Attachment_2.pdf

FRCSEINST 5103.15C

FLEET READINESS

CENTER

SOUTHEAST

HEAVY METALS

CONTROL

PROGRAM

VERIFY CURRENCY PRIOR TO USE

Code 71010 5/22/2018

FRC SOUTHEAST INSTRUCTION 5103.15C

From: Commanding Officer, Fleet Readiness Center Southeast

Subj: HEAVY METALS CONTROL PROGRAM

Ref: See appendix A

1. Purpose. Establish responsibilities and requirements for managing and implementing the heavy metals control program (HMCP) set forth in references (a) through (o). This instruction is a completed revision and should be reviewed in its entirety.

2. Cancellation. FRCSEINST 5103.15B of 21 February 2013.

3. Scope. Applies to military (Intermediate-Level), civil service personnel (Depot-Level), and contractors assigned to Fleet Readiness Center Southeast (FRCSE).

4. Responsibilities. See chapter 2.

5. Records Management. Records created as a result of this instruction, regardless of media and format, will be managed per Secretary of the Navy (SECNAV) Manual 5210.1 of January 2012.

See appendix B for details.

6. Review and Effective Date. Per OPNAVINST 5215.17A, Mission and Workforce Safety Division (code 71010) will review this instruction annually on the anniversary of its effective date to ensure applicability, currency, and consistency with Federal, Department of Defense, SECNAV, and Chief of Naval Operations policy and statutory authority using OPNAV 5215/40 Review of Instruction. This instruction will automatically expire five years after effective date unless reissued or canceled prior to the five-year anniversary date, or an extension has been granted.

7. Forms. See appendix B for details.

T. R. DEMOSS

(Signature on file in 71300)

Releasability and Distribution:

This instruction is cleared for public release and is available electronically only via the FRCSE Web site, https://teamworkflow.navair.navy.mil/cyberdocs/quickstart.asp?user=FRCSE READ:

4652435345524541443448424f4e4c59&encryptPWD=yes&show=FOLDERCONTENTS:444361 https://teamworkflow.navair.navy.mil/cyberdocs/quickstart.asp?user=FRCSE%20READ:4652435345524541443448424f4e4c59&encryptPWD=yes&show=FOLDERCONTENTS:444361 https://teamworkflow.navair.navy.mil/cyberdocs/quickstart.asp?user=FRCSE%20READ:4652435345524541443448424f4e4c59&encryptPWD=yes&show=FOLDERCONTENTS:444361 i

TABLE OF CONTENTS

CHAPTER TITLE

1 Policy and Definitions 2 Responsibilities 3 Compliance Program

4 Operations and Processes, Engineering Controls, Technology, and Schedule Implementation

5 General Work Practices 6 Regulated and Restricted Areas 7 Personal Cleaning Station 8 Signage 9 Required Facilities 10 Personal Hygiene 11 Break Rooms 12 Changing Areas 13 Shop or Work Area and Adjacent Spaces 14 Laundry 15 Personal Protective Equipment and Work Clothing 16 Respiratory Protection, Medical Surveillance, and Monitoring Plan 17 Training 18 Emergency Procedures

APPENDIX TITLE

A References B Records Management and Forms

1-1

CHAPTER 1

POLICY AND DEFINITIONS

1.1 Policy

a. The HMCP will:

(1) Apply to FRCSE production and maintenance processes involving any exposure to heavy metals and heavy metal dust.

(2) Be managed per reference (a) as detailed in this instruction.

(3) Evaluate and monitor production and maintenance processes involving heavy metals per reference (a).

b. Corrective, preventive, and improvement actions will favor the best combination of engineering controls or work practices that result in reducing exposure levels per reference (a).

c. Vacuum-assisted tooling systems will be used for all dust-generating operations. Refer to reference (b) for approved vacuum-assisted tooling systems. Any exceptions must be approved and documented by Production Planning Division (code 63100) and code 71010 via shop chain of command.

d. Equipment to support this program will be identified, procured, and managed per references (c) and (d) as supplemented by Appendix A.

e. New or replacement tools to support this program will be managed per reference (e).

f. Preventive maintenance (PM) procedures on HMCP equipment and tooling will be per the original equipment manufacturer (OEM) procedures and per references (c) through (e).

g. Deviations from OEM PM procedures will be jointly approved by code 71010 HMCP manager, Industrial Environmental Division (code 63500), and code 63100 per reference (d).

h. Clean-up, collection, handling, storage, and disposal of heavy metal waste will be managed per reference (f).

1.2 Definitions

a. Authorized Personnel. Any person authorized by FRCSE and required by work duties to be present in the regulated or restricted area or any person authorized by code 71010 or by higher regulations (e.g., inspectors, industrial hygienist technicians conducting personal monitoring, plant maintenance personnel conducting clean-up, etc.).

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b. Heavy Metal. As defined by Occupational Safety and Health Administration (OSHA) list contains some of the metals (to include their compounds) that are considered “heavy or toxic metals” and are present at FRCSE. This list is not all-inclusive: aluminum, beryllium, cadmium, chromium, cobalt, copper, iron, lead manganese, mercury, nickel, silver, tin, titanium, and zinc.

c. Medical Surveillance Action Level (MSAL). As defined by OSHA, the level of concentration for a specific substance which initiates certain required activities such as exposure monitoring and medical surveillance (MS).

(1) Chromium (VI). Is 2.5 micrograms per cubic meter of air (2.5 µg/m3) (airborne concentration).

(2) Cadmium. Is 2.5 micrograms per cubic meter of air (2.5 µg/m³) (airborne concentration).

(3) Lead. Is 30 micrograms per cubic meter of air (30 µg/m³) (airborne concentration).

