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Occupational Safety and Health Administration

(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

CONSTRUCTION INDUSTRY REGULATIONS


Subpart K – Electrical Safety
29 CFR 1926.400 – 29 CFR 1926.408

Introduction:
Electricity is such an integral part of our lives at home and in workplace
that we can tend to take its power for granted. But here’s a sobering fact.
The Bureau of Labor Statistics (BLS) in the United States of America
reported that during 1999, 278 (or about five percent) of work-related
deaths in the private sector in the United States resulted from
electrocution. Don’t become another tragic statistic.
Electrical accidents in the workplace can, for the most part, be avoided if
you use safe electrical equipment and work practices.

How Does Electricity Work:


To handle electricity safely, including working with equipment, you need to
understand how electricity acts, how it can be approached, the hazards it
presents, and how those hazards can be controlled.
Basically, there are two kinds of electricity:
 Static (stationary) Electricity
 Dynamic (moving) Electricity

This guidance notes is about dynamic electricity because that is the kind
commonly put to use. Dynamic electricity is the flow of electrons through a
conductor. An electron is a tiny particle of matter that orbits around the
nucleus of an atom. Electrons of some atoms are easily moved out of their
orbits. This ability of electrons to move or flow is the basis of electrical
current.

1
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

When you activate a switch to turn on an electric machine or tool, you allow
current to flow from the generating source through conductors (usually
wires) to the area of demand.

A complete circuit is necessary for the controlled flow of electrons along a


conductor. A complete circuit is made up of a source of electricity, a
conductor, and a consuming device (load).

VOLTS = CURRENT X RESISTANCE

Volts = Current x Resistance, is an equation known as Ohm’s Law. The


factors discussed below relate to one another as described by this equation.
This relationship makes it possible to change the qualities of an electrical
current but keep an equivalent amount of power.
A force or pressure must be present before water will flow through a
pipeline. Similarly, electrons flow through a conductor because
electromotive force (EMF) is exerted. The unit of measure for EMF is volt.

For electrons to move in a particular direction, a potential difference must


exist between two points of the EMF source. For example a battery has
positive and negative poles.
The continuous movement of electrons past a given point is known as
Current. It is measured in amperes. The movement of electrons along a
conductor meets with some opposition. This opposition is known as
Resistance. Resistance to the flow of electricity is measured in ohms. The
amount of resistance provided by different materials varies widely.
For example, most metals offer little resistance to the passage of electric
current. However, porcelain, wood, pottery, and some other substances have
a very high resistance to the flow of electricity. In fact, these substances can
be used as insulators against the passage of electric current.

2
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

What are the Hazards of Electricity:


The primary hazards of electricity and its use are:
 Shock
 Burns
 Arc-Blast
 Fires and Explosions
 Falls

Shock:
Electric currents travel in closed circuits through some kind of
conducting material. You get a shock when some part of your body
becomes part of an electric circuit. An electric current enter the body at
one point and exits the body at another location. High-voltage shocks can
cause serious injury (especially burns) or death.

You will get a shock if you touch:


1. Both wires of an electric circuit.
2. One wire of an energized circuit and ground.
3. Part of a machine, which is “Hot” because it is contacting an
energized wire and the ground.

Don’t take any chances with electricity. One mistake can cost you your life.
The severity of the shock a person receives depends on several factors:
 How much electric current flows through the body.
 What path the electric current takes through the
body.
 How much time elapses while the body is part of
the electric current.

3
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

The effect of an electric shock on a body can range from a tingle in the part
touching the circuit to immediate cardiac arrest. A severe shock can cause
more damage to the body than is readily visible.
Relatively small burn marks may be all that are visible on the outside.
However, a severely shocked person can suffer internal bleeding and severe
destruction of tissues, muscles, and nerves. Finally, a person receiving an
electric shock may suffer broken bones or other injuries that occur from
falling after receiving a shock.

Burns:
Burn can result when a person touches electrical wiring or equipment that is
improperly used or maintained. Typically, such burn injuries occur on the
hands.

4
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

Arc-Blast:
Arc-blasts occur when high-amperage currents jump from one conductor to
another through air, generally during opening or closing circuits, or when
static electricity is discharged. Fire may occur if the arcing takes place in an
atmosphere that contains an explosive mixture.

Explosions:
Explosions occur when electricity provides a source of ignition for an
explosive mixture in the atmosphere. Ignition can be due to overheated
conductors or equipment, or normal arcing (sparking) at switch contacts.

Fires:
Electricity is one of the most common causes of fire both in the home and
workplace. Defective or misused electrical equipment is a major cause, with
high resistance connections being one of the primary sources of ignition.
High resistance connections occur where wires are improperly spliced or
connected to other components such as receptacle outlets and switches.

Heat develops in an electrical conductor from the flow of current. This heat
raises the temperature of the conductor. As a result, resistance in the

5
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

conductor increases, further raising the temperature. Thus, circuits


conducting a high rate of current and generating more resistance than it can
handle, may create enough heat to cause fire.

Causes of Electrical Accidents:


As a power source, electricity can create conditions resulting in bodily harm,
property damage, or both. It is important to you to understand how to avoid
electrical hazards when you work with electrical power tools, maintain
electrical equipment, or install equipment for electrical operation.
Accidents and injuries in working with electricity are caused by one or a
combination of the following factors:
 Unsafe equipment and/or installation.
 Unsafe workplaces caused by environmental factors.
 Unsafe work practices.

Preventing Electrical Accidents:


Protection from electrical hazards is one way to prevent accidents caused by
electric current. Protective methods to control electrical hazards include:
 Insulation.
 Electrical protective devices.
 Guarding.
 Grounding.
 PPE.
 Good Work Practices

Insulation:
Insulators of glass, mica, rubber, or plastic are put on electrical conductors to
protect you from electrical hazards. Before you begin to work on any piece
of electrical equipment, take a look at the insulation (on electrical cords, for
example) to be sure there are no exposed electrical wires. Also use insulated
tools.

6
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

Electrical Protective Devices:


Electrical protective devices, including fuses, circuit breakers, and ground-
fault circuit-interrupters (GFCIs), are critically important to electrical safety.
These devices interrupt current flow when it exceeds the capacity of the
conductor and should be installed where necessary.
Current can exceed the capacity of the conductor when a motor is
overloaded, for example, when you ask a 10 horsepower motor to do the
work of a 12 horsepower motor, or when a fault occurs, as when insulation
fails in a circuit.
When a circuit is overloaded, the insulation becomes brittle over time.
Eventually, it may crack and the circuit fails, or faults.
Fault occurs in two ways. Most of the time a fault will occur between a
conductor and an enclosure. This is called a ground fault. Infrequently, a
fault will occur between two conductors. This is called a short circuit.

