ARCOR� Gen.Spec. 06.99.1
ARCOR�
ARCOR� International
a Division of AEC Corp.
General Application Specification
For
Epoxy Coating
Contents
Section I Scope
Section II General Information
Section III Surface Preparation
Section IV Application
Section V N/A
Section VI Inspection
Section VII Repairing Imperfections
Section VIII Cure
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ARCOR� Gen.Spec. 01.99.1
SECTION I
•SCOPE
1.1 ARCOR� / VICOR� coatings are high performance polymers designed for surface
protection in severe corrosive/erosive environments. They have outstanding high
temperature immersion properties, good thermal shock and aging characteristics.
When applied to a metallic or nonmetallic surface, they act as a complete barrier
against corrosive chemical attack, fluid particulate flow, low and high pH fluctuations
and temperature extremes.
1.2 A schedule for preparation and application should be devised to insure the surface
is prepared to the correct standards, then the appropriate ARCOR� / VICOR� system
applied before contamination or rust bloom occurs.
1.3 Appropriate personnel protective equipment should be utilized during blasting of
substrate containing potentially hazardous material such as lead.
1.4 Although ARCOR� / VICOR� coatings do not contain solvent, adequate ventilation
should be provided for the work area. NIOSH respirator is recommended as a
precaution.
1.5 Application personnel should wear protective clothing - eye shields, gloves and
head garments to protect them for accidental spillage and excessive skin contact.
1.6 Facilities should be provided to allow application personnel to wash with warm soap
and water to remove material BEFORE it cures.
1.7 Adequate lighting devices should be installed for all stages of preparation,
application and inspection.
1.8 If any staging or other structures are erected to facilitate application, they should be
inspected for safety prior to and during their use.
1.9 Contractors/applicators should be familiar with the methods of surface preparation
and quality control recommended herein, and/or be familiar with comparable
information provided in SSPC, NACE or ASTM reference material.
1.10 Prior to mixing and/or applying material, the contractor/applicator should have read
and understood this Specification for Application and the appropriate ARCOR� /
VICOR� technical data sheets, application sheets and material safety data sheets.
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ARCOR� Gen.Spec. 06.99.1
SECTION II
� GENERAL INFORMATION
2.1 Instruction sheets briefly outlining the use of this product are provided in every
case/unit of material.
2.2 HANDLING AND STORAGE
2.2.1 Always keep material in original sealed containers until just prior to use.
2.2.2 Store away from direct sunlight or flames. Although this material is NOT
flammable, it IS combustible. Storage temperatures should be maintained between
55°F (13°C) and 95°F (35°C). Storage temperatures should be monitored and
recorded.
2.2.3 Always keep material in a dry, clean environment. To prevent accidental
contamination by spent abrasive or debris; this product should be kept away from the
work area until a clean up has been accomplished after surface preparation. If
accidental settling occurs, remove dust and debris from lids prior to opening.
2.3 Thinning and Additives - never thin with solvents or use additives in this product.
The addition of these ingredients could dramatically alter the cure and performance of
this product.
2.4 EFFECTS OF TEMPERATURE
2.4.1 This product is temperature dependent. Cold temperatures (less then 55°F) will
cause a significant increase in viscosity (resistance to flow). Therefore, the material
should be warmed by placing the sealed canisters in a shallow pan of hot water, or
gradually warmed by placing near a heat outlet until the material temperature is
between 65-78°F (18-25°C). A microwave oven can be used to heat the base
component material. A 1-kg base unit can be heated on high for 45 seconds. Increase
or decrease time as conditions warrant. Do not use a microwave to heat the activator
component.
2.4.2 If the surface is cold, less then 65°F (18°C), this material will become stiff when
applied, making it difficult to evenly spread the material. Warm the surface with a
portable heater. Never use kerosene, gasoline, oil or propane heaters, as they will
leave a residue on the substrate, which will hinder adhesion. When heating the
substrate, pay close attention to dew point calculations.
2.4.3 Hot temperatures (80ºF+) will lower the viscosity. The higher the temperature the
more difficult it will be to apply normal thickness (15-30 mils) on vertical and overhead
areas. In such situations, a second or even third coat may be required to obtain
desired film thickness.
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ARCOR� Gen.Spec. 01.99.1
2.4.4 Ideal temperature conditions for the ARCOR�/VICOR� product, metal surface
and ambient environment are 65°-78°F (18°-25°C).
2.4.5 Cure of the product is also effected by temperature. Lower temperature will
increase the time required to cure. Higher temperature will decrease the cure time.
This characteristic also effects pot-life or working time. Consult material data sheets for
pot life and cure schedules.
* Dispensing this material into shallow pans immediately after mixing can extend Pot-life
or working time.
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ARCOR� Gen.Spec. 06.99.1
SECTION III
� SURFACE PREPARATION
NOTE: The importance of proper surface preparation should never be understated. If
applied over an inadequately prepared surface, the optimum performance properties of
this ARCOR material will not be achieved. Laboratory studies convincingly illustrate
that adhesion, heat resistance, thermal shock, impact resistance and film integrity are
all reduced in direct correlation to the inferiority of the surface preparation.
3.1 Remove grease, lubricants and oils. Use a non-polar solvent, Acetone or MEK,
which will not leave a film (Isopropyl alcohol can be used in areas with solvent use
restrictions. Be aware that larger volumes will be required and greater effort applied.).
Scrub with wire wheel or brush. If solvents are used to degrease the surface, rinse
generously with additional solvent after scrubbing.
QC HOLD POINT: Document surface cleanliness on ARCOR� QC Inspection
Report
3.2 Remove sharp edges and imperfections on the surface (e.g. weld splatter). Grind
sharp edges to a minimum radius of 1/8� (approx.). Remove or grind down weld
splatter until no sharp or abrupt edges exist. Holes and pits should be filled with a
VICOR� rebuilding compound before coating the surface.
3.3 The air used for grit blasting must be free from contaminants, such as oil and water.
The air supply should be equipped with oil and water filters. Test purity of air by
passing the air through a clean white cloth for one minute at the beginning of each work
period.
QC HOLD POINT: Document blast air cleanliness on ARCOR� QC Inspection
Report
3.4 Grit used for blasting and/or abrading must also be free from contaminants
especially chlorides. Verify cleanliness by placing a one pound representative sample
in a 5-gallon bucket of CLEAN water. No oil slick or other form of contamination,
except for grit dust, should be visible on the water surface. Chloride level can be tested
with a Surface Contamination Analysis Test Kit (SCAT). Copper slag, Coal Slag (Black
Beauty) or Aluminum Oxide abrasives may be used to attain the desired level of
cleanliness and surface profile, subject to specific project requirements and limitations.
It may be acceptable to recycle the blast abrasive, taking care to replenish with new
material every two cycles. Use a fine mesh screen to filter out debris. For best results,
limit recycles based on type of material used.
QC HOLD POINT: Document abrasive cleanliness on ARCOR� QC Inspection
Report
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ARCOR� Gen.Spec. 01.99.1
3.5 Nozzle pressure should be 100-psi ± 5 psi. Therefore, a typical system would be:
* Compressor size - 375 cfm or greater
* Compressor to pot hose size - 2-3� ID
* Pot to nozzle size - 11/2-2� ID
* Nozzle size - #5 or #6
3.6 Surface temperature must be maintained at a minimum of 5°F (3°C) above dew
point during surface preparation and application of ARCOR�/VICOR� materials.
QC HOLD POINT: Document surface temperature on ARCOR� QC Inspection
Report
QC HOLD POINT: Document dew point on ARCOR� QC Inspection Report
3.7 Employ a dehumidification system during the blasting and application stages. In
general, epoxies perform more predictably, and better overall results are achieved,
when the relative humidity is less than 60%. The possibility of rust blooms is also
reduced when relative humidity is less than 60%. Use of a minimum 1,500-CFM
desiccant-type dehumidifier should maintain relative humidities at 40% or less.
QC HOLD POINT: Document relative humidity on ARCOR� QC Inspection Report
3.8 Abrasive blast the entire surface to attain a scale free, oxide free, metal finish with a
minimum anchor profile of 3-5 mils and SSPC rating in accordance with the Product
Data Sheet. Surface profile should be taken with Testex ‘X Course� Press-O-Film tape.
Measurement of Tape profile is done with Testex Dial Thickness Gage.
QC HOLD POINT: Document surface profile on ARCOR� QC Inspection Report
3.9 Surface chloride contamination can drastically reduce the life of a coating.
Therefore, it is necessary to test freshly blasted surfaces for chlorides and ferrous ions
(Fe) using a SCAT kit (see 3.5). Chloride levels should be less than 50 PPM and Fe
should be less than 10 PPM. If higher levels are found wet the entire contaminated
substrate with deionized or demineralized water to leach out the contaminants. Allow a
minimum of 12 hours leach time. Re-blast the area and test again. If after two washes
the desired contamination levels are not attained, contact an ARCOR�/VICOR�
technical representative.
QC HOLD POINT Document SCAT results on ARCOR� QC Inspection Report
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ARCOR� Gen.Spec. 06.99.1
SECTION IV
� IV.a. Weld Stripe/Rebuilding & Primer Application
4.1 The ARCOR�/VICOR� material should be applied as soon as possible after the
surface has been prepared. Continuous use of Dehumidification to maintain less than
40% RH will minimize potential oxidation of the substrate and should allow adequate
time (approximately 12 hours) for application of the prime coat. If 12 hours is exceeded
or if Dehumidification is not maintained at less than 40% RH for the entire period or if
oxidation is visible as exhibited by a change in color of the substrate, the entire surface
should be re-blasted to clean off the oxidation layer. This cleaning blast will be less
aggressive than the original blast since profile has already been attained.
QC HOLD POINT Document relative humidity on ARCOR� QC Inspection Report
4.2 If the surface becomes contaminated with oil, grease or lubricant after blasting,
wash thoroughly with non-polar solvent. (See Section 3.1)
4.3 Be sure area is completely free from dust and spent abrasive. After removing spent
abrasive, allow particles to settle, then blow down the surface with high pressure, clean
and dry air. Next vacuum the entire surface using a brush attachment to insure all
surface dust is removed. The surface may then be solvent washed with a non-polar
solvent (MEK, Acetone) and allowed too completely dry. Solvent wash is not required.
QC HOLD POINT: Document surface cleanliness on ARCOR� QC Inspection
Report
4.4 ARCOR� recommends the application of ARCOR� S-30 Prime as the first or prime
coat. This product is specially formulated to flow into the pores of the blast cleaned
metal to effectively seal the metal from the service environment and provide a good
chemical bond to the chosen ARCOR�/VICOR� topcoat. For ferrous substrates, the
addition of zinc phosphate allows the S-30 Primer to resist corrosion undercutting when
the coating integrity has been breached.
QC HOLD POINT Document material batch # on ARCOR� QC Inspection Report
4.5 The ARCOR�/VICOR� coatings are two-component epoxies. They are packaged
in two canisters (Part A & Part B) containing the proper mix ratio. Add the entire
contents of Part B canister into the entire contents of Part A canister. Consult the
appropriate data sheets for mix ratios by volume and weight. For plural component
spray application, insure that ratio settings directly correspond to the volume ratio of the
material being applied.
4.6 Ambient and surface temperature should be at least 55°F. Although the
ARCOR�/VICOR� products will cure down to 36°F, application will be extremely
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ARCOR� Gen.Spec. 01.99.1
difficult below 55°F and curing will be very slow (See Section 2.4.2). Surface
temperature must be maintained at a minimum of 5°F (3°C) above dew point during
surface preparation and application of ARCOR�/VICOR� materials.
QC HOLD POINT Document surface temperature on ARCOR� QC Inspection
Report
QC HOLD POINT Document dew point on ARCOR� QC Inspection Report
4.7 MIX COMPLETELY! Scrape side and bottom of mixing canister with wooden
mixing stick provided with each system. Streaks indicate the material is not thoroughly
blended and further mixing is required. Mixing time is normally five minutes. A portable
pneumatic or electric hand-held mixer may also be used. A “Jiffy-Mix� blade is
recommended. Avoid hitting sides and bottom of canister with blade. This may
introduce chips from the container into the coating. After mixing in original container
material should be ‘boxed� into a clean container and mixed again for at least one
minute.
QC HOLD POINT Document mix results on ARCOR� QC Inspection Report
4.8 Consult Product Data Sheets for pot-life or working-time. Dispense into smaller
containers or paint trays to extend working life. Higher temperatures will shorten the
pot-life; lower temperatures will extend pot-life (See Section 2.5).
QC HOLD POINT Document material applied within pot-life on ARCOR� QC
Inspection Report.
4.9 As appropriate, apply S-30 Prime to all weld areas, edges, seams, joints and
structural changes in the surface, by brush or roller. Allow to set until dry to touch.
Stripe over the S-30 Prime with EE-92 using plastic squeegee applicator. Smooth
material into surrounding substrate leaving no elevated edges or uneven spots. Do not
apply beyond area coated with S-30 Prime. Insure no skips, pinholes or voids occur in
the coating.