(4) For a heavy metal that does not have a specific MSAL as defined by OSHA, half of the Permissible Exposure Limit (PEL) is used.

d. PEL. As defined by OSHA, the highest level of exposure of a specific substance that an employee may be exposed to.

(1) Chromium (VI). Is 5 micrograms per cubic meter of air (5 µg/m³) (airborne concentration).

(2) Cadmium. Is 5 micrograms per cubic meter of air (5 µg/m³) (airborne concentration).

(3) Lead. Is 50 micrograms per cubic meter of air (50 µg/m³) (airborne concentration).

e. Personal Protective Equipment (PPE). Includes, but not limited to: safety glasses, hearing protection, safety shoes, gloves, protective coveralls (disposable Tyvek®-type suit), goggles, face shields, foot covers (coverlets, booties, etc.), helmets, respirators, and aprons.

f. Production Paperwork. Paperwork used on the production floor in the production process of aircraft, parts and equipment repair, modification, and maintenance. Examples of such paperwork includes, but is not limited to: aircraft work orders, master travelers, workbooks, production control routing paperwork (including part tags and plastic bags), tool control logs, illustrated parts breakdowns, maintenance instruction manual (MIM), confined space program records or permits, and paperwork typically found on the production floor, etc.

g. Regulated Area. An area, physically identified by the employer, where an employee's exposure to airborne concentrations of chromium (VI), cadmium, lead exceeds, or can

1-2 reasonably be expected to exceed, the PEL, if the exposure exists for 30 or more days per year (12 consecutive months).

h. Restricted Area or Activity. An area or activity identified by the employer, where an employee's exposure to heavy metals does not exceed the PEL, but exposure does exist as defined by the individual industrial hygiene (IH) survey.

(1) Level I. Airborne exposures below the PEL and above the MSAL.

(2) Level II. Airborne exposures below the MSAL.

(3) Level III. Contact exposures only (e.g., lead working, touch-up primer, Alodine or Alumigold pens or sticks, plating, etc.).

i. Substrate. Underlying material.

j. Toxic Hazardous Material or Substance. Any substance; because of its quantity, concentration, or hazardous properties, may pose a substantial hazard to human health or environment.

k. Tyvek®-Type Suit. Used for simplicity purposes. A disposable protective suit or smock, hooded or non-hooded, as process requires. Other protective suits may be utilized, but must meet the same requirements met by the Tyvek® protective suit rating (e.g., Kimberly Clark A40).

l. Undergarment. Any garment worn under the visible outer clothes next to the skin.

m. Work Clothing. All clothing provided by FRCSE (e.g., dark blue coveralls, scrubs, smocks, lab coats, etc.). Not classified as PPE.

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CHAPTER 2

RESPONSIBILITIES

2.1 Production Department (code 62000) and Intermediate-Level Managers and Supervisors

a. Ensure all employees are aware of the proper work procedures for heavy metal dust control and handling.

b. Ensure the employee individual development plan (IDP) contains required annual and refresher training per reference (g).

c. Ensure all employees complete and document HMCP initial and annual refresher awareness training per reference (g).

d. Ensure employee(s) are retrained when behaviors suggest that HMCP retraining is warranted.

e. Assign a heavy metals control (HMC) subject matter expert (SME) for each branch or shop. SME responsibilities are listed in paragraph 2.2.

f. Identify, evaluate, and document heavy metal hazards and potential exposures in IH surveys utilizing the job hazard analysis program.

g. Reduce or eliminate hazards by identifying and implementing required effective controls.

These controls will be updated as processes change.

h. Ensure production personnel comply with the engineering controls and work practices documented in applicable technical directives, MIM, HMCP training materials, shop and command imposed administrative controls, and this instruction.

i. Assist the Naval Hospital Jacksonville IH department in conducting shop surveys and periodic exposure assessments.

j. Inform employees of IH sampling results per reference (a).

k. Ensure applicable employees are enrolled in the necessary MS screening based upon the recommendations listed in the IH shop survey.

l. Enforce mandatory use of vacuum-assisted systems and tooling to the greatest extent feasible for all dust-generating operations, unless an exception is identified by the assigned code 63100 and code 71010.

m. Ensure hygiene, tooling, shop or work areas, break rooms, and personal cleaning procedures are followed.

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n. Ensure the required PPE is available and used per reference (h).

o. Notify code 71010 and Naval Hospital Jacksonville IH department of any changes in shop processes that generate heavy metal dust, have contact with heavy metals, or any other hazard.

p. Inspect break rooms weekly. Ensure cleaning completion and inspections are documented on the FRCSE 5103/20 Break Room and Lunch Room Daily Cleaning Log.

q. Ensure HMCP equipment (e.g., glove boxes, blast booths, paint booths, all associated ducting, etc.) is shutdown if leaking or not functioning properly. Ensure work orders are submitted by production to correct discrepancies.

r. Maintain a vigorous “clean as you go” program to ensure all shop or work area surfaces are maintained as free as practicable of all accumulations of dust and document on FRCSE 5103/22 Dust Generating Area Daily Cleaning Log.

s. Ensure water fountains in shop areas are cleaned daily of all visible dust, debris, contaminants, and document on FRCSE 5103/23 Water Fountain/Changing Area Daily Cleaning Log.

t. Ensure changing areas are cleaned daily of all dust and debris and document on FRCSE 5103/23.

u. Ensure adjacent areas are cleaned of dust and debris weekly and document on FRCSE 5103/22.

v. Promptly correct non-compliance issues.