A device which prevents current from exceeding the conductor’s capacity


creates a weak link in the circuit. In the case of a fuse, the fuse is destroyed
before another part of the system is destroyed. In the case of a circuit
breaker, a set of contacts opens the circuit. Unlike a fuse, a circuit breaker
can be reused by re-closing the contact. Fuses and circuit breakers are
designed to protect equipment and facilities, and in so doing, they also
provide considerable protection against shock.
However the only electrical protective device whose sole purpose is to
protect people is the ground-fault circuit-interrupter. The GFCI is not an
over current device. It senses an imbalance in current flow over the normal
path and opens the circuit. GFCIs are usually installed on circuits that are
operated near water.

7
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

Guarding:
Any “live” parts of electrical equipment operating at 50 volts or more must
be guarded to avoid accidental contact. This protection can be accomplished
in several different ways. The machinery or equipment can be located:
 In a room, enclosure, or vault accessible only to qualified
personnel.
 Behind substantial screens or partitions which prevent easy
access.
 On a balcony, platform, or gallery area which is elevated and
not accessible to unqualified/unauthorized persons.
 At least eight feet above the floor of the work area.

Any entrance to an area containing “live” parts of electrical equipment must


be marked with conspicuous warning signs. These signs should forbid
entrance except by qualified persons.

8
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

Grounding:
Grounding is necessary to protect you from electrical shock safeguard
against fire, and protect against damage to electrical equipment. There are
two kinds of grounding:
 Electrical circuit or system grounding, accomplished when one
conductor of the circuit is intentionally connected to earth,
protects the circuit should lighting strike or other high voltage
contact occur. Grounding a system also stabilizes the voltage in
the system so expected voltage levels are not exceeded under
normal conditions.
 Electrical equipment grounding occurs when the equipment
grounding conductor provides a path of dangerous fault current
to return to the system ground at the supply source of the circuit
should the insulation fail.

When a tool or other piece of electrical equipment is grounded, a low-


resistance path is intentionally created to the earth. This path has enough
current-carrying capacity to prevent any buildup of voltages in the
equipment which could pose a hazard to an employee using the equipment.
Therefore, never remove the ground prong from a plug because the
equipment no longer protects you from short circuits. If you’re touching an
ungrounded tool, you will become the path of least resistance to the ground.

Grounding does not guarantee that an employee will never receive a shock,
or be injured or killed by electricity in the workplace. However, this simple
procedure will substantially reduce the likelihood of such accidents. Be sure
any equipment you work on is properly grounded.

9
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

Personal Protective Equipment:


If you work in an area where there are potential electrical hazards, your
employer must provide you with protective equipment. You must use
electrical protective equipment appropriate for the body parts that need
protection and for the work to be done. Electrical protective equipment
includes insulating blankets, matting, gloves, sleeves, overshoes, face
protection, and hard hats among other equipment specially made to protect
you from electricity.

Safe Work Practices for Handling Electricity:


If your job requires you to work with electrical equipment, you need to have
a healthy respect for the power of electricity. In general, you should be sure
that any tools you use are in good repair, that you use good judgment when
working near electrical lines, and that you use appropriate protective
equipment. Remember – if you’re not sure, don’t touch.

Lockout/Tag out:
A word to qualified employees about de-energizing electrical equipment
before you do any repairs on it or make an inspection. Common sense
dictates that electrical equipment be de-energized before working on it,
when feasible. (Circumstances where it might be infeasible to de-energize
circuitry or equipment before working on it would include hazardous
location ventilation equipment or the testing of fire alarm systems, for
example, that can only be performed when the system is energized.
Qualified persons are only permitted to perform this kind of work.)

10
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

Having electrical current unexpectedly present when you are working on a


piece of equipment is no joke! Before any repair work or inspection of a
piece of electrical equipment is begun by an authorized person, the current
should be turned off at the switch box, and the switch padlocked in the OFF
position.

The other step in this procedure is the tagging of the switch or controls of the
machine or other equipment which is currently locked out of service. The tag
should indicate which circuits or pieces of equipment are out of service.

Work at Working Safely:


Safety should be foremost in your mind when working with electrical
equipment. You face hazards from the tools themselves and the electricity
that powers them. It’s up to you to wear protective equipment whenever it’s
specified, use all safety procedures, and work with tools correctly. Never let
over confidence or complacency lead to taking unnecessary risks. If you’re
not sure – don’t touch. The following general rules apply to every piece of
electrical equipment you use:

 Be sure your electrical equipment is maintained properly.


Regularly inspect tools, cords, grounds, and accessories. Make
repairs only if you are authorized to do so. Otherwise, arrange
to have equipment repaired or replaced immediately.
 Be sure you use safely features like three-prong plugs, double-
insulated tools, and safety switches. Be sure machine guards are
in place and that you always follow proper procedures.

11
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

 Install or repair equipment only if you’re qualified and


authorized to do so. A faulty job may cause a fire or seriously
injure you or other workers.
 Keep electric cables and cords clean and free from kinks. Never
carry equipment by its cords.
 Use extension cords only when flexibility is necessary:
o Never use them as substitutes for fixed wiring.
o Never run them through holes in walls, ceilings,
floors, doorways, or windows.
o Never use them where they are concealed behind
walls, ceilings, or floors.
 Don’t touch water, damp surfaces, ungrounded metal, or any
bare wires if you are not protected. Wear approved rubber
gloves when working with live wires or ungrounded surfaces,
and wear rubber-soled shoes or boots when working on damp
or wet surfaces.
 Don’t wear metal objects (rings, watches, etc.) when working
with electricity. They might cause arcing.
 If you are working near overhead power lines of 50 kilo-Volts
(kV) or less, you or any equipment you are using must not
come any closer than 10 ft from the lines. Add 4 inches of
distance for every 10 kV over 50 kV.

Good work habits soon become second nature. Treat electricity with the
respect it deserves and it will serve you efficiently and safely.

General Requirements: 29 CFR 1926.403 :


1- The conductors and equipment required or permitted by this subpart
shall be acceptable only if approved (U.L.).
2- Electrical equipment shall be free from recognized hazards that are
likely to cause death or serious harm to employees.
3- Listed or labeled equipment shall be used or installed in accordance
with any instructions included in the listing or labeling.
4- Parts of electric equipment which in ordinary operation produce arcs,
sparks, flame, or molten metal shall be enclosed or separated and
isolated from all combustible material.

