend at least 3 feet above the upper landing surface.

g. Portable ladders with structural or other defects must not be used.

D. Passive Fall Protection Systems and Requirements:

1. Guardrail Systems.

a. The top rail of guardrail systems must be capable of withstanding, without failure, a force of at least 200 pounds applied in a downward or outward direction within 2 inches of the top edge, at any point along the top rail.

b. When the 200-pound test load is applied in a downward or outward direction, the top rail of the guardrail system must not deflect to a height of less than 39 inches above the walking-working surface.

c. Guardrail systems must have a top rail height of 42 inches +/- 3 inches.

If the working surface adjacent to the guardrail system is elevated, reducing top rail height to less than 39 inches, additional fall protection measures must be in place.

OSHE CONTROL MANUAL 220 Rev C Sheet 220-9

d. The mid rail must be located approximately half way between the top rail and the platform and be capable of supporting, without failure, 150 pounds applied in any downward or outward direction at any point along the intermediate member.

e. A toe board, when installed, must be at least 3 ½ inches high, and must be capable of supporting, without failure, 50 pounds in any downward or outward direction.

f. Flexible guardrail systems, constructed with chains, synthetic fiber, or wire rope must meet the following requirements:

(1) The rope or chain must be secured to each support and taut at all times. It might be necessary to use a positive tensioning device to reduce the sag to a minimum.

(2) The rope or chain must be free of sharp edges, burrs, or projections.

(3) The maximum deflection of the top rail when a load of 200 pounds is applied in any direction at any point on the top rail must not exceed 3 inches in one direction, which includes the free hanging sag in the rope or chain.

g. Additional Guardrail System requirements can be found within Reference D (29 CFR 1910.29).

h. Additional shipboard-specific guarding requirements:

(1) When working in the vicinity of flush manholes and other small openings of comparable size, such openings must be covered per section 220.4.D.3 (Covers), guarded per section 220.4.D.1 (Guardrail Systems), or guarded to a height of not less than 30 inches (i.e., “U” bar guards).

(2) When working around open hatches or other large openings, the edge of the opening must be guarded per section 220.4.D.1 (Guardrail Systems).

(3) Lifeline and liferail systems must meet the applicable requirements within

Reference H (NSTM Chapter 600, Hull Outfitting Equipment).

2. Parapets (e.g. roof edge, Bridge Crane Girders). Parapet height must be a minimum of 39 inches to be considered a compliant Passive Fall Protection System. If the height is less than 39 inches, then additional forms of fall protection are required.

3. Covers

a. Covers are used over floor holes and floor openings (refer to Appendix A for definitions).

b. Covers must be capable of supporting at least twice the foreseen weight (i.e., personnel, equipment, supplies).

OSHE CONTROL MANUAL 220 Rev C Sheet 220-10

c. Covers must be secured to prevent accidental displacement.

d. Covers must be clearly marked to warn of the hazard (e.g., “HOLE”, “FALL HAZARD”, etc.)

E. Active Fall Protection Systems and Requirements:

1. General Requirements

a. Active Fall Protection Systems must be utilized per the component’s intended application of use per Reference E. Newly acquired fall protection equipment must meet the latest applicable product standard under Reference E. Fall protection equipment not meeting at least ANSI/ASSE Z359.1-2007 is not authorized for use.

b. For Authorized Persons outside of the ANSI recognized weight range of 130-310 lbs., extra precautions must be made. Personal fall protection systems, per ANSI, are certified only within the capacity range of 130 to 310 lbs. The concern for Authorized Persons with a body weight of more than 310 pounds is the potential to fully deploy and bottom-out an energy absorber, exposing the Authorized Person to arrest forces greater than 1,800 pounds prescribed by the Occupational Safety and Health Administration (OSHA), as well as ANSI. The concern for Authorized Persons with a body weight less than 130 pounds is the high arrest force (G force) that they may experience.

Due to the above stated concerns, Authorized Persons outside of the ANSI recognized weight range of 130 – 310 pounds are permitted to use personal fall protection equipment as prescribed by a Qualified Person for Fall Protection as a Fall Restraint System only.