2.2 Shop or Branch HMC SME

a. Train and inform shop personnel of HMC issues and policies.

b. Coordinate with code 63100 to identify facilities and equipment needed in the shop to comply with command policies and OSHA standards.

c. At a minimum weekly, inspect assigned areas for compliance with PPE, hygiene, and housekeeping requirements.

d. Attend mandatory HMC SME meetings.

2.3 Employees

a. Follow all requirements regarding the safe work practices for the control of heavy metal dust and contact exposures to include using appropriate hygiene, PPE, and housekeeping practices.

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b. Comply with all aspects and requirements of this instruction in its entirety.

c. Report any vacuum or blasting equipment leaks immediately to supervision.

d. Report any non-compliance events immediately to supervision for action.

2.4 Research and Engineering Group (code 40000)

a. Ensure that revisions to FRCSE managed technical documentation (e.g., MIMs, local engineering specifications, drawings, etc.) do not introduce new sources of heavy metals into industrial processes unless technically required.

b. Identify and provide to production the presence of heavy metals in materials, substrates, and other similar media.

c. Coordinate new or revised local process specifications with code 71010 and code 63100 as required per reference (i).

d. Assign an HMC SME. HMC SME responsibilities are listed in paragraph 2.2.

2.5 Code 63100

a. Identify engineering controls for dust-generating processes.

b. Procure and install HMCP equipment and facilities per reference (c).

c. Identify HMCP tooling procurement requirements to the central tool room per reference (e).

d. Coordinate with code 71010 and Naval Hospital Jacksonville IH department for processes in which vacuum-assisted tooling is not feasible.

e. Maintain a spreadsheet that identifies the areas or processes where vacuum-assisted tooling use is not feasible.

f. Maintain a record that identifies pedestal equipment (sanders, grinders, etc.) to include information on vacuum-assisted status. Refer to reference (j) for guidance.

g. Coordinate the development and prototyping of new tools and equipment used in support of the HMCP.

h. Maintain a detailed plan of action and milestones (POA&M) and update as needed.

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2.6 Production Activity Control Division (code 63200)

a. Procure, manage, maintain, replace, and dispose of HMCP tools per reference (e) and as supplemented by this instruction.

b. Procure and replace portable industrial vacuum-assisted equipment used to support the HMCP per references (e) and (k) as supplemented by this instruction.

c. Ensure there are adequate supplies of materials to support HMCP (e.g., PPE, cleaning supplies, etc.).

2.7 Industrial Plant Services (code 63300)

a. Ensure maintenance personnel comply with the HMCP engineering controls and work practices detailed in references (c), (d), (f), (k), (l), (m), and this instruction.

b. Develop PM plans for HMCP equipment jointly with the code 71010 HMCP manager, code 63500, and code 63100 per reference (f) as supplemented by this instruction.

c. Identify requirements for work practices based on the work and process performed.

d. Notify code 71010 and Naval Hospital Jacksonville IH department of any new or revised requirements to work practices for maintenance processes that generate HMCP dust.

e. Develop and maintain a facility “Check and Clean” program to ensure all facility surfaces are kept as clean as practicable.

f. Maintain PM schedule and records of all cleaning conducted in regards to heavy metal requirements per reference (d).

g. Assign an HMC SME. HMC SME responsibilities are listed in paragraph 2.2.

2.8 Code 63500

a. Manage designated waste collection sites that support the HMCP per reference (f).

b. Integrate environmental program requirements with HMCP work practices, HMCP engineering controls, tool maintenance procedures, and PM procedures per reference (c).

2.9 Code 71010

a. Serve as the HMCP manager.

b. Conduct monthly inspections of designated break rooms as well as eating and drinking areas.

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c. Maintain a spreadsheet, which identifies those specific areas where broom usage is allowed.

d. Establish HMCP training program requirements.

e. Develop and maintain HMCP training courses posted via the FRCSE homepage:

https://myteam.navair.navy.mil/frc/SouthEast/cdd/SitePages/Home.

f. Communicate and coordinate HMCP training program requirements with the Career Development Division (code 73300) per reference (g).

g. Review the sampling of production processes and workspaces conducted by Naval Hospital Jacksonville IH department for heavy metals per references (a), (l), and this instruction.

h. When the IH survey identifies process controls are insufficient to reduce exposures below the PEL for stressor(s) of concern, coordinate follow-up assessments with Naval Hospital Jacksonville IH department and code 63100.

i. Identify regulated and restricted areas per reference (a) as supplemented by Appendix A.

j. Inform employees of IH sampling results via their supervisor per reference (a).

k. Coordinate with code 63100 for processes where vacuum-assisted systems and tooling is not feasible.

l. Post the most recent IH surveys on the “Occupational Safety and Health Office” section of the FRCSE homepage.

m. Coordinate the annual command-wide spring and fall cleaning event. This includes administrative and industrial areas. The scope will generally mean all surfaces from eight feet above walking working surfaces.

n. Coordinate with the IH department to ensure periodic wipe sample monitoring of designated break room surfaces for verification of levels or presence of heavy metal content in pursuit of zero presence of heavy metals.

2.10 Code 73300

a. Ensure Heavy Metal Awareness training, course 58000373, is completed annually for all FRCSE employees.

b. Ensure annual required training is added to the IDPs of employees identified in job series or positions that perform work involving heavy metal exposure (Hexavalent Chromium and Cadmium training, course 58000338, Lead training, course 58200283, and Beryllium training, course 58000374, as required).

3-1

CHAPTER 3

COMPLIANCE PROGRAM

Elements, as defined by OSHA, are required in a compliance program and are detailed further in this enclosure.

3.1 A description of each operation that involves the emission of a heavy metal, the type of machinery used, the material processed, controls in place, and crew size.

3.2 Description of operating and maintenance procedures and employee job responsibilities.

3.3 Description of how the employer will achieve compliance, such as engineering plans studies, and the use of respiratory protection.