12
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

5- Marking of electrical equipment is very important. Marking giving


voltage, current, wattage, or other ratings shall be provided. Marking
plates shall be installed in such a manner so the marking can be
examined by the inspector without removing the installed equipment
from a hard wired position.
6- Each disconnect switch or over-current device required for a service,
feeder, or branch circuit must be clearly labeled to indicate the
circuit's function, and the label or marking should be located at the
point where the circuit originates.

7- All labels and marking must be durable enough to withstand weather,


chemicals, heat, corrosion, or any other environment to which they
may be exposed.

600 Volts, Nominal, or Less:


Working Space About Electrical Equipment:
1- A minimum working space of 30 inch (76 cm) width is required in
front of electrical equipment operating at 600 volt or less. Distances
shall be measured from the live parts if they are exposed, or from the
enclosure front if the live parts are enclosed. This space permits
sufficient room to avoid body contact or elbows from contacting live
parts and metal parts at the same time while working on the
equipment. Equipment doors and hinged panels must have at least a
90 degree opening provided in the workplace.

13
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

2- Working space is not required in back of electrical equipment where


there are not any removable or adjustable parts such as circuit
breakers, fuses, or switches mounted on the back of the equipment.
All connections and services areas for maintenance must be accessible
from other locations other than the back of the equipment.

3- Where the electrical equipment is installed in or on one wall with the


wall on the other side being an insulated wall (Constructed from wood
or metal studs with the wallboard consisting of sheetrock, wood-
panels, and etc.) the minimum workspace distance shall be 36 inch
(91 cm) between the equipment and the wall.

14
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

4- Where the electrical equipment is installed one wall with the wall on
the other side being a conductive wall, the distance shall be minimum
of 36 inch (91 cm) for voltage ranging from 0 to 150 V, and the
distance shall be 42 inch (106 cm) for voltage ranging from 151 to
600 V.

5- Where the electrical equipment is installed in or on one wall with the


wall on the other side having electrical equipment mounted or set on
it. The distance shall be minimum 36 inch (91 cm) in case of voltage
ranging from 0 to 150 V. and shall be minimum 48 inch (122 cm) in
case of voltage ranging from 151 to 600 V.

6- Working space in front of electrical equipment must be free from


storage of materials and etc. Mains and over-current protection

15
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

devices are required to be accessible to the users in case of


emergencies.

7- Easy and fast access to electrical devices is essential. Special


consideration should be given to electrical equipment that is over 6 ft.
(2m) wide with 1200 Amps or more of bus containing over-current
devices, switching devices, or control devices. Such equipment must
have a clearance of 24 inches (61 cm) wide and 6.5 ft. (2 m) high at
each end for safe exit in case of a ground fault.

8- Service equipment, switchboards, panel-boards, and motor control


centers installed indoors must be provided with adequate lighting for
the safety of electrical workers servicing such equipment from the
front or rear when live parts are accessible. Lighting fixtures can be
incandescent or fluorescent as long as they provide the proper lighting
for parts to be serviced.
Lighting fixtures must have a head room clearance of at least 6.5 ft. (2
m) to give personnel sufficient room to stand in front of electrical
equipment without a treat of their head or head gear contacting metal
etc.

16
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

9- A minimum headroom clearance of 6.5 ft. (2 m) must be maintained


from the floor or platform up to the lighting fixture or any overhead
obstruction.

29 CFR 1926.404 Wiring Design and Protection:


Conductors used in electrical wiring systems must be identified properly to
protect personnel working on such systems. It is essential to know which
conductor by color represent the ungrounded hot phase conductor (live), the
grounded neutral conductor (neutral), and equipment grounded conductor
(earth) in electrical circuit. Because it is by color coding that conductors are
connected to color coded terminals of equipment.

The grounded neutral conductor of a branch circuit shall be identified by a


continuous white or natural gray color. It is an energized circuit conductor
that is connected to the earth through the system ground.

The equipment grounding conductor of a branch circuit shall be identified by


continuous green color or a continuous green color with one or more yellow
stripes unless it is bare. It is not an energized conductor under normal
conditions.

The ungrounded phase conductors can be identified with any color other
than those used for the grounded neutral conductors or equipment
conductors ( it could be Black, Blue, or Red)

17
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

Reversed Polarity:
Many pieces of equipment will operate properly even though the supply
wires are not connected in the order designated by design or the
manufacturer. Improper connection of these conductors is most prevalent on
the smaller branch circuit typically associated with standard 120 volt
receptacle outlets, lighting fixtures and cord - and plug - connected
equipment.
When plugs, receptacles, and connectors are used in an electrical branch
circuit, correct polarity between the ungrounded (hot) conductor, the
grounded (neutral) conductor, and the grounding conductor must be
maintained.

Reversed polarity is a condition when the identified circuit conductor (the


grounded conductor or neutral) is incorrectly connected to the ungrounded
or (hot) terminal of a plug, receptacle, or other type of connector.

The figure above shows an extremely dangerous situation. In this example,


the black (ungrounded) and green (grounding) conductors have been
reversed. The metal case of the equipment is at 120 volts with reference to
the surroundings. As soon as a person picks up the equipment and touches a
conductive surface in their surrounding, he will receive a serious, or even
deadly, shock.

Although the equipment will not work with this wiring error, it would not be
unusual for a person to pick up the equipment before realizing this. The
person may even attempt to troubleshoot the problem before unplugging the
power cord.

--------------------------------------------------------------------------------------------

18
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

CONSTRUCTION INDUSTRY REGULATIONS


Subpart M – Fall Protection
29 CFR 1926.500 – 29 CFR 1926.503

Introduction:

Areas or Activities Where Fall Protection is Needed:


• Ramps, runways, and other walkways.
• Excavations,
• Hoist areas.
• Form work and reinforcing steel.
• Leading edge work, unprotected sides and edges.
• Roofing works, pre-cast concrete erection
• Residential construction and other walking/working surfaces.

Fall Protection Standard:


• The rule sets a uniform threshold height of 6 feet (1.8 meters), thereby
providing consistent protection.

1
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

• Employer must assess the workplace to determine if the walking or


working surfaces have the strength and structural integrity to safely
support workers.
• Select the proper fall protection system to protect exposed employees
at 6 feet (1.8 m) or more.
• Provide the proper training.
• Protection also must be provided for construction workers who are
exposed to the hazard of falling into dangerous equipment.

Fall Protection Systems:


1. Guardrail Systems.
2. Personal Fall Arrest Systems.
3. Positioning Device Systems.
4. Safety Monitoring Systems.
5. Safety Net Systems.
6. Warning Line Systems.

