tips for reducing workplace incidents – fall protection and lockout/tagout

Tips for Reducing Workplace Incidents – Fall Protection and Lockout Tagout

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SPEAKERS

Erik Swanson U.S. Business Development Manager – 3M

Tom Campbell Global Product Manager – Brady

3M Personal Safety Division (PSD)

3M is a trademark of 3M Company. © 2013 3M. All Rights Reserved.

3M™ Fall Protection

3M™ Fall Protection – The Height of Confidence

What is Fall Protection?

Reducing or eliminating damage to people and property that can result from falls or falling objects.


Why Fall Protection?

Every year since 1992, 500 to 746 US workers died from injuries caused by falls to a lower level.

Fall protection was the most frequently cited OSHA violation in 2013.

The average cost of a fall to a lower level is $85,500 per case.

Over 55,860 workers were injured in 2012, most couldn’t work for 16 days because of the injuries. Sources: US Bureau of Labor Statistics, OSHA

Liberty Mutual Safety Index 2013


574 US workers died in falls to a lower level in 2013

1 to 2 US workers die each day


Source: US Bureau of Labor Statistics 2010, 2014

44 fatal falls (7.6%)n 2013 were caused by structural or equipment collapses

69 fatal falls (12%) were through a surface like a skylight or an open hatch

3 of every 5 fatal falls were from 20 ft. or less


45% of fatal falls are from 20 feet or less


Why Fall Protection?

Human Reaction Time and Physics Average human reaction time: 0.2 - 0.7 seconds In 0.7 seconds a body will free fall 8 feet. After 8 feet of free fall you are traveling at 15 mph. Stopping a 220lbs. person moving 15 mph.

in 1 inch (falling with straight legs) produces over 20,000lbs. of force.

in 2 feet (falling on bending legs) produces 880lbs. of force.


Regulations, Standards and Best Practices

OSHA Sets and enforces minimum safety regulations for

worker safety in the US. ANSI Z359 Industry consensus standard

Testing, Performance, Strength, Labeling etc. Comprehensive Managed Fall Protection Program


Recognizing Fall Hazards: Trigger Heights

According to OSHA, whenever you are exposed to an unprotected opening or surface that could fail to support you, the trigger heights are:

4 feet and above for General Industry 6 feet and above for Construction

Whenever there is a hazard below.


How do you protect yourself? Hierarchy of Controls

1. Eliminate the need to go to heights (Engineer out hazard)

2. Set up a physical barrier to prevent a fall (Prevention)

3. Restrain the end-user from reaching a fall hazard (Restraint)

4. Fall Arrest 5. Administrative controls to warn people of the

hazard

Active Fall Protection



Fall Restraint Fall Arrest

Work Positioning



Fall Arrest – A system designed to reduce the impact forces during fall arrest to an acceptable level as defined by product performance standards and regulatory requirements.

Impact forces are reduced by an

energy absorber worn by the user.



Fall Restraint – designed to prevent the user from reaching a fall hazard.


Positioning – allows user to work/rest at height without having to hold on with their hands



ABCDs of Active Fall Protection

A = Anchorage Systems B = Body Support (Harness) C = Connecting Devices D = Descent/Rescue/Escape

Remember to have a rescue plan!


• Non-Certified Anchorage strength requirements: • 5,000 lbs. Fall Arrest • 3,000 lbs. Work

Positioning/Rescue/Restraint • 1,000 lbs Restraint (ANSI)

• A Certified Anchorage is designed, installed and used

under the supervision of a qualified person as part of complete personal fall arrest system which maintains a safety factor of at least two times maximum anticipated force.

Anchorage

3M Confidential

• An anchorage, as defined by OSHA, is a secure point of attachment for lifelines, lanyards or deceleration devices.


Body Support

Full Body Harnesses are used to distribute fall arrest forces across the shoulders, upper thighs, chest and pelvis. They feature a center back fall arrest attachment (dorsal D-ring) for connection to the fall arrest connecting device, and may have other D-rings for use in worker positioning, travel restraint, retrieval or ladder climbing. They’re also the only form of body wear acceptable for fall arrest, and should be selected based on the work to be performed and the work environment. Body Belts circle the waist and are used for worker positioning and travel restraint. They are used in conjunction with a full body harness. A body belt must NEVER be used for personal fall arrest.

3M Confidential

No!


Connectors, such as energy absorbing lanyards or self-retracting lanyards, attach the worker’s harness to the anchorage. Types will vary depending on whether the worker needs personal fall arrest or work positioning and travel restriction:

Connecting Devices

3M Confidential


Body Support

Consideration factors before selecting: Budget D-ring configuration Hardware Size

3M Confidential


Body Support: D-Ring Configuration


Special Harnesses & Accessories

Heavier Capacity Harness Specialty Harnesses D-Ring Extenders Rescue Step (suspension trauma strap)

XXXL sizes Welding Applications

Rescue Step

D-Ring Extender


Harness Size Selection & Weight

Universal harnesses fit 90% of the population Harness sizing charts Consider total working weight including

clothing, tools, etc.