3.4 A report of technology used, or considered for use, to meet the PEL.

3.5 Air monitoring data to document the sources of heavy metal emissions.

3.6 A schedule for implementation of the program that includes documentation, such as copies of purchase orders for equipment, and construction contracts.

3.7 A plan for emergency situations that includes the use of respirators, PPE, and methods to restrict access to an area to non-essential employees until the problem is corrected.

3.8 The written program must be reviewed and updated annually or more often to reflect significant changes in the compliance status for FRCSE.

4-1

CHAPTER 4

OPERATIONS AND PROCESSES, ENGINEERING CONTROLS, TECHNOLOGY, AND

SCHEDULE IMPLEMENTATION

4.1 FRCSE Operations and Processes

a. These operations or processes include, but are not limited to: abrasive blasting, sanding, grinding, plating, soldering, blending, and painting with or on materials identified to contain heavy metals.

b. Exposures to heavy metals are identified in each shop’s IH survey. The Naval Hospital Jacksonville IH department conducts annual shop surveys which include individual hazard assessments, air monitoring and noise sampling results, MS requirements, workplace monitoring plan, and ventilation results.

c. Practices and procedures will ensure employee exposure to heavy metal dust is reduced to below the PEL where possible.

d. Processes are controlled through the use of engineering controls, administrative controls, and PPE usage.

4.2 Engineering Controls

a. Controls put in place to reduce employee exposure to heavy metal dust to the lowest possible limit prior to putting administrative or PPE controls in place. If such controls are not feasible, then the use of administrative controls for respiratory protection and PPE are required.

b. Engineering controls are based on the principles in subparagraphs 4.2b(1)-4.2b(3).

(1) Design of facility, equipment, or process to remove the hazard or substitution with something that is not or is less hazardous.

(2) If removal is not feasible, enclose the hazard to prevent exposure during normal operations.

(3) Where complete enclosure is not feasible, establish barriers, or local ventilation to reduce exposures.

c. Examples of engineering controls at FRCSE include, but are not limited to: ventilated abrasive blasting booths, ventilated sanding and paint booths, local exhaust dust collector equipment, down draft tables, and vacuum-assisted tooling.

d. Utilization of vacuum-assisted tooling will be enforced to the maximum extent possible.

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e. Engineering controls and work practices will be provided to reduce exposure to the lowest feasible level if the exposure level is above the PEL for 30 days or more.

4.3 Technology. Considered in meeting the PEL includes robotic systems, alternatives to the current chromate primers, laser paint removal processes, and new construction with state-of-the-art compliant facilities.

4.4 A Detailed Schedule of Implementation. Through a POA&M is maintained by code 63100.

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CHAPTER 5

GENERAL WORK PRACTICES

All production lines, shops, and spaces where work on aircraft and associated components occur and where the potential exists for surface contamination, any skin or eye irritation or if any hazardous or toxic material or chemical is kept in the vicinity, must comply with this instruction.

5.1 No eating, drinking, storage or preparation of food, food items (e.g., dishes, utensils, etc.), chewing gum, use of any tobacco products, or cosmetic application is allowed.

5.2 Any room or work area that is exposed to production parts, production tooling, or production paperwork will not be used for storing, preparing, or consuming food and drink.

5.3 No eating, drinking, preparation, or storage of food is allowed in unenclosed break areas within production shop spaces.

5.4 Break rooms, where eating and drinking are allowed will follow the prescribed cleaning requirements identified on FRCSE 5103/20.

5.5 Doors to the areas in subparagraphs 5.5a-5.5c will remain closed at all times (i.e., not propped open), except when entering and exiting.

a. Designated break rooms;

b. Areas where eating and drinking are allowed; and

c. Spaces that open directly to production spaces.

5.6 Enclosed adjacent spaces to production, including administrative spaces, will be maintained visually dust-free and be cleaned, at a minimum weekly, by wiping down all surfaces.

5.6 Floors will be cleaned with a high-efficiency particulate air (HEPA) filter vacuum or a wet method (e.g., mopping, wet tenant floor sweeper, etc.).

5.7 Fans will not be operated within 15 feet, in any direction, of any sanding, grinding, or spray painting operations, and will not be oriented in such a manner as to disrupt any local exhaust ventilation systems.

5.8 Fabric or cloth chairs are not allowed in designated break rooms, production shop spaces, or any open areas immediately surrounding production efforts.

5.9 Protective clothing (e.g., Tyvek®-type suit) and work clothing will not be removed from FRCSE premises.

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5.10 Street clothes will not be worn underneath a Tyvek®-type suit in regulated or level I restricted areas, within six feet of operation except under garments.

5.11 Any work clothes (e.g., coveralls, coats, etc.) to be worn in regulated or restricted level I areas will be furnished and laundered by FRCSE.

5.12 Dry sweeping with brooms is prohibited. If the use of a HEPA vacuum, wet methods (e.g., mopping), or other methods that minimize the likelihood of exposure to heavy metals have been tried and found not to be effective, a request for broom usage will be made to code 71010 for authorization. Once authorized, each broom will be identified and accounted for by the assigned work center. Identification will include the shop five-digit code and the number of the broom (e.g., 6XXXX 1 of 3).

5.13 Use of compressed air for any cleaning is prohibited unless used in conjunction with full PPE inside a fully operational ventilated exhaust booth and regulated to 30 pounds of pressure per square inch (psi) or lower.

5.14 Pressurized water fountains are authorized adjacent to production shops. They will be cleaned daily by personnel in whose shop the fountain resides utilizing FRCSE 5103/23.