1- Guardrail Systems:
• The top edge height of toprails must be 42 inches (1.1 meters) plus or
minus 3 inches (8 cm) above the walking/working level.
• Screens, midrails, mesh, intermediate vertical members must be
installed between the top edge of the guardrail system and
walking/working surface (at least 21 inches (53 cm) high.
• The guardrail system must be capable of withstanding a force of at
least 200 pounds applied on the top from both directions, midrail shall
be capable of withstanding a force of at least 150 pounds applied in
any downwards or outward direction.
• A toe-board with minimum 3.5 inches high should be installed all
around the platform and should be capable of withstanding a force of
at least 50 pounds.
• Guardrail systems shall be surfaced to protect workers from punctures
or lacerations and to prevent clothing from snagging.
• Distance Between Vertical Posts should not be more than 2.8 Ft.
• If no midrail is installed the distance between the vertical posts should
not be more than 19 inches.

2
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

3
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

2- Personal Fall Arrest Systems:


• These consist of an anchorage, connectors, and body belt or body
harness. It must do the following:
1. Limit maximum arresting force on an employee to 900 pounds when
used with a body belt.
2. Limit maximum arresting force on an employee to 1800 pounds when
used with a body harness.
3. Be rigged so that an employee can neither free fall more than 6 feet
(1.8 meters) nor contact any lower level.
4. Bring an employee to a complete stop and limit maximum decelarion
distance an employee travels to 3.5 feet (1.07 m). (shock absorber)
5. To keep at least 3 feet clearnance from the ground.

6. Have sufficient strength to withstand twice the potential impact


energy of an employee free falling a distance 6 feet or the free fall
distance permitted by the system, whichever is less.
7- The use of body belts for fall arrest is prohibited (1/1/1998) and a
full body harness is required.
8- The anchoring point must withstand a force not less than 5000
pounds.

4
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

3- Positioning Device Systems:


• Body belt or harness are to be set up that a worker can free fall no
farther than 2 feet.
• Secured to an anchorage capable of supporting 3000 pounds.

4- Safety Monitoring Systems:


• Used when no other alternative fall protection has been implemented.
• Competent person to monitor the safety of workers.
• The employer shall ensure that the safety monitor is competent in the
recognition of fall hazards.
• Is capable of warning workers of fall hazard dangers and in detecting
unsafe work practices.
• Is closed enough to work operations to communicate orally with
workers and has no other duties to distract from the monitoring
function.

5
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

5- Safety Net Systems:


• Safety nets must be installed as close as practicable under the
walking/working surface and never more than 30 feet (9.1 m) below
such levels.
• Installed with sufficient clearance underneath to prevent contact with
the surface or structure below.
• The maximum size of each safety net mesh opening shall not exceed
36 square inches nor be longer than 6 inches (15 cm) on any side.
• Each Safety net or section shall have a border rope for webbing with a
minimum breaking strength of 5000 pounds.
• Safety nets must extend outward from the outermost projection of the
work surface as follows:

6
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

• Safety nets shall be inspected at least once a week for wear, damage,
and other deterioration.
• Safety nets shall be capable of absorbing an impact force of drop test
consisting of a 400-pound (180 kilograms) bag of sand 30 inches (76
cm) in diameter dropped from the highest walking/working surface at
which workers are exposed, but not less than 42 inches (1.1 m) above
the level.
• Items that have fallen into safety nets including – but not restricted to,
materials, scrap, equipment, and tools – must be removed as soon as
possible and at least before the next work shift.

6- Warning Line Systems:


• Consists of ropes, wires, or chains, and supporting stanchions and are
set up as follows:
1. Flagged at not more than 6 foot intervals with high visibility
materials.
2. Rigged and supported so that the lowest point including sag is no less
than 34 inches (0.9 meters) from the walking/working surface and its
highest point is no more than 39 inches (1 m) from the
walking/working surface.
3. Shall be erected around all sides of roof work areas.
4. Warning lines shall be erected around all sides of roof work areas.
5. When mechanical equipment is being used, the warning line shall be
erected not less than 6 feet (1.8 m) from the roof edge parallel to the
direction of mechanical equipment operation, and not less than 10 feet
(3 m) from the roof edge perpendicular to the direction of mechanical
equipment operation.
6. When mechanical equipment is not being used, the warning line must
be erected not less than 6 feet (1.8 m) from the roof edge.

7
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

======================================

8
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

CONSTRUCTION INDUSTRY REGULATIONS

INTRODUCTION TO OSHA
INTRODUCTION:
More than 90 million Americans spend their days on the job. Until 1970, no
uniform and comprehensive provisions existed for their protection against
workplace safety and health hazards.
The Occupational Safety and Health Act (OSH ACT) was approved by
Congress in 1970, to assure so far as possible every working man and
woman safe and healthful working conditions.
In general, coverage of the Act extends to all employers in the 50 states, the
District of Columbia, Puerto Rico, and all other territories under Federal
Government.

DEFINITION:

OSHA: Occupational Safety and Health Administration


US Department of Labor.
Employers: As defined by the Act, an employer is any “person
engaged in a business affecting commerce who has
employees.
A competent person: is defined as “one who is capable of identifying
existing and predictable hazards in the
surroundings or working conditions which are
unsanitary, hazardous, or dangerous to employees,
and who has authorization to take prompt
corrective measures to eliminate them”
CFR: Code of Federal Regulations is a codification of
the general and permanent rules published in the
Federal Register by Executive departments and
agencies of the Federal Government. The code is
divided into 50 titles which represent broad areas
subject to Federal regulations. Each title is divided
into chapters which usually bear

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the name of the issuing agency. Each chapter is


further subdivided into parts covering specific
regulatory areas. Based on this breakdown, OSHA
is designated title 29-Labor, Chapter XVII.

Under Chapter XVII, the regulations are broken down into parts.
(Occupational Safety and Health Standards)
For example:
 Part 1910: General Industry Standards
 Part 1926: Construction Safety Standards

Under each part, such as Part 1910, major blocks information are broken
into subparts.
The major subparts in the 1910 standards include:

 Subpart D – Walking – Working Surfaces


 Subpart E – Means of Egress
 Subpart F – Powered Platforms, Manlifts, and Vehicle-
Mounted Work Platforms
 Subpart G – Occupational Health and Environmental
Control
 Subpart H – Hazardous Materials
 Subpart I – Personal Protective Equipment
 Subpart J – General Environmental Controls
 Subpart K – Medical and First Aid
 Subpart L – Fire Protection
 Subpart M – Compressed Gas and Compressed Air
Equipment
 Subpart N – Materials Handling and Storage
 Subpart O – Machinery and Machine Guarding
 Subpart P – Hand and Portable Powered Tools and Other
Hand-Held Equipment
 Subpart Q – Welding, Cutting and Brazing
 Subpart R – Special Industries
 Subpart S – Electrical
 Subpart Z – Toxic and Hazardous Substances