Fall Arrest Systems are prohibited for use with Authorized Persons outside of this weight range.

A Qualified Person must develop a Fall Protection Plan meeting the requirements of section 220.5.B.2 (Fall Protection Plans) for Authorized Persons outside of the ANSI recognized weight range.

2. Anchorages

a. All anchorages must be independent of any anchorages used to support or suspend platforms.

b. Certified anchorages

(1) Certified anchorages must have labels (see example Appendix C) and/or documentation stating the following as a minimum:

(a) Anchorage Strength

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(b) Number of personnel allowed to connect

(c) Qualified Person for Fall Protection certification signature, date, and contact information

(d) Inspection Due Date

(e) Permitted uses (e.g., fall arrest, fall restraint, work positioning, etc.)

(2) Certified Anchorages must:

(a) Be designed, installed, and used as part of a complete personal fall protection system.

(b) Maintain a safety factor of 2:1.

(c) Be designed and used under the direction of a Qualified Person for Fall

Protection.

(3) Certified Anchorage design:

(a) A Professional Engineer (PE) that does not maintain the qualification of a Qualified Person (QP) for Fall Protection may design the anchor point; however, a QP must evaluate the fall protection system in its entirety.

(b) A PE may do both given they maintain the qualification of a QP.

(4) Prior to use, Horizontal Lifeline anchorages, to include anchorage for temporary

Horizontal Lifelines, must be designed by a registered Professional Engineer with experience in designing horizontal lifeline systems; or designed by a Qualified Person who has appropriate training and experience.

c. Non-certified anchorages

(1) Non-certified anchorages must support the required weight set forth by the designed/directed use of the system.

(2) Non-certified anchorages must be selected by a Competent Person.

(3) Non-certified anchorage strengths must meet the following strengths per Authorized

Person attached:

(a) 5,000 pounds for fall arrest,

(b) 3,000 pounds for work positioning and rescue, and

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(c) 1,000 pounds for fall restraint.

d. In certain situations, an anchorage point cannot be installed while maintaining 100% fall protection. An Authorized Person must establish an anchorage point first for themselves, and then all personnel that will follow. This method, known as “first man-up”, is a last resort and places the Authorized Person at risk when installing an anchorage. This method is an Administrative Control and must be discussed in detail within the Fall Protection Plan signed by the Fall Protection Program Manager.

3. Fall Restraint System.

a. Anchorages must be in accordance with section 220.4.E.2 (Anchorages).

b. The Fall Restraint System must not allow the worker’s center of mass to reach beyond the edge of the walking/working surfaces.

c. Fall Restraint Systems must be used only on horizontal or low sloped surfaces (less than 4:12 pitch).

4. Personal Fall Arrest Systems.

a. Anchorages used for Personal Fall Arrest Systems must be in accordance with section 220.4.E.2 (Anchorages).

b. Connecting means (e.g., Lanyards, Self-Retracting Devices, HLLs, etc.) used in Fall

Arrest Systems must have energy absorbing capabilities.

c. Daisy-chaining connecting means is prohibited.

d. Newly acquired fall protection equipment must meet the latest applicable product standard under Reference E. Currently owned fall protection equipment not meeting at least ANSI/ASSE Z359.1-2007 is not authorized for use.

e. Systems must be configured so that the impact forces do not exceed 1,800 pounds.

f. Systems must be configured such that the Authorized Person does not contact a lower level or any obstructions in the event of a fall.

5. Personal Fall Arrest System Clearance Requirements.

a. A Competent Person, Qualified Person, or Fall Protection Program Manager must determine that the required clearance of the Personal Fall Arrest System utilized is less than the available clearance to the nearest obstruction within a Fall Protection Plan meeting the requirements of section 220.5.B.2. (Fall Protection Plans).

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b. A personal fall arrest system must be configured such that the employee will not free-fall more than six feet unless the proper energy absorber is used and the system limits the Maximum Arresting Force (MAF) to 1,800 pounds.

c. Swing fall must be considered and mitigated to the greatest extent possible. Swing-drop distance should not exceed 4’. If contact with obstructions could occur during swing fall/swing-drop, then a different mitigation method must be determined.