5.15 Tools must be free of visible dust and debris before storing in tool containers or returned to the mega center.

5.16 All drink, snack, and ice machines will be located in a space not subject to potential heavy metal dust contamination (e.g., an enclosed break room, a separate enclosed space, outside under an overhang, or a non-production associated space).

5.17 No personal items will be inside a designated regulated or restricted area.

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CHAPTER 6

REGULATED AND RESTRICTED AREAS

6.1 Regulated Areas

a. Areas will be clearly marked from the rest of the workplace in a manner that alerts employees of the boundaries of the regulated area.

b. Access will be limited to those individuals whose duties require their presence in the regulated area, required for monitoring purposes, and identified as authorized by FRCSE.

c. Examples of regulated areas: Walk-in abrasive blast booths, paint booths, and thermal spray coating booths.

d. The determination of regulated areas will be made based on results of IH surveys which show exposures over the PEL for a specific heavy metal(s).

e. A personal cleaning station, outlined in paragraph 11, must be in close proximity of the regulated area.

f. PPE will not be stored inside a regulated area.

g. PPE will be removed immediately after exiting regulated area and at personal cleaning station.

h. Vacuum all visible dust from self, to include safety shoes, work clothes, etc., prior to leaving personal cleaning station.

i. PPE will be cleaned or disposed of per the manufacturer’s requirements. Tyvek®-type suit will be disposed of every time leaving regulated area.

6.2 Restricted Areas. Numerous situations exist that may or can be classified as restricted. This section discusses some, but not all of the possible scenarios. Any sanding or grinding taking place on an aircraft line is categorized as a restricted level I area and will follow prescribed requirements.

a. Sanding, grinding, or any process (e.g., spray painting) that generates heavy metal dust on an aircraft line (level I).

(1) These areas are restricted only for the duration of the work process and related clean-up time.

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(2) The area will be cordoned off using red “Danger Restricted Area” tape with stanchions and the required “Restricted Area” signs posted. Signs will be visible on all sides of the work area, as applicable.

(3) The cordoned off area will be placed at a minimum of twice the distance of the surface being worked (e.g., three-foot area being worked, rope off six feet from the outermost edge of the point of dust generation). At a minimum, a six-foot radius will be cordoned off, unless the surface being worked is contained within the aircraft structure (e.g., fuselage, wing tank, etc.), then the area controls will be placed immediately adjacent to the structure.

(4) Establish a controlled entry point to restrict personnel access and place the personal cleaning station, as defined in chapter 7.

(5) If the process is being conducted on the aircraft above ground level (e.g., tail, fuselage, etc.), access to the immediate area being worked will be secured to personnel except those personnel authorized and in appropriate PPE.

b. Sanding, grinding, or any process (spray painting, coating spraying, etc.) that generates heavy metal dust on aircraft parts removed from an aircraft (level I or level II).

(1) Every effort will be made to conduct any sanding or grinding on these parts in a glove box, ventilated abrasive blast or sanding booth, cross draft booth, or down draft table.

(2) If unable to utilize a booth or down draft table, treat as a situation outlined in paragraph 6.2a, only if classified as a level I process in the most current IH survey.

c. A permanent area (level I) (e.g., sanding or dust control booth not defined as a regulated area) established in a work center in which heavy metal dust is generated. These areas maintain a permanent restricted access status and will be identified by the required “Restricted Area” signs and all the requirements of this section.

d. For the restricted areas described in subparagraphs 6.2a-6.2c (level I), a portable or permanent personal cleaning station, outlined in chapter 7, is required.

e. Aircraft post-strip sanding, grinding, or any other operation that exceeds the PEL or MSAL requires the entire work area to be cordoned off, and all personnel inside the restricted area must follow level I requirements previously discussed and also mentioned.

f. Persons authorized for entry to a restricted area will wear appropriate PPE as the process dictates in the IH survey and may use table 6-1 as guidance.

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Table 6-1

Level I - mainly addresses the operator directly performing the dust-generating task and those within six feet of dust-generating operation.

Level II – addresses others in a cordoned off level I area not performing the dust-generating task (e.g., sanding) and not within six feet, but inside the restricted area. This level may also include operators of stand-alone equipment (e.g., bench or pedestal sanding or grinding, buffing, post machining, blending, welding, grinding inside a curtained area etc.).

Level III – addresses physical skin contact of substance in solid or liquid form (e.g., lead working, touch-up primer, Alodine, Alumigold pens or sticks, plating, etc.).

g. For areas not specifically defined in subparagraphs 6.2a-6.2f that can be classified as level I or level II will be identified prior to the onset of dust generating process by thoroughly reviewing the shop IH survey. These types of processes may include, but are not limited to:

sanding or grinding in production side shops with, or without booths or down draft tables, sanding or grinding in mechanically exhausted booths, and sanding or grinding on aircraft lines.

h. HEPA vacuum-assisted or HEPA self-generating vacuum-assisted tooling will be utilized when performing all sanding or grinding operations, except when approved by code 71010 and code 63100.

Level Exposure Level PPE Required Street Clothes

I <PEL

>MSAL

• respirator, hood or helmet

• hooded Tyvek®-type suit

• eye protection

• foot protection

• gloves

• hearing protection

• foot covers

• welding jacket (as required)

NO

II <MSAL • hooded Tyvek®-type suit

• respirator (as required by shop worksite specific procedures (WSP))

• welding jacket (as required)

• eye protection

• hearing protection

• foot protection

YES

III Contact only As required due to process requirements. YES

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i. Vacuum all visible dust from self, to include foot protection, work clothes, hands, etc., prior to leaving the personal cleaning station area.

j. Tools, floors, and surfaces worked will be cleaned using HEPA vacuums or wet cleaning methods prior to removal of the restricted area classification.

k. Signs will not be visible when the requirement to post them does not exist (i.e., covered or turned away from view or personnel).

l. Bench or pedestal sanding, grinding, buffing, polishing, post machining, dry grinding, or blending are mostly considered restricted level II areas; refer to individual shop IH survey for PPE guidance.

m. Lead working, soldering, and brazing are mostly considered restricted level III areas;

refer to individual shop IH survey for PPE guidance.

n. When conducting sanding, grinding, or like operations on a down draft table, vacuum-assisted tooling is required. Refer to individual shop IH survey for PPE guidance.