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Each subpart is further broken down into sections. Let us look at one subpart
in detail: Subpart D – Walking – Working Surfaces.
The index of Subpart D is shown below:

SUBPART D – WALKING – WORKING SURFACES


1910.21 Definitions
1910.22 General requirements
1910.23 Guarding floor and wall openings and holes
1910.24 Fixed industrial stairs
1910.25 Portable wood ladders
1910.26 Portable metal ladders
1910.27 Fixed ladders
1910.28 Safety requirements for scaffolding
1910.29 Manually propelled mobile ladder stands and scaffolds
(towers)
1910.30 Other working surfaces
1910.31 Sources of standards
1910.32 Standards organizations

OSHA PURPOSE:
Under the OSH ACT (1970), the Occupational Safety and Health
Administration (OSHA) was created within the Department of Labor in
1971 to:
1- Encourage employers and employees to reduce workplace
hazards and to implement new or improve existing safety and
health programs.
2- Provide for research in occupational safety and health to
develop innovative ways of dealing with occupational safety
and health problems.
3- Establish “separate but dependant responsibilities and rights”
for employers and employees for the achievement of better
safety and health conditions.
4- Maintain a reporting and record-keeping system to monitor job-
related injuries and illnesses.
5- Establish training programs to increase the number and
competence of occupational safety and health personnel.

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6- Develop mandatory job safety and health standards and enforce


them effectively
7- Provide for the development, analysis, evaluations and approval
of state occupational safety and health programs.

OSHA STANDARDS:
In carrying out its duties, OSHA is responsible for promulgating legally
enforceable standards. OSHA standards may require conditions, or the
adoption or use of or more practices, means, methods or processes
reasonably necessary and appropriate to protect workers on the job. It is the
responsibility of employers to become familiar with standards applicable to
their establishments and to ensure that employees have and use personal
protective equipment when required for safety.
Employees must comply with all rules and regulation which are applicable
to their own actions and conduct.
The OSHA standards were taken from three sources: consensus standards,
proprietary standards, and federal laws in effect when the Occupational
Safety and Health Act become law.

1- Consensus Standards: are developed by industry-wide


standard-developing organizations and are discussed and
substantially agreed upon through consensus by industry.
OSHA has incorporated the standards of the two primary
standards groups, the American National Standards Institute
(ANSI) and the National Fire Protection Association (NFPA),
into its set of standards.
2- Proprietary Standards: are prepared by professional experts
within specific industries, professional societies, and
associations. The proprietary standards are determined by a
straight membership vote, not by consensus. (An example is the
Compressed Gas Association)
3- Federal Law: Some preexisting federal laws are enforced
by OSHA, including the Federal Supply Contracts; the Federal
Service Contracts Act; the Contract Work Hours and Safety
Standards Act; and the National Foundation on the Arts and
Humanities Act. Standards issued under these Acts are now
enforced in all industries where they apply.

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Horizontal and Vertical Standards:


Standards are sometimes referred to as being either “horizontal or vertical”
in their application. Most standards are horizontal or “general” which means
they apply to any employer in any industry. Standards relating to fire
protection, working surfaces and first aid are examples of horizontal
standards.
Some standards, though, are relevant only to a particular industry, and are
called vertical, or “particular” standards. Examples are standards applying to
the longshoring industry or the construction industry, and to the special
industries covered in Subpart R of 1910.

WORKPLACE INSPECTIONS
Authority to Inspect
To enforce its standards, OSHA is authorised under the Act to conduct
workplace inspections. Every establishment covered by the Act is subject to
inspection by OSHA compliance safety and health officers.
Under the Act, “upon presenting appropriate credentials to the owner,
operator or agent in charge”, an OSHA compliance officer is authorized to:
 “Enter without delay and at reasonable times any factory, plant,
establishment, construction site or other areas, workplace, or
environment where work is performed by an employee of an
employer; and to
 “inspect and investigate during regular working hours, and at
other reasonable times, and within reasonable limits and in a
reasonable manner, any such place of employment and all
pertinent conditions, structures, machines, apparatus, devices,
equipment and materials therein, and to question privately any
such employer, owner, operator, agent or employee”.

Inspection Priorities
OSHA has established a system of inspection priorities:
1- Imminent Danger
Imminent danger situations are given top priority. An immenent
danger is any condition where there is reasonable certainty the a
danger exists that can e expected to cause death or serious physical
harm immediately, or before the danger can be eliminated through
normal enforcement procedures.

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Serious physical harm is any type of harm that could cause permanent
or prolonged damage to the body or which, while not damaging the
body on a prolonged basis, could cause such temporary disability as to
require in-patient hospital treatment. OSHA considers that “permanent
or prolonged damage” has occurred when, for example, a part of the
body is crushed or severed; an arm, leg or finger is amputateed; or
sight in one or both eyes is lost.

2- Catastrophes and Fatal Accidents


Second priority is given to investigation of fatalities and catastrophes
resulting in hospitalization of three or more employees. Such
situations must be reported to OSHA by the employer within 8 hours.
Investigations are made to determine if OSHA standards were
violated and to avoid recurrence of similar accidents.

3- Employee Complaints
Third priority is given to employee complaints of alleged violation of
standards or of unsafe or unhealthful working conditions.

4- Programmed High-Hazard Inspections


Next in priority are programmed, or planned, inspections aimed at
specific high-hazard industries, occupations or health substances.

5- Follow-up Inspections
A follow-up inspection determines whether previously cited violations
have corrected.

CITATIONS AND PENALTIES


Citations issued by the Area Director
After the compliance officer reports findings, the area director determines
what citations, if any will be issued, and what penalties, if any, will be
proposed.
Citations inform the employer and employees of the regulations and
standards alleged to have been violated and of the proposed length of time
set for their abatement. The employer will receive citations and notices of
proposed penalties by certified mail. The employer must post a copy of each

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citation at or near the place a violation occurred, for three days or until the
violation is abated, whichever is longer.

Penalties:
1- Other Than Serious Violation: A violation that has a direct
relationship to job safety and health, but probably would not
cause death or serious physical harm. A proposed penalty of up
to $7.000 for each violation is discretionary. A penalty for an
other-than- serious violation may be adjusted downward by as
much as 95 percent, depending on the employer’s good faith
(demonstrated efforts to comply with the Act).

2- Serious Violation – A violation where there is substantial


probability that death or serious physical harm could result and
that the employer knew, or should have known, of the hazard.
A mandatory penalty of up to $ 7.000 for each violation is
proposed. A penalty for a serious violation may be adjusted
downward, based on the employer’s good faith, history of
previous violations, the gravity of the alleged violation, and
size of business.