4.10 Allow stripe coat to cure until dry to touch. Apply S-30 Prime over entire surface
with brush roller or sprayer. Wet mil thickness should be a minimum of 20 mils.
Monitor film thickness with a wet-film thickness gauge. Check every 10 square feet on
open areas and every 5 square feet near seams and structural changes in the surface.
All ARCOR�/VICOR� coatings are “solvent free.� This means wet film thickness will
be the same as cured film thickness. Consult ARCOR� ‘Procedures For Spray Coating
Application.
QC HOLD POINT Document wet-film on ARCOR� QC Inspection Report
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ARCOR� Gen.Spec. 06.99.1
� IV.b. OVERCOATING
4.11 Apply second coat before first coat is fully cured. Since temperature and humidity
effect cure rate, the amount of time required between coats will vary. A sound bond will
be accomplished between coats if the guidelines in the Product Data Sheets are met.
The ‘fingernail� test is commonly used to determine whether the material is still within
the overcoat window. Press your fingernail into the coating. If an imprint is easily made
then the material is still within the overcoat window. If an imprint cannot be made, or
can be made only with more than moderate effort, it can be assumed the overcoat
window has passed and the material must be brush-blasted.
QC HOLD POINT Document overcoat window on ARCOR� QC Inspection Report
4.12 Should it be required to overcoat past the specified time guidelines, the first coat
must be brush-blasted to provide a good bonding surface. It is not necessary to allow
additional cure before brush blasting can begin. A brush-blast should remove all
material gloss and provide a profile of 3-5 mils. If the recommended overcoat time is
exceeded by no more than 2 hours at 78ºF, brush blasting may not be required.
Although not generally recommended, the coating may be wiped down with MEK (or
similar Ketone solvent) to remove the high gloss and provide good intercoat adhesion
(Follow cleanliness standards outlined in Sections 4.2 and 4.3). The solvent wash
method should not be used unless recommended by an ARCORâ„? representative for a
specific circumstance.
For ARCOR� S-30 Prime, S-30, EE-95, ARCTHANE the recommended overcoat
schedule is as follows;
� 55ºF 10-12 hours @ <60% RH;
� 65ºF 8-12 hours @ <60% RH;
� 75ºF 6-10 hours @ <60% RH;
� 85ºF 4-10 hours @ <60% RH;
� 95ºF 2-10 hours @ <60% RH.
4.13 Intercoat bonding is accomplished by a chemical reaction between adjacent layers
of coating which results in a monolithic coating. Maximum adhesion is attained when
the LEAST amount of time passes between coats. Hence, adhesion decreases as
more time elapses between coats.
4.14 In general, overcoating should be accomplished as soon as the previous coat
‘tacks up�, when it is no longer ‘wet� to touch. Normally between 78ºF and 88ºF the
product will tack up in 2 to 4 hours. The next layer should be installed as soon as
possible, but within 10 hours, at these higher temperatures, for best performance. The
level of ‘tack-up� depends on the application method being used. By roller, squeegee or
brush ‘tack-up� must be firmer than if spray application is used. For roller or squeegee
a horizontal shear is applied which could disturb the prior coat if it is not sufficiently
tacked-up. Use the thumb twist to determine if roller or squeegee can be safely
applied. Put thumbprint onto coated surface and push and twist thumb with modest
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ARCOR� Gen.Spec. 01.99.1
pressure into coating. If coating is compressed wait one hour and try again. When no
compression is observed, coating may proceed.
QC HOLD POINT Document ‘tack-up� on ARCOR� QC Inspection Report
4.15 Cure time increases sharply as temperature decreases. It is important to
remember that it is the temperature of the substrate that will determine the coating
temperature, hence cure rate. At cooler temperatures it may be necessary to add heat
to accelerate the cure to comply with scheduling requirements. Between coats do not
use kerosene, gasoline or any other petroleum based heat source as they may deposit
a film of residue on the substrate or coating which will hinder adhesion or intercoat
bonding. Electric heat sources are recommended. Once all coating layers are applied
it is acceptable to use a petroleum based heat source (e.g. a torpedo heater) to
accelerate the full cure of the coating system. When using added heat be very cautious
of dew point, humidity and overcoat windows.
QC HOLD POINT Document cure time & recoat window on ARCOR� QC
Inspection Report.
4.16 Spray apply additional coats of S-30 in accordance with section 4.5-5.15 until final
film thickness is attained. Consult ARCOR� ‘Procedures For Spray Coating
Application.
QC HOLD POINT Document wet-film thickness on ARCOR� QC Inspection Report
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ARCOR� Gen.Spec. 06.99.1
SECTION VI
•INSPECTION
6.1 Coating continuity must meet NACE Condition A, 100% pinhole free coating
system.
6.2 UV-QC (if applicable). After application of S-30 Prime-UV, while still wet, the coated
surface is inspected using an ultraviolet light system. All flaws and imperfections will
show as a dark spot. All spots are touched-up with a brush or squeegee using fresh
material.
After application of a coat of S-30, while still wet, the coated surface is again inspected
using an ultraviolet light system. All flaws and imperfections will show as a light,
luminescent spot. All spots are touched-up with a brush or squeegee using fresh
material.
QC HOLD POINT Document coating continuity on ARCOR� QC Inspection Report
6.3 The final coating should be allowed to cure a minimum of 12 hours prior to DFT
(dry-film thickness) measurements.
6.4 Coating thickness should be verified with a dry-film thickness gauge.
Measurements should be made every 10 square feet on open areas and every 5
square feet around structural changes in the surface. If readings less than the specified
mil thickness are observed, three additional readings over the 10 (or 5) square foot area
should be taken. If three of the four readings are less than the minimum specified mil
thickness, the area should be identified with a chalk or marker for repair. If less than
three measurements fall below the acceptance level, an average is taken. If the
average is below the acceptance level the area is to be identified with a chalk or marker
for repair.
QC HOLD POINT Document dry-film thickness on ARCOR� QC Inspection Report
6.5 The final coating should be allowed to cure a minimum of 24 hours prior to high-
voltage spark testing.
6.6 Visually inspect coating for skips, pinholes and other film imperfections. Identify
flawed areas with chalk or marker. It is preferred and recommended that
holiday/pinhole detection be performed with the aid of an electronic, high voltage
holiday detector using a minimum of 100 volts per mil of coating. NACE currently
recommends a voltage equal to 1000V times the � mil thickness. Spark testing can only
be done on flat surfaces at least 2� away from uncoated tube ends.
QC HOLD POINT Document spark test on ARCOR� QC Inspection Report
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ARCOR� Gen.Spec. 01.99.1
SECTION VII
� REPAIRING IMPERFECTIONS AND FLAWS
7.1 If an imperfection has been detected within allowable overcoating time (See Section
4.11), wipe the area with a solvent, allow to dry and simply reapply a layer of
ARCOR�/VICOR� product. Be sure to press the material firmly into the surface and
feather edges.
7.2 If the material has cured, the area around the imperfection must be roughened by
grinding or grit blasting and solvent washed. If the surface has begun to show signs of
oxidation or rust bloom, the surface must be thoroughly abraded back to clean oxide
free metal. It is not necessary to wait until material has fully cured to begin abrading the
material. As with the substrate, a 3 to 5 mil profile is recommended.
7.3 Should the measurements taken with the dry-film inspection gauge prove to be
below film thickness specifications, all these areas should be brush-blasted (or solvent
washed depending on overcoat time).
7.4 After blasting or abrading, remove dust and spent abrasive from the surface with a
vacuum with brush attachment.
7.5 It is advisable, but not imperative, to wipe the abraded area with solvent, allow to
dry.
7.6 Apply according to Section IV.b. Apply S-30 coating over abraded area with brush
or squeegee. Feather coating into existing areas making sure not to apply coating over
unabraided areas.
7.6 Inspect according to Section VI.
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ARCOR� Gen.Spec. 06.99.1
SECTION VIII
� CURE
Epoxy coatings cure by a chemical reaction, which produces its own heat (exotherm),
causing the polymer to change from a liquid or paste-like state into a hard, durable
surfacing material. Full cure or complete polymerization is generally accomplished in 3
days at 72°F (22°C).
8.1 Cure time, as stated in Section II, is dependent upon ambient temperature and
humidity. However, the following guideline will assist in determining the extent to which
the polymer has cured for exposure to certain conditions at 75ºF.
Condition Time elapsed after application
Light movement or stress 12 hours
Shipping 36 hours
Immersion or high loading 72 hours
8.2 Force curing or “baking� the polymer dramatically reduces the amount of time
required before the polymer can be stressed or put into service. Between coats do not
use kerosene, gasoline or any other petroleum based heat source as they may deposit
a film of residue on the substrate or coating which will hinder adhesion or intercoat
bonding. Electric heat sources are recommended. Once all coating layers are applied
it is acceptable to use a petroleum based heat source (e.g. a torpedo heater) to
accelerate the full cure of the coating system. When using added heat be very cautious
of dew point, humidity and overcoat windows.
8.3 Usually heat can be applied to the polymer before it has become firm. However,
care must be exercised since applying heat to the polymer before it has become firm
may cause it to decrease in viscosity and slump down the surface.
8.4 The addition of heat or force curing also enhances the chemical, heat resistance
and physical properties of the polymer.
8.5 For ARCOR� S-30 Prime, S-30, EE-95, ARCTHANE the recommended force-cure
schedule is as follows;
� 90ºF (32ºC) 45 hours
� 95ºF (35ºC) 36 hours
�100ºF (38ºC) 27 hours
�105ºF (41ºC) 24 hours
�110ºF (43ºC) 20 hours
�115ºF (46ºC) 16 hours
�120ºF (49ºC) 12 hours
8.6 After force curing, always allow the coating to cool to ambient conditions before
subjecting it to high loading or service.
-END-
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ARCOR� Repair.Spec.07.99.1
ARCOR�
ARCOR� International
a Division of AEC Corp.
Coating Repair Specification
Contents
1.0 Definitions
2.0 Precautions
3.0 Recommended Tools & Consumables
4.0 Intercoat Coating Repair
5.0 Topcoat Coating Repair
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ARCOR� Repair.Spec.07.99.1
1.0 Definitions:
1. Holiday: Flaw or defect in the coating that exposes or could expose the
underlying substrate.
2. Stress Riser: Area of the coating, which protrudes abruptly above the contiguous
area coating level. Typically found at coating interfaces, substrate edge interfaces
or large, coating filled, substrate pitted areas.
3. Recoat Window: Time interval during which a subsequent coat of a multi-coat
system can be applied. Associated terms include minimum and maximum recoat
time.
4. Minimum Recoat Time: Time required for a coat to become sufficiently cured to
resist thickness disturbance when overcoated or lightly abraded with fine-medium
grit paper to remove unevenness or to repair defects. A general guideline
determines minimum recoat time to be 10% of full cure per coating product cure
schedule. Minimum recoat is verified by Thumb Twist Test.
5. Maximum Recoat Time: Maximum time allowed for satisfactory intercoat
adhesion without special treatment of the surface of the prior coat. Also the
minimum cure time required before heavy abrasion of coat, i.e. mechanical
sanding with medium-coarse sandpaper or use of rotary grinder or light ‘sweep�
abrasive blast. A general guideline determines minimum recoat time to be 20% of
full cure per coating product cure schedule. Maximum recoat is verified by
Thumbnail Test.
6. Thumb Twist Test: The test used to determine that an epoxy has cured sufficiently
to accept application of another coat or for light sanding with medium grit paper
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ARCOR� Repair.Spec.07.99.1
to remove unevenness or repair defects. The thumb is pressed into the coating
with moderate pressure and twisted simultaneously. If there is no visible
disturbance of the epoxy and there is no epoxy on the thumb, the coating is
sufficiently cured to accept another coat or for light sanding.
7. Thumbnail Test: The test used to determine whether or not the coating recoat
window has closed. The thumbnail is pressed into the epoxy with enough force to
deflect the nail. If no evidence of an impression remains when the thumbnail is
removed, the recoat window has closed.
8. Tie-in Zone: The feathered zone between fresh and existing coating.
9. Feather: Creating an abraded tapered transition along interfaces between coating
materials or between coating and bare substrate. Feathered edges promote
interface adhesion without the stress riser and unsightly condition that would
otherwise occur at abrupt edges.
10. Mask: To prevent inadvertent overlap onto surfaces that are not intended or are
unsuitable for overcoating.
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ARCOR� Repair.Spec.07.99.1
2.0 Precautions:
1. Preening tools may damage some surfaces or change material properties.
2. Coatings that have exceeded allowable shelf life must not be used.
3. Coating material and cleaning solvent fumes and other materials associated with
this process may be toxic. Safety measures specified on MSDS must be followed.
4. Organic fumes associated with coating material fumes in areas serviced by HVAC
charcoal filters may affect filtration systems.
5. Unused portions of coatings may be considered hazardous and must be mixed,
hardened, and disposed of in accordance with customers chemical control
procedures
6. To avoid improper mix ratios, do not mix partial epoxy kits unless mass and/or
volume ratios have been verified using mass/volume ratios as provided in coating
Data Sheet.