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CHAPTER 7

PERSONAL CLEANING STATION

Required in regulated and level I restricted areas:

7.1 Located and identified at the outermost edge, but inside of the level I restricted or immediately outside the regulated area, in conjunction with the controlled entry point.

7.2 At a minimum, the station will contain: a personal cleaning procedures sign, HEPA vacuum, respirator wipes, personal cleaning wipes, with a surface large enough to place respirators, helmets or hoods, and other reusable PPE on top of while on break or lunch. A designated waste container will be nearby for disposal of non-reusable PPE (e.g., Tyvek®-type suit and gloves).

7.3 This area will be cleaned daily at the end of the dust-generating process, or at the end of the shift (if a continuous process).

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CHAPTER 8

SIGNAGE

8.1 Signs will be posted to identify regulated and level I restricted areas.

8.2 Signs must be maintained in good condition and replaced immediately if they become illegible or damaged.

8.3 Signs will only be visible when the requirement to post them exist (i.e., cover or turn away from view of personnel when not required).

8.4 Signs must be in color and a minimum size of 10” x 14”.

a. Regulated area signs:

(1) Orange and black, Warning Regulated Area (P-11755-B).

(2) White, red, and black Danger Cadmium (P-11756-B).

b. Restricted area level I sign is yellow and black, Caution Restricted Area (P-11757-B).

8.5 Laundry bins used for holding and transporting dirty work clothing must have a sealable lid and be lined with a sealable, impermeable plastic bag. Laundry bin labels consist of:

a. White, red, and black 5” x 8”, Danger Contains Cadmium (P-11754-A);

b. White, red, and black 5” x 8”, Danger Clothing and Equipment (P-11753-A); and

c. White, red, and black 5” x 8”, Danger Clothing May Contain (P-11752-A).

8.6 All authorized break rooms where eating or drinking is permitted will have a Break Room Entry Requirements sign (8.5” x 11”) posted on all entry doors and is available on the FRCSE homepage, “Occupational Safety and Health Office” section under programs section, and then to programs heavy metals.

8.7 A personal cleaning procedures sign (11” x 17”) is required to be posted in plain view on the personal cleaning station and is available on the FRCSE homepage, “Occupational Safety and Health Office” section under programs section, and then to programs heavy metals.

8.8 All administrative office spaces adjacent to production shop floors where eating and drinking is permitted will have a STOP Notice sign (8.5” X 11”) posted and is available on the FRCSE homepage, “Occupational Safety and Health Office” section under forms.

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CHAPTER 9

REQUIRED FACILITIES

9.1 A locker will be provided for storage of street clothes for artisans when working in regulated or restricted level I areas. Lockers will be located in designated changing areas. Work items and street clothes will not be stored together.

9.2 Washing facilities will be readily accessible for removing heavy metal dust and debris from the skin.

9.3 Shower facilities will be provided for all artisans that conduct sanding, abrasive blasting, or grinding with exposures at or above the PEL for cadmium or lead.

9.4 Towels and soap will be provided for those personnel who are required to shower.

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CHAPTER 10

PERSONAL HYGIENE

10.1 Personnel performing any process, repairing, handling, or having any contact with any production part, paperwork, or equipment and entering non-industrial work spaces will wash their hands prior to entry.

10.2 All personnel performing abrasive blasting, sanding, grinding, painting, blending, soldering or plating, chemical handling, etc., will wash their hands and face thoroughly prior to eating, drinking, chewing gum, using any tobacco product, or applying cosmetics. Wet wipes do not satisfy this requirement.

10.3 All personnel will use a HEPA vacuum or wet methods to remove visible dust from PPE (e.g., protective clothing, coveralls, hoods, gloves, boots, etc.) at the conclusion of any process or when leaving area for any reason, that generates dust. See reference (k) for a list of approved vacuums.

10.4 Work clothing will be laundered by FRCSE prior to reuse and never be taken off of the premises, except for contracted laundry purposes. They will be placed in a sealed, labeled, impermeable bag or container.

10.5 Disposable (Tyvek®-type suit) protective clothing are typically a one-time use item and will not be removed until having exited the immediate regulated or level I restricted area (for any reason) and at the designated personal cleaning station. All contaminated disposable protective clothing will be disposed of in the designated waste containers provided.

10.6 Personnel performing any process involving lead or cadmium where IH sampling results have been identified as exceeding airborne concentrations at or above the PEL, must shower at the end of work shift.

10.7 Abrasive blast booth operators may utilize compressed air for initial personal cleaning inside the booth only if the air is regulated to 30 psi or less, booth is still 100 percent operating, and full PPE is on.

10.8 Utilize a HEPA vacuum to remove residual dust from PPE. See reference (k) for a list of approved vacuums.

10.9 Skin contact with any product containing any heavy metal requires immediate washing with soap and water.

10.10 Personnel handling laundry that may contain heavy metal dust will wash any exposed skin with soap and water after handling laundry and prior to eating, drinking, chewing gum, use of any tobacco products, or cosmetic application.

