Reference

AlllDl 72TE7S

IMBSIR 80-1964

Recommended Guidelines for

Safety Inspection of

Construction of ConcreteCooling Towers

H. S. LewS. G. Fattai

B. J. Hunt

Structures and Materials Division

Center for Building Technology

National Engineering Laboratory

National Bureau of Standards

Washington, D.C. 20234

January 1980

Issued February 1 980

Prepared for

Occupational Safety and Health

Administration

Department of Labor

^QC Washington, D.C. 20210

100

.U56

80-1964

1980

NBSIR 80-1964< V «

RECOMMENDED GUIDELINES FORSAFETY INSPECTION OFCONSTRUCTION OF CONCRETECOOLING TOWERS

KATIOKAX. BUMCA.tlOF eTAKDABOa

LIBRABT

NOV 2 4 1980

VO -

H. S. LewS. G. Fattal

B. J. Hunt

Structures and Materials Division

Center for Building Technology

National Engineering Laboratory

National Bureau of Standards

Washington, D.C. 20234

January 1980

Issued February 1 980

Prepared for

Occupational Safety and Health

Administration

Department of Labor

Washington, D.C. 20210

U.S. DEPARTMENT OF COMMERCE, Philip M. Klutznick, Secretary

Luther H. Hodges, Jr., Deputy Secretary

Jordan J. Baruch, Assistant Secretary for Science and Technology

NATIONAL BUREAU OF STANDARDS, Ernest Ambler, Director

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ABSTRACT

As a result of a construction failure of a natural draft cooling towerat Willow Island, West Virginia, the National Bureau of Standards (NBS)

reviewed existing Occupational Safety and Health Administration (OSHA)

construction safety and health regulations and developed guidelines foruse by the OSHA compliance officers for safety evaluation of reinforcedconcrete shell cooling tower construction.

The guidelines furnished are based on existing OSHA regulations, but high-light their application to this type of construction by pointing outcritical construction operations, their related safety aspects, and neededcompliance inspection procedures. Major regulatory provisions affectingthe basic construction plans, safety aspects of design criteria and responsi-bilities, record keeping, and inspections are summarized. Special attentionis given to construction loadings, construction sequences, hoisting systems,and personnel safety training.

Detailed identification is made of items relating to concrete inspection,concrete control, formwork operations, construction loadings, hoistingsystems, and construction safety planning.

Key words: concrete; construction; cooling tower; formwork; hoisting system;regulations; safety; standards.

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TABLE OF CONTENTS

Page

ABSTRACT iii

1. INTRODUCTION 1

2. OBJECTIVE 2

3. COOLING TOWER CONSTRUCTION 2

4. SCOPE 2

5. APPROACH 3

6. PRECONSTRUCTION PLAN REVIEW 4

6.1 Basic Construction Plan Components 4

6.1.1 Design Loads for Construction 5

6.1.2 Design Calculations 5

6.1.3 Criteria for Form Removal and Imposition of

of Construction Loads 6

6.1.4 Establishment of Benchmarks 7

6.2 Personnel Training in Construction Operation 7

7. INSPECTION TASKS DURING CONSTRUCTION PHASES 7

7.1 Concrete 8

7.2 Formwork and Form Operations 8

7.3 Construction Loadings 8

7 .4 Structural Integrity 8

7.5 Hoisting Systems 9

7.6 Detailed Personal Safety Checks 10

8. MAINTAINING SAFETY RELATED RECORDS 10

APPENDIX A - COMPILATION OF PERTINENT EXCERPTS FROM OSHAREGULATIONS A-1

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1 . INTRODUCTION

The construction of reinforced concrete structures in which the partially-completed structure plays a key role in supporting construction workersand other construction loads presents special challenges to providinga safe working environment. In recent years, many innovative conceptsto speed construction and minimize formwork have been introduced for theconstruction of cooling towers. Many of these construction schemes relyheavily on the strength of partially cured concrete to completely supportthe working platforms, formwork and other construction equipment and loads.Because partially completed concrete shell structures may be lacking inresistance to unforeseen concentrated loadings, an accident which mightordinarily be expected to cause relatively small damage could resultin a major collapse of the elements supporting the work surface.

The Occupational Safety and Health Administration (OSHA) currently enforcesexisting construction safety regulations for general concrete construction.These regulations as contained in existing Safety and Health Regulationsfor Construction of OSHA"^ include important provisions for ensuring thesafety of workmen in concrete construction. In some types of concreteconstruction the enforcement of these provisions requires considerableengineering insight and judgement.

As a result of the natural draft cooling tower construction disaster atWillow Island, West Virginia, April 27, 1978, the Center for BuildingTechnology of the National Bureau of Standards (NBS) has reviewed existingconstruction safety and health regulations currently enforced by OSHA.This report presents recommended guidelines for use by the OSHA complianceofficers for safety evaluation of reinforced concrete shell cooling towerconstruction. These guidelines are based on the existing OSHA Constructionsafety and Health Regulations, but highlight their application to reinforcedconcrete shell cooling tower construction by pointing out critical construc-tion operations, their safety aspects, and check procedures to determineif safety regulations are being observed.

These guidelines emphasize those aspects of construction operations whichcan most readily endanger a large number of workmen through disastrousconstruction collaspes and are in addition to the more usual safety checksto ensure the maintenance of a safe working environment for individualworkers. These guidelines suggest the use of OSHA specialists and

^ Department of Labor, Bureau of Labor Standards, "Safety and HealthRegulations for Construction," (29 CFR Part 1926), Washington, D.C.

1

engineering consultants to assist the local compliance officers in

assessment if safety regulations are being observed.

2. OBJECTIVE

The objective of this report is to furnish OSHA compliance officers a

guide to enforcement of current safety regulations as they apply to con-struction of reinforced concrete shell cooling towers. It specificallyis intended to alert the compliance officer to the need to evaluate the

critical safety elements of the overall construction scheme and to checkfor compliance with existing regulations designed to guard against largescale collapse during the construction process.

3. COOLING TOWER CONSTRUCTION

Construction techniques for large natural draft reinforced concrete thinshell cooling towers have evolved rapidly in the last two decades. Thesestructures are usually a large tower with a diameter and wall thicknessthat change over the height of the tower. This necessitates constantadjustment of the forms and scaffolding to accomodate the geometricchanges. Frequently, complex patented form systems are used to provideadjustments. In the early days of tower construction, support scaffoldingoften extended from the ground to the level where concrete was being placed.In more recent times, the forms and scaffolding have been suspended frompreviously completed portions of the structure and travel up the structureas construction continues. In some applications, free standing tower cranesare used to deliver materials to the construction level, while in othersystems, hoisting devices supported from the partially completed structureare used. The concrete tower is usually cast in consecutive segmentswhich are concentric rings 1.3 to 2 m (4 to 6 ft) in height. Ordinarily,a complete circular ring is cast in a single day. Several systems utilizea 1-day sequence so that a new lift is cast each working day. Theseconstruction methods place significant construction loads at very earlyages on partially matured, partially constructed structures. Some of thesesystems also place very significant hoisting loads on the partially con-structed structure. These procedures must be carefully designed andcontrolled to ensure a safe working environment.

4. SCOPE

The recommended guidelines presented in this report are divided into two

parts. The first part (Section 6 of this report) deals with items whichshould be included in a safe construction plan. Items in this categoryshould be evaluated prior to initiation of major construction or soonafter construction commences. The second category (Section 7) deals withitems which should be checked during inspections conducted after the cool-ing tower is in advanced stages of construction. In addition, buildingcode regijlations

,that require the maintenance of safety inspection records

2

are presented in Section 8. Appendix A contains a compilation of pertinentexcerpts from the OSHA regulations.

All of the guidelines are based on the existing safety regulations of OSHA.

These include:

OSHA Standards

1. 29

2. 29

3. 29

4. 29

5. 29

6. 29

7. 29

CFR 1926.20 - General safety and health provisions.

CFR 1926.251 - Rigging equipment and material handling.

CFR 1926.451 - Scaffolding.

CFR 1926.550 - Cranes and derricks.

CFR 1926.552 - Material hoists, personnel hoists, and elevators.

CFR 1926.700 - General provisions for concrete, concrete formsand shoring.

CFR 1926.701 - Forms and shoring.

Reference Standards

1. ANSI AlO. 5-1975 - Safety requirements for material hoists.

2. ANSI AlO. 8-1977 - Safety requirements for scaffolding.

3. AnSI AlO. 9-1970 - Safety requirements for concrete construction andmasonry work.

4. ASTM C31-69 - Standard method for making and curing concrete testspecimens in the field.

5. ASTM C39-72 - Standard test method for compressive strength of cylin-drical concrete specimens.

Frequent references to specific regulations are provided and a compilationof important provisions affecting construction of this type is providedin Appendix A.

5 . APPROACH

For the construction of cooling towers, it is recommended that OSHA use a

specialist-engineer/consultant to review the proposed construction planfor conformance with OSHA regulations preferably prior to initiation of

major construction or soon after construction commences. If an OSHA

3

specialist is not available, the OSHA field office should engage the ser-vices of a consultant to assist in review of the plan. The complex engi-neering aspects of the partially completed structure and the erectionsystem indicate that any such consultant must be a registered engineer.

The specialist-engineer/consultant should brief the OSHA complianceofficers on the key elements of the construction plan and suggest inspectiontechniques to check on these elements. The plan should contain specific"bench marks" against which the OSHA compliance officer can check complianceof critical tasks affecting the safety of the worker while constructionis in progress.

The approach for subsequent inspections by OSHA compliance officers shouldbe to first check the job site for overall conformance with the constructionplan and, in particular, for proper observance of the "bench marks". Thecompliance officers will also have available to them detailed records of

critical operations which are required to be kept by building code regulations.These can be checked to determine whether the "bench marks" are being regularlyobserved between visits. After general safety is inspected to ensure that

the overall work surfaces are not in danger of collapse, then more routineindividual related safety checks can be carried out.

6. PRECONSTRUCTION PLAN REVIEW

The effectiveness of OSHA safety regulations in maintaining a safe workingenvironment during construction of cooling towers can be greatly improvedby reviewing the basic construction plan in advance of the constructionoperations

.

6 . 1 Basic Construction Plan Component

The OSHA regulations require that the contractor have the responsibilityfor providing a safe working environment for his workers [29 CFR 1926.20].He is responsible that formwork is adequately designed, erected, supported,braced and maintained so that the formwork together with the partiallycompleted structure will safely support all loadings including constructionloads. [29 CFR 1926.701(a)(1) and ANSI AlO. 9-6.1]. Since this generaltype of construction clearly should be classified as complex formwork, the

formwork must be designed or approved for use by an engineer or experiencedform designer [ANSI AlO .9-6 .2 .2] . The formwork must be planned in everyparticular and designed and constructed with an adequate factor of safety[ANSI AlO .9-6 .2 . 1] . Thus, to comply with these regulations, the contractormust have a comprehensive concrete construction plan with design, or approvalfor use, by an engineer or experienced form designer acting in his behalf.