7. Ensure that use of chemicals is allowed for the work area.
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ARCOR� Repair.Spec.07.99.1
3.0 Recommended Tools and Consumables:
1. Sandpaper
2. Scraper
3. Non-woven abrasive pad such as Scotchbrite.
4. Wire brush.
5. Rotary wire brush, wheel or cup
6. Disc sander
7. Non-woven abrasive disc, wheel or cup.
8. Flapper wheel
9. Abrasive blast equipment using water and oil free compressed air for larger sweep
areas.
10. Pistol blaster for spot blast.
11. Chloride free abrasives;
� 12/40-20/40 Black Beauty;
� 25-40 mesh Steel Grit;
� 24-36 mesh Aluminum Oxide;
� 16/35-8/20 Mesh Silica Sand.
12. Quality Control equipment to monitor air and surface temperature, humidity
control equipment, dust collection equipment as required to maintain specified
environmental conditions and ensure proper air flow.
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ARCOR� Repair.Spec.07.99.1
13. Cleaning solvent MEK (methylethylketone) or Isopropyl Alcohol in solvent
controlled areas.
4.0 Intercoat Coating Repair:
4.1 Between coats: Visually inspect coating for obvious defects and stress risers
prior to application of subsequent coating.
4.2 If a minor coating defect is identified record the observation on the ARCOR®
Daily Procedure Log.
4.3 Determine whether Minimum Recoat Window has passed using Thumb Twist
Test.
4.4 Determine whether Maximum Recoat Window has passed using Thumbnail
Test.
4.5 WHEN coating has passed minimum recoat time AND has not passed
maximum recoat time, touch-up and repair can commence.
4.6 IF coating repair can be completed before the maximum recoat window is
exceeded then apply touch-up coating and blend ridges and/or lumps and level the
surface.
In order for the above test to be valid the touch-up repair must proceed
in the same direction as the coating was/is applied i.e. the first areas the coating is
applied would be the first areas tested and repaired.
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ARCOR� Repair.Spec.07.99.1
4.7 If local surface areas protrude above surrounding coating material e.g. runs or
a stress riser, or if debris or foreign matter is observed in the coating the area must be
abraded to level the surface.
4.8 Using medium grit sandpaper or an abrasive pad abrade the coating in a linear
fashion i.e. left to right or up and down.
4.9 WHEN abrading is complete, using a combination of brushing, vacuuming
and solvent wipe, REMOVE all dust and debris from the surface.
4.10 If after abrading the abraded area is determined to be lower than the
surrounding coating, as in removal of debris, apply touch-up material and level the
surface.
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ARCOR� Repair.Spec.07.99.1
5.0 Topcoat Coating Repair:
5.1 Visually inspect coating for obvious defects and stress.
5.2 If a minor coating defect is identified record the observation on the ARCORâ„?
Daily Procedure Log.
5.3 Determine whether Minimum Recoat Window has passed using Thumb Twist
Test.
5.4 Determine whether Maximum Recoat Window has passed using Thumbnail
Test.
5.5 WHEN coating has passed minimum recoat time AND has not passed
maximum recoat time, touch-up and repair can commence.
5.6 IF coating repair can be completed before the maximum recoat window is
exceeded then apply touch-up coating and blend ridges and/or lumps and level the
surface.
In order for the above test to be valid the touch-up repair must proceed
in the same direction as the coating was/is applied i.e. the first areas the coating is
applied would be the first areas tested and repaired.
5.7 If local surface areas protrude above surrounding coating material e.g. runs or
a stress riser, or if debris or foreign matter is observed in the coating the area must be
abraded to level the surface.
5.8 Using medium grit sandpaper or an abrasive pad abrade the coating in a linear
fashion i.e. left to right or up and down.
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ARCOR� Repair.Spec.07.99.1
5.9 WHEN abrading is complete, using a combination of brushing, vacuuming
and solvent wipe, REMOVE all dust and debris from the surface.
5.10 If after abrading the abraded area is determined to be lower than the
surrounding coating, as in removal of debris, apply touch-up material and
level the surface.
5.11 IF coating repair cannot be completed before the maximum recoat window is
exceeded then it is advisable to wait until maximum recoat has passed. Heat
may be applied to accelerate cure. Consult the material Data Sheet and Cure
Schedule for direction.
5.12 Once the maximum recoat window has passed Use a High Voltage Spark Test
to locate pinholes/defects. Consult ARCOR� ‘General Specification� Section
6.6 for Spark Test procedures.
5.13 If a defect is identified circle the area with a chalk and record the observation
on the ARCOR� Daily Procedure Log.
-END-
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ARCOR� SpraySpec. 06.99.1
ARCOR�
ARCOR� International
a Division of AEC Corp.
PROCEDURES FOR
SPRAY COATING APPLICATION WITH
PLURAL COMPONENT SYSTEM
CONTENTS
SECTION I GENERAL INFORMATION
SECTION II REQUIREMENTS
SECTION III OPERATION OF EQUIPMENT
SECTION IV APPLICATION
SECTION V CLEANING / MAINTENANCE
NOTE: These are general procedures and are not intended to meet the specific needs of
any particular job. Always refer to appropriate data / application / material safety data
sheets. Customization or revision may be required.
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ARCOR� SpraySpec. 06.99.1
SECTION I
We recommend the use of a plural spray component system in certain settings and
situations. There are specific guidelines for spray coating which will be outlined in the
following information. For information pertaining to all aspects of application and surface
preparation, we recommend referring to product data sheets and the General Application
Specification.
GENERAL INFORMATION
ARCOR� makes use of advances in 100%-solids technology to spray their non-solvented
coatings onto large surface areas, which would normally require many hours of labor to
coat using traditional methods. The base and activator components of the100%-solids
epoxies are heated separately which lowers the viscosity of the product to a level where it
can be atomized through an airless spray system. Traditionally, heavy epoxy material has
needed to be heated or solvented in order to reduce viscosity to a level where the material
could be atomized through a spray system. ARCOR�s plural spray system regulates and
maintains optimal heat levels of the base and activator before the parts are mixed and
immediately transferred through the whip-hose to the spray gun. The spray system is
adjustable to a wide range of mix ratios. The effective controlling of heat and mixture
shortens cure time and allows a variety of products to be used in spray application. The
plural component system also saves material because base and activator are mixed
together only as needed.
Spray application of high performance epoxies allows for coverage of more surface area
in dramatically less time. In addition, a spray application provides a consistent coating
thickness with less voids or uneven coverage areas. Spray application of epoxy reduces
overall job cost in terms of man-hours and material used. Spray technology has become
the preferred choice of spec writers and facility engineers at today’s sophisticated power
and industrial locations because of increased control of application.
ARCOR� 100%-solids epoxies can be applied with the plural component spray system to
any surface or component, which requires a protective coating. Some of the applications,
which are ideal for spray coating, are tanks, waterboxes, secondary containment,
industrial flooring and large piping. Coatings can be sprayed indoors or outdoors within
the same general parameters of hand application. Spray technology is an ideal approach to
large surface area projects, which are traditionally labor intensive.
2
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ARCOR� SpraySpec. 06.99.1
SECTION II
REQUIREMENTS
To apply ARCOR� coatings using the plural spray system, the following items are
needed on site:
Compressed air (50-90 cfm) 100 psi minimum never to exceed 110 psi to air pump
120 Volt 85 Amp service
Clean location for spray system within 200 ft of job site.
Have available (6) 20amp, 110v circuits;
� 2- Tank Heaters 120 VAC / 15 amp each (30)
� 2- Line Heaters 120 VAC / 18 amp each (36)
� 2- 50� Heated Hose 120 VAC / 15 amp each (30);
96 Total Amps;
NOTE: All electrical components should be protected from weather as they are not
watertight or explosion proof. An application crew consists of a spray person and a
person running the pump.
For optimal viscosity, the base and activator components of the epoxy must be pre-heated
to a minimum of 130° F * before being sprayed. Normal initial pre-heat time prior to start
up is one hour *.
(* Pre-heat time and temperatures vary depending on specific product. Refer to product
data and application sheets for exact figures.)
3
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ARCOR� SpraySpec. 06.99.1
SECTION III
START-UP PROCEDURE
Appropriate safety gear including masks, suits, gloves, etc. is required on site before start-
up. In addition, there should be cleaning solvent (approx. 10 gallons of MEK, Acetone or
similar Ketone), various sized containers for parts and solvent and an assortment of
brushes, probes and appropriate wrenches. The RAC tips, spray gun, static mixer, mixer
manifold and the unit are to be well maintained by soaking and cleaning with solvent. A
“clean-up� station should be established in a well-lit and ventilated area.
Insure that compressed air is clean and dry and at least 80cfm @ 100 psi. The air hose to
the pump should be 3/4� ID or larger and unrestricted. A filter and lubricator comes on
the unit (the lubricator should be filled with non-detergent oil). In cold and damp
environments where air motor icing can be a problem, we recommend a 50-50 water /
Ethylene Glycol mixture in the lubricator or straight Marvel Mystery Oil.
CHECK PUMP RATIO SETTINGS
Verify volumeteric mix ratio of coating. Set slave pump to indicated setting for material
to be sprayed. Consult ARCOR� technician with questions regarding appropriate
settings.
Insure that supply tank on slave pump is aligned so that supply hose to slave pump is
straight with no bends. Slave supply tank can be moved in and out as well as swiveled.
Secure tank in proper position by tightening two tee nut handles.
PROPORTION UNIT WITH SOLVENT
Check in-line filters. Pour five (5) gallons of solvent into the base (A) and activator (B)
hoppers. Open each hopper outlet valve to the “A� and “B� proportioning pump. Turn
proportioning pump motor air valve on. Open mixer manifold handle (back position).
Hold spray gun (without tip) above a flush bucket. While slowly turning proportioning
pump regulator to 30-40 psi, observe A and B fluid pressure gauges and insure they are
balanced. If uneven, pull trigger on spray gun until gauges balance. After balancing
gauges, close spray gun and slowly increase air pressure to 50 psi. Insure gauges remain
balanced (if unbalanced, slowly open high side fluid re-circ valve until gauges are even
and then tightly close re-circ valve). Pressure check system for leaks @ 1500 psi
tightening as necessary. Turn off pump air valve. Reduce fluid pressure to zero by
triggering the spray gun. Drain solvent from pumps, hoses and valves.
Note: Pressure gauges have an accuracy of about +/- 10%.
SOLVENT FLUSH
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ARCOR� SpraySpec. 06.99.1
Use only recommended flush solvent. Fill solvent flush pump bucket with recommended
solvent, turn on air valve and slowly adjust air pressure to 50 psi. Keep pump at 5 cycles
per minute until primed. Check for leaks and tighten as necessary. With gun and mixer
manifold handle closed (forward position), trigger spray gun and hold open. Open solvent
purge needle valve and flush. With gun open and solvent valve closed, solvent pump
should not move or cycle. If pump cycles it indicates a leak, leaky valve or bypassing
inside the pump. Repair as needed. Turn air valve off on solvent pump.
NOTE: Perform the “Solvent Pump check-out� every day before starting up.
LOADING AND STARTING CLEAN UNIT
1. Fill solvent pump compartment with solvent and perform “Solvent Pump Check-Out�.
2. Start tank heaters (heaters preset @ 135°F). Caution: Each heater will draw
approximately 15 amps or a total of 30 amps @ 120V. Each tank heater has a 20-amp
circuit breaker.
Remove heating fluid fill plug and check level of water/ anti-freeze in tank heat jacket.
Tank should be filled to top. Note: Heating elements will burn out in seconds if there is
no heating fluid in outer tank.
Turn on both tank heaters.
Optional: Turn on each tank agitator and run at low rpm then shut off.
LOADING MATERIAL INTO UNIT
The base and activator materials should be stored at 60°F to 70°F. Close hopper fluid
outlet valves and make sure drain caps are tight. (Base material goes into hopper “A�
behind pump air motor. Activator material goes into hopper “B� behind slave pump.
Pour 5-10 gallons of base into “A� hopper and 5-10 gallons of activator into “B� hopper.
Turn on tank agitators and run at low rpm, as material requires. The material in the “A�
and “B� hoppers normally needs to be heated about one (1) hour to reach 135°F.
NOTE: Preheat times differ depending on material. Refer to material data sheets for
exact times.
LOAD PUMP AND HOSE SYSTEM
TURN “A� and “B� inline heaters off. Each line heater has a 20-amp circuit breaker. The
heated hose has a 15-amp GFCI circuit breaker.
Remove gun, hose and static mixer and mixer manifold head assembly. Open mixer
manifold valves (pull handle back) direct into waste container. Open outlet valves to
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ARCOR� SpraySpec. 06.99.1
pumps for “A� and “B� hoppers. Slowly turn on pump motor air valve. Run at slow
speed. Pump material through heated hoses to remove air bubbles and solvent. Continue
clearing hoses until material flows clean from both hoppers. Close ball valves by pushing
handle toward the gun. (Closing the mixer manifold by pulling the handle toward the
spray gun is intentional. For example, if the mixer manifold is moved to another location,
the ball valves will automatically close.) Install mixer manifold outlet head. Turn on
heated hose and set to 135°F.