3- Willful Violation – A violation that the employer knowingly


commits or commits with plain indifference to the law. The
employer either knows that what he or she is doing constitutes
a violation, or is aware that a hazardous condition existed and
made no reasonable effort
to eliminate it.
Penalties of up to $ 70.000 may be proposed for each willful
violation, with a minimum penalty of $ 5.000 for each
violation. A proposed penalty for a willful violation may be
adjusted downward, depending on the size of the business and
its history of previous violations. Usually, no credit is given for
good faith.
If an employer is convicted of a willful violation of a standard
that has resulted in the death of an employee, the offense is
punishable by a court-imposed fine or by imprisonment for up
to six months, or both. A fine of up to $ 250.000 for an

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individual, or $ 500.000 for a corporation, may be imposed for


a criminal conviction.

4- Repeated Violation – A violation of any standard, regulation,


rule, or order where, upon re-inspection, a substantially similar
violation can bring a fine of up to $ 70.000 for each violation.
To be the basis of a repeated citation, the original citation must
be final; a citation under contest may not serve as the basis for
a subsequent repeated citation.

5- Failure to Abate Prior Violation – Failure to abate a prior


violation may bring a civil penalty of up to $ 7.000 for each day
the violation continues beyond the prescribed abatement date.

Additional violations for which citations proposed penalties may be


issued upon conviction:
a. Falsifying records, reports or applications can
bring a fine of $ 10.000 or up to six months in jail,
or both.
b. Violations of posting requirements can bring a
civil penalty of up to $ 7.000.
c. Assaulting a compliance officer, or otherwise
resisting, opposing, intimidating, or interfering
with a compliance officer while they are

engaged in the performance of their duties is a criminal


offense, subject to a fine of not more than $ 5.000 and
imprisonment for not more than three years.

SERVICES AVAILABLE BY OSHA


A. Consultation Assistance
Consultation assistance is available to employers who want
help in establishing and maintaining a safe and healthful
workplace. Largely funded by OSHA, the service is provided at
no cost to the employer. No penalties are proposed or citations
issued for hazards identified by the consultant.

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Occupational Safety and Health Administration
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This process begins with the employer’s request for


consultation and the commitment to correct any serious job
safety and health identified by the consultant. Possible
violations of OSHA standards will not be reported to OSHA
enforcement staff unless the employer fails or refuses to
eliminate or control worker exposure to any identified serious
hazard or imminent danger situation.
Consultation assistance includes an appraisal of all mechanical,
physical, work practice, and environmental hazards of the
workplace and all aspects of the employer’s present job safety
and health program.

B. Voluntary Protection Programs


The Voluntary Protection Programs (VPPs) represent one part
of OSHA’s effort to extend worker protection beyond the
minimum required by OSHA standards. These programs, along
with others such as expanded onsite consultation services and
full-service area offices, are cooperative approaches which,
when coupled with an effective enforcement program, expand
worker protection to help meet the goals of the Occupational
Safety and Health Act of 1970.

C. Training and Education


OSHA’s area offices are full-service centers offering a variety
of informational services such as availability for speaking
engagements, publication, audiovisual aids on workplace
hazards, and technical advice.

The OSHA Training Institute in Des Plaines, IL, provide basic


and advanced training and education in safety and health for
federal and state compliance officers; state consultants; other
federal agency personnel; and private sector employees,
employees and their representatives. Institute courses cover
areas such as electrical hazards, machine guarding, ventilation
and erognomics.

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Occupational Safety and Health Administration
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CONSTRUCTION INDUSTRY REGULATIONS

CONTROL OF HAZARDOUS ENERGY


(LOCKOUT/TAGOUT)
29 CFR 1926.417
Overview
Every workplace has the need for on-going maintenance. Installation, repair
and servicing of machines and equipment may seem routine, but can be
dangerous to employees performing the work.

Serious injury can be caused by the sudden and unexpected startup of the
machinery or equipment, contact with live electrical circuit or the
unexpected release of stored energy.
Equipment that is shut down may inadvertently be re-started or re-energized
by a co-worker, or equipment that was thought to be shut down may be
controlled by automatic processors, timers or computers and may be re-start
automatically and without warning.

OSHA estimates that failure to control hazardous energy sources results in:
 10 % of serious industrial accidents.
 28,000 lost work days injuries per year.
 Approximately 120 deaths per year.

Fortunately, these hazards can be avoided through the use of lockout/tag-out


procedures.
The Lockout/Tagout standard requires the adoption and implementation of
practices and procedures to shut down equipment, isolate it from its energy
source(s), and prevent the release of potentially hazardous energy while
maintenance and servicing activities are being performed. It contains
minimum performance requirements, and definitive criteria for establishing
an effective program for the control of hazardous energy.

All new equipment installed after January 2, 1990 must be designed to


accept lockout of its energy-isolating device.

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Occupational Safety and Health Administration
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LOCKOUT/TAGOUT – 1926.417
DEFINITIONS

Lockout – The placement of a lockout device on an energy – isolating


device, in accordance with an established procedure, ensuring that the
energy – isolating device and the equipment being controlled cannot be
operated until the lockout device is removed.

Tag-out – the placement of a tag-out device on an energy-isolating device,


in accordance with an established procedure, to indicate that the energy-
isolating device and the equipment being controlled may not operated until
the tag-out device is removed.

Lockout device – Any device that uses positive means such as a lock, either
key or combination type, to hold an energy-isolating device in a safe
position, thereby preventing the energizing of machinery or equipment.
When properly installed, a blank flange or bolted slip blind are considered
equivalent to lockout devices.

Tag-out device – Any prominent warning device, such as a tag and a means
of attachment, that can be securely fastened to an energy-isolating device in
accordance with an established procedure. The tag indicates that the machine
or equipment to which it is attached is not to be operated until the tag-out
device is removed in accordance with the energy control procedure.
Energy-isolating device – Any mechanical device that physically prevents
the transmission or release of energy. These include, but are not limited to,
manually-operated electrical circuit breakers, disconnect switches, line
valves, and blocks.

Capable of being locked out – An energy-isolating device is considered


capable of being locked out if it meets one of the following requirements:
- It is designed with a hasp to which a lock can attached;
- It is designed with any other integral part through which a lock
can be affixed;
- It has a locking mechanism built into it; or

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- It can be locked without dismantling, rebuilding, or replacing


the energy isolating device or permanently altering its energy
control capability.

Affected employee – An employee who performs the duties of his or her job
in an area in which the energy control procedure is implemented and
servicing or maintenance operations are performed. An affected employee
does not perform servicing or maintenance on machines or equipment that
must be locked or tagged.