The basic construction plan should include, but not necessarily be limited

to, the following specific items:

4

Design loads for construction.3 •

b. Design calculations.

c. Criteria for form removal and imposition of construction loads.

d. Establishment of bench marks for each stage.

6.1.1 Design Loads for Construction.

The loads used for design of the formwork and scaffolding systems shouldbe clearly listed so that they can be checked readily when consideringthe imposition of loads not foreseen in the design or the plan. Theloads considered in design should include:

1. Design loads of construction materials.

2. Dead loads of formwork and scaffolds.

3. Dead loads of hoisting systems.

4. Live loads for workers.

5. Live loads for hoisting systems plus impact.

6. Live loads for equipment plus impact.

7. Lateral loads for wind, cable tension, inclined support, impact of

concrete placement, starting and stopping of equipment.

When a partially completed and partially matured concrete shell structureis to be subjected to construction loads, the regulations require that the

contractor must confirm that the shell is designed specifically to supportsuch loads and must acquire approval for the application of such loadsfrom the engineer/architect [29 CFR 1926.701(a)(4) and ANSI AlO .9-6 .3 .4]

.

6.1.2 Design Calculations

Design calculations for the formwork system, the hoisting system, and allcomponents shall be made available at the job site

[29 CFR 1926.701(a)(2)].

These calculations may be used to assess compliance with regulations pertain-ing to construction safety. Included in these are the design of formwork,scaffolding, and hoisting assemblies, minimum strength of concrete requiredfor different phases of construction operation and the design of any otherequipment or structural component used in the construction work.

5

For ease of reference, the design calculations for the formwork and scaffold-ing systems and other supporting elements should list critical items whichwere considered in the design. These may include, but are not limited to,

the following items:

a. Loading conditions.

b. Load factors or safety factors.

c. Design unit stresses and material grades.

d. Reuse criteria for forms and associated design unit stresses.

e. Safety factors used for form accessories.

f. Any special provisions considered in the design.

6.1.3 Criteria for Form Removal and Imposition of Construction Loads

A key operation affecting worker safety is form removal and relocation.Criteria for stripping concrete forms and moving falsework shall be

set by an engineer [ANSI AlO .9-6 .4 .7] . In addition, specific pro-visions for testing field cured concrete cylinders prior to removalof forms is addressed. This requirement is a means of preventingpremature removal of forms (i.e., before the specified strength neededfor the support of construction loads is achieved). This is one of themost critical safety related provisions in cooling tower construction.

The life safety of a large number of workers is directly dependent on thestructural integrity of partially cured concrete which is used to supportthe formwork, scaffolds, various assemblies and the personnel involvedin the casting operations. This support system must not be susceptibleto initiation of a chain reaction collapse if a small part is damaged by

a minor accident. The incomplete provision for premature removal ofimportant elements can make some systems extremely susceptible to suchchain reactions. OSHA regulations require that the engineer's specifi-cations and local building codes be followed for form removal [ANSIAlO. 9-6. 4. 7] and require specific approval for the imposition of con-struction construction loads on the partially completed structure by the

engineer-architect responsible for the design of the structure [29 CFR1926.701 (a)(4) and ANSI AlO .9-6 .3 .4] . This approval will usually consistof setting certain minimum concrete strengths which must develop beforevarious operations can commence. There may be different values for differenttypes of construction operations and loadings (one value for fonn removal,another for form movement, another for hoist loading, etc.).

6

6.1.4 Establishment of Bench Marks

The key for practical enforcement is the "bench mark" which indicates a

specific measurement or check which may be used by the OSHA complianceofficer to affirm whether critical safety procedures are being adheredto during the construction process. These "bench marks" are predeterminednorms against which job records and other supplementary information acquiredfrom independent observations in the field can be compared to ensure thatsafe construction practices are being followed.

Typical bench marks may include:

a. Minimum concrete strength for form removal.

b. Minimum concrete strength for falsework movement.

c. Minimum concrete strength for operation of hoisting devicesattached to or supported by the partially completed structure.

d. Minimum concrete strength for placement of new concrete.

e. Number, size, and location of fastenings, ties, anchor devicesor other supports required so that the falsework and forms performsafely at each stage of construction.

f. Criteria to be met before removal or relocation of any fastenings,ties, anchor devices or other supports.

g. Maximum hoisting load and maximum operating speed.

h. Minimum hoist clearance and size of sheaves.

i. Size of cables and sheaves.

6 .2 Personnel Training In Construction Operation

An awareness of the critical safety aspects of the operations by allemployees in the field will be a key factor in reducing the risk of

catastrophic construction failures.

Training and education of personnel in safe conduct of work is part of

OSHA safety regulations [29 CFR 1926.20 and 29 CFR 1926.21(b)(2)]. Adetailed procedure manual for use in training personnel in safe operationsshould be developed as part of the basic construction plan. The manualshould spell out the sequence of key operations, the number and sequenceof attachments, key limits for decisions on major operations, safety checks,periodic inspection of safety-related ifems and any other action that canbe foreseen and that would prevent unsafe situations from developing duringthe operations. Key personnel shall be thoroughly trained in this planand all personnel should have basic knowledge of important details. Having

7

this key information on record will enable the OSHA compliance officersto conduct their field investigations with regard to safety education of

personnel

.

The supervisors, lift equipment operators, and the material hoists operatorsshall be trained for the operations of their particular system and shallbe particularly knowledgeable with regard to the critical safety aspectsof the overall construction plan.

An important element of this task is the training of inexperienced workersas well as job orientations of other workers not previously engaged incooling tower construction operations.

7. INSPECTION TASKS DURING CONSTRUCTION PHASE

In cooling tower construction the OSHA compliance officer must check theoverall safety of the working place as well as the detailed personal safetyrequirements normally applicable to all construction.

The nature of this type of construction requires certain specific typesof checks which involve construction operations that are critical to

the maintenance of safety. These are covered in the following sections.

7 . 1 Concrete

The development of concrete strength is affected primarily by mixproportions of material ingredients, age, and curing temperature.Particularly, in cold weather, concrete gains strength slowly. Specialcuring, such as steam curing, can accelerate strength gain. Certaintypes of cements and admixtures will slow down strength developmentwhile other types will accelerate strength development. Concretestrength therefore cannot be determined by visual inspection or by"tradition”. The safety of formwork operations often depends almostcompletely on the concrete having reached certain strength values.These values should be clearly indicated as "bench marks."

On job-site inspections, the records of tests of field cured (notlaboratory cured) concrete specimens should be checked to determinethat specimens were tested prior to formwork removal or other keyconstruction operations and that the minimum strengths required (benchmarks) were met. Failure to meet these requirements is a severe violationof ANSI AlO.9-6.4.7 and imposes great risks on the working force.

7 .2 Formwork Operations

Each individual construction system will have a series of key attachmentrequirements and construction operation sequences. "Bench marks" shouldbe established to identify these critical factors. Records for form place-ment, removal and other construction operations should be checked to

8

determine that requirements are being followed. These should be crosschecked with materials test records to see that proper strength was developedbefore operations were carried out. Visual inspection of current operationsshould be carried out to determine that all key equipment and operationsare in accordance with the construction plan. Particular attention shouldbe given to the number, location, and sequencing of attachment and anchordevices which support the traveling forms and scaffolding.

7

.3

Construction Loadings

The construction loadings for which the construction system has beendesigned should be outlined in the construction plan. Visual inspectionshould be made to determine if additional construction loadings are beingimposed. Extra equipment, material stockpiles, excess hoist loads createdby hurried operations can cause excessive construction loadings.

7

.4

Structural Integrity

If the construction operations are being supported by the partially completedstructure, the OSHA compliance officer must be concerned with the integrityof the support structure. If signs of structural inadequacy are presenta structural engineering specialist should be consulted.

Such items as severe honeycombing of concrete, exposed reinforcement,omission of reinforcement, severe cracking, gross tolerances, or crumblingconcrete indicate potential distress.

7 .

5

Hoisting System

Overall safety requirements for material and personnel hoists are specifiedin 29 CFR 1926.552 and ANSI A10.5. In addition, the hoisting system andits interaction with the construction system and the partially completedstructure should be checked. Signs of severe impact can indicate overloadon the support structure. Failure of a hoist wire rope can cause severeconsequences if the payload then impacts the scaffolding, formwork, orsupport structure.

Detailed inspection records for all hoisting machinery should be checked[29 CFR 1926.550(a)]. Specific checks should be made to determine thatrequired daily visual inspections of hoisting machinery are being performedand manufacturers’ specifications adhered to [ANSI AlO .5-16 .19] . A thoroughannual inspection of the hoisting machinery shall be performed by a compe-tent person or a government or private agency recognized by the U.S.Department of Labor. The employer shall maintain records of dates andresults of inspections for each hoisting machine and piece of equipment.The following highlight the various ANSI inspection specifications:

9

ANSI 10.5-14.2.1 - Period of inspection is defined.29 CFR 1926.25(a)(1)

ANSI AlO .5-14 .2 .2 Method of wire rope inspection is defined.

ANSI AlO. 5-14. 3.1 - Criteria for wire rope removal and replacementis given.

ANSI AlO. 5-14. 4 - Requirements for wire rope installation are given.

After the wire rope has been in use for a maximum of one month, all nutson all wire rope clips shall be retightened to the manufacturers* torquerecommendations [ANSI 10.5-15.3]. The minimum number of clips, spacingof clips and torque tightening of clips shall conform to manufacturers*recommendations [ANSI 10.5-15.2].

All drums and sheaves shall conform to ANSI 10.5, Sections 14.5.1 through14.5 .13.

Electrical communication during hoist operations shall conform to ANSI 10.5,

Section 19.0. The OSHA compliance officer shall inspect the communicationsystems according to a preestablished "bench mark" to ensure compliance.

Records of the designated inspections and conclusive findings shallbe maintained at the job site by the designated inspector and madeavailable to the OSHA compliance officer.

7.6 Detailed Personal Safety Checks

After the OSHA compliance officer has checked the construction-erectionprocedures critical to the support of work surfaces for which failuremight result in multiple injuries and fatalities, he should proceed withmore detailed and routine checks for compliance with regulations whoseviolation might result in injury to a single worker or a small group ofworkers

.