Optional: Start re-circulating by opening re-circ valves on material lines leading back to
hopper tanks. Hold catch lines inside hopper tanks to catch solvent from return lines
when first starting re-circulation. Turn on A and B inline heaters. Set @135°F. Circulate
by turning pump air valve on and running pump slowly (10 cycles per minute).
Circulating speeds hopper heat up, heats the pumps and removes air from inside the
pumps. Make sure material comes to a temperature of 135°F and no bubble popping is
evident. Run agitator at low rpm to avoid trapping air in material. Once hoppers, unit and
hose are up to heat, close A and B re-circ valves. Turn off air to motor of pump.
RATIO CHECK
To do ratio check, remove return hoses from A and B re-circ valves. Open pump motor
air valve and adjust air regulator to bring fluid outlet pressure to 800-1000 psi. Open
both re-circ valves simultaneously to establish flow (direct into clean A and B
containers). Partially close re-circ valves until A and B fluid pressures are both at 500-
600 psi. Simultaneously take A and B beaker samples from re-circ valve fluid streams to
verify ratio.
6
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ARCOR� SpraySpec. 06.99.1
SECTION IV
TEST SPRAY
NOTE: Two people are required for complete spray testing
Connect static mixer, whip hose and gun to mixer manifold. Close circulating valves.
Open manifold material valves (pull handle back). Trigger gun with spray tip removed.
Open air motor ball valve slowly to start pumping material (run pump slowly).
Pump sufficient mixed material through the gun to insure it is clean (virgin) and that there
are no solvent or air bubbles. Install appropriate spray tip.
Adjust pump air pressure until spray pattern is achieved (about 3500-psi fluid pressure).
Trigger gun to test spray fan pattern on scrap cardboard until optimal atomization is
achieved. Spray sample area to verify proper mix, ratio and cure.
PRODUCTION SPRAY
Pre-arrange all equipment within the work area so as to allow the spray operator to spray
continuously. The best spray application results are obtained with the least amount of
triggering of the spray gun.
To produce a spray fan at the tip, the pressure at the spray gun should be 3500 psi @
135°F. Adjust proportioning pump air pressure as necessary to achieve a spray fan. Set
inline heaters at 135°F with fluid in system. Using a spray tip orifice of .023 to .031 will
give a flow rate of .6 to .8 GPM. Typical tip fan used is 40°to 50°. Average tip life is
about 500 gallons. Always have a new tip ready to use. A worn out tip can cause a loss of
fan and poor coating thickness consistency. Throw worn tips away.
When spray operator stops spraying, mixed material must be immediately flushed
thoroughly from the tip, gun, whip and mixture. If not properly flushed and cleaned,
mixed material will solidify. IMPORTANT: Proper flushing is mandatory to assure
normal equipment operation and application production and to avoid down time and
repair costs.
7
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ARCOR� SpraySpec. 06.99.1
SECTION V
DAILY / WEEK STOPAGE CLEANUP: If unit will not be used for 2 or more hours.
Turn off tank heaters, inline heaters and heated hose. Turn off hopper agitators. Turn off
air supply to proportioning pump and bleed system of air. Insure pump is stopped with the
pump rods in the down position (shiny part of pump rod hidden from view).
Slowly trigger gun into waste container to relieve pressure in system. Open solvent valve
and flush mixer, whip hose, gun and tip until clean solvent can be seen.
Remove static mixer from manifold. Remove element from mixer and inspect and clean
element tube. A clean element means that the proper solvent in the appropriate quantity
was flushed.
Important: Do not place static mixer onto mixer manifold until the unit is ready to be used
again.
Remove spray tip and clean with a soft brush. Never use a knife or steel brush because it
will cause damage to the tungsten carbide tip. After cleaning the tip, it may be soaked in a
closed container of clean solvent if desired.
Remove air supply from unit. Clean all equipment so that it is spotless.
NOTE: Allow enough time at the end of the shift to completely clean the unit. The
supervisor or foreman needs to inspect the cleaning of the unit. Field experience has
proven that a thorough cleaning greatly improves performance and reliability of the unit.
Material does not need to be removed from the hoppers or pump if the unit is to be used
within 3 days. Insure that the material is circulated and/or agitated at start up each day to
prevent separation.
STORAGE AND LONG-TERM SHUT-DOWN
Follow the daily clean up schedule as described and then do the following steps.
Drain A and B material from tanks. Wash tanks with proper thinner or solvent.
Optional: Open re-circ valves and circulate 3 or 4 gallons of solvent in each hopper tank
as in the circulating mode (pump to tank). Close re-circ valves.
Purge paint from the heated hose and circulate solvent through hoses and mixer manifold
until clean. Turn off air to pump. Open re-circ valves (optional).
8
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ARCOR� SpraySpec. 06.99.1
To clean inline paint screens, open in-line filters drain valves, remove filter tank and
inspect screens for debris. Clean as needed.
Completely drain system and circulate clean solvent for several minutes.
Leave mineral spirits solvent or oil in system during long-term shut down. All pump rods
should be in down position with TSL in wet cups.
NOTICE
All statements, information and data contained herein are based upon tests and field
experience, which we believe to be accurate and reliable. However, since field conditions
vary widely, the user must determine the suitability of the equipment for particular use.
-END-
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ARCOR� ARC.Spec.07.99.1
ARCOR�
ARCOR� International
a Division of AEC Corp.
PROCEDURE FOR INSTALLATION
OF THE ARCTHANE JOINT SYSTEM
ON TUBESHEET/CHANNEL HEAD INTERFACE
1. De-water channel head and tubes. Blow down all tubes to remove residual water.
2. Grit-blast interface region i.e. 2 inches of the sheet; the crevice; and two inches onto the channel
head. An SSPC-SP-5 white metal, 3-5 mil profile is recommended.
3. If there is an existing coating on the channel head, brush blast 1-1/2 to 3� of the existing coating
directly next to the 2� strip that is prepared to bare metal.
4. Thoroughly clean the area by vacuum, brush and vacuum.
5. Install a 20 mil of ARCOR� S-30 Prime. Refer to the product Data/Application sheet. The S-30 Prime
should completely cover the prepared region feathering into the brush blasted region of the existing
coating. There should be no visible skips or “holidays.�
6. Allow the ARCOR� S-30 Prime to set up tack-free. Consult the Data/Application sheet for overcoat
window and/or the S-30 Cure Schedule chart.
7. Install a 20 mil coat of ARCOR� S-30. Refer to the product Data/Application sheet. The S-30 should
completely cover the S-30Prime and should feather into the existing coating insuring no ridge exists
between coated areas and that unprepared surfaces are not coated. There should be no visible skips
or “holidays.�
8. Allow the ARCOR� S-30 to set up tack-free. Consult the Data/Application sheet for overcoat window
and/or the S-30 Cure Schedule chart.
9. Install a bead of ARCOR� ARCTHANE into the crevice filling the joint. Use a caulking gun or similar
device to force material into the crevice. Insure that the bead bridges from the tubesheet to the
channel completely with no skips or voids. Cutting a plastic applicator corner off in a half-moon shape
creates a useful tool to smooth the ARCTHANE in the joint.
Squeegees are
Cut out with
provided in product
razor
packaging
10. Allow to fully cure before subjecting to a spark test or immersion service. Consult the ARCTHANE
Data/Application sheet or the ARCTHANE Cure Schedule chart.
11. Force cure with addition of heat as needed. Allow the surface (and the ARCOR�) to cool down to 95
degrees F or less before spark testing or immersion after a force cure.
-END-
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ARCOR� EHS.Hand.07.99.1
ARCOR�
ARCOR� International
a Division of AEC Corp.
ENVIRONMENTAL HEALTH & SAFETY HANDBOOK
Overview
�
ARCOR�s environmental, health and safety (EHS) goal is to achieve and
Incident Free Workplace. An incident is an event that causes or has the
potential to cause harm to people or the environment, or damage to equipment
or the facility. An incident can also be an event that violates or has the potential
�
to violate an ARCOR� EHS internal policy, standard , procedure or applicable
EHS government or community requirement. In order to prevent incidents, we
must all work actively to identify, evaluate, anticipate, investigate and control the
root causes of workplace hazards.
The causes of incidents fall into two broad categories: Unsafe conditions and
unsafe acts. Unsafe conditions may exist in the condition of tools and
equipment, work stations, job process or the environment (i.e. unguarded
machinery, improperly stacked material, etc.). Unsafe acts may be the result of
lack of employee training or understanding, poor attitudes toward EHS, failure to
follow set procedures or guidelines, or failure to be fit for duty (i.e. poor physical
condition, being under the influence of some form of intoxicant, or being
preoccupied with matters outside the workplace).
This handbook is an attempt to condense more specific, sometimes more
stringent programs into a single document which will promote contractor and/or
employee understanding of safe work requirements. This document in itself is
not able to cover every aspect of every job in detail. The omission of any rules
from this document does not free the contractor and/or employee from
responsibility. If at any time you are unsure of how to do a job safety, it is your
responsibility to ask your immediate supervisor for instruction. Always be alert
for hazards by asking yourself “What if the unexpected happens.�
Our goal is that each day, you will leave the facility in the same condition in
which you entered. You and your family’s happiness is dependent upon you
working safely.
1
ARCOR� EHS.Hand.07.99.1
EHS Value, Policy and Principles
Value
We will work safely in a manner that promotes the health and well-being of the
individual
and the environment.
Policy
�
It is ARCOR�s policy to operate in a safe, responsible manner which
represents the environment and the health of our employees, our contract
employees, our customers and the communities where we operate. We expect
our contract and/or employees to adopt our example. We will not
compromise environmental, health or safety values for profit or production.
Principles
�
All ARCOR� employees and contract employees are expected to understand,
promote and assist in the implementation of this policy and the accompanying
principles.
* We are all accountable for conforming with EHS Policy.
* We will work diligently to prevent incidents.
* We will practice sound environmental, health and safety management.
* We will comply with all applicable laws, regulations, and permits, and will
develop and employee more restrictive internal standards where necessary to
�
conform with ARCOR�s EHS Policy.
* We will audit our operations and report findings.
* We will sponsor activities to improve the science of environmental, health and
safety protection.
* We will report on our activities.
* We will support sustainable development, the responsible use natural
resources and energy conservation.
* We will supply safe and reliable products and services.
2
ARCOR� EHS.Hand.07.99.1
General EHS Information
A. General Rules and Information
1. Report all incidents such as injuries and/or near misses to your supervisor
immediately. All accidents involving personal injury or damage to vehicles,
property or product must be reported immediately.
2. Safety Glasses with permanently attached side shields and safety shoes are
required to be worn by all employees. Alternate or additional types of eye and
face protection such as chemical goggles or face shields may be required for
certain jobs. Personal Protection Equipment (PPE) maps and signs indicate
areas that require safety glasses. If in doubt, please contact your supervisor.
Hearing protection is required to be worn while in the production & grinding areas
of the plant, or when identified as needed (ie. JSA, SPO, etc.).
3. Do not wear loose fitting clothing, bracelets, and dangling jewelry, and/or long
hair longer than shoulder length (unless tied back or worn under a hat (that may
get entangled in equipment. For more information, see your supervisor.
4. Head protection, gloves, arm covers and other personal protective equipment
�
(PPE) are required in specific areas and for specific tasks, throughout ARCOR�.
Adhere to all PPE requirements.
5. “Horseplay� is a cause of many injuries. This term applies to any prank or
�
practical joke and is prohibited by ARCOR� rules. Scuffling, horseplay, yelling,
loud whistling and practical jokes are forbidden.
6. For most jobs, it is necessary to work with other employees. Always be aware
of their location and what they are doing to avoid injury both to yourself and your
work partners.
7. The Lockout/Tagout Procedure shall be followed. Do not attempt to repair,,
clean or clear scrap from any equipment or powered machine unless all energy
sources have been turned off and Lockout/Tagout procedures have been
followed.
8. Comply with danger and caution signs. Do not enter any barricaded area
unless you are authorized by your supervisor to do so.
9. Do not stand or walk under a suspended load.
10. Enter confined spaces only at the direction of a supervisor in accordance
with Engineering Standard 18.1 and the Confined Space Entry Procedures.
3
ARCOR� EHS.Hand.07.99.1
Examples are manholes, storage tanks, dust collectors, silos and elevators pits.
Your supervisor can answer questions you have on this procedure.
11. Walk - do not run. Watch your step. Used marked aisles and walkways.
use stairs or ladders when going from one elevation to another.
12. Keep all aisles and exists clear. Do not block access to fire fighting
equipment, fire blankets, electrical panels, switch boxes or utility shut-off valves.
These are identified either by a sign or conspicuous colored painting.
13. Keep flammable materials an combustibles in approved safety cans with
appropriate labels.