6. Work Positioning Systems.

b. Work Positioning Systems must be configured so that personnel cannot fall more than 2 feet and must be used with a secondary fall arrest system.

c. Secondary Fall Arrest System anchorages must be independent of the anchorages for the work positioning system and must meet the requirements of section 220.4.E.2 (Anchorages).

7. Vertical Lifelines (Rope Grabs).

b. Independent vertical lifelines and anchorages are required for each user.

c. Users must ensure that the fall arrestor is compatible with the rope being used.

d. Energy Absorbing Lanyards must not exceed 3 feet in length.

e. Once the work area has been reached fall arrestors must be parked as high above the worker as possible to decrease free fall.

8. Horizontal Lifelines.

a. The concern with horizontal lifelines is the force that can be generated along the length of the lifeline and, ultimately, on end anchorages. Horizontal Lifeline anchorages must be in accordance with section 220.4.E.2.b.(4) (Anchorages – Horizontal Lifelines). Clearance requirements must be provided by the Qualified Person who designed the system. The Qualified Person and/or registered Professional Engineer must follow the applicable design requirements stated within Reference E (ANSI Z359.6).

b. Temporary Horizontal Lifelines must:

(1) Be designed by a Qualified Person or pre-engineered by the OEM.

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(2) Adhere to all requirements for installation and use provided by the Qualified Person or OEM.

(3) Be installed, certified, and used under the direction/supervision of a Qualified Person or OEM.

c. Permanent Horizontal Lifelines must:

(1) Be installed, certified, and used under the direction/supervision of a Qualified Person.

(2) Be designed by a Qualified Person that supplies a user guide to define the use, inspection frequency, repair, maintenance details, fall clearances, and fall protection equipment.

(3) Have certification tags installed at the location of the horizontal lifeline.

9. Self-Retracting Devices and Lifelines (SRDs/SRLs).

a. SRDs, excluding those designed with Leading Edge capabilities (SRD-LE), must be used for vertical applications only.

i. When designing fall arrest systems that utilize SRD-LEs, the following hazards must be mitigated:

(1) Obstructions during swing fall

(2) Obstructions during free fall

(3) Friction between the SRD-LE line and the leading edge

b. Additionally, the applicable requirements within sections 220.4.E.4 (Personal Fall Arrest

Systems) and 220.4.E.5. (Personal Fall Arrest System Clearance Requirements) must be met when utilizing SRDs.

10. Climbing Ladder Fall Arrest Systems (Ladder Safety Systems).

a. Fall protection systems must be installed on fixed ladders greater than 20 feet in length or installed when ladders are mounted at elevated locations exceeding 20 feet in height.

b. The frontal D-ring of the harness must be connected directly to the traveling sleeve by way of the provided connector on the traveling sleeve or by use of a carabiner.

c. The length between the traveling sleeve and the frontal D-ring connection must not exceed 9 inches.

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d. Free fall must not exceed 2 feet when connecting to the frontal or sternal D-ring.

e. The system must be positioned to permit personnel to ascend/descend the ladder with minimal manipulation of the traveling sleeve.

f. Mounting of rigid carriers must be in accordance with OEM recommendations.

Mountings for rigid carriers are attached at each end of the carrier, with intermediate mountings spaced, as necessary, along the entire length of the carrier so the system has the strength to stop employee falls.

g. Mounting of flexible carriers and cable guides must be installed in accordance with OEM instructions. Mountings for flexible carriers are attached at each end of the carrier and cable guides for flexible carriers are installed at least 25 feet apart but not more than 40 feet apart along the entire length of the carrier.

h. Ladder safety system components must not mix with ladder safety system components from a different manufacturer. Ladder safety sleeves are specifically designed for the ladder safety line/rail/cable that accompanies it.

i. Ladder safety systems must extend three feet above the accessible walking-working surface.

j. 100% fall protection must be provided when transitioning while elevated.