8. MAINTAINING SAFETY-RELATED RECORDS

Current building code provisions (ACI , Section 1.3 and 3.1)require important construction and safety records, which are vital forthe OSHA Inspection of overall construction safety, be kept during progressof work and for two years after completion of work. In addition, these

2 Building Code Requirements for Reinforced Concrete, ACI 318-77, AmericanConcrete Institute, Detroit, Michigan.

10

provisions require that all concrete construction shall be inspectedthroughout the various work stages by a competent engineer or architect,or their competent representative normally representing the owner. Thusa designated inspector must maintain a record which covers many items whichcan indicate if construction is in accordance with the construction plan.

Some of the key items required by ACI 318-77 Sections 1.3 and 3.1 include:

a. Maintaining records for quality, proportions, mixing, placing and curingconcrete.

b. Maintaining detailed temperature and curing records in cold and hotweather.

c. Maintaining records for reinforcing placement, form placement and removal.

d. Maintaining records for any significant construction loadings on com-pleted walls.

e. Maintaining a complete record of tests of materials including concrete.

The contractor should identify individuals who are responsible for inspectingand maintaining the records of these items.

Since ANSI AlO.9-6.4.7 requires that tests shall be made on field-curedconcrete specimens prior to form removal, records of these early ageconcrete tests must be maintained as well as the more usual 28-day teststo determine quality of the mature concrete. These records should bechecked against the "bench mark" values from the construction plan.

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APPENDIX A

CONTENTS

A.l Excerpts from Safety and Health Regulations for Construction29 CFR Part 1926, Bureau of Labor Standards, Department of Labor,Washington, D.C., June 24, 1974.

A. 2 Excerpts from Safety Requirements for Material Hoists, AmericanNational Standard ANSI AlO. 5-1975, American National StandardsInstitute, New York, New York.

A. 3 Excerpts from Safety Requirements for Concrete Construction andMasonry Work, American National Standard ANSI AlO. 9-1970, AmericanNational Standards Institute, New York, New York.

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A.l Excerpt fromSafety and Health Regulationfor Construction,29 CFR Part 1926Bureau of Labor StandardsDepartment of LaborWashington , D . C

.

June 24, 1974

§ 1926^0 General rafety and healthproviaions.

(a) Contractor reqiiireTnents. ( 1 ) Sec-tion 107 of the Act requires that it shallbe a condition of each contract which Isentered into under legislation subject toReorganlaatlon Plan Number 14 of 1950(64 Stat. 1267). as defined In 5 1926.12,and is for construction, alteration, and/or repair. Including painting and deco-rating. that no contractor or subcontrac-tor for any part of the contract workshall require any laborer or mechanicemployed in the performance of the con-tract to work in surroundings or under

. working conditions which are unsanitary,hazardous, or dangerous to his health orsafety.

(b) Accident prevention responsibiU^ties. (1) It shall be the responsibility ofthe employer to initiate and maintainsuch programs as may be necessary tocomply with this part.

(2) Such programs shall provide forfrequent and regular inspections of thejob sites, materials, and equipment tobe made by competent persons desig-nated by the employers.

(3) The use of any machinery, tool,material, or equipment which is not incompliance with any applicable require-ment of this part is prohibited. Suchmachine, tool, mateiiail. or equipmentshall either be identified as unsafe bytagging or locking the controls to renderthem inoperable or shall be physicallyremoved from its place of operation.

(4) The employer shall permit onlythose employees qualified by training orexperience to operate equipment andmachinery.

§ 1926.21 Safety training and edneatioo.

. (a) General requirements. The Secre-tary Shan, pursuant to section 107(f) ofthe Act, establish and supervise programsfor the education and training of em-ployers and employees in the recognition,avoidance and prevention of unsafe con-ditions in employments covered by theact

(b) Employer responsibUity. (i) Theemployer should avafi himself of thesafety and health training programs theSecretary provides.

(2)

The employer shall Instruct eachemployee In the recognition and avoid-ance of unsafe conditions and the regu-lations applicable to his work environ-ment to control or eliminate any hazardsor other exposure to Illness or injury.

§ 1926.251 Rigging equipment for ma-terial handling.

(a) General. (1) Rigging equipmentfor material handling shall be inspectedprior to use on each shift and as nec-

essary during its use to ensure that it is

safe. Defective rigging equipment shall

be removed from service.

(2) Rigging equipment shall not beloaded in excess of its recommended safeworking load, as prescribed in TablesH-1 through H-20 in this subpart, fol-

lowing i 1926.252(e) for the specific

equipment.(3) Rigging equipment, when not in

use, shall be removed from the imme-diate work area so as not to present ahazard to employees.

(4) Special custom design grabs,hooks, clamps, or other lifting accesso-ries, for such units as modular panels,prefabricated structures and similar ma-terials, Shan be marked to indicate thesafe working loads and shaU be proof-tested prior to use to 125 percent of theirrated load.

(b) Alloy steel chains. (1) Welded al-

loy steel chain slings shaU have perma-nently aflBxed durable identification stat-ing size, grade, rated capacity, and sUngmanufacturer.

(2) Hooks, rings, oblong links, pear-shaped links, welded or mechanical cou-pling Unks, or other attachments, whenused with aUoy steel chains, shaU havea rated capacity at least equal to thatof the chain.

(3) Job or shop hooks and Unks, ormakeshift fasteners, formed from bolts,

rods, etc., or other such attachments,ShaU not be used.

(4) Rated capacity (working loadUmit) for aUoy steel chain slings shaUconform to the values shown in TtUaleH-1.

(5) Whenever wear at any point ofany chain link exceeds that shown inTable H-2, the assembly shaU be removedfrom service.

(c) Wire rope. (1) Tables H-3 throughH-14 ShaU be used to determine the safeworking loads of various sizes and clas-sifications of Improved plow steel wirerope and wire rope slings with varioustypes of terminals. For sizes, classifica-

tions, and grades not Included in thesetables, the safe working load recom-mended by the manufacturer 'for spe-cific, identifiable products shaU be fol-lowed. provided that a safety factor ofnot less than 5 Is maintained.

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(2) Protruding ends of strands Insplices on slings and bridles shall be cov-ered or blunted.

(3) Wire rope shall not be secured byknots, except on haul back lines onscrapers.

(4) The following limitations shallapply to the use of wire rope:

(I) An eye splice made In any wirerope shall have not les« than three fulltucks. However, this requirement shall

not operate to preclude the use of an-other form of splice or connection whichcan be shown to be as efficient and whichIs not otherwise prohibited.

(II) Except for eye splices in the endsof wires and for endless rope slings, eachwire rope used in hoisting or lowering,or in pulling loads, shall consist of onecontinuous piece without knot or splice.

(ili) Eyes in wire rope bridles, slings,

or bxrll wires shall not be formed by wirerope clips or knots.

(iv) Wire rope shall not be used if, inany length of eight diameters, the total

number of visible broken wires exceeds10 percent of the total number of wires,

or if the rope shows other signs of ex-cessive wear, corrosion, or defect.

(5)

.When u-bolt wire-rope clips areused to form eyes. Table H-20 shall beused to determine the number and spac-ing of cUps.

(1) When used for eye splices, theu-bolt shall be applied so that the “u”section is in contact with the dead endof the rope.

(d) Natural rope, and synthetic fiber—(1) General. When using natural or syn-thetic fiber rope slings. Tables H-15, 16,

17, and 18 shall apply.(2) AU splices in rope slings provided

by the employer shall be made in accord-ance vdth fiber rope manufacturersrecommendations.

(1) In manlla rope, eye splices shallcontain at least three f\iU tucks, andshort splices shall contain at least six full

tucks (three on each side of the center-line of the splice)

.

(li) In layed synthetic fiber rope, eyesplices shall contain at least four fuUtucks, and short splices shall containat least eight full tucks (four on eachside of the centerline of the splice)

.

(ill) Strand end tails shall not be

trimmed short (fiush with the surface

of the rope) immediately adjacent to the

full tucks. This precaution applies to

both eye and short splices and all types

of fiber rope. For fiber ropes under 1-inch

diameter, the tails shall project at least

six rope diameters beyond the last full

tuck, fk>r fiber ropes 1-inch diameter andlarger, the tails shall project at least 6

Inches beyond the last full tuck. In ap-plications where the projecting tails maybe objectionable, the tails shall be ta-

pered and spliced into the body of the

rope using at least two additional tucks

(which will require a tail length of ap-

proximately six rope diameters beyondthe last fuU tuck)

.

(iv) For all eye splices, the eye shall

be sufficiently large to provide an in-

cluded angle of not greater than 60* at

the splice when the eye is placed over the

load or support.

(V) Knots shall not be used in lieu ofsplices.

(e) Synthetic webbing (.nylon, poly-ester, and polypropylene). (1) The em-ployer shall have each synthetic websling marked or coded to show:

(1) Name or trademark of manufac-turer.

(U) Rated capacities for the type of

hitch.(iii) Tj-pe of material.

. (2) Rated capacity shall not be ex-

ceeded.(f) Shackles and hooks. (1) Table

H-19 shall be used to determine the safeworking loads of various sizes of shack-les. except that higher safe working loadsare permissible when recommended bythe manufacturer for specific, identifia-

ble products, provided that a safety fac-

tor of not less than 5 is maintained.(2) The manufacturer's recommenda-

tions shall be followed in determining thesafe working loads of the various sizes

and types of specific and identifiable

hooks. All hooks for which no applicablemanufacturer’s recommendations areavailable shall be tested to twice the in-

tended safe working load before they are

initially put into use. The employer shadl

maintain a record of the dates and re-

sults of such tests.

.

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§ 1926.451 Scafifolding.

() General retjuirements. (1) Scaf-folds shall be erected tn accordance withrequirements of this section.

(2) The footing or anchorage for scaf-

folds shall be sound, rigid, and capableof carrying the maximum Intended loadwithout settling or displacement. Un-stable objects such as barrels, boxes,loose brick, or concrete blocks, shall notbe used to support scaffolds or planks.

(3) No scaffold shall be erected,moved, dismantled, or altered except\inder the supervision of competentpersons.

(4) Guardrails and toeboards shall beinstalled on aU open sides and ends ofplatforms more than 10 feet above theground or floor, except needle beam scaf-folds and floats (see paragraphs (p) and(w) of this section) . Scaffolds 4 feet to

10 feet in height, having a minimumhorizontal dimension in either directionof less than 45 inches, shall have stand-ard guardrails Installed on all open sides

and ends of the platform.(5) Guardrails shall be 2 x 4 inches,

or the equivalent, approximately 42inches high, with a mldrall, when re-

quired. Supports shall be at intervals notto exceed 8 feet. Toeboards shall be aminimum of 4 Inches in height.

() Where persons are required towork or pass under the scaffold, scaffolds

shall be provided with a screen betweenthe toeboard and the guardrail, extend-ing along the entire opening, consistingof No. 18 gauge U.S. Standard wire Vi-inch mesh, or the equivalent.