Authorized employee – An employee who performs servicing or


maintenance on machines and equipment. Lockout or tag-out is used by
these employees for their own protection.

Energy sources – Any electrical, mechanical, hydraulic, pneumatic,


chemical, gas, thermal or other energy source that could cause an injury to
the affected personnel.

Residual pressure – The remaining energy in a system after activation of


the disconnect (stored energy).

SCOPE AND APPLICATION


 Applies to general industry employment and covers the
servicing and maintenance of machines and equipment in

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which the unexpected start-up or the release of stored energy


could cause injury to employees.

ENERGY CONTROL PROGRAM


 Intended to prevent the unexpected energizing or the release
of stored energy in machines or equipment on which servicing
and maintenance is being performed by employees.

 Consists of documented energy control procedures, an


employee training program, and periodic inspections of the
procedures.

 Employers have flexibility to develop a program that meets


the needs of their particular workplace.

ENERGY CONTROL PROCEDURE


 The written procedures must identify the information that
authorized employees must know in order to control
hazardous energy during service or maintenance.

 At a minimum, it includes, but is not limited to, the following


elements:
- A statement on how the procedure will be used;
- The procedural steps needed to shut down, isolate, block,
and secure machines or equipment;
- The steps designating the safe placement, removal, and
transfer of lockout/tag-out devices and who has the
responsibility for them; and
- The specific requirements for testing machines or
equipment to determine and verify the effectiveness of
locks, tags, and other energy control measures.

 Procedure must include the following steps:


(1) Preparing for shutdown
(2) Shutting down the machine(s) or equipment
(3) Isolating the machine or equipment from the
energy source(s),

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(4) Applying the lockout or tag-out device(s) to the


energy-isolating device(s)
(5) Safely releasing all potentially hazardous stored or
residual energy, and
(6) Verifying the isolation of the machine(s) or
equipment prior to the start of service or
maintenance work.

 In addition, before lockout or tag-out devices are removed and


energy is restored to the machines or equipment, certain steps
must be taken to re-energize equipment after service is
completed, including:
(1) Assuring that machines or equipment components
are operationally intact
(2) Notifying affected employees that lockout or tag-
out devices are removed from each energy-
isolating device by the employee who applied the
device.

ENERGY-ISOLATING DEVICES
 Guards against accidental machine or equipment start-up or
the unexpected re-energization of equipment during servicing
or maintenance.
 These include, but are not limited to, manually-operated
electrical circuit breakers, disconnect switches, line valves,
and blocks.
 Two types: those capable of being locked and those that are
not.
 When the energy-isolating device cannot be locked out, the
employer must use tag-out or modify or replace the device to
make it capable of being locked.
 When using tag-out, employers must train their employees in
the limitations or tags.
 Whenever major replacement, repair, renovation or
modification of machines or equipment is performed and
whenever new machines or equipment are installed or

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purchased, the energy-isolating devices for such machines or


equipment must be lockable.

REQUIREMENTS FOR LOCKOUT-TAGOUT DEVICES


Whichever devices are used, they must be singularly identified, must be the
only devices used for controlling hazardous energy, and must meet the
following requirements:
 Durable – Lockout and tag-out devices must withstand the
environment to which they are exposed for the maximum
duration of the expected exposure. Tag-out devices must be
constructed and printed so that they do not deteriorate or
become illegible,
 Especially when used in corrosive (acid and alkali chemicals)
or wet environments.
 Standardized – Both lockout and tag-out devices must be
standardized according to either color, shape, or size. Tag-out
devices must also be standardized according to print and
format.
 Substantial – lockout and tag-out devices must be substantial
enough to minimize early or accidental removal. Locks must
be substantial to prevent removal except by excessive force of
special tools such as bolt cutters or other metal cutting tools.
Tag means of attachment must be non-reusable, attachable by
hand, self-locking and non-releasable, with a minimum
unlocking strength of no less than 50 pounds. The device for
attaching the tag also must have the general design and basic
characteristics equivalent to a one-piece nylon cable tie that
will withstand all environments and conditions.

 Identifiable – Locks and tags must clearly identify the


employee who applies them. Tags must also warn against
hazardous conditions if the machine or equipment is energized
and must include a legend such as the following: DO NOT
START, DO NOT OPEN, DO NOT CLOSE, DO NOT
ENERGIZE, DO NOT OPERATE.

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EMPLOYEE TRAINING
 The employer must provide effective initial training and
retraining as necessary and must certify that such training has
been given to all employees covered by the standard. The
certification must contain each employee’s name and dates of
training.
 The employer’s training program for authorized employees
(those who are charged with the responsibility for
implementing the energy control procedures and performing
the service and maintenance) must cover, at minimum, the
following areas:
- Details about the type and magnitude of the hazardous
energy sources present in the workplace, and
- The methods and means necessary to isolate and control
those energy sources (that is, the elements of the energy
control procedure)
 Affected employees (usually the machine operators or users)
and all other employees need only be able to (1) recognize
when the control procedure is being implemented, and (2)
understand the purpose of the procedure and the importance
of not attempting to start up or use the equipment that has
been locked or tagged out.
 Every training program must ensure that all employees
understand the purpose, function and restrictions of the energy
control program and that authorized employees possess the
knowledge and skills necessary for the safe application, use,
and removal of energy controls.
 Training programs used for compliance with this standard,
which is performance-oriented, should deal with the
equipment, type(s) of energy, and hazard(s) specific to the
workplace being covered.
 Retraining must be provided, as required, whenever there is a
change in hob assignments, a change in machines, equipment
or processes that present a new hazard, or a change in energy
control procedures.

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 Additional retraining must be conducted whenever a periodic


inspection reveals, or whenever the employer has reason to
believe, that there are deviations from or inadequacies in the
employee’s knowledge or use of the energy control procedure.

PERIODIC INSPECTIONS
 Periodic inspections must be performed at least annually to
assure that the energy control procedures (locks and tags)
continue to be implemented properly and that the employees
are familiar with their responsibilities under those procedures.
 In addition, the employer must certify that the periodic
inspections have been performed. The certification must
identify the machine or equipment on which the energy
control procedure was used, the date of the inspection, the
employees included in the inspection, and the name of the
person performing the inspection.
 For lockout procedures, the periodic inspection must include a
review, between the inspector and each authorized employee,
of that employee’s responsibilities under the energy control
procedure being inspected.
 When a tag-out procedure is inspected, a review on the
limitation of tags, in addition to the above requirements, must
also be included with each affected and authorized employee.