11. Connecting Components (e.g., snap hooks, carabiners, etc.)

a. Component connections must be compatible. It is possible for two components to be compatible with each other when properly configured and used, but to be incompatible when configured and/or used in a different manner (e.g., large snaphooks within AWPs used for fall restraint are compatible, but not compatible when used for fall arrest).

b. Connections made within any part of a personal fall protection system must be compatible to prevent forced rollout, gate loading, and transverse loading.

F. Accessing Unguarded Rooftops:

1. Prior to accessing a rooftop, permission must be granted by the shipyard’s OSHE Office and the Building Manager.

2. Rooftop accesses must be secured and/or appropriately posted to prevent unauthorized access, stating that a Fall Hazard Survey and Protection Plan is required beyond the points of entry.

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3. A Fall Hazard Survey and Protection Plan must be conducted for all rooftops where access is needed. Each roof top Fall Hazard Survey and Protection Plan requires two people to complete:

(1) a Competent Person to conduct the Fall Hazard Survey and Protection Plan, and (2) a person to serve as the safety observer to ensure personnel stay well away from edges while conducting surveys.

1) Competent Person(s) must not perform work while conducting the survey.

4. Flat roofs or roofs having a pitch of 4:12 or less can be evaluated from the roof surface.

5. Sloped roofs must be evaluated via an AWP when the roof pitch is greater than 4:12 (18.5 degrees), the surface is slippery, or roofing material is fragile.

Passive fall protection methods are not acceptable for use on roofs that are greater than

4:12 pitch.

6. Additionally, all roof work fall protection requirements within Reference D (29 CFR 1910.28(b)(13)) must be met.

G. Purchasing, Inspection, Storage, Care, and Maintenance of Fall Protection Equipment:

1. Purchasing.

a. Fall Protection Program Managers must approve the purchase of all fall protection equipment.

b. Fall protection equipment must meet the criteria of Reference E (ANSI Z359).

(1) Electrically rated harnesses must meet the ASTM F887 standard.

(2) When purchasing, the most recent ANSI standard for each component must be specified.

c. All equipment purchased for use in fall protection systems must be properly labeled and serialized for the purpose of tracking required maintenance. New inventory must be entered into an inspection and maintenance program prior to issue.

2. Inspection.

a. Annual Detailed Inspection.

(1) Annual detailed inspections of fall protection equipment must be performed annually from the date the equipment was put into service, unless otherwise specified by the Competent Person, Qualified Person, or Fall Protection Program Manager.

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(2) Annual Detailed Inspections must be accomplished by a Competent Person other than the Authorized Person and documented.

b. Tool Room Re-issue Inspection must be performed:

(1) Prior to reissue to the Authorized Person when the Annual Detailed Inspection is not yet required.

(2) By Competent Persons or Equipment Inspectors who have received knowledge-based training on fall protection equipment inspections in accordance with this chapter.

c. Authorized Person’s Inspection.

(1) The Authorized Person must perform a pre-use inspection before accepting or using any fall protection equipment.

(2) The Authorized Person must inspect their issued equipment prior to returning the equipment to the tool room.

d. Fall protection equipment must be inspected for:

(1) Absence or illegibility of markings (e.g., ANSI standards, gate strengths, etc…).

(2) Absence of any elements affecting the equipment form, fit, or function.

(3) Evidence of defects in or damage to hardware elements, including cracks, sharp edges, deformation, corrosion, chemical damage, excessive heating, alteration, and excessive wear.

(4) The inspection must include the snap hooks, carabiners, hardware, cable, chain, rope, webbing, stitch patterns, full body harness, and impact indicators for any defects or unsatisfactory conditions. See Appendix D (Example Inspection Attributes record) for assistance during inspection.

e. Equipment that does not meet the inspection requirements must be removed from service, destroyed, provided to the Fall Protection Program Manager for disposition, or undergo appropriate service prior to reissue/use.

(1) Equipment that has been impacted must be provided to the FPPM for disposition.

f. Inspection records must be maintained for the life of the equipment on all equipment available for distribution.

g. Specialized Fall Protection Equipment.

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(1) Some equipment might require the Qualified Person or OEM to perform recertification on specialized equipment (i.e., self-retracting lifelines, automatic descent control devices, ladder climbing devices, and horizontal lifelines). Follow all OEM instructions for recertification. The Fall Protection Program Manager must track recertification.