(7) Scaffolds and their componentsshall be capable of supporting withoutfailure at least 4 times the maximum in-tended load.

(8) Any scaffold including accessoriessuch as braces, brackets, trusses, screwlegs, ladders, etc. damaged or weakenedfrom any cause shall be hnmediately re-paired or replaced.

(9) All load-carrying timber mem-bers of scaffold framing shall be a mini-mum of 1,500 flber (Stress Grade) con-struction grade lumber. All dimensionsare nominal sizes as provided in theAmerican Lumber Standards, except thatwhere rough sizes are noted, only roughor undressed lumber of the size specifiedwill satisfy Tninimnm requirements.

(10)

All planking shall be Scaffold

Grades, or equivalent, as recognized byapproved grading rules for the species of

wood used. The maximum permissible

spans for 2- x 10-lnch or wider planksshall be as shown in the following:

Tabls Ij-3

Matebial

Full thickness Nominalundressed thicknesslumber lumber

Working load (pA.f.).„... 25 fiO 76 25 60

Permissible span (it.)__. 10 8 6 8 6

1 Nominal thickness lumber not recommended for

heavy duty use.

(11) The maximum permissible spanfor 1V4- X 9-inch or wider plank of full

thickness shall be 4 feet with mediumduty loading of 50 p.sff.

(12) All planking of platforms shall

be overlapped (minimum 12 Inches), or

secured from movement.(13) An access ladder or equivalent

safe access shall be provided.(14) Scaffold plaiiks shall extend over

their end supports not less than 6 inches

nor more th^ 12 inches.(15) The poles, legs, or uprights of

scaffolds shall be plumb, and securely

and rigidly braced to prevent swayingand displacement.

(16) Overhead protection shall be pro-vided for men on a scaffold exposed to

overhead hazards.(17) Slippery conditions on scaffolds

shall be eliminated as soon as possible

after they occur.(18) No welding, burning, riveting, or

open flame work shall be performed onany staging suspended by means of fiber

or synthetic rope. Only treated or pro-tected flber or synthetic ropes shall beused for or near any work involving theuse of corrosive substances or chemicals.Speciflc requirements for boatswain’schairs and float or ship scaffolds arecontained in paragraphs (1) and (w) of

this section.

(19) Wire, synthetic, or fiber rope usedfor scaffold suspension shall be capable of

supporting at least 6 times the ratedload.

(20) The use of shore or lean-to scaf-folds is prohibited.

(21) Lumber sizes, when used in this

subpart, refer to nominal sizes exceptwhere otherwise stated.

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(g) Outrigger scaffolds. ( 1 ) Outriggerbeams shall extend not more than 6 feetbeyond the face of the building. The in-board end of outrigger beams, measuredfrom the fulcnim point to anchoragepoint, shall be not less than 1 V2 times theoutboard end in length. The beams shallrest on edge, the sides shall be plumb, andthe edges shall be horizontal. The ful-crum point of the beam shall rest on asecure bearing at least 6 inches in eachhorizontal dimension. The beam shall besecured in place against movement andshall be securely braced at the fulcrumpoint against tipping.

(2) The Inboard ends of outriggerbeams shall be securely anchored eitherby means of struts bearing against sills

in contact with the overhead beams orcelling, or by means of tension memberssecured to the floor Joists underfoot, orby both if necessary. The inboard ends ofoutrigger beams shall be secured agsdnsttipping and the entire supporting struc-ture shall be securely braced in both di-rections to prevent any horizontalmovement.

(3) Unless outrigger scaffolds are de-signed by a registered professional engi-neer competent in this fleld, they shall beconstructed and erected in accordancewith Table L-13. Outrigger scaffolds, de-signed by a registered professional engi-neer, shall be constructed and erected inaccordance with such design.

Tabls L-13—MiKiMtTM Nominal 3n* and MAxnroiiSpacinq or M£mbsr3 or Odtbigoeb Scattolds

VfRTjmMTT) scaffoldload.

Light duty Medium duty

25 pgj. . 60pj.i.

Outrigger 2 T 10 In . 3 1 10 In;Maximum outrigger 10 It. 0 In . . 6(t. Oln.spacing.

PIftnlr1ng._ ... 2 1 10 InGuardrail ... 2x4 In— 2 T 4 In.

Guardrail uprights... 2 I tin . 2x lln.Toeboards 4 in. (mini- 4 In. (mini-

mum). mum).

(4) Flanking shall be laid tight andshall extend to within 3 Inches of thebuilding wall. Planking shall be securedto the beams.

(5) Guardrails made of lumber, notless than 2x4 Inches (or other materialproviding equivalent protection)

, ap-proximately 42 Inches high, with a mid-rail of 1 X 6 inch lumber (or other ma-terial providing equivalent protection),and toeboards, shall be Installed at allopen sides and ends on all scaffolds morethan 10 feet above the ground or floor.Toeboards shall be a mlnlmmn of 4Inches in height. Wire mesh shall be in-stalled in accordance with paragraph(a)( 6 ) of this section.

§ 1926.552 Material Hoists, personnelhoists, and elevators.

(a) General requirements. (1) Theemployer shall comply with the man-ufacturer’s specifications and limitations

applicable to the operation of all hoists

and elevators. Where manufacturer'sspeciflcations are not available, the lim-

itations assigned to the equipment shall

be based on the determinations of a pro-fessional engineer competent in the field.

(2) Rated load capacities, recom-mended operating speeds, and special

hazard warnings or instructions shall beposted on cars and platforms.

(3) Wire rope shall be removed fromservice when any of the following con-ditions exists:

(1) In hoisting ropes, six randomlydistributed broken wires in one rope lay

or three broken wires in one strand in

one rope lay;

(it) Abrasion, scrubbing, flattening, orpeening, causing loss of more than one-third of the original diameter of theoutside wires;

(ill) Evidence of any heat damage re-sulting from a torch or any damagecaused by contact with electrical wires;

(Iv) Reduction from nominal diam-eter of more than three sixty-fourthsInch for diameters up to and Includingthree-fourths inch; one-sixteenth inchfor diameters seven-eighths to IVeinches: and three thirty-seconds inch fordiameters 1

V

4 to 1 Inches.(4) Hoisting ropes shall be Installed

In accordance with the wire rope manu-facturer's recommendations.

(5) The Installation of live booms onhoists is prohibited.

( 6 ) The use of endless belt-type man-Ufts on construction shall be prohibited,

(b) Material hoists, (1) (i) Operatingrules shall be established and posted atthe operator's station of the hoist. Suchrules shall Include signal system andallowable line speed for various loads.Rules and notices shall be posted on thecar frame or crosshead in a conspicuouslocation, including the statement “NoRiders Allowed."

(ii) No person shall be allowed to rideon material hoists except for the pur-poses of inspection and maintenance.

(2) All entrances of the hoistwasrsshall be protected by substantial gatesor bars which shall guard the full widthof the landing entrance. All hoistwayentrance bars and gates shall be paintedwith diagonal contrasting colors, suchas black and yellow stripes.

(1) Bars shall be not less than 2- by4-lnch wooden bars or the equivalent,located 2 feet from the hoistway line.

Bars shall be located not less than 38

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Inches nor more than 42 inches abovethe hoco:.

(il) Gates or bars protecting the en-trances to holatwavs shall be equippedwith a latching device.

(3) Overhead protective covering of2-tnch planMng. %-lnch plywood, orother solid material of equivalentstrength, shall be provided on the topof every material hoist cage or platform.

(4) The operator’s station of a hoist-ing machine shall be provided with over-head protection equivalent to tight

planking not less than 2 inches thick.The support for the overhead protectionShan be of equal strength.

(5) Hoist towers may be used with orwithout an enclosure on all sides. How-ever, whichever alternative is chosen, thefonowing applicable conditions shall bemet:

(1) When a hoist tower is enclosed, it

shan be enclosed on siU sides for its en-tire height with a screen enclosure of

'Vi-lnch mesh. No. 18 UJ3. gauge wire orequivalent, except for landing access.

(ii) When a hoist tower is not en-closed, the hoist platform or car shall betotally enclosed (caged) on all sides for

the full height between the floor and theoverhead protective covering with %-inch mesh of No. 14 UjS. gatige wire orequivalent. The hoist platform enclosureshall include the required gates for load-ing and unloading. A 6-foot high en-closiire shall be provided on the imusedsides of the hoist tower at ground leveL

(6) Car arresting devices shall be in-stalled to function in case of rope failure.

(7) All material hoist towers shall bedesigned by a licensed professional engi-neer.

(8) All material hoists shall conformto the requirements of ANSI A10.5-1S69,Safety Requirements for MaterialHoists.

§ 1926.'533 Base-mounted drum hoists.

(a) General requirements. (1) Ex-posed moving parts such as gears, pro-

jecting screws, setscrews, chain, cables,

chain sprockets, and reciprocating or

rotating parts, which constitute a hazard,

shall be gtiarded.

(2) All controls tised during the nor-

mal operation cycle shall be located

within easy reach of the operator’s

station.

(3) Electric motor operated hoists

shall be provided with:

(1)

A device to disconnect all motors

from the line upon power failure and not

permit any motor to be restarted until

the controller handle is brought to the

“off” position;

(ii) Where applicable, an overspeed

preventive device:

(ill) A means whereby remotelyoperated hoists stop when any control isineffective.

(4)

All base-mounted drum hoists inuse shall meet the applicable require-ments for design, construction, installa-tion, testing, inspection, maintenance,and operations, as prescribed by themanufacturer.

Subparf Q—Concrete, ConcreteForms, and Shoring

§ 1926.700 General provision*.

(a) General. All equipment and mate-rials used in concrete construction andmasonry work shall meet the applicablerequirements for design, construction. In-spection, testing, maintenance and oper-ations as prescribed in ANSI AlO.9-1970,Safety Requirements for Concrete Con-struction and Masonry Work.

§ 1926.701 Forms and shoring.

(a) General provisions. (1) Form-work and shoring shall be designed,erected, supported, braced, and main-tained so that it will safely support all

vertical and lateral loads that may beImposed upon it during placement of

concrete.(2) Drawings or plans showing the

Jack layout, formwork, shoring, workingdecks, and scaffolding, .shall be availableat the jobsite.

(3) Stripped forms and shoring shall

be removed and stockpiled promptlyafter stripping, in all areas in which per-sons are required to work or pass. Pro-truding nails, wire ties, and other formaocessories not necessary to subsequentwork shall be pulled, cut, or other meanstaken to eliminate the hazard.

(4) Imposition of any constructionloads on the partially completed struc-ture shall not be permitted unless suchloading has been considered in the de-sign and approved by the engineer-architect.

