General Safety Rules For Structural Steel Fabricators

SAFETY
General Safety Rules

for Structural Steel
Fabricators
GENERAL SAFETY
RULES FOR STRUCTURAL
S T E E L FA B R I C AT O R S
AMERICAN INSTITUTE OF STEEL CONSTRUCTION, INC.

One East Wacker Drive, Suite 3100 Chicago, Illinois 60601
2004 by American Institute of Steel Construction, Inc. All rights reserved.
This publication or any part thereof must not be reproduced in any form without permission of the publisher.
Disclaimer
Contents
This publication is intended to present practical work rules to

assist in achieving a higher level of employee safety in shops that
fabricate structural steel. This publication is not intended to replace
or supersede federal, state, or locally mandated safety standards.
Compliance with the general rules set out in this publication does
not assure compliance with OSHA or other safety standards.
Trained safety professionals should be consulted for application
of the general rules presented in this publication to individual
fabrication facilities.
1st PrintingJune 1981

2nd PrintingJanuary 1990
1st Revision, 1st PrintingNovember 2000
SECTION
PAGE
Foreword............................................................................................ iv
1. Personal Protection .................................................................. 1
2. General Safety Rules ................................................................ 8
3. Cranes and Hoists .................................................................. 14
Electric Overhead Cranes (Cab Operated) ..............................114
Floor Operated Cranes and Hoists ..........................................118
Standard Crane Signals ............................................................224
Alloy Chain Capacities ..........................................................126
4. Material Handling ................................................................127
5. Punching and Shearing ........................................................ 35
6. Reaming and Drilling ............................................................ 37
7. Fitting and Bolting ................................................................ 41
8. Arc Welding ..........................................................................143
9. Flame Cutting (Burning), Cambering
and Heat Straightening ........................................................ 47
10. Chipping and Grinding ........................................................ 53
11. Machine Shop ........................................................................ 57
12. Mobile Equipment ................................................................ 59
Railway ....................................................................................159
Fork Lifts, Tow Motors, Trucks, etc. ....................................162
Straddle Carriers ......................................................................164
13. Electrical Work ...................................................................... 66
14. Maintenance and Repair ...................................................... 69
15. Radiation (X-ray, Cobalt, etc.) ............................................ 72
16. Housekeeping .......................................................................... 75
17. Use of Ladders ...................................................................... 76
18. Scaffolds .................................................................................. 79
19. Hydraulic and Mechanical Jacks ........................................ 87
20. Painting ....................................................................................188
21. Abrasive Blasting .................................................................. 91
22. Fire Prevention ...................................................................... 94
23. Off the Job Safety ................................................................ 98
Publication Number F502(10M1100)

2000, American Institute of Steel Construction. All rights reserved.
A MERICAN I NSTITUTE
OF
S TEEL C ONSTRUCTION

Personal Protection 1
1. Personal Protection
Foreword
In the interest of safety, this Manual was developed by a committee
drawn from members of the American Institute of Steel
Construction (AISC). Careful consideration was given to the problems
peculiar to the Fabricating Industry, recognizing that many of the
variable conditions encountered in the industry do not lend
themselves to narrowly defined regulations. Therefore, it is intended
that the Manual should be interpreted and administered with sound
judgment consistent with good safety practices.
AISC has compiled this booklet to help its members achieve the
humanitarian and economic benefits of an effective safety
program. These recommendations reflect the experience of steel
fabricators as well as the suggestions of employees, supervisors,
and safety specialists throughout the steel fabricating industry.
Mostly they are common sense precautions that all workers should
take. They are, of course, subject to local instructions, regulations,
and codes where applicable.
The success of any accident prevention program is to a great
extent dependent on the interest and wholehearted support of
supervision. It is the first line supervisor who has the greatest
burden of responsibility in putting the recommendations into practice. Workers should expect to receive the benefit of the supervisor's
knowledge and know that strict compliance will be expected of
them. In return, it is expected that the supervisor will have the
cooperation of the workers and that they will constantly use thought
and care to perform their work safely.
Make sure you understand the safest way of doing your work.
Do not hesitate to ask when in doubt. Pay particular attention to
General Safety Rules and Material Handling Rules, as well as
the sections which apply to your work.
Your safety and welfare is of vital interest to your family, fellow
workers, and management. With your complete cooperation we can
reach the goal of Safety for All.
Report Every Injury Promptly, No Matter How Slight
Wear clothes and protective accessories suitable for the

work at hand.
1.1
Wear clothes that are suitable for your work. Buttoned long
sleeve shirts should be worn when burning, welding,
grinding, or performing other types of work where sparks or
hot metal are present or where the work involves the handling of acid, galvanizing, etc.
1.2
Be sure that any clothing you wear is not of a highly

flammable material. Cotton and wool and fire-retardant
treated cloth is recommended where flame, heat, or sparks
are present. Special precautions are necessary with respect
to certain types of thermal underwear. Clothing made with
synthetic fiber should be selected and worn with caution.
Synthetic fibers melt at lower temperatures and increase the
potential severity of a burn injury.
1.3
It is advisable to wear steel-toed safety shoes or boots on the

job. Metatarsal (instep) protection is highly recommended.
Steel-toed Boot
Metatarsal Boot
Lets All Work Together for Safety
iv
OF
OF

2 General Safety Rules for Structural Steel Fabricators
1.4
The wearing of an approved hard hat (safety cap/hard hat,

but not a bump cap) is recommended.
Hard Hat
Bump Cap
1.5
Generally, gloves should be worn except when operating

lathes, milling cutters, boring mills, drill presses, or other
types of machinery with revolving spindles or cutting tools
or where they may interfere with the safe operation of
control buttons on floor or platform-operated cranes.
1.6
Neckties, loose, torn or ragged clothing create a special

hazard when operating lathes, drill
presses, reamers, and other
machines with revolving
spindles or cutting tools,
and shall not be worn
while working.
1.7
Pants guards (clips, elastic, or rubber bands) should be

worn by employees performing operations where the pants
legs could be caught by a revolving drill or reamer bit.
1.8
ANSI approved type eye protection is required in all plant

areas. Face shields or similar protection should be worn in
addition to basic eye protection when grinding, chipping,
burning or doing other work where there is an unusual
hazard from flying particles. Described below are a few
types of recommended eye protection. AISC makes no
recommendation as to specific manufacturers; however, all
safety glasses should meet ANSI Standard Z87.1, Eye &
Face Protection.
Heavy Impact Goggles provide protection from heavy
impact, dust, smoke, cinders, and welding glare. May be
worn with or without spectacles. Not suitable for continuous
close-up exposure to welding glare.
Heavy Impact Goggles
Burner Goggles provide protection from light and sparks

from burning torch, impact, dust, cinders and weld glare.
May be worn with or without spectacles.
Burner Goggles
OF
OF

Face Shields provide protection from impact, dust, cinders

and welding glare. Not adequate for continuous close-up
exposure to welding operations. Use in conjunction with
general-purpose spectacles for heavy impact work, chipping,
grinding, pickling and galvanizing operations. (Note: Also
available in shaded lens and frames.)
frame readily adjusts to face, so this is particularly suitable

for dust protection. May be worn with or without spectacles.
Does not protect from weld glare. Not suitable for heavy
impact. Note: Shaded lens available, but refer to
above-noted comments for clear spectacles.
Cover-all Plastic Monogoggles
1.9
Welders are required to wear approved safety glasses in

addition to welding helmet. When welders are regularly
working very close to one another, it may be desirable to
use safety glass lens having a shade value of 1.5 or 1.7.
(Note: These shaded lenses have equal resistance to ultraviolet light transmittance, but they have a loss of 38% and
50%, respectively, in visible light. Thus, while some glare
reduction will be achieved, the visible light reduction may
present an unacceptable, unsafe condition.)
1.10
Unless contact lenses have to be worn for medical reasons

(such as following a cataract operation) they should not be
worn in the shop, because dust and other contaminants may
cause secondary problems of irritation, itching, watering and
infection. (Also see Rule 8.7.)
1.11
Fall protection is required when working aloft. Lanyards

shall be anchored to an appropriate tie off point except when
moving or changing work locations or when working from
permanent walkways, platforms, etc., equipped with
guardrails.
1.12
Inspect fall protection equipment before each use. Notify

your supervisor immediately if any defects are found in the
safety equipment.
1.13
Always wear a life vest when working on floating

equipment or while engaged in any work over the water.
Face Shield
General Purpose Spectacles (Clear) provide protection

from light or medium impact, dust and cinders. Does not
protect from weld glare. Face shield must be used in
conjunction with general-purpose spectacles when
performing other heavy impact work. Note: Also available
with shaded lens, but attention is directed to the
consequential reduction of visible light when they are
used. (See Rule 1.9.)
General Purpose Spectacles
Cover-All Plastic Monogoggles (Clear) provide protection

from light or medium impact, dust and cinders. Soft vinyl
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1.14
Respirators, suitable to the type of work being performed,

must be worn when power wire brushing, spray painting,
sand or grit blasting, burning or welding on painted
surfaces, etc. Respirators shall be maintained in accordance
with the manufacturers recommendations. Respirators
should not be transferred from one person to another until
they have been cleaned and sterilized. Turn in any respirator
that seems to be defective. (Under special circumstances,
such as burning steel coated with paint in confined areas,
welding in confined areas, or spraying epoxy paints, air line
respirators are recommended. Check with your supervisor
before starting such work.)
Ear Muffs
Respirators, including disposable dust mask type equipment,

should be NIOSH or Bureau of Mines approved.
Disposable Ear Plugs
Dust Mask
Insert-type Ear Plugs
1.16
Rings or other jewelry should not be worn in the shops or

yards.
1.17
Pure oxygen should not be used for ventilation or cooling

purposes.
Air Line Respirator
Cartridge Type Respirator
1.15
Proper fitting earplugs or muffs must be worn where

hazardous noise situations exist. Some form of ear
protection should also be worn where there is an unusual
hazard of sparks, molten metal or flying particles from
welding, burning or gouging.
OF
OF

2. General Safety Rules
General Safety Rules 9
2.10
Do not pile material or equipment so that it obstructs safety

equipment. Crane ladders, fire fighting equipment, exits,
electrical panels, switch boxes, stretchers, etc., must be kept
free of obstructions at all times. Aisles and roadways must
be kept clear.
2.11
Use a good ladder equipped with safety feet. Always use

both hands when going up or down a ladder. Be sure that
the ladder is properly secured, both top and bottom. Where
a ladder cannot be secured, a person must hold it while
anyone is climbing, descending or working from it. (Refer
to Section 17 for Ladder Safety Requirements.)
2.12
Never point a compressed air hose or tool at anyone or use

compressed air for dusting clothing.
2.13
Be as familiar as possible with surrounding areas, presence

of other employees, and operation so that you can foresee
possible dangers. Be familiar with in-plant emergency telephone communications, first aid stations, emergency shower
and eye wash stations, stretcher locations, fire extinguisher
locations, and emergency exitways.
2.14
Never stand over an airline, hydraulic line, or any line under

pressure. If an air hose breaks, do not go near it or attempt
to grab it until the air pressure is shut off.
2.15
Properly barricade floor openings, open manholes, machine

foundations, and pits for repair purposes, and close them as
soon as possible. Where the lighting is poor, a red light
should be installed in addition to the barricade. If the sides
of a trench or excavation do not appear to be firm and
secure, notify your supervisor immediately.
2.16
Crewmembers and authorized personnel only are permitted

to ride railroad cars, locomotives, cranes, trucks and other
mobile equipment.
2.17
Flammable liquids such as gasoline, solvents, etc., must be

handled in approved safety containers with flame arrestors.
2.18
Never oil, remove guards or attempt to repair machinery

while it is in motion. Do not climb on machinery while
oiling or greasing, always use a ladder if practical. Only
authorized personnel should make repairs of machinery.
Be constantly on alert for unsafe conditions or acts and

report such to your supervisor.
2.1
Keep work area in clean and orderly condition with

necessary equipment and material neatly arranged. Do not
allow drift pins, bolts, weld rod stubs, or small material to
accumulate on the shop floor or in the work area. Place
paper sacks, lunch papers, etc., in containers provided. It is
important that every employee keep his own work place
clean and obstacle free.
2.2
If you are in doubt about the safe or proper way to do a job,

get instructions from your supervisor before proceeding.
2.3
Be constantly on the alert for unsafe conditions or acts and

report such to your supervisor.
2.4
Horseplay is not permitted. Do not distract or interfere in

any way with a person performing his job.
2.5
Do not leave your work area unless your work or personal

needs require it.
2.6
Running through the shops or any part of the plant is

prohibited except in an emergency. Always use designated
aisles and walkways. Be alert for tripping hazards such as
railroad tracks, hose, cable, rough or uneven surfaces, and
projecting material.
2.7
Using, possessing, or being under the influence of any

intoxicant or illegal drug is prohibited at all times. Legal
drugs that impair or compromise work performance will
result in the worker being sent home.
2.8
Thoroughly cleanse the skin after working with oil, grease,

paint or chemicals. Failure to do so may result in skin
trouble.
2.9
Do not walk, crawl, or stand beneath suspended loads at

any time or pass between swinging loads and fixed objects.
OF
OF

2.19
2.20
Use the right tool for the right job; its easiest and safest.
Never hammer with a wrench, pry with a file, etc. Never
use a hardened steel hammer to strike punch dies, spindle
holder or other hard tools. Use a soft-head hammer. Be sure
wrenches are the proper size for the nut or head of bolt.
2.28
Stay well in the clear of loads being moved or handled by

any type of conveyance. Be sure to keep
your hands and body clear of moving
parts of machinery or equipment.
Rule 2.30
2.29
Check for the safety of all persons

before operating any machinery or
equipment.
Observe all signs, barricades, etc., concerning radiographic

and x-ray work.
2.21
When using a wrench, pinch bar or turning dog, position

yourself so that if the tool slips, you will not fall or
otherwise be injured.
2.22
When moving about the plant, be alert for locomotive

engines, forklifts, and other mobile equipment. Be particularly
alert for such equipment at blind corners or when crossing
railroad tracks. Where possible, allow at least a ten foot
clearance when moving or working around railroad cars.
2.23
If oil, grease, paint, or any other slippery substances are

spilled on the floor, wipe them up immediately, or use
approved absorbents, so that you or others will not slip or
fall.
2.24
Operate only equipment that your supervisor has authorized

you to use and only in the area in which you have been
directed to work.
2.25
All safety guards must be in place before operating any

machine or equipment. Only authorized personnel may
remove guards. They must be replaced as soon as the work
is completed and before the machine is put back into
operation.
2.26
Equipment must be locked out prior to starting any repairs

or maintenance. Never attempt to open the switch or operate
equipment that is under repair. (Repairmen testing
equipment may operate it with guards removed provided
adequate precautions are taken.) Make sure equipment is in
a zero energy state before repairs are started.
2.27
Never tie down, block out, or otherwise make inoperative

any type of safety device or guard.
OF
OBEY ALL
NO SMOKING
SIGNS
2.30
Never smoke in the templet, carpenter,

or paint shops, storehouse, oxygen or acetylene storage areas, oil house, gasoline or diesel filling stations
or
any
other
area
where
smoking
is
prohibited.
2.31
Do not attempt to brake or slow down moving machinery

with your hands or a makeshift device. Use the machine
brake if it has one, otherwise wait for it to stop of its own
accord.
2.32
Observe all caution and danger signs that are posted in the
plant or shop areas. Also pay attention to all warning
signals of cranes and other material handling equipment.
2.33
Avoid wearing oily or paint-soaked clothing. If your

garments become coated with such substances, keep away
from fires or operations where hot metal or sparks may
ignite the clothing.
2.34
When assembling steel members with crane or hoist, always

have sufficient number of bolts or pins in the piece to totally
secure it before unhooking the crane or hoist. Similarly,
when disassembling steel sections, always leave a sufficient
number of bolts or pins in the member to fully secure it
until the lifting equipment is completely hooked to the piece
and supporting the load.
2.35
All tools, whether company property or personally owned,

should be maintained in first-class condition. Tools with
loose or mushroomed heads or defective handles should be
repaired or replaced immediately.
2.36
If temporary scaffolds are needed, be sure the scaffold is

safe and adequate for the work. Use only approved type
scaffold boards. Inspect scaffold daily for defects. (See
Section 18 on Scaffolds.)
OF