LOCKOUT/TAGOUT PROCEDURES
The following are the procedures necessary for effective lockout/tag-out:

Step 1: Preparation and Notification


Before servicing or installing equipment, you must be able to answer the
following questions:
 What is the type of energy source on the equipment?
 What are the potential hazards related to the energy source?
 What steps are necessary to control the energy source?
 Who needs to be notified that the equipment will be shut
down for service?

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Occupational Safety and Health Administration
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Once these questions have been answered, notify all affected employees that
a lockout procedure is about to begin and that the equipment will be shut
down for service.

Step 2: Shut Down the Equipment


Follow the company’s safety procedures and/or the manufacturer’s
instructions. Be aware that some equipment has special shut-down
procedures (for example, computer-controlled equipment)
Make sure all energy sources have located and shut down. (Some machines
have more than one power source – all must be shut down).

Step 3: Isolate the Equipment


Equipment should be isolated by:
A. Shutting off the main breaker or control switch
B. Closing valves
C. Disconnecting process lines
D. Pulling plugs

Note: For complex machines or equipment, refer to the manufacturer’s


control diagram detailing the locations of all isolation points, including
breaker panels, switches, valves, etc.

Step 4: Attach the Lock and Tag


Each employee who is performing maintenance is responsible for locking
and tagging the equipment. Each employee whose duties require them to
work on equipment must be provided with their own lock and key.
If more than one employee is involved in the maintenance, multiple locking
devices must be used to allow each maintenance employee to lock and tag.
This prevents one employee from accidentally starting up the equipment
while another employee is still working.

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Occupational Safety and Health Administration
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Never use another employee’s lock and never lend your own.
When all energy sources are locked, apply a tag to the power source. Make
sure the tag is filled out completely and correctly.

Step 5: Release any Stored Energy


After locking and tagging equipment, you must make sure that any stored
energy on the equipment is released. This is done by:
 Inspecting equipment to make sure all parts have stopped
moving.
 Bleeding electrical capacitance (stored charge)
 Venting or isolating pressure or hydraulic lines from the work
area, leaving vent valves open
 Draining tanks and valves
 Releasing the tension on springs or blocking the movement of
spring-driven parts.
 Blocking or bracing parts that could fall because of gravity
 Blocking, clamping or chaining any switches or levers that
could be moved into the start position
 Clearing lines containing process materials that are toxic, hot,
cold, corrosive or asphyxiating
 Monitoring the process to make sure that the work you are
doing will not result in an accumulation of stored energy.

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Occupational Safety and Health Administration
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Step 6: Test Equipment to Verify that All energy Has Been Released or
Controlled
To make sure that all kinetic and stored energy has been released or
controlled, you must:
 Clear personnel from danger areas.
 Test the start switches on the equipment to confirm that all
power sources have been shut down and switches can’t be
moved to the “on” or “start” position.
 Check pressure gauges to make sure that all lines are de-
pressurized and stored energy has been released.
 Secure all blocks, clamps, chains and cribs.
 Check electrical circuits to make sure that voltage is at zero.
 Secure blanks (used to block feed chemicals) and make sure
they are not leaking.

Because some machinery and equipment can be remotely controlled, you


must consider equipment to be energized and in motion at all times except
when you have personally locked it out of operation and tested equipment to
verify that the energy state is zero.
If all tests are passed, begin working on equipment.
Once you have confirmed that all energy sources have been controlled and
locks and tags are in place, it is safe to begin the maintenance work.
While working, you should avoid any actions that could re-activate the
equipment.
When installing new piping or wiring, you should make sure the lockout is
not bypassed.

11
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

SAFE STARTUP PROCEDURES


Once the maintenance or installation is completed, the equipment can be re-
started. These are the procedures to follow for safe startup:

Step 1: Preparing for Startup


You must make sure the area is safe for restart by:
 Making sure all equipment components are fully assembled
and operational.
 Making sure all safety guards are in place.
 Removing all tools from the equipment and the work area.
 Removing all braces, pins, blocks, cribs and chains.
 Reconnecting all pressure tubing, pipes and hoses and closing
all valves.
 Clearing the work area of all personnel.

Step 2: Remove Lockout Devices and Tags


Except in emergencies, each lockout device must be removed by the
employee who put it on.

Step 3: Notify Affected Employees


Notify all personnel in the area that maintenance, servicing or installation is
complete, lockout/tag-out has been removed and the machine/equipment is
ready to be re-started.

Once all three steps are completed, it is safe to start up the equipment.

LOCKOUT AND TAGOUT DEVICES


Lockout Devices:
 Must be provided to each employee
 Must only be used for the purposes of lockout/tagout
 Must be able to withstand the environment that they are
exposed to for as they are in place.
 Must be standardized by color, shape and size.

12
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

Tag-out Devices
 Must be standardized by color, shape, size and format or print
 Must contain warnings such as “DANGER – DO NOT
OPERATE THIS MACHINE”
 Must have space for the name of lock or tag owner, date and
purpose of the lockout/tag-out.

TAGOUT ONLY
A tag-out system can be used instead of a lockout system in the following
situations only:
 When an energy isolating device cannot be locked out
 When the employer can prove that a tag-out system provides
the same amount of protection as a lockout system.

If a “Tag-out Only” system is used, the tags must be placed at all isolation
points, and you must follow all safety procedures.

Note: After January 2, 1990, any equipment that is replaced, renovated or


modified must be able to accept a lockout device.

SPECIAL SITUATIONS
Some situations may occur in the workplace that require additional
procedures to perform safe lockout/tag-out.

Removing someone else’s lock: A lock may be removed by someone other


than the employee who placed the lock only under the following conditions:
 The employee whose lock is to be removed is not available to
remove the lock after servicing has been completed.
 All reasonable efforts have been made to contact the
employee to inform him/her that the lock has been removed.
 The employee is contacted and informed that the lock is
removed prior to the employee starting work on the next work
shift.

13
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

Shift Changes: If maintenance on a piece of equipment will extend beyond


one shift, provisions must be made to have employees from the new shift
place their locks on the lockout device before they begin work on the
equipment. This must be done without any interruption in lockout/tag-out
protection.

Outside Contractors: If outside contractors will be working on equipment


inside your facility or workplace, you must make provisions to inform them
of your lockout/tag-out procedures. If the contractor’s procedures are
different from yours, you must make an agreement with the contractor as to
which procedures will be followed. All employees working on the project
must be notified of any changes in their own procedures.

Temporary Re-activation: If the equipment being serviced must be


temporarily re-activated (for example, to test the equipment as part of
installation), all startup and lockout/tag-out procedures must be followed.

14
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

1
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

2
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

3
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

4
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

5
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

******************************************************

6
Occupational Safety and Health Administration
(OSHA)
USA Department of Labor
January 2005 Wagdi Fouad Seffain – Authorized OSHA Trainer

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