(2) Unique instructions provided by the OEM, which might arise due to conditions of use, must be retained as a Reference for the life of the equipment, and must be made available to the user.

3. Storage. Store fall protection equipment in a cool, dry, safe environment to prevent damage from environmental factors such as heat, light, excessive moisture, oil, chemicals and their vapors, or other degrading elements.

4. Care and Maintenance.

a. When laundering is required, it must be performed in accordance with the OEM instructions.

b. During annual inspections, all fall protection equipment removed from service or requiring maintenance must be identified by the inspector and notated on an inspection attributes record remark sheet and either provided to the Fall Protection Program Manager for disposition or destroyed. (See Appendix D, Example Inspection Attributes Record).

220.5 RESPONSIBILITIES:

All Shipyards, which have personnel exposed to fall hazards, are required to establish a comprehensively managed fall protection program. The fall protection program must be in writing and approved by Code 106. Per Reference A, a comprehensive managed Fall Protection Program includes the following:

(1) Command, unit, or activity Policy

(2) Duties and Responsibilities

(3) Workplace Surveys and Assessment of Fall Hazards

(4) Fall Hazard Prevention and Control, including the Preparation of Fall Protection and

Prevention Plans.

(5) Training

(6) Inspection, Storage, Care, and Maintenance of Fall Protection Equipment

(7) Rescue Procedures

(8) Fall mishap reporting

(9) Audits and Evaluation

A. Subject Matter and Program Requirements:

1. Norfolk Naval Shipyard is the Cognizant Lead Yard (CLY) for this chapter. The CLY must:

OSHE CONTROL MANUAL 220 Rev C Sheet 220-19

a. Initiate chapter revisions when changes or modifications to Federal, DOD, Navy, or NAVSEA requirements (whether in actual content or interpretation of same) are received which would affect the content of the OSHE Control Manual (OSHECM) chapter.

b. Specify NAVSEA or other Federal technical manuals, instructions, etc., with which revisions are in compliance.

c. Maintain the OSHECM chapter under a three-year revision cycle, as follows:

(1) On an ongoing basis, compile a list of changes that might be required to the chapter.

(2) Each calendar year, prepare a memorandum for CLY OSHE Director review recommending one of three courses of action:

(a) No changes are required; continue to the following year’s annual review.

(b) Minor changes are required; determine if the changes are significant enough to proceed with revision or capture the recommended changes and save them for the next revision.

(c) Major changes are required; revise the chapter in accordance with the OSHECM Process. (Refer to OSHE Control Manual, Chapter 101 (Administrative), section 101.4.C.)

(3) At the end of each three-year revision cycle, certify that the chapter is still acceptable as shipyard policy. If the CLY determines the chapter to be acceptable (i.e., relevant), continue to the following three-year revision cycle. If the CLY determines the chapter not to be acceptable, make a recommendation to SEA 04R to cancel the chapter, including the justification for doing so. If the chapter is cancelled, utilize reference A until such revision is complete.

2. All shipyard departments, shops, and codes that perform work within the scope of this document must:

a. Comply with the requirements of this instruction regardless of the site location where personnel are working when fall hazards exist.

b. Delineate and assign responsibilities in the implementation of a managed fall protection program.

c. Ensure that assigned personnel have the necessary skills, knowledge, training, and expertise to manage, administer, and implement the fall protection program.

3. The fall protection program must be organized, as follows:

a. The Fall Protection Program Manager must:

OSHE CONTROL MANUAL 220 Rev C Sheet 220-20

(1) Be trained in accordance with section 220.5.C.1 (Fall Protection Program Manager Training).

(2) Be trained in accordance with section 220.5.C.3. (Competent Person Training).

(3) Develop, implement, monitor, and evaluate the fall protection program.

(4) Approve/concur on Fall Hazard Survey and Protection Plans when administrative controls are used.

(5) Have knowledge of current regulations and standards.