2.37
When welding, burning, etc., in confined areas, special

means of ventilation may be required. Check with your
supervisor before working in such areas. (See Section 8 on
Arc Welding.)
2.45
Use caution when using a maul so that you do not strike

yourself or another. When driving out pins, knocking out
rivets, etc., be sure that you and other men are in the clear
in the event the maul misses or glances off the pin or material.
Rule 2.38
2.46
When handling material with a hoist or crane, avoid pulling

the material toward you. Push it away from you. You will
then be in a position to get in the clear should the need
arise.
2.47
When using air tools, always turn off the air at the outlet to
relieve pressure before disconnecting hose.
2.48
Never use your finger to check the alignment or condition

of holes in material.
2.49
When a drift pin becomes exceptionally tight or frozen in a

hole, it should be burned off and drilled out of the hole. Do
not continue to batter the pin with a maul and backout
punch or with pneumatic equipment, as this may shatter the
pin and cause further spalling.
2.50
Only qualified welders shall weld supports for staging or

scaffolding, or make welds attaching lifting hitches, lugs,
etc. Avoid any prying action on welds supporting scaffolding.
2.51
Make frequent inspection of drift pins, steel wedges and

striking tools for indications of wear such as mushrooming,
spalls, and cracks. Do not use any such tools that are in bad
order. Turn them in for repair or for scrapping. Do not weld
on hand hammers, sledges, wrenches, or any other hardened
steel tools.
DONT USE...
MAKESHIFT
2.38
WORK
PLATFORMS
Do not use a bolt keg, bucket or any other makeshift device

as a work platform or for access to other elevations. Use
ladders or approved type scaffolds for such work.
2.39
Observe all posted speed signs when operating mobile

equipment in the plant.
2.40
When using C or other types of holding clamps, be sure

they are sufficiently tight to prevent slippage of material.
Do not overtighten by using a pipe or wrench for additional
leverage.
2.41
Clamp or otherwise secure small or light material before

attempting to ream, drill, grind, etc.
Rule 2.42
ATTENTION:
ONLY
DO
2.42
2.43
2.44
AUTHORIZED
ELECTRICAL
PERSONNEL
WORK
!
2.52
Only authorized personnel are permitted to do electrical

work. Do not use electric extension cords, weld leads, etc.,
unless they are properly insulated.
Keep air hose, electric cable, etc., clear of hot slag or other
hot material.
2.53
Avoid using electrical equipment while standing on damp or

wet surfaces or when hands are wet. Always disconnect
cord at the receptacle or shut off current before attempting
to remove or replace a broken light bulb.
When using tubular or other types of tiered scaffolding, be

sure that each tier of the scaffold is tied to the structure to
prevent overturning.
2.54
The lending of tools, machinery, equipment, or other

company property to contractors working in the plant should
be avoided. Lending of such items should require the written
approval of the plant manager.
All electrical equipment must be properly grounded. Report

any defects to your supervisor.
OF
OF

2.55
When you are relieved from a job that has unusual, partially
concealed, or concealed hazards, immediately inform the
person relieving you that such hazards exist. Be specific.
2.56
Flagmen or watchmen assigned to protect personnel doing

maintenance work, etc., shall not engage in conversation or
other activities which would interfere with their assignment.
3. Cranes and Hoists

Use cranes as they are intended to be used. Be aware of
people near loads and do not move loads over people.
These instructions are for the purpose of increasing safety,

efficiency, and proper operations of cranes.
As a crane operator, you play an important part in operations
and have a great responsibility for the safety of others. Read these
rules carefully and become thoroughly acquainted with them. Keep
the book handy for ready reference.
Cooperate with the other men on the floor. See that your cranes
are kept clean and in good repair. Run them so as to prevent delays
and accidents. Suggestions for improvement of safety or efficiency
will be appreciated.
Cranes and Hoists 15
and vision tests are recommended. In some situations State

and or Federal law require physical examinations. Operators
should at least meet the minimum physical qualifications
specified in ANSI B30.2, Overhead and Gantry Cranes.
3.3
Board or leave your crane only at authorized locations.
3.4
When leaving the cab to get off the crane, place controllers
in the off position and open all switches.
3.5
While repairs are being made, or when you go on top of the

crane, place controllers in off position, open all switches,
and lock the main switch(es) where possible. Where not
possible, place danger signs.
3.6
Keep boom (beam) blocks and hooks a safe height above

the floor. During the time that the crane is unattended,
always have the load resting on the ground. (See Rule 3.33.)
3.7
Do not carry materials up or down a ladder; use a hand line,

attaching it to the structure, never to
your person. Keep both hands free
Do not
when going up or down ladders.
throw
or
An operator shall not eat or read
3.8
while actually engaged in operating

a crane. Liquids are not allowed in
the crane cab at any time.
drop
anything
from the
cranes cab.
Rule 3.9
Electric Overhead Traveling Cranes

(Cab Operated)
3.9
Do not drop or throw anything from

the cab. Horseplay is prohibited.
3.1
3.10
A
fire
extinguisher
shall
be
available in each cab. Familiarize yourself with its use.
3.11
Do not argue with men on the floor. Any disagreement must

be taken up with the supervisor.
3.12
You are responsible for the daily inspection and for reporting
unsafe conditions of your crane.
3.13
Report any electrical, mechanical or other defects

immediately to your supervisor. (Notify the relieving
operator of any problems.)
3.14
Examine and test controllers prior to placing them in

operation for each shift. They must be kept in good working
3.2
Only a regularly authorized and fully qualified operator

shall operate any cab-controlled crane. The operator must
pass the company medical examination, examinations to
prove that he can operate the equipment safely, and he must
be familiar with equipment parts and their uses. (Exception:
Learner may operate under direct supervision of authorized
operator and both should be in the cab at the same time.
Repairman or inspector may operate only if fully qualified
and authorized.)
Crane operators should have a pre-employment physical
examination and vision test. These tests should be repeated
on a regularly scheduled basis. Annual physical examinations
OF
OF

order. When controllers are equipped with latches holding

them in neutral position, these latches must be kept in
working condition.
3.18
Use standard signals as shown on the chart, Rule 3.77. Take

signals from only one man at a time. Ordinarily, lifts should
not be made without a signal. The member of the floor
crew who gives the signal must always make sure that
everyone is in the clear.
3.15
Cleanliness of crane, cab or pulpit is your responsibility.

Use containers for trash and waste. Unnecessary articles
should not be kept in or on cranes.
3.19
3.16
Test limit switches and brakes, and make a visual inspection

of cables at the start of each turn, and at any time they seem
not to be in good order.
Do not overload the crane or sling. When in doubt as to the

weight of a lift, consult your supervisor. (Also see Rule 3.78
for chart of alloy chain capacities.)
3.20
Do not close main switch until you are certain the

controllers are centered.
3.21
Move controller step-by-step, allowing motors to speed up

gradually, except for magnetic type controllers which are
timed and stepless.
3.22
Before starting to lift, center trolley and bridges over the

load. Side pulls must not be made except on instructions
from the supervisor. Do not use trolley or bridge motors to
pull railroad cars or buggies, unless the hoist falls are reaved
to pull the load with only vertical motion of the falls and
no side motion.
3.23
Do not make lifts or move your crane, regardless of signals,

if in your judgment someone is in a position to be injured.
Always obey an emergency stop signal.
3.24
Before lifting, determine so far as possible whether load is

properly hooked up. This is a joint responsibility of the
operator and the men on the floor.
3.25
Use your warning signal sufficiently to warn people in the

path of the load. Do not carry loads over people.
3.26
Do not use limit switch to stop hoist. Limit switches are for
emergency purposes only.
3.27
Do not operate hoist while limit switches are inoperative.
3.28
When limit switches are inoperative, only operate with

extreme care. The repairs to the limit switches should be
made as soon as possible.
3.29
If power goes off, immediately place controllers in off

position and pull out the switches.
3.17
Remove all loose objects, such as nuts and bolts, from

cranes and walkways. Report any defects or temporary
obstructions on walkways, stairs and ladders.
Rule 3.18
Use standard signals only.
OF
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3.30
Do not operate bridge or trolley until load is hoisted free of

the floor.
3.31
When moving trolley or bridge, keep loads and chains high

enough to clear all obstructions. Be sure that hooks are
fastened back into the chain or ring wherever possible. Do
not carry extra chains on the crane hook while moving
loads.
Floor Operated Cranes and Hoists

The following safety rules apply to power-operated cranes
controlled from a floor or platform, such as jib, monorail, overhead
travelling gantry, stiff leg derrick, hoists, etc.
3.43
Only qualified employees designated by the supervisor shall

be permitted to operate such equipment.
3.32
Do not set a load in an unsafe place. Loads should be set

down on blocking and chains pulled out by hand.
3.44
Do not make a lift or move equipment if anyone is in a

position to be injured.
3.33
Lower a load or magnet to the ground or floor before leaving

crane.
3.45
3.34
When two or more cranes are used in handling a load, time

your moves carefully to avoid possible confusion; use only
one signalman.
3.35
Do not bump another crane.
Familiarize yourself with the handles of control ropes so

that you can tell without looking which is the hoisting and
which is the lowering control. Each control rope shall be
marked to indicate the direction it controls. Similarly, when
using pendant controls, familiarize yourself with the
location and function of each button. The function of each
button should be indicated on the pendant control.
3.36
Do not allow anyone to ride on a load, a hook, a lifting

device, or chains.
3.46
3.37
Proceed with caution when a repairman places temporary

bumpers such as rail stops, on the track. The repairman
should notify you when the bumpers are placed. Warning
signs shall be placed on the ground and/or in another
visible location during repairs.
Never raise a load before chains are securely hooked and

the hookers hands and feet are free and in the clear. Do not
raise hooks before the unhooking is completed, and be
especially alert for lugs or brackets on the members that
may foul the hooks and cause the load to turn over.
3.47
Remember when a bundled load is picked up that the

material will tend to nest and create pinch points.
Similarly, when a load is landed, it will tend to roll or
spread out. Make certain you and others are alert and in the
clear of such movements. Keep all parts of the body away
from lifts being raised or lowered.
3.48
When starting or stopping movements of bridge and trolley,

move controls step by step, allowing motors to speed up or
slow down gradually, except for magnetic type controllers
which are timed and stepless.
3.49
When raising or lowering a load, proceed slowly and make

sure the load is under control.
3.50
Before starting to hoist, the trolley shall be centered over

the load.
3.51
Side pulls (where load block is not hanging plumb) are not
permitted except under specific direction of the supervisor.
3.38
Bumping into runway stops is prohibited.
3.39
Oxygen, acetylene or other high-pressure tanks are not to be

carried by cranes except when securely fastened in a
suitable carrier such as a cradle, or a platform with sides.
3.40
Wood blocks or short lengths of steel should not be carried

loosely on tops of loads.
3.41
Outside crane operators, when leaving at the end of their

turn, shall set the bridge brake or lock it in some approved
manner.
3.42
Capacities shall be marked on both sides of the equipment

where the letters and/or numbers can be easily seen from
the ground.
OF
OF

3.52
Do not use trolley or bridge motors to pull railroad cars or

buggies unless the hoist falls are reaved to pull the load
with only vertical motion of the falls and no side motion.
3.53
Take slack out of chains or slings gradually.
3.54
No load shall be carried over people.
3.55
If anyone is in the path of travel, stop and clear the area.
3.56
Do not allow anyone to ride a load, hook, lifting device or

chains, except for inspecting wire rope under controlled
conditions.
3.57
When gloves may interfere with safe operation of the

control buttons, they should not be worn.
3.58
Stand in the clear so that if load swings, slips or spills, you

will not be injured.
3.59
Make sure hook block and attachment will clear adjacent

equipment or material.
3.60
When unhooking material, always clear hooks and chains;

hold them away from material that can be tipped over if the
empty hook should catch.
3.61
Do not drag slings, chains, etc., along the floor.
3.62
Do not carry extra chains in the crane hook.
3.63
Wood blocks or short lengths of steel should not be carried

loosely on tops of loads.
3.64
Capacities shall be marked on both sides of the equipment

where the letters and/or numbers can be easily seen from
the ground.
3.65
Do not overload the crane, hoist, or sling. When in doubt as

to the weight of a lift, consult your supervisor. (Also see
Rule 3.78 for chart of alloy chain capacities.)
3.66
Such equipment shall not be used to carry oxygen,

acetylene, or other high-pressure cylinders unless carried in
an approved carrier.
3.67
Bumping into runway stops is prohibited.
3.68
Never bump another crane.
OF
3.69
A path should be provided for travel of the person operating

overhead travelling cranes with pendant controls.
3.70
Report to the supervisor defective or missing safety

equipment and mechanical or electrical defects without delay.
3.71
When letting go of control pendant, do not allow it to swing

freely. Avoid leaving operating ropes or control cables
hanging in passageways.
3.72
Unstable equipment located out of doors shall be secured

against wind movements.
3.73
Limit switches shall be checked at the beginning of each

shift or turn that the equipment is used. Do not use limit
switch to stop hoist. Limit switches are for emergency use
only.
3.74
Means for effecting an automatic return to the off position should be provided on controls of floor-operated cranes
and monorail hoists.
3.75
At all times, use due care and sound judgment in the

operation of such equipment to prevent injury to any
person, damage to equipment or material.
OF

Crawler, Locomotive and Truck Cranes
OF
3.76
The above signals apply to cranes moving on rubber tired

wheels or on caterpillar treads, as well as on tracks. When
operating near electric power lines extreme care should be
taken that the boom or load line does not touch the power
line. Operators should keep all parts of the equipment at
least 10 feet distant from a 50 kv line, and add 0.4 inches
distance for each 1 kv over 50 kv. Should the boom or
hoisting cable come in contact with a power line, the
operator should not climb down from the cab to the
ground while the rig is energized.
OF