Important Points

Wear your harness snugly, A loose harness may cause: Bodily injury Fall out of harness Choking

Harness should be 100% on or 100% off. Remember, never use a body belt for fall

arrest!

No!

No!


Self Retracting Devices (SRDs) How they work Types and applications Advantages

Sealed

SRL

Personal SRL

Dual-leg Personal SRL


Connecting Devices – Retractables

Consideration factors before selecting: SRL vs. Lanyard

Fall clearance Cost

Work environment Cable Web

Single leg vs. dual leg

3M Confidential


The core range of self-retracting lanyards includes: 7 ft. web to 50 ft. stainless steel cable lanyards Durably designed to be used in harsh

environments such as construction, roofing, mining and petroleum industries

Housing options available in impact modified nylon, polymer or aluminum

Manufactured with 3,600 lb. gate-rated hardware, and meets the requirements of ANSI Z359.12-2009 standards

Extend the service life of the product through the 3M™ Retractable Repair Program

3M Confidential




ReLoad™ Series – 7 to 50 ft. web/cable MS Series – 11 ft. web RLD Series - 10 to 50 ft. cable

3M Confidential

ReLoad MS-11 RLD



6.5 ft. clearance required


Connecting Devices – Lanyards Consideration factors before selecting: Clearance Work environment

Web vs. cable

Energy Absorber External vs. internal

Application/task – connecting hooks Single leg vs. dual leg (100% tie-off) Work area – length 3 ft. vs. 6 ft.

3M Confidential

SafeLight

SafeAbsorb XTRA


Connecting Devices – Lanyards

SafeLight – Economy SafeAbsorb – Mid Range SafeAbsorb XTRA Expandable – Premium

3M Confidential

SafeLight SafeAbsorb SafeAbsorb XTRA


Connecting Devices – Lanyards

12-ft Free Fall Heavy worker

Tie-back

Welding

Standard 6-ft. Free Fall

Dual-leg, stretchable

Positioning

Adjustable length


Connector Components: Snaphooks/Carabiners

5,000 lbs. breaking strength 2 movements to open Self-closing and self-locking

Gate Strength 3,600lbs.



Compatible vs. Incompatible Connections


Connector Components: Energy Absorbers

Maximum Weight Capacity

Maximum Free Fall

Maximum Arresting Force


Free fall variation based on anchorage location


Avoiding Contact with the Lower Level….

3M Confidential


Required Considerations for Active Fall Protection Systems

Inspection Clearance Swing fall Rescue


Anchorage Connectors

Roofing Concrete Pipe and I-Beam Steel

Fixed vs. mobile Permanent, temporary or reusable


Ladder Safety System

Any fixed ladder that exceeds 24 ft. must have fall protection. Traditionally ladder cages have been used, however they can cause injuries in the event of a fall. Benefits of a ladder safety system include: • Safer than cages in the event of a fall • Easier and less costly to install and maintain than ladder cages


Self-Trailing Rope Grab

Applications Clearance Safe Practices


Static Rope Grab

Applications: Restraint/ Fall Arrest


Aerial Work Platforms Restraint/Fall Arrest


12-foot Free Fall Lanyards Heavy Worker Lanyards

12 –foot FF lanyards require 19 feet of clearance measured from the standing surface.

Heavy Worker Lanyards

require 19 feet of clearance as measured from the anchorage point that is shoulder height or above.


Leading Edge Retractables (SRL-LE)

Applications Clearance Special considerations

Energy Absorber


Rescue and Escape

OSHA 1926.502 (d) (20):

The employer shall provide for prompt rescue of employees in the event of a fall or shall assure that employees are able to rescue themselves.

OSHA 1910.66 (e)(v)(8):

The employer shall provide for prompt rescue of employees in the event of a fall or shall assure the self-rescue capability of employees.


Rescue at Heights: Simple, Safe, Planned and Practiced

Hierarchy Self Rescue

Climb to safety Use a Personal Rescue Device (PRD)

Assisted Rescue, Rescue with an aerial work platform Simple rope rescue Professional standby rescue

Never Cut Never Improvise Be Prepared and Practice


Suspension Trauma Prolonged suspension in a

harness can cause death

Orthostatic intolerance may be defined as “the development of symptoms such as light-headedness, palpitations, tremulousness, poor concentration, fatigue, nausea, dizziness, headache, sweating, weakness and occasionally fainting during upright standing”. “Research indicates that suspension in a fall arrest device can result in unconsciousness, followed by death, in less than 30 minutes.”

Rescue must be prompt because of the Hazards of suspension

trauma

A 3M Rescue Step™ may help to reduce the effects of suspension trauma and may increase tolerable suspension time.


Thank you!

Lockout/Tagout – Controlling Equipment Hazardous Energies

Lockout / Tagout – Purpose

To protect workers involved in the maintenance and servicing of equipment from the dangerous effects of hazardous energy. This is achieved by isolating and locking or tagging out all hazardous energy sources.