14. Put all scraps and waste materials into proper receptacles. keep oily an
paint covered rags in closed metal containers.
15. Do not create or contribute to any risk or unsanitary condition.
16. Do not unnecessarily distract the attention of any employee who is working.
17. Possession or consuming of any intoxicating beverages or illegal drugs on
the premises is forbidden. Reporting for work while under the influence of
intoxicants or drugs or while suffering form the effects of the same is also
forbidden.
18. Stay clear of any belt conveyors or transfer equipment. Do not cross over or
under such equipment that is in motion or may be put in motion except at
crossovers provided (your supervisor will point out such equipment to you).
19. Operate only the machine or equipment which you are authorized to
operate.
20. Seat belts must be worn at all time by operators of mobile equipment that is
equipped with seat belts.
21. Seat belts must be worn by drivers and passengers of personal or rental
vehicles being used for official company business.
22. Report all hazards, unsafe tools or equipment to your supervisor.
23. Use fire extinguishing equipment (only if you have been trained at
�
ARCOR�) on fires and/or directed. Notify the Maintenance Supervisor when fire
equipment has been used so it can be services.
24. Glass containers (bottles, jars, etc.) and aerosol containers are not to be
brought onto the job site.
4
ARCOR� EHS.Hand.07.99.1
25. Do not sue compressed air or gasses to blow PVC powder or dust off any
part of your body or clothing. This practice can lead to serious injury.
26. Guards on equipment are put on for your safety. Do not disable or operate
equipment without all guards in the proper position.
27. Employees need to follow Safe Job Procedures (JSA’s) when performing
their jobs.
28. Practice safe lifting techniques. keep the body upright; lift with the leg
muscles and not with the back. Avoid overexertion caused by improper lifting,
pulling, pushing or reaching.
29. Wear hand pads or gloves when handling hot materials, sharp-edged scrap
or rough materials on all jobs and as instructed by your supervisor.
30. Remove nails from barrels, crates and any other places where they might
cause accidents. Dispose of boards with protruding nails.
31. Keep floors clean. Oil or grease is especially dangerous on floors near
machines, sharp-edged tools or scrape metal. Spilled powder or resin needs to
be cleaned up immediately.
32. Arrange materials carefully and securely. Do not pile or place objects or
materials near machines or in such a position that they can fall or block
passageways.
33. When stacking materials, avoid leaving projecting edges or points.
34. Suggestions that will help in safe job performance or identify unsafe
conditions or practices are needed. Suggestion can be brought to your
supervisor.
35. All machinery/work areas must be kept clean by the employee. Damaged or
defective equipment should be promptly reported to your supervisor.
36. Never stand skids or similar items on end and lean them against a wall,
support post, railing, etc.
37. Be sure no one could be injured before you start any machinery or operate
valves and switches.
38. Keep out or the areas that are barricaded or marked restricted. There may
be work in process that may cause dangerous conditions to exist.
5
ARCOR� EHS.Hand.07.99.1
39. Check all tools before using them. inspect for defects and report them to
your supervisor.
40. When lifting always be sure to sue the proper lifting technique. When
possible utilize lifting equipment or obtain help.
41. Operate only equipment for which you have been trained. If you are not
sure of operating procedures for a piece of equipment that you are required to
run, it is your responsibility to inform your supervisor.
42. Tank tops and shorts are not allowed to be worn while on the job.
Excessively loose clothing should not be worn, as it increases the possibility of
becoming caught in moving machinery.
43. All mobile equipment operators (lift trucks, tuggers, cranes, etc.) must be
trained to operate the equipment.
44. Heat stress can affect anyone. Environmental conditions which include high
temperatures, high humidity, air movement, and personal variables such as work
rate, general health and conditioning can affect your body’s ability to deal with
high heat.. be aware of your environment; know which factors increase risk.
drink plenty of water all day before you feel thirsty. Wear appropriate clothing,
loose and lightweight. Stay in shape. eat light regular meals. Know your special
risk such as age, recent illnesses, high blood pressure, heart disease, allergy
medication or diabetes. Pay attention to warning signs such as not feeling well,
weakness, inattention, dizziness, excessive headaches or nausea that can be
preliminary stages of heat stress. Recognize symptoms and seek appropriate
care. Unrecognized and untreated signs can lead to more serious health
problems.
For more detailed safety rules refer to:
Department Job Safety Analysis (JSA's)
6
ARCOR� EHS.Hand.07.99.1
B. Protective Equipment
The terms “employee� and “operator� also refers to any contract
employee.
1. Eye Protection
* All employees and visitors must wear ANSI-approved safety glasses with side
shields which meet ABP’s requirements when entering all Plant Operational
�
areas. Any questions, see your ARCOR� representative.
* Employees working with chemicals with a potential of splash or spray, must
wear a protective face shield or acid splash goggles.
* Operators using saws, grinders, or similar type equipment must wear goggles.
2. Foot Protection
Employees and visitors are required to wear steel toed safety shoes in the
production areas,
warehouse and job sites.
3. Work Clothing
Personal protective apparel such as protective jackets, aprons, arm guards and
the correct glove must be worn per individual department rules.
Hearing Protection (See Hearing Conservation Section)
4.
Hearing protection is required in manufacturing areas and must be worn on jobs
�
designated by the ARCOR� Representative.
5. Head Protection
Head protection must be worn on job sites are all times.
Respiratory Protection (See Respiratory Protection Program
6.
Section)
When air contaminants are generated by a work process, it is preferable to
control them using substitution of a less toxic material or controlling the
contaminants using engineering controls. When this is not feasible respiratory
protection may be necessary. Prior to using a respirator all employees must:
* Be trained in the use and limitations of the respirator.
* Be fit-tested to ensure proper fit of the respirator.
7
ARCOR� EHS.Hand.07.99.1
* Have medical clearance to use a respirator.
7. Hand Protection
Some jobs require the use of gloves. The type of glove will depend on the task
�
being done. Check with your ARCOR� supervisor.
C. Reporting Hazards
Once a hazard is recognized, it must be reported. reporting hazards is one of
the most important ways you can help ensure a safe work place. Often an
employee can spot problems sooner than anyone else because he/she is very
familiar with work place conditions. Once a problems has been identified, take
action to eliminate the hazard and if you are unable to do this, report the issue to
your supervisor.
D. Housekeeping
The foundation for a safe, healthy and pleasant work place is good
housekeeping. Each employee is responsible for keeping his/her immediate
work area well organized and the floors free of debris and litter.
* Return all tools and equipment to proper storage place after use.
* Keep materials and equipment out of aisles.
* Clean up all spills immediately.
* Place trash and scrap in the proper containers.
* Pick up all trash from floor.
* Restrooms and water coolers are provided for your convenience and comfort.
Please help keep them clean and sanitary.
* Metal scrap containers are for metal scrap only. never place any other material
in these containers.
* Exits must be kept clear at all times.
Hand/Power Tool Safety
Hand tools can make jobs safer, easier and more efficient. however, if used
improperly hand tools can cause serious injuries. Always use hand tools as they
are intended to be used and maintain them properly.
* Inspect your tools daily to ensure they are in proper working condition.
Damaged or defective tools must be tagged-out and reported to your supervisor
immediately.
* Hand tools should be carried in a tool box, bag or tool vest.
8
ARCOR� EHS.Hand.07.99.1
* Power saws, grinders and other power tools must always have the proper
guards in place.
* Portable electric grinders and other power tools must always have the proper
guards in place.
* Hand tools should be used for their intended purpose only. The design
capacity of hand tools should not be exceeded by unauthorized attachments.
* Cords and hoses must be kept out of aisles and off stairs and ladders.
* Electric cords must be unplugged and the airline must be deactivated before
adjusting or loading electric or pneumatic tools (i.e. nail guns, staplers, drills,
etc.).
Compressed Air & Gas Safety
A. Compressed Air
* Compressed air used for clearing shall not exceed 30 psi of pressure.
* Compressed air MUST NOT be used to dust off clothing or any part of the body
or be directed at any person. Compressed air or foreign bodies may enter the
body and cause severe injuries or death.
* Use only hoses and couplings designed to handle compressed air and inspect
them before each use.
B. Compressed Gas Cylinders
* Keep cylinders out of contact with grease, acids, salt, heat and flame. Do not
handle cylinders or apparatus with greasy hands or gloves. Never use white
lead, oil, grease or pipe compound on welding equipment joints. Oil or grease in
the presence of oxygen under pressure can cause an explosion.
* Do not handle cylinders roughly. They must be properly fastened before using
or moving on a vehicle or hand cart. Cylinders, full or empty must be secured
when standing vertically while in use and/or in storage.
* While in storage or being transported, cylinders should have the valves shut
off and the supplied protective covers in place.
* Never use a cylinder without a suitable reducing valve and regulators.
9
ARCOR� EHS.Hand.07.99.1
* Never interchange oxygen regulators, hose or other appliances with similar
equipment for other compressed gases.
* Always crack the valve of oxygen cylinder before connecting the equipment to
purge the opening of any foreign material.
* Protect cylinders from accumulation of ice and snow. If necessary to melt ice
from acetylene cylinders, use warm water.
* Oxygen and acetylene (or other fuel gas) cylinders must be separated by at
least 20 feet or by a non-combustible barrier at least five (5) feet high, having a
ire resistance rating of at least on-half hour.
* Arc welding electrode or ground leads shall not be hung over compressed gas
cylinders.
Manual Material Handling
Most back injuries result from improper lifting. According to the principles of
biomechanics, the worst lifting situation occurs when the body is extended over
the load; the lower back becomes a fulcrum supporting the weight of the body,
plus the weight of the load. Twisting in this position invites injury. Keep your
back upright to shift the weight on the more powerful leg muscles and reduce the
lever effect.
If the load is too heavy, too large of unstable, get help. Use hoists or lift trucks
when possible.
Portable Ladder Safety Rules
* Only trained employees shall use portable ladders.
* For overhead work use the proper type of ladder. Never use make-shift
ladders or stand on equipment.
* Ladders are for climbing. They are not to be used for levering, bracing,
scaffolding or any other purpose which might weaken the structure or create an
unsafe condition.
* Straight ladders should be equipped with safety shoes and be properly tied-off
at the top an blocked at the bottom where possible.
10
ARCOR� EHS.Hand.07.99.1
* Straight ladders will be placed at the proper angle. Place ladder so the base is
out on-fourth the vertical distance against which the ladder is leaning. The top of
a ladder which is being used to access to an elevated work area must extend at
least three (3) feet beyond the supporting object.
* Always face the ladder when ascending and descending, and always maintain
three (3) points of contact with the ladder. Never carry objects in your hands
while climbing a ladder. Use a rope or other methods to raise and lower tools
and materials from heights.
* Do not over reach outside the side rails of a ladder. Keep your waist inside the
side rails of a ladder.
* Do not splice ladders to make them longer
Mobile Equipment Safety Rules
1. The main responsibility for safe operation of any mobile equipment lies with
the operator. However, pedestrians must be aware of vehicular traffic in their
area and be appropriately cautious around mobile equipment.
2. Only authorized employees who have been trained may operate mobile
equipment.
3. It is the duty of the truck operator at the beginning of each shift to conduct a
vehicle pre-use inspection.
4. The inside speed limit is 4.5 mph, which is a fast walk. Use extra care in
congested areas, when making turns, or on rough floors or pavement. The
outside speed limit is 6.5 mph.
5. Face the direction that you are traveling. Never back up without looking to
see that it is clear to do so.
6. When traveling, keep the forks as low as possible.
7. If line of travel is blocked by workers or pedestrians, slow down or stop if
necessary and sound the horn.
8. Be sure that your truck is properly and carefully loaded. DO NOT attempt to
handle loads beyond the rated capacity of the truck.
9. Do not allow any person to walk under raised forks.
10. Do not allow any person to ride the forks, platform or load.
11
ARCOR� EHS.Hand.07.99.1
11. Park vehicle in a safe place when not in use. Do not obstruct crossings,
passageways or roadways.
12. When an industrial vehicle is left unattended, the load engaging means shall
be lowered, controls neutralized, the power off and brakes set. The operator
may leave the engine running only if he is within 25 feet and can see the vehicle.
The other requirements still apply.
13. Stunt driving, racing and horseplay with vehicles will not be permitted.
14. Always wait until the vehicle is completely stopped and emergency parking
brake is set before dismounting.
15. Sound horn at all blind corners, when passing other vehicles, pedestrians or
workers, or whenever there is a stop sign indicating horn use. Never use horn to
startle people.
16. Obey all traffic signs.
17. When loading or unloading trucks and trailers, check that the truck brakes
are set and properly place wheel chocks to prevent movement.
18. Report all incidents whether they involve personal injury, equipment, material
damage, collision or material upsets to your supervisor immediately.
19. When floors are slippery with oil, grease, or water, clean up the area if
possible, or reduce your speed and notify your supervisor immediately.
20. When lifting personnel on a fork truck an approved safety platform firmly
secured to the lifting carriage must be used.