Standard Crane Signals
HOIST. With forearm

vertical, forefinger pointing up,
move hand in small horizontal
circle.
LOWER. With arm

extended downward, forefinger pointing down, move
hand in a small horizontal
circle.
BRIDGE TRAVEL. Arm

extended forward, hand
open and slightly raised,
make pushing motion in
direction of travel.
TROLLEY TRAVEL.
Palm up, fingers closed,
thumb pointing in direction
of motion, jerk hand
horizontally.
STOP. Arm extended, palm

down, move arm back and forth.
EMERGENCY STOP. Both

arms extended, palms down,
move arms back and forth.
MULTIPLE TROLLEYS. Hold up

one finger for block marked
1 and two fingers for block
marked 2. Regular signals
follow.
MOVE SLOWLY. Use one

hand to give any motion
signal and place other hand
motionless in front of hand
giving the motion signal.
(Hoist slowly shown as
example.
MAGNET IS DISCONNECTED.
Crane operator spreads both
hands apart, palms up.
OF
OF

3.77
Material Handling 27
When handling material by crane, it is an absolute

requirement that the proper signal be given the crane
operator. Hookers-up should never overload. See that the
load is properly balanced before giving signal to craneman
to make any further move. Keep your hands in the clear at
all times and stand in a safe position as the load is moved.
Crane operators should watch out for persons working below
and keep loads, chains and hooks clear of men and materials.
4. Material Handling
Block stack and secure material to avoid tipping and
shifting.
4.1
Before entering any railroad car, see that the track is

protected with a blue flag or other approved type warning
device so that the railroad crew will not couple to the car.
Any applicable federal standards should be followed. No
one shall remove a flag or other approved type warning
device except the person who places it. (Exception: In the
event that such person does not remove his blue flag or
device and cannot be located, the supervisor, after making a
thorough check of the track in question, may remove the
flag or device.)
4.2
When working in drop-end gondolas, check the condition of

the latches and hinges on the end gates. Be sure the end
gate is properly secured so that it will not fall when material
is moved. Use extreme caution when raising or lowering the
end gates.
4.3
Employees shall not remain in cars when they are being

moved.
4.4
Do not stand or walk on sides of cars and do not attempt to

step or jump across the end gates when going from one car
to another.
4.5
Men must get out of the car when conditions of car,

material, or both do not enable them to assume a safe
position. Insofar as possible, hookers should move to the
opposite end of the car from that where material is being
loaded or unloaded after chains or other lifting devices are
properly hooked.
Alloy Chain Capacities

Working load limits for heat treated grade 80 alloy steel chains, in pounds
Single Types
S or C
90o
Double-Branch Type D
60o
45o
30o
15o
Chain Size
7/32
2,500
4,300
3,550
2,500
1,300
9/32
4,100
7,100
5,800
4,100
2,100
3/18
7,300
12,600
10,300
7,300
3,800
1/2
13,000
22,500
18,400
13,000
6,700
5/8
20,300
35,000
28,500
20,300
10,500
3/4
29,300
50,500
41,500
29,300
15,200
7/8
39,900
69,000
56,500
39,900
20,700
52,100
90,000
74,000
52,100
27,000
1 1/4
81,400
141,000
115,000
81,400
42,100
3.78
Refer to the above chart to check alloy chain capacities.

(See Rules 3.19, 3.65, and 4.11.)
OF
OF

4.6
When manually removing any blocking or other dunnage

from cars or trucks, employees must see that no one is in
the area where material will be thrown or placed.
4.7
When loading or unloading trucks, all drivers must be out

of the cab and in the clear of any loading operations, except
when the cab is equipped with a protective roof. Similarly,
outside truck drivers are not permitted on the bed or trailer
of the truck during loading operations. If the driver must
inspect the load and tie-down arrangement, all loading
operations must be suspended during this inspection.
4.8
In carrying loads with other workmen, always give adequate

warning of any action on your part, such as dropping your
end of the load. Keep in step; it makes the load easier to
handle.
4.9
When lifting, bend the knees, elbows tight against the body,
and keep the back nearly vertical. Then grasp the object
firmly and raise by straightening the legs. In this way, the
work is done by the leg muscles and strain is relieved from
the weaker back muscles. Always get help for lifting where
the load is too heavy for one person.
4.10
When piling material, build a solid sturdy pile. Make sure

there is a firm foundation and do not pile the material so
high that an unsteady pile results. In piling pipe, round bars,
or other materials that may roll, be sure to use a sufficient
chock at the base of the material.
4.11
Determine the weight of the load and select the proper size
and type of hooks, chains, etc. Be familiar with capacity
charts of such equipment. (See Rule 3.78 for chart of alloy
chain capacities.)
4.12
Always stand clear of the load so that if it swings, slips, or

spills, you will not be injured. Do not stand between material
that could be struck by a moving load.
4.13
Keep hands and feet clear of pinch points. Be alert for

nesting or rolling of material as it is raised or lowered or
when landing on skids, blocks or buggies.
Rule 4.9
Equalize the strain.

OF
OF

Rule 4.14
Always grasp above the load.
4.14
Always grasp chains or slings above the load (above the

hook if possible) when holding slack before hoisting. If
necessary to guide load with your hand, be sure your
fingers and hands are on the outside of the material or
otherwise positioned so that they cannot be caught inside
the material or between the load and adjacent material.
OF
4.15
Be alert for kinks in chains. Knots in chains are not

permitted. Protect chains or slings with softeners where they
pass over sharp corners or edges.
4.16
Be sure that all chains, hooks, shackles, etc., are in good

condition. Always use proper bolt or pin with shackles. Do
not use common fitting bolts. Inspect frequently and report
any defects to your supervisor.
4.17
Never land material too close to ends of skids or other supports

where it may fall. Keep bolts or pins in the ends of skids
or provide other means to prevent material falling off.
4.18
Moving material on skids requires care. Moving one piece

may cause other pieces to fall. It is the duty of the
signalman and operator to see that no one is in danger.
4.19
Stack detail material so that it will not fall.
4.20
When necessary to step over skids or to walk across

material on skids, do so with caution. Avoid bumping your
shin or knee and be alert for bolts, dogs, pins, blocks, oil,
etc. that may cause you to fall.
4.21
When moving shop buggies by hand, be certain that feet

and hands are in the clear. Do not make contact with other
loads to stop buggies. Push buggies from rear wherever
possible, and face direction of travel.
4.22
When taking loaded buggies through doorways of shop or

congested areas, always send a man ahead to clear the track
and warn others of the approaching buggy.
4.23
Load shop buggies in a safe manner. Never exceed safe

heights and always use side stakes, keeper plates, pins, or
other means on buggies to secure the load.
4.24
Be alert for any unexpected turning or movement of

suspended loads or stacks of steel.
4.25
Use blocking as required: Minimum of 4 x 4 on angles,

beams, tees, channels, zee bars, etc. Be sure material is
adequately supported on skids, blocks, or buggies. Use only
hardwood blocking that is in good order.
4.26
In stacking material, blocks must be placed directly over

each other and insofar as possible at right angles to the
material. Blocks must be of sufficient length and uniform
OF

size to hold the stack securely, but not long enough to

engage other stacks. Avoid the use of small multiple lengths
of blocking to make up a single length.
4.27
In stacking material, if at all possible, keep material of the

same size stacked together. This makes a more stable pile
and conserves space.
4.28
Do not pile extra-long material on top of short material.

Not more than 25 percent of the total length of the top
material should overhang the material under it.
4.29
If necessary to pile small beams on top of larger beams,

blocks must be placed between the flangesnot across the
flanges.
4.30
Using wood blocks for bridging between individual

members or between stacks of material is prohibited.
4.31
When stacking a heavy lift of beams or girders with the

flanges horizontal, always use 6 x 6 or two 4 x 4 blocks
side by side at each blocking point.
4.32
Do not leave blocking, chains, cable, hose or tools lying

about the floor after you are finished with them. Keep aisles
and areas between skids clear and free of tripping hazards.
Maintain good housekeeping standards at all times.
4.33
Use a hoist or crane where loads are too heavy to handle by

hand.
4.34
Maintain a good handhold and footing when handling material

by hand. Be alert for sharp edges and burrs or for material
that may be hot from burning, welding, grinding, etc.
4.35
When turning material with a hand dog or pinch bar,

position yourself so that if the tool slips you will not fall or
otherwise be injured. In turning material on skids, always
turn material in a direction away from yourself.
4.36
4.37
Keep the areas near railroad or industrial tracks clear. A

clearance of 30 inches from industrial tracks and 5 feet
from the nearest rail of a railroad track must be maintained.
When handling material by crane, standard crane signals
must be used. Always be sure that the crane operator can
see you. (Refer to standard crane signals, Rules 3.76 and
OF
3.77.) Only one person at a time should give hand signals

to the crane operator.
4.38
Be sure that loads will clear all equipment and other

obstacles before giving the crane operator a signal to move.
See that other employees are in the clear before moving
any loads.
4.39
Avoid overloading equipment or lifting devices. Place chains

and hooks so that loads are equally distributed and
balanced. The block and trolley must be directly over the
load. See that loose bolts, washers, nuts, blocks, etc., are off
loads before they are moved.
4.40
Be certain that all plate hooks, dogs, etc., are properly

hooked before allowing loads to be hoisted. Plate clamps,
alligator clamps, grab clamps or screw clamps must not be
used to make a vertical lift of more than one plate or piece
of steel at a time.
4.41
Use clamps, grabs and hooks as intended.
4.42
Use double chains when lifting rods or pipe and see that
each chain is properly secured around the load.
4.43
Loads must not be carried over railroad cars or other vehicles

in motion. No load should be carried over people.
4.44
When unhooking material, be sure the chains are completely

clear of the lift before signaling the craneman to hoist. When
load is set down, allow sufficient slack in the chains to
permit the load to settle. Do not reach under the load to
remove the chains. Pull the chains free of the load by hand
before signaling to hoist. Be alert for lugs, brackets, wing
plates, etc., on the blind side that may engage hooks or
chains and tip the member over.
4.45
Brace or clamp girders and other high members, which are

in an upright position, to the skids or rails before releasing
the crane hooks.
4.46
Before cleaning, painting, heating, or straightening girders

in upright position, be sure they are properly braced or
clamped to prevent overturning. A minimum of 4 clamps is
required. Additional clamps should be used on extra-long
pieces.
OF

4.47
Keep bolts, pins, washers, etc., in containers. Do not allow

them to accumulate on the shop floor.
4.48
Do not stack material across the sides of trays, or from one

tray to another.
4.49
Do not make side pulls with a crane or hoist except when

properly authorized by your supervisor. Do not use trolley
or bridge motors to pull railroad cars or buggies unless the
hoist falls are reaved to pull the load with only vertical
motion of the falls and no side motion.
4.50
Whenever possible, blocking must be in place before crane

moves into position to lower load. When placing blocks
under loads, hold the blocks so that your fingers are to the
sides of the block and not between the block and the load.
4.51
It is prohibited to ride on crane hooks, chains, lifting devices

or loads being carried by cranes, except for inspecting wire
rope under controlled conditions,
4.52
Do not pile material in aisleways or passageways. Keep

material behind designated aisle lines.
4.53
Hookers and material handlers are responsible for the weight

of the lifts moved by cranes. They must familiarize themselves with the capacity of the cranes; they must be able to
estimate the weight of lifts; they must know the capacity of
hooks, clamps and chains, etc., used. As an additional
precaution, crane operators are instructed not to move a lift
which, in their opinion, is unsafe, but must immediately
notify the supervisor.
4.54
When operating a crane in the vicinity of gantries, hoists or

other projecting handling equipment, always check to see
that the crane and load will clear the equipment before
making any moves.
4.55
Insofar as possible, beams should be stored in the various

shops with the web horizontal rather than vertical. This
makes for more stable piling.
4.56
When separating or spreading material, use a pry bar or

spud wrench rather than your hands. Where beams or other
materials are nested together, stand at the ends so you will
be in the clear if material falls or turns over.
OF
Punching and Shearing 35
4.57
When loading material on trucks or trailers, use temporary

sidestakes, chocks or other suitable means to contain
material until chain binders are fastened. Stand clear of
binder handle. Do not add pipe extension to handle.
4.58
Small or loose material must be wired, banded or placed in

trays or on pallets before sending from shops for shipping
or painting.
4.59
When working around piles of beams or other material,

avoid crossing over skids or between stacks of material. Use
regular walkways or cross at ends of skids.
4.60
Tag lines should be used for turning and handling of large

members, and for any other situations where supervision
deems necessary.
5. Punching and Shearing

Inspect equipment regularly. Do not load equipment
beyond its capacity.
5.1
Make certain guards are in place on all foot switches on

punches.
5.2
Know the capacity of your machine with respect to

thickness of material and sizes of holes.
5.3
Frequently check your machine for defective dies and

punches or shear blades.
5.4
Lock out main switches and safely block the treadle before
changing punches or dies, or shear blades, or before making
any repairs.
OF

Reaming and Drilling 37
5.5
When a machine has been turned off for repairs or

adjustment, lockout devices or tags must be used to make
sure it will not be turned on except by the repairman.
5.15
Stay within the capacity of all hoists and lifting devices,

chains, hooks, etc. be familiar with capacities for such lifting
equipment.
5.6
Be certain that the punch and bottom die are in proper

alignment to avoid breakage. Also make certain the setscrew,
which holds die in block, is tight.
5.16
5.7
Punches that are broken off in material should be burned

out when possible. Do not attempt to use your hands to
remove the broken punch. Do not attempt to drive out such
pieces with a maul and backout punch or drift pin.
When using special grab hook chains or other equipment for

rolling material, make certain the hook is properly secured.
Be especially alert when slacking off to reposition the chain
or hook.
5.17
Load material safely so that it can be unloaded and handled

safely at the next workstation.
5.8
Notify your supervisor if sound in punching is a sharp,

ringing one. The steel may be silicon or other hard alloy
that requires special attention.
5.9
Keep fingers out of the area of cutting edges and other

exposed moving parts.
5.10
When punching detail on close gage, be sure you grasp the

piece at the sides and keep your fingers clear of pinch
points. For close work use templet clamps.
5.11
After positioning material for shearing, keep hands and

fingers clear while blade is cutting. Be alert for whipping
ends, etc.
5.12
Hands must not be used to remove chips, rust or other

material from the machines. Use a brush or other suitable
means.
5.13
Keep machinery clean, free of tools, slugs, rags and scrap.
6. Reaming and Drilling

Do not misuse machinery. Do not use equipment that
does not appear to work as intended.
6.1
Check the machine frequently for any defects and turn in

any equipment that appears to be in bad order. Check the
electrical cable for breaks or loose connections, proper
grounds, etc. Be sure that the handles are tight and free of
any breaks.
6.2
Poor operation may indicate that the tool is defective.