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A. 2 Excerpts fromSafety Requirements for Material HoistsAmerican National Standard ANSI AlO. 5-1975American National Standards InstituteNew York, New York

The Excerpts from ANSI AlO. 5-1975 arereproduced herin by permission of theAmerican National Standards Institute,New York, New York 10018.

American National StandardSafety Requirements for

Material Hoists

1. General

1.1 Scope. This standard applies to material hoists

used to raise or lower materials during construction,

alteration, or demolition. It is not applicable to the

temporary use of permanently installed personnel

elevators as material hoists.

1.1.1

This standard shall not apply to:

(1) Elevators constructed and operated in con-

formance with American National Standard Safety

Code for Dumbwaiters, Escalators, and Moving Walks,

A17.1-1971, including Addenda A17. la-1972, A17.1b-

1973, and A17.1c-1974

(2) Personnel hoists constructed and operated in

conformance with American National Standard Safety

Requirements for Personnel Hoists, A1 0.4- 1973

(3) Manlifts constructed and operated in confor-

mance with American National Standard Safety Stan-

dard for Manlifts, A90. 1-1969, including Supplement

A90.1a-1972

1.2 Purpose. This standard is designed to provide pro-

tection for those engaged in occupations requiring the

use of material hoists and sets forth the minimum re-

quirements for that purpose.

1.3 Exceptions. In cases of practical difficulties, unnec-

essary hardships, or new developments, exceptions to

the literal requirements may be granted by the enforcing

authority to permit the use of other devices or methods,

but only when it is clearly indicated that equivalent pro-

tection is thereby secured.

2. Related Standards

2.1 General. This standard is intended for use in con-

junction with the standards listed in 2.2 and 2.3.

2.2 American National Standards (See Section 24)

‘

American National Standard Safety Requirements for

Scaffolding, A 10.8- 1969

American National Standard Safety Standard for Me-

chanical Power Transmission Apparatus, B15. 1-1972

American National Standard National Electrical Code,

Cl-1971 (NFPANo. 70-1971)

American National Standard Installation of Portable

Fire Extinguishers, Z1 12.1-1974 (2nd ed) (NFPA No.

10-1974)

2.3

American Institute of Steel Construction^

AJSC S3 10, Specification for the Design, Fabrication,

and Erection of Structural Steel for Buddings, Feb 12,

1969

3.

Definitions

In this standard the following defiiutions shall apply:

approved. Accepted as satisfactory by a duly consti-

tuted administrative or regulatory authority.

bucket. A metal container attached to the cage or cage

frame and used to distribute concrete or other materials

to various elevations.

cage/car. The load-carrying unit, consisting of a plat-

form, a top, and a full or partial side enclosure.

car-arresting device. A device that will stop and hold the

car with its rated load in the event of the failure of the

wire rope, rack, pinion, or other car suspension means.

cathead. The structure for the support of the overhead

sheaves.

equivalent. Denotes an alternate design, feature, device,

or protective action that provides an equal degree of

safety.

gross load (static load). The ma.ximum load imposed on

all rope by the platform, cage, car, or bucket and its

rated load.

' Available from American National Standards Institute, Inc,

1430 Broadway, New York, N.Y. 10018.

’ Available from American Institute of Steel Constructioit,

101 Park Avenue, New York, N.Y. 10017.

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(

hoistway. A temporary shaftway — the space traveled

by the platform or bucket.

hoistway enclosure. The structure that isolates the

hoistway from all other parts of the building and on

which the hoistway doors or gates and door or gate

assemblies are installed.

inside hoists. Hoistways contained entirely within the

building being served and which sometimes use the

building structure itself for the support of the top

beams, guide rads, and appurtenant parts necessary for

the proper functioning of the platform.

iive/luffing boom. A boom that does not operate on a

fixed radius and is capable of vertical movement.

mast (tower). A vertical structure that supports and

guides the platforms or buckets (and the counterweight,

when used) on the outside of the mast structure.

material hoist. A mechanism for use in connection with

the hoisting of construction or demolition materials. It

is equipped with a platform, car, cage, or bucket that

moves vertically on guide members.

platform. The load-carrying unit, including the frame,

that directly supports the load.

rated load. The maximum live load for which the hoist

structure is designed to operate.

rope. Refers to wire rope only.

shall. The word “shall” is to be understood as manda-

tory.

should. The word “should” is to be understood as ad-

visory.

tower. A vertical structure that supports and guides the

platforms or buckets (and the counterweight, when

used) within or on the tower structure.

4.

Requirements for Hoist Towers

4.1 Construction. Structural members of material

hoist towers shall be constructed of strong, sound

timber, steel, or other structural materials.

4.2 Initial Inspection. Before the hoist is placed in ser-

vice, and each time after the tower is extended, all

parts of the tower or mast, cage, bucket, boom, plat-

form, hoisting machine, guys, and other equipment

shall be thoroughly inspected by qualified and com-

petent personnel.

4.3 Periodic Inspection. All sheaves, racks and pinions,

guy ties, bolt connections, miscellaneous clamps.

braces, and similar parts shall be regularly inspected

after the installation is initially placed in operation

and as required. (Monthly inspections are recommended.)

All broken, defective, and worn parts shall be repaired

or replaced immediately.

4.4 Car-Arresting-Device Test. Before the hoist is

placed in service and every four months thereafter, a

car-arresting-device test shall be performed in accor-

dance with 1 1.9.6.

4.5 Design. All material hoist towers, masts, guys or

braces, counterweights, drive machinery supports,

sheave supports, platforms, supporting structures and

accessories shall be designed by licensed professional

engineers.

5.

Design and Construction of Foundations

Hoist-tower foundations shall be constructed to sup-

port the tower’s intended live and dead loads safely

and shall not exceed the safe bearing capacity of the

ground or floor upon which they rest.

6.

Erection

6.1 Vertical Alignment. Hoist towers shall be plumb.

6.2 Guide Rails. The guide rails of hoists shall be of

structural metal, or the equivalent, securely fastened,

and shall deflect no more than 1/4 inch under normal

operation.

6.3 Grounding. Hoist towers shall be electrically

grounded.

6.4 Hoist-Tower Enclosures. Hoist towers may be used

with or without an enclosure on all sides. However,

whichever alternative is chosen, applicable conditions

in 6.4.1 through 6.4.3 shall be met:

6.4.1 When a hoist tower is enclosed, it shall be en-

closed on all sides for its entire height by a wire-screen

enclosure of not less than No. 19 U.S. gage wire or

equivalent material, with openings not exceeding 1/2

inch, securely fastened to the tower structure, with

openings formed onto each landing.

6.4.2 When a hoist tower is not enclosed, the hoist

platform or car shall be totally enclosed as set forth

in 11.7.

6.4.3 For hoists located outside of structures, the

enclosures, except those at the lowest landing, may be

omitted on the sides where there is no floor or scaffold

adjacent to the hoistway. Enclosures on the building

f ^'^<4

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Table 1

Minimum Sizes of Various Members in Wooden Towers

CapacityHeight fromTop Down

(ft)

Post

Sizes

(in)

Horizontal

Tie

Sizes

(in)

Diagonal

Brace

Sizes

(in)

MaximumTie Spacing

(in)

Platform

(lb)

Bucket

(yd^

To 500 Top to 72 4X4 1 X 6 1 X 6 6

500 - 72 to 198 4X6 2X6 1 X 8 6

1000 1/4 Top to 72 4X4 1 X 6 1 X 6 6

1000 1/4 72 to 126 4X6 2X6 1 X 8 6

1000 1/4 126 to 198 6X6 2X6 1 X 8 6

2000 1/2 Top to 80 4X6 2X6 1 X 8 8

2000 1/2 80 to 128 4X6 2X6 1 X 8 8

2000 1/2 128 to 208 6X6 2X6 2X6 8

4000 1 Top to 80 4X6 2X6 2x6 8

4000 1 80 to 128 6X6 2X6 2X6 8

4000 1 128 to 208 6X8 2X8 2x6 8

10. Requirements for Inside Hoists

10.1 Enclosure. The sides of the hoistways not used

for entrances shall be enclosed on each floor for their

entire height with wire mesh or equivalent material and

reinforced to withstand a horizontal force of 100

pounds per square foot, applied at any point. The open-

ings in the mesh shall not exceed 1/2 inch.

10.2 Covering at Cathead. Protective covering of heavy

planking shall be provided at the cathead of all hoists

to prevent objects falling down the hoistway.

11. Hoist Platforms and Cages

11.1 Prohibition of Riders. Workmen shall be pro-

hibited from riding the hoist platform except for autho-

rized inspection and maintenance. A sign shall be posted

on the car frame or enclosure; NO RIDERS ALLOWED.

11.2 Rolling Equipment. When wheelbanows or other

rolling equipment are transported, they shall be held

securely in place on the hoist platform. The platform

shall be level with the landing prior to loading or unload-

ing rolling equipment.

11.3 Overhead Protection. Overhead protective cover-

ing of 2-inch planking, 3/4-inch plywood, or other solid

material of equivalent strength shall be provided on the

top of every material hoist cage or platform to prevent

objects falling on the workmen loading or unloading

the hoist.

11.4 Hinged Covers. The protective covering on the

top of the cage or platform may be made in hinged sec-

tions that can be raised when long material is hoisted.

Hinged covers shall be designed and constructed so that

they cannot strike any part of the tower.

1 1.5 Seeming Long Material. When a cage or platform

is used for long material, the several pieces of the mate-

rial shall be securely fastened together and made fast

to the cage or platform so that no part of the load can

fall or project beyond the sides of the cage or platform.

11.6 Slip-Resistant Floors. Platform floors covered

with metal shall have a slip-resistant surface.

11.7 Platform Enclosme. When a hoist tower is not

enclosed, the hoist platform shall be totally enclosed

(caged) on all sides, including the roof, for the full dis-

tance between the floor and the cage top. The walls

and the gates of the cage shall be constructed of 2-inch

No. 14 U.S. gage wire mesh, or the equivalent. The

hoist platform enclosure will include the required gates

for loading and unloading.

11.8 Load-Rating Plate. A load-rating plate shall be

attached to the hoist to indicate the live load capacity

of:

(1) The platform with the cage installed

(2) The bucket and supporting structure

11.9 Car-Arresting Safety Device. A car-arresting de-

vice shall be used with a material platform or a platform

installed in conjunction with a bucket, and it shall con-

form to the requirements given in 1 1 .9.1 through 1 1 .9.6.

However, under no circumstances shall it be required to

satisfy the requirements of American National Standard

Safety Requirements for Personnel Hoists, A 10.4- 1973.

1 1.9.1 The car-arresting device, when engaged, shall

be capable of stopping and holding the platform with

its rated load.