(6) Provide guidance to Authorized Persons, Competent Persons, Qualified Persons, employees, purchasing, human resources, and engineering on matters pertaining to the fall protection program.

(7) Ensure that personnel exposed to fall hazards and other personnel involved in the program receive effective/adequate training as outlined in Reference A.

(8) Participate in all investigations involving mishaps related to falls from heights by reviewing incident reports, taking corrective action to eliminate causes, reporting to management, and maintaining an incident reporting system.

(9) Conduct periodic program evaluations and ensure improvements are implemented by appropriate organizations.

(10) Conduct periodic surveillances to validate compliance with this chapter.

(11) Audit and evaluate the fall protection program annually to validate compliance with this chapter.

(12) Have access to the QPS/OSHE DR reports quarterly for the purpose of trend analysis.

(13) Maintain records of the Fall Hazard Survey and Protection Plans, and Rescue Plans submitted by Competent and Qualified Persons.

(14) Track recertification of specialized fall protection equipment.

b. Qualified Persons for Fall Protection must:

(1) Serve as an engineer with a recognized engineering degree, or possess a professional certificate and extensive knowledge, training, and experience in fall protection. The Qualified

OSHE CONTROL MANUAL 220 Rev C Sheet 220-21

Person for Fall Protection must be trained in accordance with section 220.5.C.2 (Qualified Person Training).

(2) Maintain the qualifications of a Competent Person in accordance with section

220.5.C.3 (Competent Person Training).

(3) Support the fall protection program in areas of expertise, including system design, horizontal lifeline design, structural analysis, calculation of arresting forces and fall clearances, testing, anchorage certification, methods of control, equipment selection, administrative controls, and compliance with regulations and standards.

(4) Submit their Fall Hazard Survey and Protection Plans and Rescue Plans to the Fall

Protection Program Manager for assessment and recordkeeping.

c. Competent Persons for Fall Protection must:

(1) Be trained in accordance with section 220.5.C.3 (Competent Person Training).

(2) Conduct Fall Hazard Surveys and identify all fall hazards prior to Authorized

Persons being exposed.

(3) Develop and implement Fall Protection Plans in compliance with this chapter.

(4) Develop Rescue Plans and pre-incident plans as required.

(5) Participate in all investigations of all falls under their purview.

(6) Have knowledge of current regulations and standards.

(7) Evaluate, conduct, approve and maintain all Fall Hazard Survey and Protection Plans under their purview.

(8) Assist Authorized Persons, and Supervisors of Authorized Persons, as requested.

(9) Submit Fall Hazard Survey and Protection Plans and Rescue Plans to the Fall Protection Program Manager for assessment and recordkeeping.

d. Supervisors of Authorized Persons for Fall Protection must:

(1) Be trained in accordance with section 220.5.C.6 (Authorized Person Training) or 220.5.C.3 (Competent Person Training).

(2) Understand the policies and procedures of this chapter, as well as the direction of

Competent and Qualified Persons.

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(3) Review jobsite prior to work and request Fall Hazard Survey and Protection Plans and Rescue Plans when fall hazards are identified.

(4) Brief personnel on Fall Hazard Survey and Protection Plans and Rescue Plans as required.

It is not the intent of this requirement that Supervisors of Authorized Persons are the only personnel that can brief an Authorized Person. Competent Persons, Qualified Persons, or

Work Leaders/Zone Managers familiar with the work and trained as an Authorized Person/Competent Person can also perform a brief on the Fall Hazard Survey and

Protection Plan, or Rescue Plan.

(5) Verify employees are qualified before assigning work requiring the use of fall protection equipment.

e. Authorized Persons for Fall Protection must:

(1) Be trained in accordance with section 220.5.C.6 (Authorized Person Training).

(2) Understand the policies and procedures of this chapter, as well as direction of

Competent and Qualified Persons.

(3) Report unsafe or hazardous conditions to the supervisor.

(4) Properly inspect, use, store, and care for their fall protection equipment.

(5) Be briefed on the Fall Hazard Survey and Protection Plan, and Rescue Plan as required prior to commencing elevated work.