21. When ascending or descending grades the loaded fork shall be driven with
the load upgrade.
22. Portable LP tanks may be stored only in racks provided for this purpose. Do
not store cylinders on the ground.
23. On forklifts with seat belts installed, it is mandatory for operators to properly
wear the belt.
12
ARCOR� EHS.Hand.07.99.1
Fire Prevention and Flammable Liquids Safety Rules
1. Only use a fire extinguisher if you have been trained by your employer an
based upon your level of confidence an training.
2. Fire extinguishers have a rating prominently displayed on them that identify
what class of extinguisher they are. The rating follows:
Fire extinguishers can be of more than on Class, with Class ABC being a
common extinguisher available. Class ABC extinguishers can be used on paper
or wood, flammable liquids or electrical fires.
3. Become familiar with the location, operation and use of fir extinguishers in
your area.
4. Fire fighting equipment and fire aisles must be kept clear and ready for use at
all times. Never block sprinkler heads with stored materials.
5. Only approved solvents should be used for cleaning and degreasing.
6. Use as little solvent or flammable liquid as necessary to do the job. Keep
solvents in a labeled safety container and do not use around sparks or open
flame.
7. Flammable liquid containers must be closed while not ins use.
8. Do not attempt any work involving a source of ignition near a pit, sewer, drain,
manhole or enclosed space where flammable gases may be present. Wait until
the area has been declared safe for hot work (See your supervisor.)
* Class A - used for normal combustible materials such as paper or wood.
* Class B - used for flammable liquids.
* Class C - used for electrical fires.
* Class D - used for flammable metals, such as, sodium, magnesium and
aluminum.
9. Good housekeeping is our best protection against fires. Do your part by
disposing of all scrap, wiping, rags, paper, rubbish, etc. in proper containers.
10. Make sure all electrical equipment is in good condition. Such things as worn
or frayed extension cords, defective plugs and outlets, overloaded fuses and
circuits are all fire hazards.
13
ARCOR� EHS.Hand.07.99.1
11. Obey “NO SMOKING� signs. Discard tobacco products and matched in
appropriate containers. Observe the smoke free work environment policy and
smoke only in designated areas.
12. Flammable liquids must be stored and used in appropriate containers. (i.e.
FM approved).
13. When flammable liquids are not being used, they should be stored in
flammable liquid storage cabinets or designated areas.
14. Use appropriate bonding and grounding when transferring flammable liquids
to another container.
14
ARCOR� EHS.Hand.07.99.1
Written Program Overview
A. Confined Space Program
The confined space program addresses hazards within areas such as pits,
machinery or other enclosed areas. Confined spaces have been reviewed and
are marked with confined space signs. Unauthorized entry into confined spaces
is strictly prohibited.
Definitions
ACCEPTABLE ENTRY CONDITION: conditions that must exist in a permit
space to allow entry and to ensure that employees involved with a permit-
required confined space entry, can safely enter into and work within the space.
ACCEPTABLE ENVIRONMENTAL CONDITIONS: confined space workplace
conditions in which uncontrolled hazardous atmosphere are not present, and
which include any additional environmental criteria the employer may require for
employee entry into a confined space.
ATTENDANT: an employee stationed outside the confined space, trained as
required by this Standard, assigned to monitor the employees inside this space
and other spaces within the limits as authorized by the location.
AUTHORIZED ENTRANT: an employee who is authorized by the employer to
enter a confined space.
BLANKING OR BLINDING: the absolute closure or a pipe, line or duct, by
fastening across its bore a solid plate or “cap� which completely covers the bore:
which extends at least to the outer edge of the flange at which it is attached; and
which is capable of withstanding the maximum upstream pressure.
CONFINED SPACE: an enclosed space which:
a) Is large enough an so configured that an employee can bodily enter and
perform assigned work;
b) Has limited or restricted means for entry or exit (examples are tanks,
vessels, oils, pits and diked areas);
c) Has one or more of the following characteristics:
� contains or has known potential to contain a hazardous atmosphere;
� contains a material with a potential for engulfment of an entrant;
� has an internal configuration such that an entrant could be trapped or
asphyxiated by inwardly converging walls, or a floor which slopes
downward and tapers to a smaller cross section; of
15
ARCOR� EHS.Hand.07.99.1
� contains any other recognized serious safety or health hazard.
ALL CRITERIA MUST BE CONSIDERED IN EVALUATING A CONFINED
SPACE.
DOUBLE BLACK AND BLEED: the closure of a line, duct or pipe by locking and
tagging a drain or vent which is open to the atmosphere in the line between two
locked-closed valves.
EMERGENCY: any occurrence (including any failure of hazard control or
monitoring equipment) event(s) internal or external to the confined space which
could endanger entrants
ENGULFMENT: surrounding and effective capture of an employee by a liquid or
finely divided solid substance.
ENTRANT: an employee authorized to enter a confined space. May serve as
an attendant if this is approved by the permit. May be fully trained employee to
approve entry by others, and may enter the space covered by the permit
provided by the attendant is informed.
ENTRY: the act by which a person intentionally passed through an opening into
a confined space and includes ensuing work activities in that space. The entrant
is considered to have entered as soon as any part of the entrants face breaks th
plane of an opening into the space.
ENTRY PERMIT: the written or printed document established by the employer,
the content of which is based on the employers hazard identification and
evaluation for that confined space (or class or family of confined spaces is a
number of spaces may contain similar hazards) and is the instrument by which
the employer authorizes his or her employees to enter that confines space.
ENTRY PERMIT SYSTEM: the location’s written procedures for preparing and
issuing permits for entry and returning the permit space to service.
HAZARDOUS ATMOSPHERE: an atmosphere which exposes employees to a
risk of death, incapacitation, injury or acute illness from one or more of the
following causes:
a) A flammable gas, vapor, or mist in excess of 10 percent of its lower
explosive limit (LEL);
b) An airborne combustible dust at a concentration that obscures vision at a
distance of five feet (1.52 m) or less;
16
ARCOR� EHS.Hand.07.99.1
c) An atmospheric oxygen concentration below 19.5 percent of above 22
percent.
d) Any atmospheric condition recognized as immediately dangerous to like of
health (IHLH).
HOT WORK PERMIT: the employer’s written authorization to perform
operations which could provide a source of ignition such as riveting, welding,
cutting, burning or heating.
IMMEDIATE DANGEROUS TO LIFE OF HEALTH (IDLH): any condition which
poses an immediate threat of life; may result in irreversible or immediate, severe
health effects; may result in eye damage; irritation or other conditions which
could impair escape from the confined space.
INERTIN: rendering the atmosphere of a confines space non-flammable, non-
flammable, non-explosive or otherwise chemically non-reactive by such means
as displacing or diluting the original atmosphere with steam or a gas that is non-
reactive with respect to that space.
IN PLANT RESCUE TEAM: a group of two or more employees designated and
trained to perform rescues in confines spaces in their plant.
ISOLATION: the separation of a permit space from unwanted forms of energy
which could be a serious hazard to confined space entrants. Usually
accomplished by such means as blanking or blinding; removal of misalignment of
pipe sections or spool pieces; double block and bleed; or lockout and tagout.
LINE BREAKING: the intentional opening of a pipe, line or duct that is or has
been carrying flammable, corrosive or toxic material, an inert gas, or any fluid at
a pressure or temperature capable of causing injury.
LOW HAZARD CONFINED SPACE: a confined space where there is an
extreme low likelihood that an IDLH hazard could be present and where all other
serious hazards have been controlled.
NON-PERMIT CONDITION: any condition or set of conditions whose hazard
potential exceed the Condition limits stated in the entry permit.
NON-PERMIT REQUIRED CONFINED SPACE: a confined space that does not
contain or with respect to atmospheric hazards, have the potential to contain any
hazard capable of causing death or serious physical harm.
OBSERVER: an individual stationed outside the confined space who is trained
as required and who monitors the authorized entrants inside the confined space.
17
ARCOR� EHS.Hand.07.99.1
AN observer may monitor not more entrants nor more space that the entry
permits specifically authorizes.
OXYGEN DEFICIENT ATMOSPHERE: an atmosphere containing less than
19.5 percent oxygen by volume.
OXYGEN ENRICHED ATMOSPHERE: an atmosphere containing more than 22
percent oxygen by volume.
PERMIT REQUIRED CONFINED SPACE: a confined space that has one or
more of the following characteristics:
a) contains or has potential to contain a hazardous atmosphere
b) contains a material that has the potential for engulfing an entrant
c) has an internal configuration such that an entrant could be trapped or
asphyxiated by inwardly covering walls or by a floor which slopes downward and
tapers to a small cross-section; or
d) contains any other recognized serious safety or health hazard.
RETRIEVAL LINE: a line of rope secured at one end to the worker by a chest-
wait or full-body harness, with the other end secured to either a lifting (or other
retrieval) device or to any anchor point located outside the entry portal.
ATMOSPHERIC CHECKS:
� Combustible gas, vapor levels must be below 10% of the Lower Explosive
Limit (LEL).
� The oxygen content must be between 19.5 % and 22% (% by volume of
air).
� The carbon monoxide (CO) level must be below 35 ppm for unrestricted
work. At levels between 35-100 ppm, an employee may work under the
following restrictions:
1. Only 15 minutes exposure per hour is permitted AND
2. Continuous air monitoring is required. At levels greater than 100 ppm, a
supplied air respirator (airline or SCBA) must be used. Respirator users must be
trained an qualified on the device to be used. This requirement applies no
matter how short the duration of the task.
18
ARCOR� EHS.Hand.07.99.1
B. Hazard Communication
The hazard communication program ensures that employees have the
information necessary to understand the hazards of a material, protect
themselves from the hazards, and use the material in a safe manner. Material
Safety Data Sheets (MSDS) and container labels can be used to determine the
hazards of the materials that you use. There are several locations in the plant
where MSDS are maintained. See your supervisor for the closets MSDS.
�
No material may be brought upon ARCOR� International without prior
�
approval by the ARCOR� EHS Department.
19
ARCOR� EHS.Hand.07.99.1
C. Lockout/Tagout Program
This program details the tagout/lockout program for working with equipment that
has energy sources such as hydraulic, pneumatic or electric which could
accidentally be released and injure an employee working onto equipment or
employees in the area.
�
The following is ARCOR�s program for lockout/tagout. Contract
employees must understand and comply with this program or use a similar
�
program which must be reviewed and approved by your ARCOR�
Representative.
General Instructions
In order to maintain strict control of tagout/lockout procedures, only employees
that have been trained and who are qualified to lockout/tagout will be authorized
to shut down or restore equipment or process to operation and perform
tagout/lockout procedures.
Lockout. Under the new OSHA standard, the use of a padlock is the preferred
method of locking out equipment before service work is performed. In most
cases, equipment can be locked out by physically installing a lock on electrical
switch gear, valves, levers. etc, to prevent movement until it is returned to
service. In order to comply with this standard, the following provisions for
equipment lockouts will apply:
1. All authorized employees will be issued a long-shank padlock that is
individually keyed for their own use.
2. Each padlock will be tagged with the authorized employee’s name and
operating department.
3. Each lock will have two keys, one for the authorized employee to whom the
lock is issued and one for his/her department supervisor (unless a submaster
key system is used).
4. The department supervisor will be responsible for control of spare keys and
for maintaining a list of the locks issued, including extra locks.
5. In the event a key becomes lost, the supervisor will be responsible for having
the lock re-keyed or replaced.
6. The department supervisor will control use of the spare or master keys in the
event that one of his/her authorized employees is unavailable to remove the lock.
Under such circumstances, the supervisor will verify that the person is not at the
facility, and make a reasonable attempt to contact him/her to inform him/her of
20
ARCOR� EHS.Hand.07.99.1
the removal. If efforts to contact the employee are unsuccessful, then a
company padlock, controlled by the supervisor can be sued until the employee is
notified so repair work can be resumed.
7. If the employee(s) whose tagout/lockout has been removed cannot be
reached, the supervisor will be required to notify he employee by telephone or
written notice before the employee(s) return to work. In such instances the form
entitled “Notice of Tagout/Lockout Removal� will be used as documentation.
8. Whenever a lockout is performed a red “DO NOT OPERATE� tag must be
placed through the shank of the padlock.
9. Annual reviews of tagout/lockout procedures will be documented by plant and
corporate safety personnel to ensure that correct procedures are being followed.
10. Under revised OSHA standards, new or modified equipment purchased or
renovated after October 31, 1989, must be adapted with lockable, isolated
devices. It will be the responsibility of the Purchasing, Maintenance and
Engineering departments to purchase, install or design such devices on new or
modified equipment in the future.
Lockout. Under some circumstances the use of a padlock to isolate electrical or
mechanical energy may not be practical or feasible. In such cases, a tagout or
equipment using a “DO NOT OPERATE� tag can be used. However, it must be
clearly understood that lockout will be given first consideration. The following
provisions will be used when equipment is tagged out for servicing:
* Only authorized personnel as outlined in “General Instructions� above will be
permitted to fill out an place a tag out.