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CHAPTER 11

BREAK ROOMS

11.1 At a minimum, break rooms will be cleaned daily prior to the main meal of the corresponding shift utilizing FRCSE 5103/20.

11.2 All surfaces will be made of non-porous materials.

11.3 No brooms or cloth chairs are allowed.

11.4 All surfaces are required to be wiped down, including vending machines, fans, televisions, etc.

11.5 Clean under items such as microwave ovens, coffee pots, etc.

11.6 Floors will be mopped daily.

11.7 Doors must remain closed at all times, except when entering and exiting.

11.8 Ensure the Entry Requirements sign is posted on all doors.

11.9 Ensure tacky mats are placed inside every entrance, cover the entire entrance (minimum of two), positioned to capture both feet upon entry, and are maintained in a tacky status at all times.

11.10 The only PPE allowed in break rooms are safety glasses, hearing protection, safety shoes, and gloves used solely to clean the break room.

11.11 Ensure a command provided wipe cleaning station is at each break room entry (except those leading to the outside, then which the door should be labeled as “Exit Only”), and remains stocked and usable at all times.

11.12 FRCSE 5103/20 will be maintained in a conspicuous place in the break room and be retained for a rolling six months. A supervisor will inspect assigned break rooms and sign the log at the end of each week verifying completion of cleaning requirements and log.

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CHAPTER 12

CHANGING AREAS

12.1 Changing areas will be cleaned daily and documented on FRCSE 5103/23. The log will be posted on the door or in the immediate vicinity of an entrance.

12.2 All surfaces will be cleaned of all dust and debris. If the changing area is in conjunction with a restroom and the floors are mopped daily by a contracted cleaning company, then the floor does not need to be mopped again unless a visual inspection requires it.

12.3 No personal items or dirty work items are allowed to be stored out in the open in the changing area. “Dirty” work shoes may be stored in a dirty locker if provided. Personal items are to be stored in a “clean” locker if provided.

12.4 All surfaces in changing area will be non-porous.

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CHAPTER 13

SHOP OR WORK AREA AND ADJACENT SPACES

13.1 Dust generating industrial spaces will be cleaned daily at the end of the dust generating process. This includes all surfaces and equipment surrounding the immediate work area and areas nearby that can reasonably be expected to be exposed to the dust. Document cleaning utilizing FRCSE 5103/21 Dust Generating Area Daily Cleaning Log.

13.2 Open spaces adjacent to dust generating industrial spaces will be cleaned at a minimum weekly. Adjacent spaces typically extend out to the walls and include all surfaces within those spaces (e.g., desks, shelving, tool boxes, tables, work benches, computers stations, pre-ex bins, conduits, electrical boxes, etc.). Document cleaning utilizing FRCSE 5103/22.

13.3 All non-industrial work spaces adjacent to dust generating industrial spaces will be maintained visually clean. Cleaning is required to be completed weekly and includes wiping down of all surfaces. Floors will be mopped or vacuumed. Doors to these adjacent spaces must remain closed at all times, except when entering and exiting.

13.4 After each operation of an abrasive blast booth or glove box, the operator will conduct a complete exterior visual inspection and clean the area of any dust or media that was released.

Leaks must be repaired prior to continuing booth operations.

13.5 All spills and releases of heavy metal dust will be cleaned up promptly with either a HEPA-filtered vacuum as the primary method or wet methods that minimize the likelihood of dust being reintroduced into the atmosphere.

13.6 Compressed air will not be used to remove dust or debris from any person, surface, or part unless the compressed air is used in conjunction with a ventilation system (inside a fully operational booth) designed to capture the dust cloud created by the compressed air and reduced at or below 30 psi.

13.7 Cleaning equipment must be handled in a manner that minimizes the re-entry of heavy metal dust into the workplace.

13.8 Only approved HEPA-filtered vacuum cleaning equipment or wet floor sweepers will be used. See reference (k) for a list of approved vacuums.

13.9 Employees engaged in shop, work area clean-up will vacuum in a manner that minimizes the dust becoming airborne, maintaining awareness of wind, or air direction and speed, and remain upwind of the shop or work area clean-up process.

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13.10 When cleaning shop equipment, to include glove boxes and vacuum cleaners, personnel will follow the operator PM procedures. Critical precautions may include:

a. Wearing all PPE prescribed (e.g., protective eyewear, respirator with P100 filter cartridges, protective gloves, and disposable Tyvek®-type suit, etc.).

b. Avoid introducing dust into the air when opening doors or access panels, emptying contents, removing any parts, and when closing equipment.

c. Vacuums found to be leaking will be immediately turned off, red tagged, and repaired before they are allowed to be returned to service. Production shops are responsible for submitting work orders to code 63300.

d. Empty the vacuum cleaner, or wet floor cleaning equipment into designated waste containers.

13.11 Tools

a. The same PPE worn during operation of the tools will be utilized during cleaning.

b. Tool cleaning will be performed prior to leaving a regulated or restricted area.

c. Tools will be cleaned by the user prior to storage in a toolbox or being returned to a mega center.

d. Examples of tools covered by this work practice include but are not limited to:

pneumatic sanders and grinders, vacuum-assisted attachments and shrouds, exterior of HEPA vacuum equipment, hoses, and exterior of air hoses.

13.12 Cleaning Procedures

a. All tools used for sanding or grinding operations will be cleaned by HEPA vacuum, wiping with a tack cloth, or wet wipe.

b. Tools are deemed “clean for storage” when all visible dust and debris are removed from exterior surfaces of the tooling and its components.

c. Upon completion of cleaning, dispose of used cleaning materials in a shop designated waste container.

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CHAPTER 14

LAUNDRY

14.1 Work clothes contaminated or exposed to heavy metals will be placed in labeled laundry bins at the end of use or at a minimum at the end of a shift.