1 1.9.2 The car-arresting device shall be securely at-

tached to the frame of the platform or bucket in such

manner that the platform will not become separated

from the car-arresting device under the conditions cited

in 11.9.1.

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1 1.9.3 Any platform used with a car-arresting de-

vice shall be capable of meeting the conditions cited in

1 1 .9.1 without resultant failure or loss of its load.

11.9.4 Any material hoist structure, including tower

components, guide rails and their attachments, and any

parts affected by the action of the car-arresting device,

when subjected to the conditions cited in 1 1.9.1 shall

sustain the platform with its rated load without struc-

tural failure.

11.9.5 The car-arresting device shall be activated by

a positive means in the event of car suspension failure,

and when engaged shall be released only by raising the

platform from the stopped position.

11.9.6 Car-arresting devices shall be tested in accor-

dance with 1 1.9.6.1 through 1 1.9.6.3.

11.9.6.1 For rope-supported cars the test shall

be conducted in the following manner:

(1) Pull a loop in the lifting rope and attach the test

rope to each side of the loop above the bucket or plat-

form

(2) Raise platform or bucket to allow the load to be

supported by the test rope

(3) Cut the test rope to allow the load to fall and

activate the car-arresting device

1 1.9.6.2 For car suspension other than rope sup-

ported, the test shall be conducted by creating an over-

speed condition of the car.

11.9.6.3 Structural components shall be in-

spected for damage after the test and before the hoist

is placed in operation again.

12. Buckets

12.1 Work in the Pit. When men are required to work

in the pit, the bucket shall be shored on two sides with

timbers, or their equivalent, of sufficient strength to

support the bucket. Timbers shall not protrude into an

adjacent hoistway.

12.2 Prohibition of Riding. Workmen shall be pro-

hibited from riding the bucket except for authorized

inspection and maintenance.

13. Booms

13.1 Fixed Radii. All booms mounted on a material

hoist tower shall operate at fixed radii.

13.2 Live Booms. Live booms shall be prohibited.

13.3 Boom Location. Booms shall be located so that

at no time will a boom or its load be directly above the

hoist operator’s normal working position.

14.

Material Hoist Wire Rope and Sheaves14.1

Breaking Strength. All hoisting rope shall be of

such breaking strength as to provide a minimum factor

of safety of 7. The factor of safety (F) shall be calcu-

lated by the following formula:

where

S = Manufacturer’s rated breaking strength of one

rope

N= Number of parts of rope under load

W = Maximum gross load

14.2 Wire Rope Inspection

14.2.1 Periods of Inspection. Inspection periods

shall be set up for each material-hoist wire rope. The

frequency of inspection shall be determined by con-

sideration of environment, degree of hazard to materials,

frequency of operation, and the frequency with which

the rope is subjected to its capacity limits. Inspections

shall be made before initial use and not less often than

once each month thereafter.

14.2.2 Method of Inspection. The entire working

length of the wire rope shall be inspected. Thorough

inspection shall be made of the rope sections that pass

over sheaves, drums, or contact saddles, or which make

opposing turns. The rope close to end attachments shall

be carefully inspected.

14.2.3 Inspection of Wire Rope on Idle Equipment.

The wire rope on equipment that has been idle or shut

down for a period of one month or more shall be com-

pletely inspected prior to operation.

14.2.4 Inspection of Surfaces Contacted by Wire

Rope. Sheaves, guards, guides, drums, flanges, and other

surfaces contacted by wire rope during operation shall

be examined at the time of inspection. Any condition

harmful to the rope in use at the time shall be corrected.

14.3 Wire Rope Removal and Replacement

14.3.1

Wire rope with one or more of the following

defects shall be removed or replaced immediately:

(1) Corrosion.

(2) Broken wires:

(a) One or more valley breaks. (A valley break is

a wire break occurring in the valley between two adja-

cent strands.)

(b) Six randomly distributed broken wires in one

rope lay. (A rope lay is the length of rope along which one

strand makes a complete revolution around the rope.)

NOTE: If a broken wire or wires are localized in the end attach-

ment of an operating rope and this condition may be eliminated

by making a new attachment, this may be done instead of re-

placing the entire rope.

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(3) Abrasion: Abrasion, scrubbing, flattening, or

peening causing loss of more than one-third of the ori-

ginal diameter of the outside wires.

(4) Kinking: Severe kinking, crushing, bird caging,

or other damage resulting in distortion of the rope

structure.

(5) Heat damage: Evidence of any heat damage re-

sulting from a torch or caused by contact with electri-

cal wires.

(6) Reduction of rope diameter: Reduction from

nominal diameter of more than 3/64 inch for diameters

up to and including 3/4 inch, of more than 1/16 inch

for diameters 7/8 to 1-1/8 inches, and of more than

3/32 inch for diameters 1-1/4 to 1-1/2 inches. (Marked

reduction in diameter indicates deterioration of the

core.)

14.4 Wire Rope Installation. Hoisting ropes shall be in-

stalled in accordance with the wire rope manufacturer’s

recommendations. The hoisting ropes shall be secured

to the drum, counterweight, or platform by clamps or

by an approved equivalent means.

14.5 Drums and Sheaves

14.5.1 Pitch Diameter. Pitch diameters of drums

shall be a minimum of 24X the nominal rope diameter.

The drum flange shall extend at least 2 inches radially

beyond the last layer of rope when the platform, cage,

or bucket is at the highest point of travel.

14.5.2 Rope Turns on Drum. The winding drum

shall have not less than three turns of rope when the

platform, cage, or bucket is at the lowest point of

travel.

14.5.3 Wire Rope Grade. All hoisting wire rope

shall be improved plow steel grade or stronger, and

equal in flexibility to 6 X 19 classification wire rope.

The joining of hoisting ropes by splicing is prohibited.

14.5.4 Clearance at Cathead. There shall be at least

4 feet of clearance between the cathead sheave and the

hoisting-rope fastening on the platform, cage, or bucket

when either is at the uppermost terminal or landing.

14.5.5 Sheave Groove

14.5.5.1 The arc of the bottom of the sheave

groove shall be smooth and concentric with the bore or

shaft of the sheave. The centerline of the groove shall

be in a plane perpendicular to the axis of the bore or

shaft of the sheave above.

14.5.5.2 Sheave grooves shall be machined or

cast, providing the bottom of the groove has a radius

subtending an arc of 150 degrees and conforms to

Table 2.

14.5.6 Minimum Sheave Diameter. Load-bearing

sheaves for wire rope shall be grooved to accommodate

the rope and shall have a diameter at least 20X that of

the wire rope. For minimum tread diameter of sheaves

Table 2

Groove Radii for New and

Reconditioned Sheave Grooves

Wire Rope(nom dia)

Groove(min)

RootRadius

(max)

1/4 0.140 0.150

5/16 0.170 0.180

3/8 0.205 0.215

1/2 0.265 0.275

5/8 0.330 0.340

3/4 0.390 0.400

7/8 0.460 0.475

1 0.525 0.540

1-1/8 0.585 0.6001-1/4 0.655 0.670

Table 3

Minimum Ratio of Rope Diameter

to Sheave Tread Diameter

Diameter Minimumof Hoisting Tread Diameter

Rope of Sheaves*

(in) (in)

1/4 5

5/16 6-1/2

3/8 7-1/2

1/2 10

5/8 12-1/2

3/4 15

7/8 17-1/2

1 201-1/8 22-1/2

1-1/4 25

•Based on 20X rope diameter.

see Table 3. (The diameter of a sheave is measured at

the bottom of the grooves.)

14.5.7 Prohibition of Fiber Rope Sheaves. Sheaves

intended for use with fiber rope shall not be used with

wire rope.

14.5.8 Defective Sheaves. Defective and worn

sheaves that may cause equipment failure or damage

to the wire rope shall be replaced. If pUlow blocks are

used, they shall be mounted on top of beams and se-

curely bolted. Open bearings shall not be used.

14.5.9 Prohibition of Snatch Blocks. No snatch

blocks or hood-type sheaves shall be used on any hoist

tower.

14.5.10 Sheave Material. All sheaves shall be of steel,

or the equivalent.

14.5.11 Sheave Bearings. All sheave bearings shall

have ball or roller bearings, or bearings lined with bab-

bitt or other equivalent bearing metal.

14.5.12 Bearing Lubrication. Sheave bearings shall

be provided with adequate means for lubrication.

14.5.13 Bolt and Pin Specification. All bolts and

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pins securing sheaves and drums shall comply with

AISC S3 10, Feb 12, 1969 (see 2.3).

15. Wire Rope Fastenings

15.1 Wire Rope Attachment. Ropes shall be securely

attached with drop-forged steel wire rope clips and

thimbles or other approved equivalent fastening de-

vices. When extra wire rope is carried on top of the

frame of the hoist platform, a drum and clamp tie-

down or equivalent-type anchoring device, which will

not damage the wire rope, shall be used.

15.2 Qip Number, Spacing, and Torque. The mini-

mum number of wire rope clips, spacing of clips, and

tightening torque of clips shall be in accordance with

the instructions of the clip manufacturer.

15.3 Retightening of Clips. After the rope has been

in use for a maximum of one month, at each inspection

the nuts on all wire rope clips shall be retightened to

the torque recommended by the clip manufacturer.

Qips work loose because of oscillating tension stresses

as well as vibration, and shall be checked periodically

for tightness.

16. Hoisting Machines

16.1 Capacity. Hoisting machines shall be designed,

installed, and maintained to raise and lower vertically

the rated load plus the weight of equipment and ropes.

16.2 Brakes. The hoisting machine shall be equipped

with brakes capable of stopping and holding 125% of

its rated hoisting capacity under all operating condi-

tions.

16.3 Stability. The hoisting machine shall be secured

in position so as to prevent lateral movement, shifting,

or dislodgment.

16.4 Location and Arrangement. The location and ar-

rangement of the hoisting machine, tower, and related

sheaves shall be such as to assure proper wrapping of

the wire rope on the drum to prevent “overriding,”

fouling, improper spacing, or any other condition that

will cause damage to the wire rope or hoisting machine

16.5 Manning. The hoisting machine shall be attended

by the operator, who shall not leave the controls while

the load is suspended or the master clutch is engaged.

16.6 Blocking and Bracing. Blocking and bracing shall

be provided between the hoisting machine and the

tower to prevent the transmission to the tower of any

unbalanced lateral forces resulting from the pull of the

hoisting ropes.

16.7 Machinery Platform Rails. When hoisting ma-

chinery is set on an elevated platform, the platform

shall be designed and constructed to support the in-

tended load without failure and shall be provided with

guardrails and toeboards that conform to American

National Standard Safety Requirements for Scaffolding,

AlO.8-1969.