Electrical shorts and failure of the machine to stop when the
switch is turned to off position are specific examples of
defective equipment.
6.3
Do not use a bit with dull edges, burrs, or nicks. Such bits
should be turned in to the tool room.
6.4
When using gantry drills or reamers, be sure that everyone

is in the clear before moving the gantry.
6.5
To prevent kickback in the event the bit lodges, safety bars

should be used on portable reamers, where possible.
Rule 5.14
Keep floors clean of tripping hazards.
5.14
Keep the floor around your machine clean, dry and free of
tripping hazards.
OF
OF

6.6
Portable reamers should have a deadman (constant pressure)

control.
6.7
Never wear any loose or ragged clothing while reaming,

and keep all parts of the body away from the rotating spindle
and bit. Trouser guards should be worn as needed by gantry
drill or reaming operators.
6.8
Never fasten the switch on a reamer or drill in the on

position.
6.9
Never use your hands to guide the reamer bit into the material
or to slow down the rotation of the bit or the reamer spindle.
Rule 6.10
Use two people on a reamer.
OF
Reaming and Drilling 39
6.10
Two people are required for the operation of the standard

hand reamer. Never attempt to operate with only one person.
Always coordinate your movements so that the machine is
under complete control at all times. Maintain a firm grip on
the handle, good footing, and be alert for sudden kickbacks
of the machine.
6.11
Handle reamers with care. Never drop them or land other

material on top of reamers, as such practices will easily
damage the equipment.
6.12
Never attempt to place or change a drill or reamer while the

spindle is still revolving.
6.13
Be extremely cautious when necessary to work above floor

level, such as when working from scaffold or from the top
of fabricated members. Make certain that your work
platform or area is adequate in every respect. A safety bar
should be used under these conditions.
6.14
Use a stick to remove chips or cuttings from rotating drills.

Never use your hands.
6.15
When reamers are not in use, they should be placed on

stands or at other designated spots.
6.16
Keep bit straight in hole while entering, reaming or drilling,

and removing, so that unit will not stick or bind.
6.17
Do not remove one handle for close corner reaming without

permission from your supervisor. When one handle is
removed, the other must be supported against steel to
prevent its turning.
6.18
Clamp or otherwise secure small or light material before

attempting to ream or drill. Never attempt to keep the
material in position by holding it with your hands or by
standing on it.
6.19
Do not apply excessive pressure so as to speed up the

cutting action of the bit, as this will often cause the bit to
lock in the hole. Apply only sufficient pressure so that the
tool cuts in a normal manner.
6.20
When drilling or reaming through exceptionally thick

material, the bit should be removed occasionally and the
OF

Fitting and Bolting 41
chips cleaned out. If chips are allowed to accumulate, the

bit may become jammed.
7. Fitting and Bolting
6.21
If the machine starts to vibrate excessively, it should be

stopped, repositioned, and started again.
Use tools of the correct size. Control detail material

that can fall or tip.
6.22
Electric cables and extension cords should be placed where

they will not present a tripping hazard or be subjected to
damage from mobile equipment.
6.23
Never attempt to remove a broken drill or reamer bit with

a backout punch, center punch, drift pin or hammer.
6.24
Use safety chain on magnetic drills when drilling in a

horizontal position.
6.25
Do not use a steel hammer or other hard object to seat the

bit and socket. Use a wood block or a soft hammer to wedge
the socket and bit into the machine. Be sure that the flat
edge of the socket is in proper alignment with the flat edge
of the reamer or drill bit.
6.26
Use properly fitted wrenches and do not work with wrenches

that have worn or sprung jaws. Also, inspect the fitting bolts
for worn or misshapen nuts and heads from which wrenches
are likely to slip. Do not use a wrench as a hammer.
6.27
In horizontal reaming, the reamer handles should be held at

or near waistline elevation. If possible, avoid reaming with
handles above the shoulders or overhead. In so far as
possible, both workers should stand at the same elevation
and be approximately the same height.
6.28
When reaming into a box section, be sure no one is inside

who could be caught when bit goes through.
7.1
Use only proper size wrenches. Return misfit or defective

wrenches to the tool room for replacement. Do not work
with wrenches that have worn or sprung jaws. Do not alter,
repair, or allow any welding to be done on fitting wrenches.
Inspect fitting bolts for worn or misshapen nuts and heads
from which wrenches are likely to slip. Do not use a wrench
as a hammer.
7.2
Keep material piled in an orderly manner. Do not leave your

tools lying around for others to trip over.
7.3
If temporary scaffolds are needed, be sure the scaffold is

safe and adequate for the work. Use only approved scaffold
boards. Inspect scaffolds daily for defects. The supervisor
prior to use must approve each scaffold. (See Section 18 on
Scaffolds.)
7.4
When using a hydraulic jack, be certain that it is secure and

centered on the blocking and load. Keep the jack perpendicular to load to avoid kickout or slipping. Be sure the
footing and ram are free of oil or grease. (Refer to Section
19 for rules concerning use of jacks.)
Rule 7.5
Use caution when placing detail material.
OF
7.5
Place detail material so it will not slip or fall.
7.6
When assembling girders, etc., in an upright position, the

stiffeners should be placed on the floornot leaned up
against the web or other material.
7.7
Clamp or otherwise secure fillers to hold them to web plates,

preparatory to bolting or drifting. Never remove the last bolt
OF

Arc Welding 43
holding a fill to web plate until you have checked the area
and are sure that everyone is in the clear.
7.21
Open-end or spanner wrenches with sprung openings shall

not be used.
7.8
Detail material such as stiffeners and fillers that are too

heavy to safely handle by hand should be handled by crane
or hoist.
7.22
7.9
Maintain good handhold and footings when manually

handling detail material. Be alert for sharp edges and burrs.
Leverage devices, such as pipe extensions, shall not be used

to give greater leverage to an open-end or spud wrench. If
the wrench is designed for use with a pipe extension, only
an approved length of pipe shall be used.
7.23
Open-end wrenches shall have jaw openings that match the

bolts being tightened. Shims shall not be used to adjust the
jaw opening.
7.10
Check grinder for guard and grounding before using and be

sure the cables do not present a tripping hazard for you or
others.
7.11
Open valves gradually on air hose or tools so as to avoid

sudden kickback.
7.12
When bolts or drift pins are being knocked out, care shall
be taken to keep them from falling.
7.13
Bolts, nuts, washers, and pins shall not be thrown. They

shall be placed in bolt buckets or other approved containers
and raised or lowered by using a line when they cannot be
passed from hand to hand.
7.14
Impact wrenches shall be provided with a locking device for

retaining the socket.
7.15
Never use wire, nails or spikes to hold the socket on impact

wrenches. Instead, use the standard pin or other locking
device provided.
8. Arc Welding
Avoid shock and heat hazards. Safeguard eyesight.
STOP :
Welders Study Section 8!
7.16
Impact wrenches must be disconnected from the power

source before they are adjusted or repaired.
8.1
Keep gloves, shoes, clothing and other protective apparel as

dry as possible, so as to avoid electric shocks.
7.17
Airline hose sections shall be tied together or a quick

disconnect couplet shall be used to join the sections.
8.2
7.18
Containers shall be provided for storing or carrying bolts or

drift pins.
When welding in confined areas, special means of

ventilation may be required. Check with your supervisor
before working in such areas.
8.3
7.19
Employees shall be instructed in the proper care and use

of bolting equipment and in the proper method of bolt
installation and tightening.
7.20
The air hose shall not be used to pass impact wrenches from
one employee to another. If the impact wrench cannot be
handed from one employee to another, a rope shall be
provided to pass the wrench.
When welding material that may give off dangerous toxic

fumes such as lead alloy and paint. Bureau of Mines or
NIOSH approved respirators must be worn unless the fumes
are adequately removed by artificial ventilation. Check with
your supervisor before welding under such conditions.
8.4
Welding equipment should be used only with in its rated

capacity.
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8.5
Welding should be stopped if any abnormal equipment

condition arises. Work should not be resumed until
authorized by the supervisor.
8.6
Only qualified and authorized persons shall repair welding

equipment.
8.7
Contact lenses shall not be worn while welding. (Also see

Rule 1.10.)
8.8
Welders are required to wear approved safety glasses in

addition to welding helmet. When welders are regularly
working very close to one another, it may be desirable to
use safety glass lens having a shade value of 1.5 or 1.7.
(Note: These shaded lenses have equal resistance to ultraviolet light transmittance, but they have a loss of 38% and
50%, respectively, in visible light. Thus, while some glare
reduction will be achieved, the visible light reduction may
present an unacceptable, unsafe condition.)
8.9
8.10
Welders should inspect the area in which they are to work

to be sure that it is clear of objects which might fall or
which otherwise might cause injury when vision is obstructed
by the welding helmet.
Welders must use caution to avoid electric shock from
welding equipment and from other sources. When handling
the electrode holder or cable, the welder must avoid
electrical contact between his body and objects connected to
the work or ground of the welding circuit. Rules 8.11
through 8.16, below, are especially important in preventing
electric shock.
8.11
Welders must not stand in water while changing welding

electrodes in the electrode holder.
8.12
Welders must not handle the electrode holders from two

different machines at the same time.
8.13
Electrode holders must not be dipped in liquids to cool

them.
8.14
When a welding machine is in operation, the cable should

not be looped over the shoulders or around any part of the
body.
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Arc Welding 45
8.15
Welders should not wear rings, metal wristbands, or other

jewelry.
8.16
Welders shall not change polarity of the welding machine

while welding is in progress.
8.17
When welders carry electrodes on their person, they should

be in a proper container.
8.18
Electrodes shall be removed from the electrode holder when

welding is interrupted for other activity or when the
equipment is left unattended.
8.19
The power supply to welding machines or welding

transformers shall be shut off when work is completed,
when the equipment is to be left unattended, or when the
equipment is to be moved.
8.20
Any discomfort or injury to the eyes or other parts of the

body caused by exposure to ultraviolet rays from the arc or
by welds slag or scale should be reported to the supervisor,
and the welder should obtain medical treatment.
8.21
When welding is done in areas not ordinarily used for such

work, screens should be used to protect other workers and
passersby from the radiation from the arc. Persons in the
vicinity should be warned against watching or looking
directly at the welding arc.
8.22
Welders should place welding cable, ventilating hose, and

other equipment so that it is clear of high voltage power
cables, steam lines, moving shafting, ladders, and stairs.
8.23
Welding current return circuits or grounds must carry their

current without hot or sparking contacts, without heating of
conductors or their joints, and without passage of current
through equipment or structures which might be damaged or
made unsafe by the welding current or its voltage. In
particular, welding current must not be allowed to pass
through:
Acetylene, fuel gas, oxygen, or other compressed gas
cylinders.
Tanks or containers used for gasoline, oil, or other
flammable material.
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Pipes carrying compressed air, steam, gases, or

flammable liquids.
Conduits carrying electrical conductors.
Chains or wire ropes.
Metal handrailings or ladders.
Machines, shafts, bearings, or weighing scales.
Flame Cutting (Burning), Cambering, and Heat Straightening 47
9. Flame Cutting (Burning),

Cambering, and Heat
Straightening
Wear PPE meant for cutting. Handle cylinders
carefully.
8.24
Welding electrode stubs must not be thrown on floors, decks,

staging, or scaffolds. They shall be collected in a container
for safe disposal.
8.25
Welders must avoid starting fires. Before starting to weld,

the vicinity in which the welding is to be done must be
inspected carefully. Combustible material shall be moved
away or shielded from all heat with fireproof material.
Where welding is being done on a floor, deck, wall, bulkhead, or other partition, the welder must be sure there is no
fire hazard on the opposite side. A fireguard shall be posted
if any hazard is present.
9.1
Use standard burning goggles or approved burning face

shield recommended for this type of work. (Refer to Rule
1.8 on eye protection.)
9.2
Wear proper gloves and shirts with long sleeves when

burning. High-top shoes or boots and trousers without cuffs
are recommended. Clips or elastic bands around the bottom
of the trousers will help prevent slag entering the shoes.
Avoid burning while wearing ragged or oily clothes.
8.26
No welding shall be done in or near areas where there may

be flammable materials, explosive gases or vapors.
9.3
8.27
No welding or preheating is to be done on or in any tank,

pipeline, compartment, or container which has contained
flammable material until it has been thoroughly purged and
cleaned, and approval given by your supervisor. Any
openings that might allow flammable gas or vapor to leak
into the structure shall be sealed securely before any welding
is started. Ventilation sufficient to keep the space purged of
flammable gases or vapors shall be supplied when any
welder is required to work inside such a tank, pipeline,
compartment, or container. If welding is to be done only on
the outside of the structure, the interior shall be purged
continuously with steam or inert gas to prevent any fire or
explosion.
Respirators suitable for the type of work being performed

should be worn, as recommended in Section 1 on Personal
Protection.
9.4
Should the material you are cutting give off irritating fumes
or smoke, notify your supervisor immediately.
9.5
Use the proper names of gases when referring to them: that

is, acetylene, oxygen (not air), MAPP, carbon dioxide, etc.
9.6
Keep burning hose and other equipment arranged in an

orderly manner, so that they will not be knocked over, run
over, or present a tripping hazard.
9.7
Use no oil, grease, or any other lubricant on apparatus.

Burning equipment does not need lubrication. Oil or grease
in the presence of oxygen under pressure may react
violently. Do not handle cylinders or apparatus while hands,
gloves, or clothing is greasy.
9.8
Inspect the torch, hose, regulators, etc. frequently. Do not

attempt to tape burning hose. Defective equipment should
be turned in for replacement or repaired by qualified
personnel.
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9.9
Use leak test solution (soapy water) to test for leaks.
9.10
Do not use compressed air, gas or oxygen to blow out

burning hoses, clean burning equipment, or purge gas
pipelines. Ordinary compressed air may contain moisture
and oil.
9.11
Never interchange regulators, hose, and other burning

apparatus. Use equipment according to manufacturers
recommendations.
9.12
Make certain that all connections are secure, and all fittings
tight. Dont force connections that do not fit.
9.13
Cylinders shall be repaired only by the manufacturer or

qualified vendor.
9.14
Only trained personnel should manifold cylinders.