14.2 Bins must be lined with a sealable, impermeable bag and have a closable, sealable lid.

14.3 If liner is to be removed from the bin for any reason (other than for transporting for cleaning to a designated contractor pick-up bin), it must contain the same labels as the bin.

14.4 Bins must be located inside the changing area.

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CHAPTER 15

PERSONAL PROTECTIVE EQUIPMENT AND WORK CLOTHING

15.1 PPE and work clothing will be provided at no-cost to the employee.

15.2 Tyvek®-type suits and suitable alternates are not intended for personal comfort, and will not be worn out of the immediate shop or work area regardless of why the Tyvek®-type suit is worn.

15.3 PPE and work clothing will not be removed from FRCSE premises under any circumstances. Safety shoes and safety glasses worn in regulated or restricted areas can only be removed from FRCSE premises if thoroughly cleaned of all visible dust and debris by HEPA vacuum or wet methods.

15.4 All furnished work clothing will be cleaned, laundered, and replaced as needed by FRCSE.

15.5 Appropriate PPE is required to be worn prior to entering a regulated or restricted area and must only be removed at the personal cleaning station and disposed of in a shop designated waste container each time it is removed from the body.

15.6 After spraying paint or primer, artisans will assess suitability of Tyvek®-type suit for reuse (e.g., overspray). At a minimum, dispose of the Tyvek®-type suit at the end of shift.

15.7 If gloves and Tyvek®-type suit are prescribed for the process, then the gloves are to be worn inside Tyvek®-type suit. If the Tyvek®-type suit does not have elastic bands on the end of the arms, or it is not sealed snuggly, utilize any method or material to effectively close any gaps.

If gloves have to be worn on the outside of the Tyvek®-type suit, they must be sealed to prevent any contaminants from getting inside gloves and suit.

15.8 Foot covers (e.g., booties, protective suits with booties attached, coverlets, etc.) will be worn for all processes in regulated and level I restricted areas, unless they create a safety hazard themselves.

15.9 For additional information regarding PPE requirements, see reference (h).

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CHAPTER 16

RESPIRATORY PROTECTION, MEDICAL SURVEILLANCE, AND MONITORING PLAN

16.1 The appropriate respirator will be used when engineering controls and work practices cannot reduce employee exposure below the established PEL.

a. Respirators will be provided per reference (a).

b. See reference (m) for all respirator requirements, which includes training, proper use, fit, cleaning requirements, etc.

c. Refer to individual shop WSPs and IH survey for further requirements and guidance.

16.2 MS

a. Employees who are or may be exposed at or above the MSAL 30 days or more per year are enrolled in the appropriate MS program.

b. For the requirements of a specific MS program, see references (a) and (n).

16.3 Monitoring Plan

a. Personal

(1) Prescribed personal monitoring is completed by Naval Hospital Jacksonville IH department.

(2) Initial monitoring will be performed for each job task that generates heavy metal dusts or fumes to determine the extent and degree of employee exposure.

(3) If initial exposure monitoring results indicate exposure at or above the MSAL for any heavy metal, periodic monitoring will be repeated per the applicable OSHA standard for that heavy metal.

(4) If initial exposure monitoring results indicate exposure is below the MSAL, at least one more sampling of the task will be performed to assure employee exposure is below the MSAL. Additional periodic monitoring will be repeated at the discretion of the IH or if any change in the task, workplace, or equipment used could result in additional heavy metal exposure.

(5) Written notification to employees must be completed within 15 days of receipt of the laboratory results and must include the corrective action being taken to reduce exposure to or below the PEL.

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(6) Monitoring records will be maintained for at least 40 years, or for the duration of employment plus 30 years, whichever is longer.

b. Shop. FRCSE’s standing policy of “Clean As You Go” will be enforced at all times. In addition to this requirement, shop supervisors will ensure a thorough visual inspection of all production spaces they are responsible for, are inspected daily and free of any accumulations of dust and debris, and take appropriate action when and if necessary.

c. Break Room. Daily and weekly visual inspections will be conducted by the assigned supervisor and be signed for on FRCSE 5103/20. The Occupational Safety and Health specialist for the area will conduct a monthly inspection of the break rooms. The IH department will conduct wipe sampling per reference (o).

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CHAPTER 17

TRAINING

17.1 All employees will complete Heavy Metal Awareness training, course 58000373, annually.

17.2 For those employees with exposures or potential exposures to specific heavy metals identified in shop IH survey, will complete Heavy Metal Awareness training, course 58000373, Hexavalent Chromium and Cadmium training, course 58000338, Lead training, course 58200283, and Beryllium training, course 58000374, as applicable. Additionally, training will include a local instruction review with the compliance plan and their current shop IH survey.

Training is required annually.

17.3 Training will be provided prior to or at the time of initial assignment to a job involving potential exposure to heavy metals present in their work environment.

17.4 Employee participation and proof of understanding of training (e.g., written quiz) will be maintained. A grade of 100 percent is considered passing.

17.5 All training will be recorded and include the identity of the employee trained, the signature of the person who conducted the training, and the date of the training. This will be recorded in the Employee Master Maintenance Application.

17.6 Training records must be maintained for the length of employment and only the latest quiz will be maintained by the individual’s parent shop.

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CHAPTER 18

EMERGENCY PROCEDURES

An emergency situation is classified as a substantial release of heavy metal dust into the environment from a rupture, equipment failure, etc.

18.1 Immediately cease operations, secure the area as much as possible initially, contact the supervisor, and contact code 71010 and code 63500.

18.2 Prevent further migration and keep other employees out of the vicinity.

18.3 Employees not essential to correcting the…