16.8 Hoisting Rope Guards. Hoisting ropes within 7

feet of floor or ground shall be guarded by an enclosure

or fence.

16.9 Gear Guards. All gears on hoisting machines shall

be guarded in conformity with American National Stan-

dard Safety Standard for Mechanical Power Transmission

Apparatus, B1 5.1 -1972.

16.10 Prohibition of Multiple Unit Operation. No more

than one platform, cage, boom, or bucket operated by

any one hoisting machine shall be in motion at the same

time.

16.1 1 Brake Drums. Brake drums shall be kept free of

oil, grease, or any other substance that reduces their ef-

ficiency.

16.12 Mechanical Brakes. Mechanical brakes shall be

so installed as to stop movement of the winding drum

and shall be equipped with a positive acting device, de-

signed as part of the hoist, that will hold the brake in

the engaged position.

16.13 Ratchet and Pawl. Each friction-clutch-driven

winding drum hoisting machine shall be equipped with

an effective pawl and ratchet capable of holding the

rated load capacity when it is suspended.

16.14 Engine Exhaust. Internal-combustion-engine

exhaust pipes shall be arranged to exhaust away from

workmen and from combustible materials. A muffler

shall be installed to reduce the noise.

16.15 Fuel Cans. Safety cans shall be used for handling

fuel for internal-combustion engines. When gravity-type

fuel systems are used, a cutoff valve shall be installed

between the internal-combustion engine and the fuel-

supply tank.

16.16 Refueling Precautions. Open lights, flames, or

spark-producing devices shall be kept at least 25 feet

away while intemal<ombustion engines are being re-

fueled, and no person shall smoke or carry lighted

smoking materials in the immediate area. The engine

shall be stopped during refueling.

16.17 Fire Extinguishers. An all-purpose fire extin-

guisher for Class A, B, and C fires, which meets the

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requirements of American National Standard Installa-

tion of Portable Fire Extinguishers, Z1 12.1-1974 (2nd

ed) (NFPA No. 10-1974), shall be part of the hoisting

equipment.

16.18 Hoisting during Maintenance. Material hoisting

shall not be carried on while men are engaged in erec-

tion, maintenance, or repair of the hoisting machine.

16.19 Daily Inspection. All hoisting machines, includ-

ing brakes, gears, levers, and wire rope, shall be visually

inspected daily. All broken, worn, or defective parts

shall be repaired or replaced when discovered.

16.20 Electrical Equipment Protection. Electrical

equipment shall be grounded in conformance with

American National Standard National Electrical Code,

Cl-1971 (NFPA No. 70).

16.21 Direct-Coupled Machine Brakes. Electric-motor,

direct-coupled-drive hoisting machines shall be pro-

vided with a mechanical automatic motor brake, or an

equivalent device, to hold the load automatically in

case of power failure.

16.22 Rack and Pinion Drives. For rack and pinion

drives the pinions and rack shall be of steel with a mini-

mum safety factor of 4. The drive may be located on

the counterweight or on the platform.

16.23 Hoisting Machine Location. The hoisting ma-

chine shall be located so that no part of it or its enclo-

sure extends into the hoistway.

16.24 Power Failure Disconnect. Electric-motor-oper-

ated hoists shall be provided with a device to automati-

cally disconnect all motors from the line upon power

failure and not permit any motor to be restarted until

the controller is brought to the off position.

16.25 Machine Controls. Hoisting machines of more

than one-drum capacity shall have bank or console con-

trols.

17.

Operator Qualification

When required by law, each operator, before starting

the job and at least annually thereafter, shall obtain a

physician’s certificate of fitness.

18.

Protection of Operator

18.1

Overhead Protection. The operator of a hoisting

machine shall be provided with overhead protection

equivalent to tight planking not less than 2 inches thick.

The support for the overhead protection shall be of

equal strength.

18.2 Enclosure, The area occupied by the hoisting ma-

chine and its operator shall be protected from the ele-

ments and shall be heated in cold weather.

18.3 Prohibition of Open-Flame Heaters. No open-

flame heaters shall be allowed inside any operator’s en-

closure. When other types of heaters are necessary,

they shall be properly vented.

18.4 Heater Requirements. Heating systems shall be

installed in compliance with American National Stan-

dard Safety Requirements for Temporary and Portable

Space Heating Devices and Equipment Used in the

Construction Industry, AlO. 10-1970.

18.5 Lighting. Lighting adequate for maintenance and

operation of the hoisting machine shall be provided,

but in no case shall it be less than 5 footcandles.

18.6 Glass. All glass used in the operator’s enclosure

shall be safety glass, or the equivalent.

19. Signal Systems

19.1 Hand Signals. Hand signals may be used on a sin-

gle drum hoist when the hoist tower does not exceed

50 feet in height provided that the signals are clearly

visible to the operator at all times.

19.2 Electrical Communication. A closed-circuit elec-

trical communication system shall be used when the

height of the tower exceeds 50 feet and on all multiple

well towers regardless of height.

19.3 Speaker Location. The electrical intercommunica-

tion system shall be a two-way system with a speaker

located at the hoist operator’s position so that he can

hear from and talk to each station.

19.4 Electrical System Protection. All wires and de-

vices used in connection with the signal system shall be

protected from the weather.

20. Indicators

A positive system shall be used to indicate when the

load has reached specific positions.

21.

Electric Motors

21.1 Motor Installations. Motor installations shall be

made in accordance with provisions of applicable local

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codes and American National Standard National Elec-

trical Code, Cl-1971 (NFPA No. 70-1971).

21.2 Switches. Only enclosed switches with grounded

cases and fuses or circuit breakers shall be used.

21.3 Control Panels. Control panels shall be enclosed,

and unauthorized persons shall not be permitted access

to such panels.

21.4 Emergency Electrical Cutoff. An emergency

means shall be provided within reach of the operator

to cut off the electric power.

22.

Landings and Runways

22.1 Design. Landing platforms and runways that con-

nect the hoistway or tower to the building shall be de-

signed and constructed to sustain the maximum intended

load without failure. Metal-covered floors or platforms

shall have slip-resistant surfaces.

22.2 Railings. Railings and toeboards that conform to

American National Standard Safety Requirements for

Scaffolding, AlO.8-1969, shall be placed on the open

sides of runways connecting the tower to the structure.

22.3 Overhead Protection. All landing platforms where

workmen may be exposed to falling objects shall be

provided with a solid overhead protection composed of

2-inch planking or the equivalent.

22.4 Barricades. A barricade shall be required at each

landing. The barricade shall extend a minimum distance

of 6 feet laterally along the outer edge of the landing

from each side of the hoistway or runway and shall ex-

tend a minimum distance of 36 inches above the level

of the landing, runway, or structure floor. The material

used for the barricade shall be of No. 19 U.S. gage wire

mesh, or the equivalent, with openings not exceeding

1 /2-inch.

22.5 Working Platforms. Working platforms of ample

size and strength, and railings and toeboards that con-

form to American National Standard AlO.8-1969 shall

be built at each level where men are required to work,

such as bucket dumps and hopper headers.

22.6 Housekeeping. Access to and the arei around

landings and the hoisting machine shall be kept clear

of rubbish and waste material.

22.7 Prohibition of Material Storage. Materials shall

not be stored on landing platforms or landing runways.

23.

Capacity Statement and Design

23.1 Design. All material hoist towers, masts, etc, shall

be of such design that maximum intended loads will

not stress any members beyond safe limits established

by applicable engineering formulas.

23.2 Booms and Auxiliary Equipment Loads. The de-

sign shall provide ample strength for loads imposed by

the use of booms attached to a tower or mast. Where,

in addition to the loaded platform or bucket, auxiliary

equipment or other load-bearing devices are supported

by the tower, the tower shall be built to withstand

these additional loads and stresses safely. The rated

load, specified by the manufacturer, shall not be ex-

ceeded.

24.

Revision of American National Standards

Referred to in This Document

When the following American National Standards re-

ferred to in this document are superseded by a revision

approved by the American National Standards Institute,

Inc, the revision shall apply:

American National Standard Safety Requirements for

Personnel Hoists, A 10.4- 1973

American National Standard Safety Requirements for

Scaffolding, AlO.8-1969

American National Standard Safety Requirements for

Temporary and Portable Space Heating Devices and

Equipment Used in the Construction Industry, AlO. 10-

1970

American National Standard Safety Code for Dumb-

waiters, Escalators, and Moving Walks, A17. 1-1971,

including Addenda A17. la-1972, A17. lb-1973, and

A17.1C-1974

American National Standard Safety Standard for Man-

lifts, A90.1-1969, including Supplement A90. la-1972

American National Standard Safety Standard for Me-

chanical Power Transmission Apparatus, B 15. 1-1 972

American National Standard National Electrical Code,

Cl-1971 (NFPA No. 70-1971)

American National Standard Installation of Portable

Fire Extinguishers, Z1 12.1-1974 (2nd ed) (NFPA

No. 10-1974)

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A. 3 Excerpts fromSafety’ Requirements for

Concrete Construction and Masonry WorkAmerican National Standard ANSI AlO. 9-1970American National Standards InstituteNew York, New York

The excerpts from ANSI AlO. 9-19 70 arereproduced herein by permission of the

American National Standards Institute,1430 Broadway, New York, New York 10018.

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6. Formwork Construction

6.1

General. Section 6 deals with the design,

releasing, and raising of formwork. It also

deals with the design, fabrication, and han-dling of forms. Formwork must be adequatelydesigned, erected, supported, braced, andmaintained so that it will safely support all

vertical and lateral loads that may be applieduntil such loads can be supported by theconcrete structure.

6.1.1 Good housekeeping shall be main-tained at all times, and stripped lumber and

materials intended for reuse should be cleanedof nails and wire and removed from the im-mediate work area.

6.1.2 Lumber, concrete, form hardware,and other materials shall not be permitted toaccumulate on walers, scaffolds, and walk-ways.

6.1.3 Fire protection shall be provided inareas where wood forms and other com-bustible materials are being used.

6.1.4 Watchmen or fireguards shall be pro-vided where salamanders or similar heatersare used to provide winter protection,

6.1.5 Where tarpaulins or other flammablematerials are used to form protective en-closures for winter protection, the materialshall be fire-resistant and installed so as toprevent contact with the heating unit.

6.1.6 Form supports and wedges shall bechecked during concrete placement to preventdistortion or failure.

6.2

Form Design6.2.1 Any form, regardless of size, shall be

planned in every particular and designed andconstructed with an adequate factor of safety.

In addition to computable loading, additional

form pressures may result from impact duringconcrete placement, sudden lowering of tem-peratures retarding the set and increasing theliquid head or static pressure, vibrations of

the form or concrete, uneven stressing re-

sulting from failure or weakening of formmembers, or impact from concrete buckets or

placing equipment. As a result, an adequatefactor of safety is required to offset these

unpredictable conditions.