Manifolds should be installed per manufacturers
instructions.
9.15
Do not leave the valves of empty cylinders open. Close the

valve before replacing valve cap.
9.16
All cylinders, empty or full, should be stored away from

open flame, furnaces, radiators, flammable and volatile
liquids, or other hot places. In hot weather they should be
protected from the suns rays as much as is practical.
9.17
Cylinders should be stored, transported and used in an

upright position. In storing, secure them with a chain or bar
to prevent toppling. See that protection caps are in place
when cylinders are not in use or are being moved. (Use of
upright burning buggies is recommended.)
Rule 9.20
Transport cylinders with care.
9.20
Cylinders should not be lifted or transported by slings,

magnets, or hooking onto cap. Use a cradle, platform, buggy,
or other safe, suitable means.
9.21
Never use cylinders as rollers or supports. These are devices

that may be easily damaged and are not designed for such
use.
9.18
Cylinders containing different gases should be stored in

separate locations or separated by flameproof dividers.
9.22
9.19
Cylinders should not be handled roughly; do not drop them

or permit them to fall or strike other cylinders or material
violently.
Do not allow cylinders to come in contact with live wires

or ground wires from electrical equipment. Welding current
must not be allowed to pass through cylinders.
9.23
Never permit any open flame to come into contact with any
part of a cylinder. Never open the valve on any cylinder
near sparks, flame, or other welding and cutting work.
9.24
Leaking cylinders should be: (1) kept away from flame,

sparks, and other potential fire sources; (2) taken outside
building away from possible sources of ignition; (3) properly
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tagged to explain trouble; and (4) immediately reported to

your supervisor.
9.25
If a cylinder catches fire at the valve, the valve should be

closed, if possible. If it catches fire at another point, the
area should be vacated and the fire department called.
9.26
Never use gases from the cylinders without using regulators

to reduce the pressure.
9.27
Before installing the regulator, crack the valves of the

cylinders momentarily to clear the valves of any dust, dirt,
or other foreign material that may have accumulated during
storage.
9.28
If a regulator shows excessive creep (pressure building up

when torch valves are closed), close cylinder valves and
have regulator repaired.
9.29
Keep a clear space between cylinders and the work so that

regulators and cylinder valves can always be reached quickly
in event of trouble.
9.30
Do not pull or jerk on the regulator with the hose when

moving to a new position.
9.31
Never use a torch to warm up freezing regulators.
9.32
Never test pressure by holding torch tip against your hand

or fingers.
9.33
Before lighting the torch, when burning or cambering, always

open valves and check gauges to insure that you have proper
pressure. Lack of pressure in either line may result in an
explosion in the hose.
9.34
Before lighting the torch, look around to make sure that

flame, sparks, or hot metal will not be likely to start a fire.
Keeping the area clear of paper, rubbish, and other flammables
will help to prevent fires.
9.35
Make certain that hot slag or sparks will not fall on or strike
people, scaffold ropes, safety lines, any hose, flammable
substances or materials. Protective shields should be used
when necessary.
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9.36
Use a standard friction-spark lighter or stationary pilot flame

to light torch. Never use a match, cigarette, cigarette lighter,
etc.
9.37
Do not re-light torch on hot work in a pocket or small

confined space. Use the lighter. (In re-lighting a torch from
hot metal, the gases do not always ignite instantly, and, in
a small pocket, ignition may be violent.)
9.38
Never leave a torch inside a vessel or closed container. Do

not take cylinders into confined spaces. A leak might result
in a disastrous explosion or fire.
9.39
When stopping work for an hour or longer, close the cylinder

valves and release the pressure in the regulators. Make
certain the torch is out and valves are closed tightly when
its not in use.
9.40
Never burn on any closed container that has held flammable

substances, such as gasoline, oil, or solvents. Vapors
accumulated or generated within such containers may cause
a violent explosion. All containers and gas lines must be
fully purged before any burning is started.
9.41
Do not burn over or near spray painting of any kind, whether

or not the sprayed material is flammable. The same
precautions apply where cleaning solvents or other
flammables are being used.
9.42
When burning any piece, be sure you will not fall when
cutting is being done or is completed. Be sure that piece
burned off will not fall or swing and strike you or others.
Do not saw off the limb you are sitting on.
9.43
Never do any burning on a concrete floor, because of the

possible explosion of the concrete. If practical, raise the
material to be cut at least 12 inches above the concrete or
shield the concrete from the flame.
9.44
Never do any cutting or burning with material lying on the

cylinders.
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Oxygen, Acetylene or Other Flammable Gas

Distribution Systems
9.45
No repairs or alterations shall be made on pipelines except

by authorized employees under direct supervision.
9.46
When performing any work near these lines, be extremely

careful that the lines are not damaged. Be extremely careful
when using a burning torch so as to avoid cutting into lines.
9.47
Under no circumstances shall these lines be used as

supports for hoisting material, nor shall other attachments
be made with out proper authorization.
9.48
In case of an emergency, turn off the nearest valve upstream

from the source of trouble.
9.49
When a burning station is not in use, the valve should be

closed and plug cap replaced.
9.50
Avoid directing a stream of sparks or molten metal against

the pipeline or burning stations.
9.51
Use a proper regulator when using pipelines.
9.52
Do not attach any equipment to the burning stations that is

not fitted for that purpose.
9.53
Open flames and fires, etc., are prohibited in the vicinity of

oxygen, acetylene, or other flammable gas pipeline stations.
9.54
Fuel gas leaks at the burning station can usually be detected

by odor. Shut off gas and report any leaks immediately to
your supervisor.
Chipping and Grinding 53
10. Chipping and Grinding

Wear eye protection. Inspect tools and wheels daily.
Treat bits and wheels with care.
Chipping
10.1
Inspect chisels and gun daily. Turn in any defective equipment

for repair. Oil gun at least once a day.
10.2
Inspect air hose for any loose connections. Keep hose out
of aisles and in orderly fashion to prevent a tripping hazard.
10.3
Where practical, shields should be set up to protect persons

in the vicinity of a chipping operation from flying chips.
10.4
Never point a chipping hammer at anyone. Never throw the

tool down or use it as a hammer to remove chipped metal.
10.5
Open the valves gradually on air hose or tools so as to

avoid sudden kickback.
10.6
Remove the chisel from the gun when not in use.
10.7
Maintain safe footing and be sure that the material you

are chipping is clamped or otherwise secured to prevent
movement.
10.8
Be alert for slippery spots when working inside of boxed

sections, cylinders, etc.
10.9
When chipping tack welds apart, hold chisel so that fingers

will not be caught when the weld breaks.
Grinding
10.10 All abrasive wheels shall be equipped with an approved
type guard. Inspect guard daily; have defects corrected before
using the grinder. If the grinder cannot be used to grind a
fillet, a different tool must be used. Guards should not be
removed from any equipment while in use. Guards must be
replaced immediately upon completion of that portion of the
work.
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Chipping and Grinding 55
10.11 New abrasive wheels and guards are to be installed by

authorized employees only. A tachometer should be used to
test the machine speed each time a new wheel is installed.
Tests should be made with wheel inside a test box.
10.12 The governor on each grinder should be checked a
minimum of once each month by an authorized employee.
10.13 Inspect the abrasive wheels daily for any cracks or defects.
Where any damage is evident, the wheel should be removed
from service.
10.14 If there is any indication of excessive speed or malfunction
of the governor, the tool must be taken out of service
immediately. All repairs must be made only by authorized
employees.
10.15 Avoid dropping the grinder on the floor or bench, bumping
against material, or other careless handling which may
damage the wheel. A wheel that has been dropped should be
checked for damage. If in doubt, return the wheel to be
checked inside a test box.
10.21 Oil the governor daily or as recommended in the tool

lubrication instructions.
10.22 See that the wheel is properly dressed at all times. Do not
use a wheel with broken edges.
10.23 Do not stand directly in front of a stationary grinder when
first starting up.
10.24 The maximum clearance allowed between the wheel and the
tool rest is 1/8 inch. Do not attempt to make any
adjustments to the tool rest while the grinding wheel is in
motion.
10.25 In dressing tools, be sure to hold the tool to be ground
firmly against the tool rest in front of the wheel. Side
grinding is prohibited unless grinder is designed for that
purpose.
10.16 Make smooth grinding contact with the work. Avoid

bumping or impact action. Dont jam portable grinder into
corners, etc.the wheel may shatter.
10.17 Never force grinding so that the motor slows noticeably or
the work gets hot.
10.18 When grinders are not in use, they should be stored in a
safe place, preferably on a storage stand. They should not
be stored on a raised surface where someone can trip over
the air line and knock the grinder to the floor.
10.19 Allow the wheel to run idle a few seconds before applying
to the work.
10.20 Keep in mind that the most constant causes of wheel
breakages are:
a. Improper mounting of the wheel.
b. Improper speed.
Rule 10.26
c. Abusive operation.
Safety shields must be present when using

grinders.
d. Careless handling and storage.
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Machine Shop 57
10.26 Safety shields must be present as recommended by the

manufacturer when using stationary grinders.
11. Machine Shop
10.27 Do not wear gloves when using stationary grinders.
Keep hands and loose clothing away from moving or

rotating equipment.
10.28 Repairmen or toolroom attendants should observe the

following:
a. Ring Test and inspect each wheel for cracks or breaks.
Never use a stone that has any indication of cracks or
other damage.
11.1
Stop all machines before adjusting, cleaning, oiling or

repairing.
11.2
Avoid talking with or otherwise distracting an operator of

equipment while it is in operation.
11.3
Use the right tool for the job. Do not use a hardened steel
hammer to strike punch dies, spindle holders or other hardened
tools or equipment. Use a soft hammer for such work.
11.4
Always turn off the main switches when changing saws,

drills, etc.
11.5
Never attempt to place or change a drill or reamer while the

spindle is still revolving. Do not tighten work on any
machinery while the equipment or the material is rotating.
f. Handle abrasive wheels carefully to prevent dropping,

bumping or other action that is likely to cause damage.
11.6
Be sure that you have sufficient light to see what you

are doing.
g. Abrasive wheels should be stored in a dry area in a room

not subject to extreme temperature changes. Keep in mind
that dampness or extreme temperature changes may effect
the bonding of the wheels.
11.7
A restricted area must be designated around machines with

moving beds such as planers. Always place proper
warnings. This same precaution applies to any machine to a
noticeable extent, particularly when it extends into aisles,
walkways, etc.
11.8
Never use your hands to remove chips or shavings from a

machine or work table. Use a brush, stick or other approved
means.
11.9
Do not place your hand or any part of your body on or in

the moving parts of a machine.
b. Check the maximum operating speed of the abrasive

wheel (shown on manufacturers tag) against the machine
speed. Machine speed must never exceed maximum operating speed of stone.
c. Abrasive wheel should fit snugly, but not tight on the
spindle or bushing. Never alter the hole in the wheel or
force the wheel on the spindle.
d. Tighten the nut only enough to hold the abrasive wheel
firmly.
e. If an abrasive wheel breaks, flanges and spindles should
be carefully inspected for damage before a new wheel is
mounted.
h. Abrasive wheels must be stored in cabinets, racks or bins

so as to protect them from chipping or breakage. The
storage area should be accessible only to supervisory and
authorized repair personnel.
11.10 Keep your hands from between the dies of a press which
is in operation. Use tongs or other devices for handling
the material.
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11.11
Never leave tools so that they may creep, be thrown or fall

when the machine is started.
11.12 Do not grasp a belt to start or stop a machine or attempt to

shift a belt by hand.
11.13 Never crawl through or under a belt.
11.14 Do not rely on your hands to prevent material from turning
while using a cutting tool. Always see that the material is
properly clamped or secured.
11.15 Do not reach through or over a machine so that cutters or
revolving parts come in contact with your body or clothing.
Avoid wearing anything that may become entangled in
moving parts. Do not wear gloves, jewelry, neckties, etc.,
when operating machinery.
11.16 Long hair should be tied back or otherwise covered or protected. (Very important for operation of rotating equipment.)
Mobile Equipment 59
12. Mobile Equipment

Only authorized personnel can operate mobile
equipment. Use extra care when operating near blind
spots.
12.1
Only authorized employees are permitted to operate mobile

equipment. Operators using medication shall not operate
equipment without the express permission of medical
personnel or their supervisor.
12.2
Crewmembers only are permitted to ride on locomotives,

railroad cars, cranes, trucks, and other types of motorized
equipment, except as authorized by supervision.
12.3
Check brakes, flashing lights, horn, and steering at the start

of each work shift. Report any defects immediately to your
supervisor.
12.4
Stop at all doorways, blind corners, roadway crossings, or

other areas where an unusual hazard exists. Do not proceed
until you are positive the way is clear.
12.5
Always sound a warning signal (bell, horn, or whistle) when

approaching people or where there is any unusual
congestion of men and equipment. Be especially alert where
there are unusual shop noises.
12.6
Observe all posted speed limits.
12.7
Be sure that you have your equipment under control at all

times, and travel at speeds which will enable you to stop
immediately in case of an emergency.
12.8
Maintenance, repairs or adjustments are to be made by

authorized personnel only.
11.17 Never leave keys in chucks while working on lathes, etc.

11.18 Stop the lathe before removing tools from the tool post.
11.19 Do not allow chips or cuttings to accumulate around your
machine.
11.20 All files shall be provided with wood or composition handles.
11.21 Use extreme caution when using sandpaper or emery cloth
on rotating material.
11.22 When operating a drill press, avoid forcing or feeding the
drill too fast.
11.23 Always make sure that all guards are in place before
operating machines, except when it is necessary to operate
the machine for making repairs.
Railway
12.9
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Comply with regulations concerning blue flags and other

safety devices that have been installed for the protection of
workmen in cars or near railroad tracks.
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Mobile Equipment 61
12.10 Yard switching must not be done at a speed in excess of 15

miles an hour.
12.22 Never move the engine until the ground crew gives proper
signal. Use standard railroad signals for engine operations.
12.11 Do not make a flying switch; it is a very dangerous and

unnecessary practice.
12.23 The bell or whistle warning must be given at all crossings,

intersections, crosswalks, or other areas where an unusual
hazard exists. Be sure to check for overhead cranes and
workmen before entering a area.
12.12 The person acting as brakeman must always ride the

forward end while making a shift. He should ride on the
side of the car with his feet on the stirrup and with his
hands holding the grab irons. He normally should ride on
the same side as the operator, so that he will be in a
position to give signals.
12.13 When coming on or off the main running tracks, always
throw the switch back to proper position.
12.14 Train crewmen, except operator, should use elastic bands or
approved type leg bands around trouser cuffs, so as to
minimize tripping hazards.
12.15 Use extreme caution when necessary to get on or off moving
cars. Never attempt to get off or on a moving car in the
immediate area of the switch stand.
12.16 Any defects in tracks or switches must be reported immediately.
12.17 Do not go between a locomotive and a car or between cars,
for any purpose, when either is moving or when coupling is
about to be made.
12.18 Couplings must be adjusted while cars are standing still and
the brakeman must move to a safe position before signaling
the operator to move.
12.19 Brakemen must never use their feet to adjust couplers. Use
the hand for operating the coupling lever and stand facing
the direction of the movement and engineer so that proper
signals can be given.
12.20 Before shifting cars, the brakeman must make sure that
everyone is in the clear and that there are no car pulls
attached.
12.21 Cars should not be poled except where necessary, and then
only with steel-bound poles provided on locomotives. The
use of ordinary lumber is prohibited.
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12.24 No running is permitted through shops or over tracks. Always

step over rails-not on the ball of the rail.
12.25 Train crews must stop their train 50 feet from cars on which
people might be working. Check for clear track, then
proceed with caution.
12.26 Keep the platforms, ladders and steps clear of all tripping or
slipping hazards.
12.27 Be sure that cars are properly braked before leaving them
uncoupled from the engine. If necessary to place a wood
chock under the wheels of a car, keep your fingers on top
of the chock and away from the rail.
12.28 When getting on a moving locomotive, make sure that you
have a firm grip on the hand grabs and that one foot is
firmly placed on the step as you swing your body in toward
the locomotive.
12.29 Allow plenty of room for safety when walking around the
ends of standing railroad cars or locomotives. Always expect
the equipment to move.
12.30 Turn angle cock, shutting off the air, before snapping or
uncoupling the air hose.
12.31 Avoid blocking cross traffic. Break cars at crossings if train
is to be parked without engine.
12.32 Be sure that brakes are set and the car is properly blocked
when parked.
12.33 Be extremely cautious when moving in close clearance
areas. This is particularly important when going around
curves or when operating on parallel tracks. Be alert for any
material that may be protruding on or near the tracks or
from cars. Always face in the direction of travel.
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12.34 Plant safety rules prohibit the placing of any material within
five feet of an operating track. Report any safety violations
of this nature immediately to your supervisor.
12.35 When throwing the switch lever, be sure that your hands
and feet are in the clear of the switch ball.
12.36 Do not leave the locomotive engine unattended while motor
is running.
12.37 Do not move cars that are loaded in an unsafe manner.
Report any such conditions to your supervisor immediately.
Before moving flat cars, check for any overhanging wire,
banding or dunnage that might cause an accident.
12.38 Trainmen must be on guard to protect themselves against
stopping, starting, lurch or jerk of the equipment.
12.39 Operators must not move the engine in either direction in
the blind. Stop the engine immediately, with or without cars,
when moving on hand signals if the signal disappears from
view.
12.40 Operators are responsible for the proper management and
care of the engine in their charge. Do not permit anyone to
handle the engine and do not leave the engine while on
duty, except in case of necessity or emergency.
12.41 Always check the front end of standing railroad car to insure
that everyone is in the clear before bumping or coupling.
12.42 Situations not covered by these rules demand sound
judgment in applying correct principles of safety. In case of
doubt, always take the safe course.
Fork Lifts, Tow Motors, Trucks, and Mobile