* All tagouts must contain the name of the person.
* The tags must be attached to the energy source shut off mechanisms with a
self-locking plastic or nylon tie wrap capable of withstanding at least 50 pounds
of force.
Warning Tags:
* A yellow WARNING tag will be used to prevent operation of equipment which
could result in damage or create a potential hazard.
* WARNING tags can be issued by any supervisor, manager, Safety or
Engineering personnel. these tags will be used to remove from service until
repairs or installation work can be completed.
21
ARCOR� EHS.Hand.07.99.1
* The red DO NOT OPERATE tag is designed to protect people, the yellow
WARNING tag is designed to protect equipment.
Warning Tagout Procedure (yellow tag):
* When a piece of equipment is found in need of service or repair that is beyond
the scope and responsibility of the equipment operator, it will be his responsibility
to contact his/her supervisor and report it.
* The supervisor will stop operations if necessary, complete a yellow tag and
place on the machine controls and contact the Maintenance Department.
* When repairs have been completed, the individual who placed th yellow tag or
a designated alternate will be contacted to approve the work and remove the tag
for release to operation.
* WARNING tags can also be used to remove obsolete or unsafe equipment
form service, pending its disposal or scrapping.
Tagout/Lockout of equipment does not include routine servicing or adjustments
that are done under normal production operations; however, if guards or safety
devices are removed or bypassed, or if employees are required to place any part
of their body in a point of operation or they are exposed to other hazards that
could result in injury, then tag/out lockout procedures must be followed.
Tagout/Lockout Procedure. Mechanically powered equipment of process.
Examples of this type of equipment include, but are not limited to,,those that are
powered by internal combustion engines, air, hydraulics, gas, steam, gravity or
spring tension.
* Review the proposed work with the supervisor in charge of he equipment to
determine what service is needed an coordinate shut-down of the equipment
process.
*Use normal stop procedures to shut down equipment and place it in the “off� or
“safe�
position.
*Tagout/Lockout the isolating devices in the “safe� or ‘off� position and try the
lockout to make certain it cannot be moved.
* Test the machine start controls to make sure the isolating devices have
provided a complete shutdown and that nothing can be moved. Use chocking
where necessary.
22
ARCOR� EHS.Hand.07.99.1
* Test and inspect for stored air, gas, steam, hydraulics, etc. That may remain in
piping, cylinders, etc as necessary.
* Also note that closed valves may leak an that capping, disconnection may be
needed.
* Tagout bleed valves in the open position and tagout disconnected piping at
both
ends.
* Review equipment blue prints and related technical information as needed to
insure all energy sources have been identified and brought to a zero energy
state.
Tagout/Lockout of Electrically Powered Equipment. Examples of this
equipment include, but are not limited to welders, AC/DC motors and drives,
transformers, lighting systems, generators, power distribution systems, heating
elements, battery powered equipment, charges, etc.
Electrical disconnect devices are required to be clearly labeled and kept up-to-
date and be available for use by authorized personnel to conduct installation or
repairs. Only qualified personnel are permitted to conduct electrical work.
* Review the proposed work with the supervisor in charge of he equipment to
determine what service s needed and coordinate shut-down of the equipment or
processes.
* Use normal stop procedures to shut down equipment and do not disconnect
main switches or circuit breakers while the equipment is under a load. Safe
procedures to prevent electrical hazards will be determined before any circuit is
energized or deenergized to prevent arching, fire or explosions.
* Lockout and tagout the isolating disconnect switches and/or circuit breakers in
the “off� position and try the lockout to make certain in cannot be moved.
* Test the machine start control to make sure the isolating devices have provided
a complete shut-down. use chocking as necessary.
* Test and inspect for stored energy as discussed above in “Mechanically-
powered Equipment or Process�.
* When electrical work is involved, the blades of he disconnect switch must be
verified visually that they are opened and a meter to check phase-to phase and
phase-to ground readings must be made to insure all electrical energy has been
disconnected or discharged. Particular attention must be given to in-line
23
ARCOR� EHS.Hand.07.99.1
capacitors or backfeed voltages. Therefore, any electrical associated exposed
contact surfaces that may be touched will be tested.
* The use of push buttons, toggle switches, pressure switches, limit switches or
similar control circuit devices for tagout/lockout protection is not permitted.
* Pulling fuses cannot be substituted for tagout/lockout. One switch may feed
several motors individually fused. In such cases, disconnect, tape or tagout the
wires from the load side of the fuse clips.
* At any time a tagout is used without a lock for electrical work, at least one
additional safety measure as a fail-safe must be used (i.e. opening of an extra
disconnect device, blocking of another control switch, or removal of an isolating
circuit).
* In instances where plug/cord equipment is being serviced, a red “DO NOT
OPERATE� tag will be filled out an attached to the plug end of the cord.
Restoration of Equipment to Service. When equipment repair or servicing has
been completed the following procedures will be implemented to restore
equipment service.
* The authorized person(s) who performed the servicing and placed the
tagout/lockout will verify that all repairs have been completed and that all
equipment safeguards have been replaced and will then notify those who placed
the yellow WARNING tag that the equipment is ready.
* The person who placed the WARNING tag (or the alternate) will go to the site ,
inspect the work and coordinate the start-up of the equipment.
* Before the tagout/lockout is removed, the person who conducted the service
work will inspect the equipment to ensure that all tools, blocking, or other
equipment or components are operational.
* All affected people will be notified of the start-up and removal of he
tagout/lockout, an the area will be inspected to make certain all people have
been cleared out of the area to a safe location.
* Each lockout an/or tagout device will be removed by the individual who placed
it.
* The person who placed the yellow tag will then approved the repairs, remove
the tag, sign it off, and give it to the service person to document that the
equipment has been released.
24
ARCOR� EHS.Hand.07.99.1
* In some situations, it may be necessary for maintenance personnel to start up
equipment for testing before it is ready to be released. This may require the
temporary removal of tagout/lockout devices. The same cautions stated above
must be followed. When testing has been completed, tagout/lockout procedures
must again be applied t bring equipment back to a zero state of energy.
Tagout/Lockout Procedures for Shift Changes
* When an authorized service person cannot complete a job by the end of the
work shift, it my be necessary to turn over the job to another coworker on the
following shift. When an authorized person leaves at the end of his/her shift,
his/her individual tagout/lockout must be removed and replaced with the
following shift workers tagout/lockout.
* In the event that no one is available to take over the job during the shift
change, the maintenance supervisors must be contacted to make arrangements
for service continuation. The maintenance supervisor can use a “company� tag
and lock that are under his personal control until the job is assigned to another
person.
* In the event that a worker leaves without removing a personal tag/lockout, refer
to “Lockout� #6 and #7 on pages 20 & 21.
Multiple Tagout/Lockout. In some situations a number of service personnel
may be involved in a repair or installation job that requires a multiple
tagout/lockout, especially for jobs involving multiple departments or outside
contractors. In such instances, a scissors clasp or multiple locking hasp will be
used to ensure the safety of each individual that is working on the equipment.
Group Tagout/Lockout
* Under some circumstances, where multiple work groups are working on a
common job, it will be necessary to conduct a group tagout/lockout.
* There are currently four (4) types of group tagout/lockout methods that are
suggested under OSHA regulations.
* Each of these tags usually involve th use of lock boxes which control the keys
to multiple locations and crews or the assignment of one responsible person to
control the tagout/lockout of particular groups.
* In cases of group tagout/lockout procedures, the four tags permitted by OSHA,
which are outlined in the addendum to this practice should be referred to.
25
ARCOR� EHS.Hand.07.99.1
26
ARCOR� EHS.Hand.07.99.1
Contractors Tagout/Lockout Procedures
* Whenever it is necessary for a contractor to conduct repairs or do installation
�
work on company premises, the project must be reviewed first with an ARCOR�
representative from the Engineering or the Maintenance Department to
determine the need to institute a tagout/lockout or equipment or process,
�
especially in those instances where multiple work crews or ARCOR� personnel
are involved.
* Contractors who have a tagout/lockout procedure will be responsible for using
their own locks and tags and must demonstrate that their procedures comply
with OSHA Standard 1910.147.
* Contractors� tagout/lockout procedures and tags will be reviewed and
�
communicated to any affected ARCOR� employee before work begins.
�
* In those instances where ARCOR� personnel are working along with
contractors, each will arrange for a separate tagout/lockout for their respective
employees� safety.
* Contractors who do not have a tagout/lockout procedure will still be require to
�
follow OSHA Standards. In such instances, the respective ARCOR�
maintenance manager of supervisor can review our procedures with them and
arrange for a temporary loan of padlocks and tags, which will be under the direct
control of the contractor until they can provide their own.
* Contractors who do not have a tagout/lockout procedure will be encouraged to
provide their own tags, locks and procedures in order to be eligible to bid on
future company contracts.]
* The Purchasing Department will notify contractors in writing of their need to
comply with tagout/lockout provisions to maintain bidding eligibility.
Tagout/Lockout Training
* In order to comply with OSHA Standard, an in-house training program to review
�
and communicate ARCOR� procedures and OSHA requirements will be
conducted for authorized personnel and those who may be affected. Refresher
training will be conducted annually.
* Additional reinforcement will be incorporated in new and transferred employee
orientations, during employee contacts and through group safety meetings.
27
ARCOR� EHS.Hand.07.99.1
Enforcement
* It will be the responsibility of each plant and division manager through their
respective supervisors and staff to enforce the use of tagout/lockout procedures.
* Failure to use tagout/lockout procedures when required will result in disciplinary
action. Any employee who attempts to remove, alter, bypass or in any way
override a tagout/lockout without authorization may be terminated. Contractors
who fail to observe tagout/lockout procedures may be removed from the work
site and restricted from future bidding on company contracts.
Addendum to Group Tagout/Lockout Procedures from OSHA Instruction
STD 1-7.3
Type A: Each authorized employee places his/her personal lock or tag upon
each energy isolating device and removes it upon departure from that
assignment. Each authorized employee verifies or observes the de-engergizing
of the equipment.
Type B: Under a lockbox procedure, a lock or job-tag with tab is placed upon
each energy isolation device after de-energizing. The key(s) and remove tab(s)
are then placed into a lockbox. Each authorized employee assigned to he job
then affixed his/her personal lock or tag to the lockbox.
As a member of a group, each assigned employee verifies that all hazardous
energy has been removed or the energy isolating device turned on until the
appropriate key or tab is matched to its lock or tag.
Type C: After each energy isolating device is locked/tagged out and the
keys/tabs placed into a master lockbox, each servicing/maintenance group
“principal� authorized employee places his/her personal lock or tag into a satellite
lockbox to which each authorized employee in that specific group affixes his/her
personal lock or tag. As a member of a group, each assigned authorized
employee verifies that all hazardous energy has been rendered safe. Only after
the servicing/maintenance functions of the specific subgroup have been
concluded and the personal locks or tags of the respective employees have been
removed from the satellite lockbox can the principal authorized employee
remove his/her lock from the master lockbox.
Type D: During operations to be conducted over more than one shift (or even
days or weeks), a system such as described here might be used. Single
locks/tags are affixed upon a lockbox by each authorized employee as described
in Type B or Type C above. The master lockbox is first secured with job-lock
before subsequent locks by the principal authorized employees are put in place
on the master lockbox. the job-lock may have multiple keys if hey are in sole
28
ARCOR� EHS.Hand.07.99.1
possession of he various primary authorized employees (on one each shift). As
a member of a group, each assigned authorized employee verifies that all
hazardous energy has been rendered safe. In this manner, the security
provisions of he energy control system are maintained across shift changes
while permitting re-energizing of the equipment a any appropriate time or shift.
Specific Lockout/Tagout
1. Switch gear in main switch gear rooms will be locked out by the shift change
electrician and/or he supervisor. To lock out the handle type, you turn off an lock
the handle in the “off� position. Write on the tag the equipment you’ll be working
on and where it is located. Switch gear with breakers. Turn off the breaker an
insert a scissors clasp through the eyelids. Apply padlock and tag. Write on tag
where you will be working.
2. Switch gear out in the plant with handles. Pull fuses, look the door, not the
handle. Apply tag.
3. On disconnects, pull the handle to the “off� position, look the handle and apply
tag. As an extra precaution, you may take the fuses out.
4. Working on extruders: Turn all three (3) power sources off a cabinet, lock
handle and both doors and apply tag. Working in cabinet: Lock an tag all
sources. Watch out for multiple power sources.
5. Watertable: Turn handle to “off� position, lock and tag.
6. Perm Puller: Turn handle of “off� position, lock and tag.
7. Working in cabinet or panel anywhere in the plant on one circuit only: Turn off
breaker and pull fuses. Lock panel or cabinet door (if lockable) and apply tag. If
door is not lockable, tag the door and place a tag on the breaker or fuse block.
8. Circuits that have disconnects out of sight: Use mechanic’s lock on
disconnect that is in sight. Use supervisor’s lock on disconnect that is out of
sight.
9. Working on dies or cord connected piece of equipment: Lock and tag the
plug.