(6) Have any necessary equipment before accessing an area requiring personal fall protection.

f. Fall Protection Equipment Inspectors must:

(1) Be trained in accordance with section 220.5.C.3 (Competent Person Training) or section 220.5.C.7 (Fall Protection Equipment Inspector Training).

(2) Inspect fall protection and fall rescue equipment in accordance with section 220.4.G.2.

g. All personnel must:

i. Receive fall hazard awareness training, in accordance with section 220.5.C.8 (Employee general awareness training).

OSHE CONTROL MANUAL 220 Rev C Sheet 220-23

ii. Report any worksites that require a Fall Hazard Survey and Protection Plan to a supervisor before accessing the worksite.

B. Reports, Reporting Requirements, and Records:

1. Fall Hazard Surveys and Fall Protection Plans.

a. A Competent Person, Qualified Person or Fall Protection Program Manager must conduct a Fall Hazard Survey of a work location prior to personnel working at unguarded/unprotected heights. Fall Hazard Surveys must contain the following:

(1) Work location (building, facility, space, etc.)

(2) Associated hazards within the location.

(3) Location of the fall hazard(s).

(4) Existing mitigation measures (e.g., guardrails, covers).

(5) Fall Hazard Risk Assessment in accordance with Reference J.

(6) Proposed mitigation measures.

(7) Anchorage strengths and locations (as applicable).

(8) Available clearance(s) at the location.

(9) Rescue plan (as applicable).

2. Fall Protection Plans.

a. Personnel utilizing personal fall protection equipment, or working at unguarded heights, are required to have a Fall Protection Plan. The Fall Protection Plan is equivalent to a permit to work at heights for Authorized Persons. A Competent Person, Qualified Person, or Fall Protection Program Manager must approve the Fall Protection Plan prior to work being executed.

The Fall Protection Plan must be kept at the work site at all times. For ease of use, a Fall Hazard Survey and Protection Plan template is available within Appendix E. Fall Protection Plans must include:

(1) Description of the fall hazards that will be encountered by Authorized Persons.

OSHE CONTROL MANUAL 220 Rev C Sheet 220-24

(2) Type of Fall Protection/Prevention methods or systems used for every phase of work.

(a) If Administrative Controls are selected, further approval from the Fall Protection Program Manager is required. Furthermore, a reason for the infeasibility of a conventional secondary fall protection system must be given.

(3) Validation of training requirements for Authorized Persons.

(4) Type of fall protection equipment and systems provided to the employees that might be exposed to fall hazards.

(5) Identification of anchorages (certified and/or non-certified, location(s)).

(6) Complete setup procedure(s) for access.

(7) Clearance requirements for free-fall distances and for total fall distances including available and required clearance.

(8) Instructions for assembling, use and dismantling of the system(s), including descriptions of all the components.

(9) Any limitations of the system.

(10) Applicable manufacturers’ standards and drawings.

(11) The name of Competent and/or Qualified Person that developed the plan.

(12) Rescue plan and procedures (required for Fall Arrest Systems).

3. Rescue Plans

a. When Authorized Users are utilizing a Fall Arrest System a Rescue Plan must be in place.

Rescue Plans are a part of the Fall Hazard Survey and Protection Plan and must be site-specific.

In the event of a fall emergency services must be contacted. Rescue Plans must address the following:

(1) Procedure for contacting emergency services. This must take into account:

(a) Exact location of the fallen individual.

(b) Whether a technical rescue is needed. If the individual is suspended or rescue at heights is needed, state that a technical rescue is needed.

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(c) Condition of the suspended individual (e.g., conscious vs. unconscious, able to self- rescue, injuries sustained, etc.)

(2) Type(s) of rescue.

(a) Self-Rescue (e.g., Authorized Person is able to safely pull themselves to the nearest structure and rescue themselves, Authorized Person utilizes descent control device).

(b) Assisted Rescue (e.g., stationing an AWP onsite to rescue a suspended individual, providing a portable ladder for the suspended individual, utilization of descent control devices, etc.).

(c) Jurisdictional Public or Government Emergency-Response Agency Rescue.

b. Jurisdictional Public or Government Emergency-Response Agency Rescue requires the development of a…