Equipment
12.43 Inspect the vehicle at the beginning of shift. (Check safety
equipment such as the lights, horn, brakes, steering.) Report
any defects immediately to your supervisor.
12.44 Only qualified and designated employees are permitted to
operate vehicles. No one except the operator is permitted to
ride on such vehicles, except as authorized by plant
management.
OF
Mobile Equipment 63
12.45 Obey all speed limits, signals and signs. Slow down at
intersections and railroad tracks. Sound the horn when
approaching building entrances and exits or blind corners.
Stop at all doorways, turns, railroad tracks, or other areas
where an unusual hazard may exist.
12.46 Use extreme caution when operating in the vicinity of people.
Keep your vehicle under control at all times, and operate at
speeds that will enable you to stop immediately in the event
of an emergency.
12.47 Be sure the loads are proper as to capacity, balance and
projections. Use proper warning flag on extended loads.
12.48 When leaving vehicles unattended, be sure to shut off motor,
apply brakes, and remove keys. Lower the forks on lift
trucks.
12.49 Always shut off the motor when refueling. Smoking is
prohibited when refueling, or in the vicinity of fuel tanks.
12.50 Fuel tanks must be properly clamped and secured.
12.51 Operators are responsible for the proper piling of material.
Keep designated areas clear.
12.52 For normal operation of tractors, face the controls. For other
movements, look in the direction of travel.
12.53 Do not make a move unless you are positive that you are
not endangering anyones safety, or doing damage to
material or equipment.
12.54 Do not drive or park under suspended loads.
12.55 Be sure the aisles or roadways over which you expect to
travel are clear. Do not drive over obstacles or material
which may cause the load to fall.
12.56 Use caution when boarding or leaving the vehicle. Use the
steps or platforms provided.
12.57 Be sure the lift is landed on solid blocking or even flooring
before lowering the load. Do not leave a load in an unstable
or unsafe manner.
12.58 When using dock plates, be sure they are properly anchored.
12.59 Unsafe driving or horseplay is prohibited.
OF

12.60 Avoid sudden stops except in an emergency. Such stops

may dislodge the load.
12.61 Do not use bumper blocks to stop vehicle.
12.62 Watch the overhead clearance. Keep clear of the edges of
loading docks or other elevated work areas.
12.63 Spread the forks to suit the load width. Lift, lower, and
carry loads with the mast vertical or tilted back, never forward.
12.64 Never place your arms or legs between the uprights of the
mast or outside the running lines of the vehicle.
12.65 Brake to a full stop before changing from forward direction
to reverse or from reverse to forward.
12.66 For better vision with bulky loads, drive backward.
12.67 When moving shop buggies, the load should be pushed. If
necessary to pull buggies, a chain or tow cable must be
used to attach the buggy to the tractor or other vehicle.
12.68 Do not strike matches, use lighters, or any type of open
flame around or close to battery compartments or gas tanks.
12.69 Keep the vehicle free of all objects and materials that are
not essential to the normal and successful operation of the
vehicle.
12.70 Be extremely careful when operating equipment over soft,
rough or uneven ground, operate your vehicle at all times at
a speed consistent with the load, roadway, aisle space, etc.
Be constantly on the alert for people who may walk or
move unexpectedly in front of your vehicle.
12.71 Remember: Pedestrians always have the right-of-way.
Mobile Equipment 65
12.75 Inspect the machine at the beginning of each shift. (Check

lights, horn, steering, flashing lights, wheel alarms, etc.)
Report any defects promptly to your supervisor.
12.76 Be sure that all special safety devices (flashing amber light
and wheel alarms) are in good operating order. If they are
not, do not operate the equipment.
12.77 Always sound the horn and be certain that the way is clear
before moving the carrier in any direction.
12.78 Where there is an unusual congestion of personnel or
material, or if carrier is required to enter into any operating
facility, or there is a question of clearance, special
precautions must be taken.
12.79 When a signalman is provided, the operator must await his
signal before moving.
12.80 Headlights should be turned on before moving the carrier to
alert anyone directly in front.
12.81 No one shall ride on the carrier unless such procedure is
approved by the plant managers office. Where approval is
granted, a seat alongside of the cab, to the right of the
operator and located so that it will not interfere with his
vision, shall be provided. This seat shall have armrests and
a back. The seat shall be securely fastened, and a safety seat
belt must be provided and used.
12.82 The rider must be in the seat before the carrier is moved,
and he shall not move around on the carrier until it is
stopped.
12.83 If the vehicle is to be left unattended, shut off the engine,
set the brakes and lower the lifting forks to the ground.
12.72 Do not allow other operations or people to distract you.

Keep your mind on the job at hand at all times.
12.73 Seat belts must be worn at all times by the operator and the
passengers.
Straddle Carriers
12.74 Only qualified and authorized drivers are permitted to operate
this equipment.
OF
OF

Electrical Work 67
13. Electrical Work
13.11 When necessary to work on a hot circuit, always use rubber

gloves and stand on a rubber mat if practical.
Avoid working on hot circuits. Follow the Lock out Tag out program.
13.12 Never work on any circuit where surrounding areas are

damp or wet until circuit has been completely killed and
grounded.
13.13 Always use a voltage tester to determine voltage of any
circuit, regardless of circuit voltage label.
13.1
Only authorized employees are permitted to do electrical

work.
13.2
Do not start any electrical installations, alterations, etc.,

unless you have authorization or proper supervision.
13.3
If the job involves work on or near overhead cranes or

runways, you must observe all safety rules with respect to
such work. (Refer to Section 14 for rules on Maintenance
and Repair.)
13.4
Fall protection is required when working aloft. Lanyards

permanent walkways, platforms, etc., equipped with
guardrails.
13.5
Do not use extension cords or electric hand tools with

exposed wires. Turn them in for replacement or repair.
13.6
Only authorized persons are permitted to enter a

powerhouse or a substation.
13.7
13.8
13.9
Shut off and lock all switches before starting to work on

electrical equipment. Each person working on a circuit must
use his personal lock to lock out a switch and no circuit
shall be re-energized until all locks are removed. Make
sure the machine is in a zero mechanical state.
Do not handle tools or perform other work in such manner
as to damage cables or wires in the vicinity. If in doubt,
consult your supervisor.
Assume that all circuits are live until they have been
thoroughly checked and proven dead. Never work on a live
circuit if it is possible and practical to de-energize the circuit.
13.14 Never screw a light bulb into a live socket. Disconnect the
cord at the receptacle or throw switch.
13.15 Never energize a new installation without first placing
voltage labels on electrical equipment.
13.16 No portable electrical equipment shall be installed or repaired
without making proper grounding connections. If double
insulated portable electric tools are used, proper
identification labels shall be attached.
13.17 Do not touch a metal frame or case if it is ungrounded and
you are in contact with ground or a grounded object.
13.18 Tag, mark, or post suitable signs to warn other workmen of
possible dangers involved in the work.
13.19 Do not depend on insulated handles of tools to work on
hot lines. Use rubber gloves, mats, etc., as required by
plant safe work procedures.
13.20 Never leave a hot line unguarded or uninsulated in an area
where other people could come in contact with it.
13.21 Do not depend upon insulationit may be defective. Take
all precautions the same as though live parts were bare.
13.22 When working overhead, see that proper warning signs are
placed so as to notify people below. Be sure that all hand
tools, etc., are secured against falling.
13.23 Use only hand tools and equipment suited to the work being
done, so as to reduce the danger of short circuits.
13.24 Use wooden ladders when working on or near live electric
lines.
13.10 Treat low voltage circuits with the same respect as those of
higher voltage.
OF
OF

13.25 Report immediately to your supervisor any conditions of

equipment or lines under test which may endanger life or
property.
13.26 Do not use bare fingers or hands to determine whether a
circuit is live. Never remove or replace fuses except by
means of suitable appliances provided.
13.27 Before closing a switch, have full knowledge of the circuit
and the reason for the switch being open. Be sure nobody
is in a position to be injured when the switch is closed.
Maintenance and Repair 69
14. Maintenance and Repair

Follow the Lock out - Tag out program. Only perform
repairs that are sound and return equipment to a safe
condition.
14.1
13.28 Never use a fuse heavier than the capacity of the circuit.
Also never attempt to bridge a fuse.
No maintenance, repairs or alterations should be started

without authorization or proper supervision.
13.29 Never tamper with any electrical wiring or apparatus.

13.30 Never install any wiring or make any other electrical
installations that do not meet plant safety standards.
13.31 Remember: In dealing safely with electrical power, there is
no such thing as being almost right. An electrical
procedure or installation is either right or it is wrong.
Rule 14.2
Lock out all sources of power and movement

before working on machinery.
14.2
OF
Lock out controls and switches before beginning repairs or

maintenance on any machine. Only the person placing the
lock is allowed to remove it. Never begin work until all
OF

moving parts of the machinery have stopped in a fixed

position. Make sure the machine is in a zero mechanical
state.
14.3
Repairs, adjustments or alterations to machines or

equipment are to be made only by authorized employees
who have been thoroughly instructed in the safe way to do
the job. Notify the operator before starting such work.
14.4
Haphazard repairs are prohibited; take time to set up safe

scaffolding, ladders, and other rigging. Check all your tools
and equipment to be sure they are in good order.
14.5
Do not go on any overhead crane, crane runway, or building

where work involved is near or at crane runway level, for
any purpose, without permission from your supervisor and
the supervisor in charge of crane operations.
14.6
14.7
14.8
14.9
When working on or about crane runways, notify cranemen

on that and adjoining runways and place rail stops as required.
The department head should also be notified when the crane
or runway is to be temporarily out of service. Use service
lights where available.
Before starting work on overhead cranes, pull and lock the
main switches and place rail blocks where necessary.
Barricade or flag the area below where required, so as to
warn others of the danger zone.
When making repairs to overhead cranes, the crane should
be moved to a location where it will cause the least
interference with other cranes and with other operations on
the floor.
If necessary to work around rotating shafts, couplers, etc.,
use extreme caution. Do not permit any part of your body
or clothing to come into contact with the moving machinery.
Hair should be tied back, covered, or otherwise protected.
14.10 Treat all electrical circuits as though they were alive.
Maintenance and Repair 71
14.12 Keep oil and grease away from all oxygen and acetylene
equipment.
14.13 Fall protection is required when working aloft. Lanyards
working from elevated work areas equipped with guardrails.
14.14 Spilled grease or oil must be cleaned up immediately.
14.15 When working overhead, use care to prevent tools and
materials from falling. When repairs are completed, see that
all loose objects are removed.
14.16 Rubber gloves must be thoroughly inspected and tested
periodically and before being used on high-tension work.
14.17 Remove all loose equipment, especially when working
overhead. Replace all guards, covers, and other safeguards
prior to putting equipment back into service.
14.18 Keep fire extinguishers nearby when working on greasy
machines or near combustible material. This is particularly
important when you are burning or welding.
14.19 Areas where gases, solvents, and cleaning fluids are used
should be well ventilated. Keep such flammables away from
an open flame or an electric arc.
14.20 Special precautions are necessary in shutting down hydraulic
or air-operated machinery. Check with your supervisor for
instructions.
14.21 Handling of small tools, material, etc., from ground level to
men working above shall be accomplished by the use of a
hand line or a suitable type container. Tools and materials
shall not be thrown from one level to the other.
14.22 Where planks are used to span girders or where other types
of temporary scaffolds are needed, the supervisor in charge
should follow the procedures as set forth in Section 18 on
Scaffolds.
14.11 Always properly barricade floor openings, open manholes,

machine foundations, and pits for repair purposes, etc., and
close them as soon as possible. Where the lighting is poor,
a red light should be installed in addition to the barricade.
OF
OF

15. Radiation (X-Ray,

Cobalt, etc.)
Radiation (X-Ray, Cobalt, etc.) 73
15.8
A controlled area should be established for each type of

operation in which radiation devices are used. The boundary
of this area shall be established at a distance from the
radiation source so that the radiation along its perimeter
shall not exceed two milliroentgens per hour (mrh).
15.9
A barricade shall be provided about the controlled area.