NOTE: Normal production operations are not covered under the LO/TO standard. Those activities are covered under the OSHA 1910 Subpart O, Machine Guarding Standard.

Lockout or Tagout – Which one when?

LOCKOUT Placing lock(s) on an energy isolating

device making it physically impossible for anyone to operate it or the equipment being controlled until the lock is removed. Required when isolating devices are capable of being locked out.

TAGOUT Placing a tag on an energy isolating

device to warn others that the energy isolating device and the equipment being controlled should not be operated. Appropriate if isolating device cannot be locked out.

Lockout / Tagout – Who is Responsible?

Authorized Employees Perform lockout / tagout activities to subsequently service or maintain the equipment

Affected Employees Work in or around the equipment where servicing or maintenance is occurring but do not have responsibility for locking the equipment out

Employer Responsibility: The employer is ultimately responsible Employee Training Retraining Requirements Contractors

Elements of a Comprehensive Equipment Lockout Safety Program

5-Step Best Practice Approach:

1. Create company-wide energy control policy

2. Create machine-specific lockout procedures

3. Identify and mark all energy control points

4. Train employees and promote awareness of safe work practices

5. Equip employees with the proper lockout tools and warning devices

Steps 1 & 2: Company Policy & Equipment Procedures

Step 1: Policy • Written guide to help the employer properly

implement OSHA CFR 1910.147 in the workplace

https://www.osha.gov/SLTC/controlhazardousenergy/program.html

Step 2: Equipment-Specific Procedures Make Them Visual • Intuitive • Expedient • Workforce Turnover • Contractors • Written Instruction Limitations

Step 3: Identify Energy Isolation Points

Valves, switches, breakers, plugs Utilize Tags, Signs & Labels Add Energy Source ID Messages Consider DIY Industrial Label Printers

Locate & identify all points

Step 4: Train Your Employees

Training Videos Training Posters Procedure Station Warning Signs Floor Stands Barricades OSHA website

Osha.gov

Training & Communication Tools

Step 5: Provide Proper L/O Products

1. Durable

2. Standardized

3. Substantial

4. Identifiable

LO/TO Product Requirements

Step 5: Brady Safety Padlocks

• Compact & lightweight • Key-retaining functionality • Nonconductive, non-spark • Durable & shock-resistant • Exclusive worker control • 9 colors • Available KA or KD • Key charting and laser

engraving options • Compact version also

available

• Color-anodized bodies ideal for safety lockout

• Same reserved keyway as nylon safety locks

• Excellent corrosion resistance

• Greater physical security • 9 colors • Key-retaining option also

available

• Greater physical security • Unique key-retaining

functionality ideally suited for safety lockout

• Color-coded bumpers • Available KA or KD

Nylon Safety Padlocks Laminated Steel Padlocks Aluminum Padlocks

Step 5: Lockout Tool & Warning Devices

Typical Usage Concerns

Versatility

Durability

Ease of use

Portability / compact storage

Security (positive restraint)

Common Devices

Electrical (Circuit Breaker / Plug) Lockouts

Valve (Gate/Ball/Plug/Butterfly Lockouts

Cable Lockouts

Equipment Control Switches & E-Stops (Safety Covers)

Electrical Lockouts

Circuit Breaker Lockouts Broadest line available Fit a wide range of breaker sizes Easy application – thumbwheel operation Helpful circuit breaker reference guide

Circuit Breaker Lockout Reference Guide

Circuit Breaker LO Device Application Video

http://www.bradyid.com/bradyid/downloads/downloadsPageView.do?file=Circuit_Breakout_Lockout_Brochure.pdf

http://www.bradyid.com/bradyid/cms/contentView.do/11542/gp.html

Valve Lockouts

Cable Lockouts

Multi-Purpose Cable Lockouts • Flexible use on gate valves, electrical disconnect switches, panels and more • Push button self-winding mechanism on mini-cable lockout retracts into body; cinches cable tight

All Purpose Cable Lockout Mini Cable Lockout

Hasps & Tags

Steel Lockout Hasps Vinyl-coated high tensile steel with

rust-resistant plating

Standard Tags Heavy Duty (encapsulated, erasable) Polyester Cardstock

HD and Poly tags meet OSHA’s 50 lb. pull test for use as Tagout devices Wide variety of legends, languages Photo ID tags are also available

Group Lockout and Kits

Lockout Kits / Application Circuit Breaker Electrical Valve Combination

Group Lockout Variety of sizes and constructions

available based on application needs

http://www.bradyid.com/bradyid/cms/contentView.do/13258/gp.html

Additional Resources

New LO/TO eBook http://forms.bradyid.com/LotoEBook

Circuit Breaker Lockout Reference Guide

Safety Padlocks Corrosion Whitepaper

Safety Padlocks Brochure

Lockout Equipment Checklist

Technical Data Sheets for more than 70 lockout devices

Lockout Device Installation Videos

To watch this presentation again and view more G2 talks on-demand visit, graybar.com/G2archive

Questions?

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tips for reducing workplace incidents – fall protection and lockout/tagout

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