6.2.2 The thoroughness of planning anddesign shall be governed by the size, com-plexity, and intended use of the form. Form-work which is complex in nature or which will

be subjected to unusually high concrete pres-

sures shall be designed or approved for use byan engineer or experienced form designer.

6.2.3 Unit stresses for use in the design of

formwork, exclusive of accessories, should

conform to applicable codes and specifications

in Formwork for Concrete, American Con-crete Institute Special Publication No. 4,

1969. When fabricated formwork, shoring, or

scaffolding units are used, manufacturers’ rec-

ommendations for allowable loads may be

followed if supported by test reports or suc-

cessful experience records.

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6.2.4 Forms of a temporary nature withlimited reuse shall conform to allowable

stresses as specified in appropriate design

codes or specifications for temporary struc-

tures or for temporary loads on permanentstructures, as approved by the authority hav-

ing jurisdiction.

6.2.5 Where a considerable number of re-

uses are intended and where the forms to be

used are fabricated from material such as

steel, aluminum, or magnesium, it is recom-

mended that the formwork be designed as a

permanent structure carrying permanentloads.

6.2.6 The minimum safety factors shownin Table 1, which are based on ultimate

strength of the accessory, shall be used in the

design and use of formwork hardware andaccessories.

6.2.7 For safety considerations relating to

the design of shores, see Section 8, Vertical

Shoring.

6.3 Loads6.3.1 Vertical Loads. Vertical loads consist

of a dead load plus an allowance for live load.

The weight of formwork together with the

weight of freshly placed concrete is dead load.

The live load consists of the weight of work-

men, equipment, runways, and impact, andshall be computed in pounds per square foot

(psf) of horizontal projection. (See 8.1.5.)

6.3.2 Lateral Loads. Braces and shores

shall be designed to resist all foreseeable later-

al loads such as wind, cable tensions, inclined

supports, impact of placement, and starting

and stopping of equipment. The assumed val-

ue of load due to wind, impact of concrete, andequipment acting in any direction at eachfloor line shall not be less than 100 pounds per

lineal foot of floor edge or 2 percent of total

dead load of the floor, whichever is greater.

Wall forms shall be designed for a minimumwind load of 10 psf, and bracing for wall formsshould be designed for a lateral load of at least

100 pounds per lineal foot of wall, applied at

the top. Walls of unusual height require spe-

cial consideration.

6.3.3 Special Loads Formwork shall be

designed for all special conditions of construc-

tion likely to occur, such as unsymmetricalplacement of concrete, impact of machine-delivered concrete, uplift, and concentrated

loads.

Table 1

Design Capacities of Formwork Accessories* J

Accessory Safety factor Type of construction

Form tie 1.5 Light formwork; or ordinary single lifts at grade and 16 ft or less above grade

2.0 Heavy formwork; all formwork more than 16 ft above grade or unusuallyhazardous

Form anchor 1.5 Light form panel anchorage only; no hazard to life involved in failure

2.0 Heavy forms—failure would endanger life—supporting form weight and con-crete pressures only

3.0 Falsework supporting weight of forms, concrete, working loads, and impact

Form hangers 1.5 Light formwork. Design load including total weight' of forms and concrete,with 50 psf minimum live load is less than 150 psf

2.0 Heavy formwork; form plus concrete weight 100 psf or more; unusuallyhazardous work

Lifting inserts 2.0 Tilt-up panels

3.0 Precast panels

Expendable stranddeflection devicest

2.0 Pretensioned concrete members

Re-usable stranddeflection devicest

3.0 Pretensioned concrete members

• Design capacities guaranteed by manufacturers may be used in lieu of tests for ultimate strength.

fThese safety factors also apply to pieces of prestressing strand which are used as part of the deflection device.

tThis Table is reproduced from Ainerican National Standard Recommended Practice for Concrete Formwork, A145. 1-

1968 (ACI 347-68). Copyright 1967 by the American Concrete Institute. Reprinted by permission.

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6.3.4 Construction Loads. Imposition of

any construction loads on the partially com-pleted structure shall not be permitted unless

such loading has been considered in the design

and approved by the engineer-architect.

6.4

Placing and Removal of Forms6.4.1 When moved or raised by crane, ca-

bleway, A-frame, or similar mechanical de-

vice, forms shall be securely attached to wire

rope slings having a minimum safety factor of

5. Use of No. 9 tie wire, fiber rope, and similar

makeshift lashing shall be prohibited.

6.4.2 Taglines shall be used in moving pan-els or other large sections of forms by crane or

hoist.

6.4.3 All hoisting equipment, including

hoisting cable used to raise and move forms,

shall have a minimum safety factor in-

corporated in the manufacturer’s design, andthe manufacturer’s recommended loading

shall not be exceeded. Field- or shop-fabri-

cated hoisting equipment shall be designed or

approved by a registered professional engi-

neer, incorporating a minimum safety factor

of 5 in its design. Panels and built-up formsections shall be equipped with metal hoisting

brackets for attachment of slings.

6.4.4 Forms intended for use where there is

a free fall of over ten feet shall be equippedwith adequate scaffolding and guardrails, or

employees working on the forms shall be re-

quired to wear safety belts during forming andstripping operations. Form scaffolding shall

be designed and constructed as provided in

Section 7 unless an alternative design is spe-

cifically approved by the authority having

jurisdiction.

6.4.5 Vertical forms being raised or re-

moved in sections shall not be released until

adequately braced or secured. Likewise, over-

head forms shall not be released until ad-

equately braced or secured.

6.4.6 Workmen or others at lower levels

shall be protected from falling materials, andappropriate warning signs shall be erected

along walkways.

6.4.7 Forms shall not be removed pre-

maturely. The concrete should be adequately

set in order to permit safe removal of the

forms, shoring, and bracing. Engineer’s speci-

fications and local building codes shall be

adhered to in determining the length of time

forms should remain in place following con-

crete placement. In addition, tests shall be

made on field-cured concrete specimens in

order to insure that concrete has obtained

sufficient strength to safely support the load

prior to removal of forms.

6.4.8

When field operations are not con-

trolled by the engineer’s specifications or local

building codes, under ordinary conditions

form and supports shall remain in place for

not less than the periods of time shown in

Table 2. These periods represent cumulative

number of days or fractions thereof, not neces-

sarily consecutive, during which the tem-

perature of the air surrounding the concrete is

above 50* F. If high-early-strength concrete is

used, these periods may be reduced as ap-

proved by the engineer-architect. Conversely,

if low-temperature concrete or retarding

agents are used, these periods may be in-

creased at the discretion of the engineer-archi-

tect,

6.5 Vertical Slip Forms6.5.1 Slip forms shall be designed and con-

structed, and the form movement carried out,

under the immediate supervision of a person

or persons experienced in slip form design andoperation. Drawings prepared by a qualified

engineer, showing the jack layout, formwork,

working decks, and scaffolding, shall be avail-

able at the jobsite, and followed.

6.5.2 The steel rods or pipe on which the

jacks climb or by which the forms are lifted

shall be especially designed for the purpose.

Such rods must be adequately braced wherenot encased in concrete.

6.5.3 Jacks and vertical supports shall be

positioned in such a manner that the vertical

loads are distributed equally and do not ex-

ceed the capacity of the jacks.

6.5.4 The jacks or other lifting devices

should be provided with mechanical dogs or

other automatic holding devices to protect

against failure of the power supply or the

lifting mechanism.6.5.5 Lifting shall proceed steadily and

uniformly and shall not exceed the pre-

determined safe rate of lift, A jacking system,

which provides precise, simultaneous move-ment of the entire form in small preselected

increments, is recommended for large struc-

tures,

6.5.6 Lateral and diagonal bracing of the

forms shall be provided to prevent excessive

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NBS*114A (REV. s-78)

U.S. DEPT. OF COMM.

BIBLIOGRAPHIC DATASHEET

1. PUBLICATION OR REPORT NO. 2»Gov^t.. Aec^sfoi No>i

4. TITLE AND SUBTITLE

Recommended Guidelines for Safety Inspection of Constructionof Concrete Cooling Towers

5. Publication Date

6. P»(oTOmg,Ofgam2aaotv Code

7. AUTHOR(S)

H. S. Lew and S. G. Fattal

8. Performing Organ. Report No.

9. PERFORMING ORGANIZATION NAME AND ADDRESS

NATIONAL BUREAU OF STANDARDSDEPARTMENT OF COMMERCEWASHINGTON, DC 20234

lintt No. .

11. Contract/Grant No.

12. SPONSORING ORGANIZATION NAME AND COMPLETE ADDRESS rSh-.et, City, st^te, ZIP)

Occupational Safety and Health AdministrationDepartment of LaborWashington, D.C. 20210

13. Type of Report & Period Covered

15. SUPPLEMENTARY NOTES

I! Document (jescribes a computer program; SF-185, FIPS Software Summary, is attached.

16, ABSTRACT (A 200^worxi or less factual ^uaunary of most significant information* If document includes a significant bibliography or

literature survey, mention it here*)

As a result of the natural draft cooling tower construction disaster at WillowIsland, West Virginia, the National Bureau of Standards (NBS) reivewed existing

Occupational Safety and Health Administration (OSHA) construction safety and

health regulations and developed guidelines for use by the OSHA complianceofficers for safety evaluation of reinforced concrete shell cooling tower

construction

.

The guidelines furnished are based on existing OSHA regulations, but highlight

their application to this type of construction by pointing out critical construc-

tion operations, their safety aspects, and needed compliance inspection procedures.

Major regulatory provisions affecting the basic construction plans, safety

aspects of design criteria and responsibilities, record keeping, and inspections

are summarized. Special attention is given to construction loadings, construction

sequences, hoisting systems, and personnel safety training.

Detailed identification is made of items relating to concrete inspection, concrete

control, formwork operations, construction loadings, hoisting systems, and

construction safety planning.

17. KEY WORDS ("s/x to twelve entries; alphabetical order; capitalize only the first letter of the first key word unless a proper name;

separated by semicolons)

Concrete; construction, cooling tower; formwork; hoisting system; regulations;

safety; standards

18. AVAILABILITY Unlimited 19. SECURITY CLASS 21. NO. OF(THIS REPORT) PRINTED PAGES

lIj For Official Distribution. Do Not Release to NTISUNCLASSIFIED

' Order From Sup. of Doc., U.S. Government Printing Office, Washington, DC20402, SD Stock No. SN003-003-

20. SECURITY CLASS 22. Price(THIS PAGE)

Order From National Technical Information Service (NTIS), Springfield,

VA. 22161UNCLASSIFIED

USCOMM-OC

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