Blinking red lights and clearly visible signs showing the
standard radiation symbol shall be placed along the perimeter.
Target marking safety rope (alternating black and yellow
colors) shall be used to indicate the controlled area. All
individuals shall be cleared from this area before operating
the radiation device and the area policed to prohibit entrance
therein by any person.
Monitor all radiation exposure.
15.1
The use and control of any radioactive materials or sources

must be in accordance with State or Federal regulations.
15.2
All individuals directly engaged in radiography should be

equipped with a film badge and a pocket chamber or
dosimeter. Each person shall wear the film badge (and pocket
dosimeter or pocket chamber if such is required) that is
specifically assigned to him, in such a manner as to
accurately reflect his exposure. The loss of any personnel
monitoring equipment shall be immediately reported to the
supervisor and a proper replacement obtained before
reentering a restricted area.
15.3
Measurements of radiation dosage (exposure) should be

made at an interval designated by plant management. A
record of each individuals radiation (exposure) should be
kept at the plant. A yearly summary of the record should be
placed in the individuals personnel file.
15.4
All personnel working with radiation sources or frequenting

restricted areas shall immediately consult the supervisor
when there is a question regarding radiation control or
protection, performance of equipment, procedure or other
such situations.
15.5
15.6
15.7
No employee shall be permitted to perform radiography

prior to having successfully completed a training program.
Natural sources may be used only by licensed employees.
No radiography shall be performed with sealed sources
unless calibrated and operable survey instrumentation having
a range of at least 2 milliroentgens per hour (mrh) through
1000 milliroentgens per hour is available and used.
The operation of radiation equipment should be conducted
by a management employee or should be performed under
his direct supervision.
OF
15.10 Crane travel should be prohibited over the controlled area

when the radiation device is in operation, unless a radiation
survey has shown that the crane operator will not be exposed
to radiation in excess of two milliroentgens per hour (mrh).
15.11 Whenever a remote-controlled source-handling device is
used, the radiation intensity at the operators position shall
be measured during the extension of the source to insure
that it has not become immobile in the source tube.
Following each exposure shot, the device shall be surveyed
to insure that the source has been returned to the shielded
position before anyone is permitted to enter the potential
radiation area.
15.12 Radiation devices shall be secured under lock and key when
not in use or unattended, to prevent their operation by
unauthorized individuals. All containers for storing
radioactive material when it is not in use must limit
radiation to two milliroentgens per hour (mrh) measured at
any point on the surface of the storage container.
15.13 Radium sources shall be stored in ventilated areas to prevent the accumulation of radon gas.
15.14 A record shall be maintained of all uses of sealed sources
for radiographic purposes. Such records shall include a
description of the exposure device or storage container, the
identity of the user, the kind and quantity of the radioactive
material, the location of and the date of use. An individual
utilization log shall be maintained for each such device.
OF


Observe rules in Section 15
This sign means Radiation: Beware
Housekeeping 75
16. Housekeeping
Keep walkways clear. Put scrap and debris where it
belongs.
16.1
RADIOACTIVE
AREA
15.15 Should an emergency occur, radiation sources located in the

affected area should be turned off if an x-ray machine, or
returned to the storage container if a radioactive material
source, provided such action does not jeopardize the safety
of personnel. The area in which the emergency is located
shall be immediately evacuated and only personnel qualified
to take remedial action shall be admitted.
15.16 The disposal of radioactive materials shall be accomplished
only by the return of the material to the original supplier or
by other means approved by the Nuclear Regulatory
Commission, or other governmental agency having such
jurisdiction.
OF
Good housekeeping is essential to a good safety record and

is a vital part of any successful safety program. Simply
stated, it means keeping your job and the surrounding area
as clean and orderly as possible. Good housekeeping will
enable you to do a better job with less chance of getting
hurt.
Section 16
Good housekeeping means keeping

on top of it each day!
16.2
Keep all materials out of aisles and walking areas.
16.3
Return your tools and other equipment to their proper storage

place after use. During use, keep them orderly.
16.4
Clean up immediately any oil, water or other slipping

substances that are spilled on the floor.
16.5
Keep the shops clear of scrap steel, punchings, and shavings.
16.6
Do not leave blocking, chains, cable, hose or tools scattered

about the floor after you are through with them. Blocking
should be piled in convenient places.
16.7
Return all empty bottles, cans, or other containers to their

proper place.
16.8
Properly dispose of material such as empty paint cans, oily

rags, etc., promptly. They can cause fires. Keep your locker
neat and free of soiled clothing and trash.
16.9
Pick up tripping hazards such as bolts, nuts, pins, weld rod

stubs, pieces of scrap material, scrap wood, etc.
OF

Use of Ladders 77
16.10 Employees must not deface, mark, mar or destroy any

building, machinery, warning signs, bulletin boards or any
other equipment.
17.3
If possible, extend ladder at least 36 feet above the point

where it is intended to reach. Do not work higher than the
third rung from the top on straight ladders.
16.11 Keep all stairways, landings, etc., free of any tripping

hazards. Report any instances of inadequate lighting to your
supervisor immediately.
17.4
Slant the ladder at about a 75-degree angle. (Base should be

one-fourth of ladder length from wall or point directly under
the top support).
16.12 Place all trash or garbage in the proper container.
17.5
All straight and extension ladders should be equipped with

safety feet. Do not use the fly section of an extension ladder
without the base section.
17.6
For overhead work, use a proper type of ladder. Do not use

makeshift devices such as bolt kegs, steel drums, etc.
17.7
If a ladder must be used near a door or a passageway, it

must be properly protected. If possible, the door should be
locked; otherwise, warning signs or barricades must be
erected.
17.8
Always face the ladder. Keep both hands free for holding
on when going up or down. Use a hand line or other approved
means for raising or lowering tools and materials.
17.9
Use ladders that are of the correct length for the work
involved. Avoid over-reaching to either side when working
from a ladder. A good rule of thumb is to limit your reach
to 12 inches beyond the side rails.
16.13 Keep lunch areas clean.
17. Use of Ladders

Secure ladders on firm level ground. Face the ladder
and use two hands.
17.1
Inspect all ladders before use. Check the side rails and rungs
for any defects. Be sure the ladder is free of oil, grease or
other slippery material. Do not use a damaged or defective
ladder. Tag or mark damaged or defective ladders
Dangerous, Do Not Use and withdraw them from service
for repair or destruction.
Rule 17.2
17.10 Remember that all metal ladders are conductors of

electricity. Do not place them on or near live electrical lines.
Assume all wires are hot until you are sure they are not.
17.11 Do not throw tools or materials up or down to a workman
on a ladder.
17.12 Never attempt to slide down a ladder.
Secure all ladders on firm, level ground.
17.13 Do not use a ladder as a guy, brace, skid or for any purpose
other than that for which it is designed.
17.14 Do not splice short ladders together to make a long ladder.
17.2
Place ladder on firm, level ground so that it will not sink or

slip. Tie or otherwise secure ladders at the top. Where ladder
cannot be secured, someone should hold it while anyone is
climbing, descending or working from it. Make sure each
rung has sufficient clearance for safe footing and grip.
OF
17.15 Made sure your hands and shoes are clean, dry and free of
any grease, etc., before climbing a ladder.
OF

17.16 Be extremely careful when working from a ladder in an

area where overhead cranes or hoists are working. Be sure
the crane operators are aware of your position. If necessary,
check with your supervisor so that a safetyman can be
stationed to protect you.
17.17 Avoid placing a ladder against a window sash. If necessary,
lash a board to the ladder to provide bearing on the wall at
each side of the window.
17.18 The top section of an extension ladder must always be
lowered before moving from one location to another.
17.19 Do not paint a ladder and do not allow paint or other
foreign material, which would cover up defects in the rungs,
side rails, etc., to accumulate on the ladder.
Scaffolds 79
18. Scaffolds
Assure all fasteners and members are in place. Do not
overload the scaffold.
18.1
All scaffolds and work platforms must be inspected and

approved by a competent person prior to use.
18.2
Inspect scaffold boards, and supports before each use and

report any defects to your supervisor.
18.3
Guard rails and toe boards are required on all scaffolds and
scaffold-related work platforms and walkways that are more
than 10 feet above the ground or floor. Needle beam
scaffolds, painter picks and other similar types are excepted
from this rule.
18.4
Guard rails, wherever used, should consist of a top rail or

wire rope, approximately 42 inches high with a mid-rail or
rope.
18.5
Where supports for scaffolds, walkways, railings, etc., are

welded, a welder who has been determined to be competent
shall perform the welding. The supervisor in charge shall
inspect the scaffold as well as the weld before putting it into
use. Be sure to avoid prying actions on welds.
18.6
Planks used for scaffolds should be of an approved type.

The ends should be reinforced to prevent splitting. A 15/16inch hole may be bored in the center 6 inches from each
end for use of drop bolts.
18.7
Planks should overhang their end supports not more than 12

inches nor less than 6 inches, or should be fastened in place.
Drop bolts should be used in the end of scaffold planks to
prevent them from slipping off their supports.
18.8
All scaffolds and work platforms should be at least two

planks wide. Workers should not work from a single board.
18.9
All swinging scaffolds should be tied into the structure to

prevent swaying.
17.20 Never lean a ladder against loose boxes, barrels, round

objects, or other unsafe supports.
17.21 Be sure the top section of an extension ladder is locked
securely before attempting to climb. Make sure rung locks
are resting securely on rung. After rung locks are set, tie
halyard snug so top part of ladder is secure.
OF
OF


Rule 18.10
Scaffolds 81
table on next page for length of span of the catenary cable

between supports, size of cable, and sag required.
NEVER EXCEED
C A PA C I T Y
ON
SCAFFOLD
18.10 The number of workers on a scaffold shall not exceed the

number it is designed to carry. The combined weight of
workers, tools, and material shall not exceed the capacity
for which the scaffold is designed.
working from permanent walkways, platforms, etc., equipped
with guardrails.
18.19 Where the platform is not suspended, but is rested on

bearings of some kind, such as part of the structure, special
precautions must be taken to prevent its slipping from its
bearings.
18.20 Where the scaffold is not suspended, consideration should
be given to removing the stirrups if they constitute a
tripping hazard.
Cable Suspensions for Scaffolds and Safety Lines
18.12 Where it is not possible to tie off safety lines to the

structure, a lifeline should be rigged for this purpose.
Lifelines may be vertical or horizontal. If vertical, use 3/4inch Manila rope. If horizontal, use a 5/8-inch wire rope,
with proper sag. (See Cable Suspension Chart on next page.)
Lifelines shall be suspended independently of the scaffold.
18.13 Tie off the lanyard, when possible, before getting onto the
scaffold. Do not unfasten the line until you are off the
scaffold. Workers shall not jump onto scaffolds.
18.14 Lanyards must be tied off at a level above the scaffold and
should be kept as short as possible. Avoid sharp edges.
18.15 Keep scaffolds completely free of rivets, drift pins and other
loose objects. Such items present a tripping hazard.
18.16 Scaffolds shall be kept free of ice, snow, mud, oil and other
materials which may create a hazard.
H
T
S
L
P
=
=
=
=
=
Horizontal Force from Load P in lbs.

Tension in Cable (Assume T = H for small sags)
Sag in feet
Span length in feet
Load in lbs.
Then H =
18.17 Not more than two workers should be permitted on painters

swinging scaffolds at one time, except where more than two
stirrups with corresponding hooks, blocks, and ropes are
used, in which case one additional worker may be permitted
for each additional stirrup.
PL
4S
18.18 Where the scaffold is to be supported by catenary wire rope,

some positive device must be used so there is no possibility
that the platform can slip off the catenary cables. See the
OF
OF

Scaffolds 83
Tubular Steel Scaffolding

Values of H* in lbs. per each 500 lbs.
of Load (P)**
Span (L)
in feet
Sag (S)
1 - 0
2 - 0
3 - 0
5 - 0
20
2,500
1,250
835
500
40
5,000
2,500
1,670
1,000
60
7,500
3,750
2,500
1,500
100
12,500
6,250
4,170
2,500
*H from weight of supporting rope is not included.

**Values of H for higher loads P can be obtained by direct ratio. For example for Sag
1500
S = 2 feet and Load P = 1500 lbs. H =
x 1250 = 3750 lbs.
500
8.21
While the scaffold is in use by any person, it shall rest upon

a stable footing and shall stand plumb. The casters or wheels
shall be locked in position. Each tier of the scaffold should
be securely tied to the structure.
18.22 All locking and connecting pins must be provided and used.
If these items are not available, some positive means of
tying the sections together must be employed. All wing nuts
or locking devices shall be tight.
18.23 If the nature of the work is such as to require use of the fall
protection, the safety line must be tied off independently of
the scaffold.
18.24 Work platforms shall be tightly planked for the full width of
the scaffold, except for necessary entrance openings. Planks
should be secured in place.
18.25 No one is permitted to remain on the scaffold while it is
being moved.
18.26 Freestanding towers must be guyed or otherwise secured to
the structure. (See typical scaffolding sketches on the
following pages.)
Strength of Wire Rope with Factor of

Safety of 4.
Dia. (inches)
18.27 Scaffold erection, dismantling and user training must be

conducted by a competent person prior to use.
Working Load (lbs.)
5/8
8,350
3/4
11,900
7/8
16,100
20,900
Tubular Steel Scaffolding

18.21 While the scaffold is in use by any person, it shall rest upon
a stable footing and shall stand plumb. The casters or wheels
OF
OF

Bracket for Scaffold at Girder
Scaffolds 85
A Frame Scaffold Support
Bracket for Scaffold at Girder
A Frame Scaffold Support
NOTE:
All planking should be Douglas
Fir 2 x 12 x 12- 0 rough, or
of other material of equivalent
strength.
NOTE:
1) All planking should be
Douglas Fir 2 x 12 x 12- 0
rough, or of other material of
equivalent strength.
2) Bolts must be tightened
securely before utilizing bracket
as scaffolding.
OF
OF

Hydraulic and Mechcanical Jacks 87
19. Hydraulic and

Mechcanical Jacks
Safeway Tubular Scaffold
Prevent damage to hoses. Set jacks on solid supports at

the proper angle.
NOTE:
Height must not exceed
four times the least
base dimension unless
scaffold is tied to the
structure.
19.1
Check the ram and pump as well as hose for any leaks or
other damage. Report any defects to the supervisor or to the
repairman.
19.2
Always select a jack of sufficient capacity. Never overload

or exceed the capacity of the jack. Do not use cheaters to
gain additional leverage.
19.3
Make sure the jack is secure and centered on the blocking

and load. Keep the jack perpendicular to load to avoid
kickout or slipping. Be sure the footing and ram are free of
oil or grease.
19.4
Do not rely on jacks alone to support load on which men

are working. Use hard wood blocking to support the load in
case of jack failure.
19.5
Use extreme caution to prevent damage to hydraulic hose.

Do not kink or drag hose over material. Keep hose away
from flames or hot objects.
19.6
Repairs to hydraulic hoses, jacks and pumps are to be made

only by authorized personnel.
19.7
Do not carry hydraulic jacks by the hose and do not pull on

hose to free the jack.
19.8
Always stand clear of hose when pressure is applied so you

will not be injured in case of hose failure. Fluid escaping
through small hose and hydraulic equipment can cause
serious injuries.
19.9
While jacking horizontally, tie a rope on the jack when

necessary to prevent the unit from falling.
Safeway Tubular Scaffold
NOTE:
All planking should be Douglas Fir
2 x 12 x 12- 0 rough, or of
other material of equivalent strength.
OF
OF

19.10 Operate the jack slowly and with even strokes. Use caution
that hands do not get caught between the handle and other
nearby obstructions.
Painting 89
20.4
Wear gauntlet gloves, overalls, or other clothing that will

give you the greatest protection from paint.
20.5
Respiratory equipment with a NIOSH or Bureau of Mines

approval must be worn when power wire brushing, spray
painting, grit or sand blasting. Keep your respirator clean
and in good working order. Change the cartridges and filters as often as necessary to provide proper protection.
Respirators shall be maintained in accordance with the
manufacturers recommendations. When the vapor can be
detected, the filter should be changed on the respirator.
Respirators must be sterilized before transferring to others.
Report any defects in your respiratory equipment
immediately to your supervisor.
20.6
Face shields must be worn in addition to your regular safety

glasses when power wire brushing.
20.7
Take advantage of natural air movement so dust and spray

will not blow back in your face.
20.8
Do not keep your lunch with your working clothes. Do not

eat, smoke, or chew while painting.
20.9
Do not spray any kind of paint, oil or any flammable

liquids near welding, burning or any other flame.
19.11 Keep hands and feet from under suspended loads while
jacking.
19.12 Lower the jack slowly and carefully, taking care not to pinch
the hose.
19.13 Consult with your supervisor if there is any question as to
the safer operation of the equipment.
19.14 Do not weld lugs, brackets, etc., to jacks.
19.15 Do not rely on a rivet head, spud wrench or drift pin in a
hole as support for base or ram of jack. Use steel brackets
of proper design or hard wood blocking.
20. Painting
Prevent fire hazards. Avoid physical contact with wet
paint and inhaling fumes by using PPE.
20.1
Read paint warning labels. Some paints contain hazardous

material that might enter your system through the skin, the
mouth, and the lungs. These harmful substances are taken
into the system most commonly by inhalation, but just as
readily in eating or putting the hands to the mouth.
20.10 Spray painters must not spray toward each other or where
there is any possibility of spray or vapor striking the head
or face of any other people in the area.
20.11 Painting between girders or other large members is prohibited
unless they are properly braced or clamped. Use girder
clamps on girders wherever possible. Smaller pieces should
be safely spaced or secured to prevent chain reaction toppling.
20.12 When airless spraying, nozzle tip must not be allowed to
contact any part of the body. Also, when cleaning up the
gun, be sure that the pressure is off, so that any accidental
tripping of the trigger will not cause an injury.
20.2
Obviously, personal cleanliness is most important. Wash

carefully before you eat. Bathe daily. Change work clothes
frequently. At least once each week is recommended.
20.13 Never point an air hose at another employee or use

compressed air for dusting or cleaning your clothing.
20.3
If you have any exposed cuts or sores, be sure they are

properly bandaged before starting work.
20.14 Do not strike a match, smoke, or use any open flames around
paint or other flammable materials. Observe all No
Smoking signs which are posted around the plant.
OF
OF

Abrasive Blasting 91
20.15 Always use safety cans with flame arresters for handling
any flammable liquids such as naptha, solvents, etc.
21. Abrasive Blasting
20.16 Inspect your paint and spray equipment frequently. If any

equipment is not in good working order, have it replaced or
repaired by an authorized person.
Beware of the hazards of abrasive blasting. Avoid

getting abrasive shot in the eye.
20.17 If your clothing is covered with paint or solvents, do not

stand or walk near salamanders or open fires.
20.18 Have a good handhold and footing when handling material
by hand. Do not step or walk on material that has wet paint
on it. Be extremely careful when handling material that has
recently been painted.
20.19 When turning material with a hand dog or pinch bar,
position yourself so that you will not fall or otherwise be
injured if it slips.
21.1
Only authorized employees are permitted in the Abrasive

Blasting Area.
21.2
All personal protective equipment, air supply to operator,

etc., must be checked prior to use.
21.3
A Bureau of Mines or NIOSH approved air-supplied

sandblasting helmet or mask must be worn by all operators
of abrasive blasting equipment, except where blasting
operation is enclosed and separated from operator, as with
Wheelabrator or Pangborn machines. Approved gauntlets
and apron or coat should also be worn.
21.4
The operator should have a physical examination (including

x-ray) before assignment to this type of work, and at least
annually thereafter.
21.5
Operator should keep his hood on at all times when blowing

loose abrasive from the material, shoveling abrasives, or
performing other work which causes dust.
21.6
If helpers or other personnel are exposed to dust from the

operation, including cleaning up, they should wear approved
protective equipment appropriate for the degree of exposure.
This would include dust-type respiratory and tight-fitting
eye protection. (See Rules 1.8 and 1.14.)
21.7
The operator and helper (if required) should discuss the

operation and their moves before starting the work.
21.8
Operators and helpers should have signals worked out so as

to coordinate the work and communications. Signals should
be simple and easily understood.
21.9
Check all hose connections, nozzle, etc., before starting

work. Be alert for weak spots in the hose.
20.20 Do not use compressed air to dry or clean small parts that
are held in the hand.
20.21 Keep area adjacent to railroad tracks clear. A clearance of
30 inches from narrow gauge tracks and 5 feet from
standard gauge tracks must be maintained.
permanent walkways or platforms equipped with guardrails.
OF
OF

Abrasive Blasting 93
21.10 Refer to rules on material handling. Be sure material is

properly secured and spaced before starting blasting
operations.
21.21 Dust from alloys containing titanium, magnesium, and some

other metals may create a fire and explosion hazard. Check
with your supervisor when blasting such metals.
21.11 Small objects, loose blocking, etc., which might be driven

through the air by the blast, should be removed prior to start
of work.
21.22 When practical, blasting should be done in a separate

structure, an area isolated by partitions, or in a restricted
outside area.
21.12 The nature of the work requires that the operator be extremely
careful of his footing and movements during blasting
operations.
21.23 All food and drink should be kept out of the blasting area.
21.13 Abrasive materials should be removed from steel before

handling or loading, so as to prevent slipping hazards.
21.14 Care must be used to keep lines from becoming entangled,
cut, separated, or pulling the operator off balance. Special
precautions should be taken when working from a ladder,
scaffold, or above floor or ground elevations.
21.15 Operator must maintain firm grip and be in complete
control of nozzle at all times, particularly when pressure is
turned on. Never aim nozzle in the direction of anyone
within the immediate area. Also keep hands away from the
nozzle opening.
21.16 When shutting down the equipment, the operator should be
positive that the hose pressure is relieved before turning
away from the blasting area.
21.17 Blasting nozzles should be equipped with automatic cutoff
valves or dead man controls in the event the operator loses
control.
21.18 Blasting equipment should be grounded to prevent static
sparks when it is used on tanks, etc., which contain or have
contained volatile substances. Such tanks, etc., should be
purged before blasting.
21.19 Sandblast hose should be equipped with an anti-static inner
tube (natural gum treated with carbon black) to prevent
electrical shock.
21.20 Steel to be blasted, if coated with red lead, epoxies,
chromium, cadmium, or other toxic materials, may require
special-type respirators. Check with your supervisor before
starting work on such material.
OF
21.24 Use a special blower unit of a type not involving internal

lubrication to provide the helmet air supply.
21.25 Gasoline engine units are not recommended for use with
air-supplied respirators.
21.26 If air is supplied to the helmet from plant compressed air
lines or oil lubricated compressor, an air-cleaning device,
pressure-regulating valves, and other items are recommended
as set forth in NIOSH Specifications.
21.27 Anti-freeze, corrosion inhibitors, or such substances should
not be added to compressed air systems from which air is
taken for breathing purposes.
21.28 Air fed to the helmet should be at the pressure recommended
by the respirator manufacturer.
21.29 Compressors supplying breathing air should not be operated
near the exhausts of internal combustion engines, sewer
manholes, abrasive blasting, painting, large electric arcs, or
sources of smoke or other contaminants. Intakes should be
provided with filters for removing contaminants in
respirable-size range.
21.30 If rust inhibitives are used on material after blasting,
precautions should be taken to protect against hazards
resulting from breathing spray or contacting the solution.
This is especially important if the solution contains either
chromates or dichromates. The concentration of respirable
dust or fume in the breathing zone of the operator shall be
kept below the levels specified by the State or Federal Safety
Standards.
OF

22. Fire Prevention
Fire Prevention 95
22.8
When working on wooden docks or piers where burning or

welding must be done, a stand-by hose line must be laid out
and charged or connected to water hydrant. Area must be
wet down thoroughly after burning or welding is completed.
22.9
Use of salamanders is not recommended, but if they are

used, they should be located only where there is good
ventilation and they should be guarded.
Know where fire control equipment is and how to use

it. Report fire hazards.
22.1
In the event of a fire, you should know where the nearest

fire extinguisher is located in your department. Learn where
they are and what type of fire they are recommended for.
22.2
Notify your supervisor if you notice any condition or act

which you believe to be a fire hazard.
22.10 Do not clean clothing with oxygen, gasoline, solvents, or

other flammable agents. A spark may ignite your clothing.
If your clothing catches on fire, Do not run! Smother the
flame. If necessary, roll on the floor or ground to put out
the flame.
22.11 Do not use oil, gasoline, similar flammable liquids, or oxygen
to start or increase the intensity of a fire.
Rule 22.3
ATTENTION:
22.12 Inspect fire extinguishers each month and annually.
KEEP
How to operate a fire extinguisher
FILLED
FIRE
EXTINGUISHERS
AT
ALL
TIMES
22.3
All extinguishers must be turned in for refilling, inspection

and retagging after use.
22.4
When fighting fires, the first few moments are the most
important. The proper and prompt use of extinguishers at
the start of a fire will often control the fire and avoid heavy
losses.
22.5
Carbon tetrachloride is banned as an extinguishing agent.

Remove any carbon tetrachloride fire extinguishers from
service, dispose of safely according to local or federal
standards, and replace with an appropriate type extinguisher.
22.6
Keeping your work area, lockers, etc., clean and free of

rubbish will help in the prevention of fires.
22.7
Fire equipment should be used only for preventing or

controlling fires. Standpipes, hydrants, hoses, etc., should
not be used for any other purpose, except with specific
permission of the plant manager.
OF
REMEMBER:
PASS
P =
P U L L THE PIN
A=
A I M T H E N O Z Z L E AT T H E B A S E O F
THE FLAMES
S =
S Q U E E Z E TRIGGER WHILE HOLDING

EXTINGUISHER UPRIGHT
S =
S W E E P EXTINGUISHER FROM SIDE TO SIDE,

COVERING THE AREA OF THE FIRE
WITH THE EXTINGUISHING AGENT
OF

Fire Prevention 97
Types of Fire Extinguishers, page 1

[image 22.12]
OF
OF

23. Off the Job Safety
Notes 99
Notes
Drive safely.
At best, life is short. Accidental death and injury can make it even
shorter. Therefore, preventing accidents is important, whether at
home, on a hunting trip, at the beach, driving a car, or on the job.
The following suggestions are for your safety away from your job:
1. When youre driving, concentrate on the road, your car, and
other cars. Expect the worst and then maybe it wont happen.
Wear seat belts and shoulder belts.
2. As a pedestrian . . .
Look both ways before stepping from the curb.
Cross at the intersection.
Never step out from between parked cars.
On highways, walk on the left side, facing traffic.
3. Watch your step. Keep steps and stairways clearthen walk
them, dont run!
4. There is pleasure in doing-it-yourself, but dont do-yourselfin. Do it with care and dont over-do-it.
5. Things like gasoline, paint thinner, lye, kitchen cleaners, and
bug sprays can do things like explode, burn, damage eyesight,
hurt skin, poison the body. Handle all chemical products carefully
and keep them up and out of reach of small children.
6. Teach your children safety habits. Watch out for cars when
crossing the street, playing in the street, riding bikes. Keep
knives and other sharp objects out of reach. Put away medicines.
7. Watch for fire hazards: worn-out wires, material too close to
very hot items like stoves, electric heaters, irons, and candles;
dont use worn-out appliances.
8. When you need help, ask for it quickly! Keep numbers of the
Fire Department, Ambulance Service, and Police Department
posted by your telephone.
9. Be alert; dont take chances!!! Accidents can happen to you
anywhere
watch out for them.
OF
OF

Notes
Notes 101
Notes
OF
OF

Notes
Notes 103
Notes
OF
OF

Notes
OF


General Safety Rules For Structural Steel Fabricators

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SAFETY

General Safety Rules

AMERICAN INSTITUTE OF STEEL CONSTRUCTION, INC.

This publication is intended to present practical work rules to

1st PrintingJune 1981

Publication Number F502(10M1100)

2004 by American Institute of Steel Construction, Inc. All rights reserved.

Wear clothes and protective accessories suitable for the

Be sure that any clothing you wear is not of a highly

It is advisable to wear steel-toed safety shoes or boots on the

Lets All Work Together for Safety

2004 by American Institute of Steel Construction, Inc. All rights reserved.

2 General Safety Rules for Structural Steel Fabricators

The wearing of an approved hard hat (safety cap/hard hat,

Generally, gloves should be worn except when operating

Neckties, loose, torn or ragged clothing create a special

Pants guards (clips, elastic, or rubber bands) should be

ANSI approved type eye protection is required in all plant

Heavy Impact Goggles

Burner Goggles provide protection from light and sparks

2004 by American Institute of Steel Construction, Inc. All rights reserved.

4 General Safety Rules for Structural Steel Fabricators

Face Shields provide protection from impact, dust, cinders

frame readily adjusts to face, so this is particularly suitable

Cover-all Plastic Monogoggles

Welders are required to wear approved safety glasses in

Unless contact lenses have to be worn for medical reasons

Fall protection is required when working aloft. Lanyards

Inspect fall protection equipment before each use. Notify

Always wear a life vest when working on floating

General Purpose Spectacles (Clear) provide protection

General Purpose Spectacles

Cover-All Plastic Monogoggles (Clear) provide protection

2004 by American Institute of Steel Construction, Inc. All rights reserved.

6 General Safety Rules for Structural Steel Fabricators

Respirators, suitable to the type of work being performed,

Respirators, including disposable dust mask type equipment,

Disposable Ear Plugs

Insert-type Ear Plugs

Rings or other jewelry should not be worn in the shops or

Pure oxygen should not be used for ventilation or cooling

Air Line Respirator

Cartridge Type Respirator

Proper fitting earplugs or muffs must be worn where

2004 by American Institute of Steel Construction, Inc. All rights reserved.

8 General Safety Rules for Structural Steel Fabricators

2. General Safety Rules

General Safety Rules 9

Do not pile material or equipment so that it obstructs safety

Use a good ladder equipped with safety feet. Always use

Never point a compressed air hose or tool at anyone or use

Be as familiar as possible with surrounding areas, presence

Never stand over an airline, hydraulic line, or any line under

Properly barricade floor openings, open manholes, machine

Crewmembers and authorized personnel only are permitted

Flammable liquids such as gasoline, solvents, etc., must be

Never oil, remove guards or attempt to repair machinery

Be constantly on alert for unsafe conditions or acts and

Keep work area in clean and orderly condition with

If you are in doubt about the safe or proper way to do a job,

Be constantly on the alert for unsafe conditions or acts and

Horseplay is not permitted. Do not distract or interfere in

Do not leave your work area unless your work or personal