Remember to check for any stored energy before starting work. If in doubt, seek
the assistance of the company electrician or your supervisor. Only company
issued locks are to be used.
29
ARCOR� EHS.Hand.07.99.1
D. Fall Hazard Control Program
This program has been developed to ensure that employees who must work
from heights are adequately trained and protected from fall hazards. This
program has been developed through a process of fall hazard identification,
assessment, prioritization, implementation of engineering controls, training and
procedures.
Four Basic Methods of Preventing and Controlling Fall hazards
There are four (4) basic methods of preventing and controlling fall hazards:
1. On going education and training.
2. Procedural changes.
3. Equipment or tool changes.
4. Fall protection.
On going education and training keeps plant employees awareness levels
from dropping. It ensures that all employees, managers, superintendents,
supervisors and hourly employees, know the dangers of falls and the importance
of preventing and controlling falls. The training provides knowledge for
identifying and solving problems. For example, all employee’s would be taught
the “three points of contact� method when using ladders.
Procedural changes start with the managers. Using Standard Operating
Procedures (SOP), Job Safety Analysis (JSA), Areas Safety Analysis (ASA), and
Equipment Safety (ESA) as monitoring tools, these changes can have an
immediate impact while physical changes may be delays waiting for manpower.
Equipment or tool changes are physical changes or additions to a work area.
These changes may include items such as catwalks, guardrails, gates, warning
signs or using a different tool to complete a task.
Fall protection is the utilization of personal safety equipment designed to
protect you after a fall. Equipment used includes harness, lanyards and nets.
Fall Prevention
Fall prevention prevents exposure to a fall. Fall prevention is any means used to
reasonably prevent exposure to an elevated fall hazard(s). Examples include
floors, walls, guardrails, and isolating an area.
30
ARCOR� EHS.Hand.07.99.1
There are three (3) methods of prevention:
1. Equipment or tool changes. Eliminates a hazard through redesign,
elimination, relocation or repair of equipment or tools.
2. Procedural changes. Changes the method of doing a task. Good
procedural changes can completely eliminate the fall exposure.
3. Physical changes or additions to the work area. Eliminates a hazard by
redesigning the work area.
Examples of Fall Prevention
Prevent slips and trips by:
1. Vigilant housekeeping
2. Using footwear that matches the job
3. Proper lighting
4. Using contrasting colors
5. Slip resistant surfaces
6. Awareness education and training
Prevent portable ladder accidents by:
1. Making sure the ladder fits the job
2. Using the 4:1 rule (set the base out from its support one foot for
every four feet of working ladder height)
3. Trying the ladder off properly
4. Using the three (3) points of contact method
5. Training in ladder safety inspection
6. Training in the proper use of a ladder
Fall Protection
Fall protection is the use of an engineered, personal system that will arrest a free
fall. Examples include lanyards, life lines, harnesses and nets. Fall protection
systems have three components: an anchor point, a body support and a
connector. It is used ONLY when fall prevention is not feasible due to location,
cost or practicality.
There are four (4) considerations in designing a fall protection system:
1. Anchor points must be approved by engineering
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ARCOR� EHS.Hand.07.99.1
2. It should not interfere with the work task and the required
mobility
3. It is used as a tool for positioning and restraint
4. It must address the need for emergency retrieval after a
controlled fall has occurred
Anchor Points Requirements
The following are examples of what can be used as anchor points. This is not an
all inclusive list.
�
* Per OSHA & ARCOR� standard 18.2 all anchor points must be rated at 5000
lb.
or a 2:1 anticipated load safety factor. Use 1000 lb. load for single anchor
point.
* Guard post and guardrails built with 6� or larger steel pipe or square tubing in
sound condition.
* All building columns
* All identified anchor points in personal lifts and fork truck platforms
Anchor points must be approved y engineering. Required by OSHA and
ARCOR� Engineering Standard 18.2
Column wraps must be placed directly above a horizontal support or horizontal
member.
The lanyard anchor point should not be lower than the harness D-ring except in
personnel lifts or if the free fall distance cannot exceed six (6) feet. If this criteria
cannot be met, use a retractable lanyard.
The following are examples of what should NOT be used as anchor points
unless approved y engineering. This is not an all inclusive list.
* Handrails
* Ladders
* C-Clamps
* Bolt holes (sharp edges on hole)
* Electrical conduit or pipe runs (dependent on diameter, length or support
member)
* Guard post and guardrails built with less than 6� steel pipe or square tubing
32
ARCOR� EHS.Hand.07.99.1
Although it is acceptable to wrap a lanyard and hook it back to itself, use of a
column wrap is preferred. The column wrap with its pad eliminates the possibility
of the lanyard being cut by the object being used as an anchor.
Rules for Using Snap Hooks
* Never attach two (2) snap hooks together
* Never attach two or more snap hooks to on D-ring
Guard Rail Requirements
* Guard open-sided platforms or walkways four (4) feet (1.2 m) or more, above
the adjacent area using a standard railing on all open sides except where there
is entrance to a ramp, stairway or fixed ladder.
* Equip rail with a toeboard or curb beneath the open sides when persons must
pass underneath where there is moving machinery, where falling materials could
create a hazard.
* Provide standard railing and toeboard on open sided walkways, platforms, or
runways, regardless of height when located above or adjacent to dangerous
equipment, open tanks, degreasing, etc.
Personnel Protection at Floor Openings
* Permanent floor openings created by pits, hatchways, manholes, stairs and
ladders shall be guarded to prevent persons from falling into or through the
opening.
* Open pits shall be enclosed on all exposed sides with a standard railing and
toeboard.
* Pit and trap door floor openings, infrequently used and/or where traffic is
required to pass across the opening, shall be guarded with a properly designed
floor opening cover. For example, every manhole floor opening shall be normally
covered by a standard manhole cover.
* While the cover is not in place, the pit or trap opening shall be constantly
protected by removable standard railings.
OSHA Regulation: Designated Areas for Pits and Roofs
33
ARCOR� EHS.Hand.07.99.1
When determining solutions to fall hazards, use ARCOR� engineering
standards and OSHA standards.
Designated areas may be used as an alternative to a guardrail if the workers
within that area are not exposed to fall hazards. However, the work must be of a
temporary nature: for example, maintenance work on a roof or in a pit. If there
are fall hazards inside the designated area, anyone inside the area must be
protected.
The designated area is established by use of the following warning barrier
equipment:
* Stanchion to withstand 16lbs. of force at 30� above its base to provide
adequate warning to anyone who may bump against it.
The line between the stanchion must:
1) Have a minimum tensile strength of 500 lbs. to assure that the line is more
substantial than string.
2) Be visible from 25 feet.
3) Be 34�-39 feet above the floor.
* The perimeter of the area must be at least six (6) feet from the area being
guarded, but as close as the work being done will permit.
* Entry to the designated area shall be posted with the standard “Designated
Area� sign.
All excavations, temporarily open pits and two level fall hazards or four (4) feet or
greater shall be addressed using one or more of the following:
* Eliminate
* Guard
* Designated Area
* Fall Protection
Fall Protection General Requirements
* Fall protection is required when exposed to heights of four (4) feet or greater.
* Special circumstances less than four (4) feet may require the use of fall
protection.
34
ARCOR� EHS.Hand.07.99.1
* All fall protection systems must be approved by engineering.
* New vendor equipment cannot be brought into plant without approval of the fall
protection team.
* A 2:1 safety factor may be used for engineering systems. Engineering
Standard 18.2, refer to page 4/8 for load on horizontal life lines. Load for single
anchor point is 1000 lbs.
* Maximum free fall distance is six (6) feet.
* Safety harnesses have replaced belts and shall be used with a shock
absorbing or retraceable lanyard.
* Never attach a snap hook directly to a horizontal life line. An attachment point
is provided by the vendor of the horizontal life line, or a carbine may be used.
* Shock absorbing end of the lanyard is fastened at the body harness.
* Fall protection shall be used when operating personnel lifts including but not
limited to JLG’s, fork truck platforms and scissor lifts.
* The lanyard anchor point should not be lower than the harness D-ring except in
personnel lifts or if the free fall distance cannot exceed six (6) feet. If this criteria
cannot be met use a retractable lanyard.
* Although it is acceptable to wrap a lanyard and hook it back to itself, use of a
column wrap is preferred. The column wrap with its wear pad eliminates the
possibility of the lanyard being cut by the object being used as an anchor.
Never hook two lanyards together. Equipment manufactures and OSHA do not
permit this.
NOTE: This is not intended to be a complete list of fall prevention/protection
rules and regulations. Other rules that apply include:
* ARCOR Engineering Standard 18.2 Fall Prevention/Protection.
* Applicable OSHA regulations, 1910 and 1926.
* Department Rules.
35
ARCOR� EHS.Hand.07.99.1
Eyebolt Requirements
* Do not use eyebolts on singular lifts unless absolutely necessary.
* Loads should always be applied to eyebolts in the plane of the eye, not at
some angle to this plane.
* Shoulder eyebolts must be properly seated (should bear firmly against the
mating part) otherwise the working loads must be reduced substantially. A steel
washer or spacer may be required for proper seating.
* No greater load should be allowed than that given under rated capacity in each
of the tales of dimensional data.
* To obtain greatest strength from an eyebolt, it must fit reasonably tight in the
hole into which it is screwed to prevent unscrewing due to twist of cable.
Tightness and seating must be checked after initial load.
* Eyebolts should never be painted or otherwise coated when used for lifting, as
such coatings will very likely over up flaws.
* To attain the rated capacity listed fro eyebolts, full thread engagement allowing
1/2 turn for alignment to the plane of the eye, is necessary.
Maximum Gaps Between Fall Prevention Structures
* A gap in existing equipment of 6� or less is acceptable.
* New fall prevention structures (handrails, barriers, etc) shall not contain
openings unrestricted in height, 20� above the floor or higher, or more than 4�
wide.
* Existing openings of more than 6� shall be rendered safe by reducing the gap
width of 4� or less. Modifications shall maintain strength and dimensional
requirements of OSHA 1910.23.
Ladder, Pick, Scaffold Safety
* For any overhead work, always use the proper type ladder. Never use
makeshifts.
* Metal ladders and scaffolds shall not be used unless authorized by your
supervisor when working on or near electrical outlets.
36
ARCOR� EHS.Hand.07.99.1
* Ladders and scaffolds (including picks) should be inspected by the person
using this equipment for defects prior to each use (Missing safety feet or shoes,
cracked rungs, damaged side rails, etc).
* Straight ladders must be equipped with safety feet.
* Straight ladders should be lashed at the top, if possible, or blocked or held at
the bottom.
* Ladders placed near doors or aisle way should be held at the bottom.
Warning signs or barricades should be erected.
* Straight ladders should be placed using the 4:1 rule (set the base out from its
support one foot for every four (4) feet of working ladder height.
* Always face the ladder when climbing down. Use both hands. Hand tools and
other equipment should be hauled up and down with a hand line.
* Do not overreach; move the ladder across the floor from floor level as your
work progresses.
* For additional information on portable ladder usage, refer to OSHA Standard
1910.25, 1910.26 and 1926.450.
* Ladders must not be used to make part of a scaffold.
* Do not splice ladders together to make a longer ladder.
* Do not leave ladders unattended unless they are securely anchored.
* Make sure your hands and shoes are reasonably dry and free of grease before
climbing a ladder.
* Always clean ladders and return to their proper storage area after use.
* Always have three (3) point contact when climbing a ladder.
* When a portable ladder is used to access a structure it should extend at least
three (3) rungs beyond the access point.
* When using scaffold refer to OSHA Standard 1910.28 and the Free Fall
hazard Decision Tree.
* When using scaffolding or pick refer to the Fall Hazard Decision Tree.
37
ARCOR� EHS.Hand.07.99.1
Dictionary of Terms
ACCESS: Movement by physical or mechanical means to reach a workstation.
AERIAL LIFTS: Mechanical devices such as man lifts, man baskets, scissor lifts
and bucket trucks used for access to heights. The term “skip box� is reserved for
materials used only on construction sites.
ANCHORAGE: A secure point of attachment for lifelines, lanyards or
deceleration devices.
BODY BELT: A strap you can secure around your waist and attach a lanyard or
device for fall arrest.
CARABINER: Double locking ring used to connect system components.
DECELERATION DISTANCE: The vertical distance between the belt of harness
attachment point, at the activation of the fall arrest equipment, and that
attachment point once the individual comes to a complete stop.
DIFFERENT LEVEL FALL: An accident where you fall below the level you were
standing or walking on (e.g. you fall below foot level).
D-RING: An attachment point(s) on the belt or harness for a device or lanyard.
Sometimes erroneously named for a carbabiner snap hook.
EQUIPMENT & TOOL CHANGE: Re-design, elimination or relocation of fixed
equipment.
FALL ARREST OR FALL PROTECTION SYSTEM: A lanyard or device, along
with other necessary components, designed and tested to function together in
preventing a fall from occurring or to minimize the potential for compounding
injury.
FREE FALL DISTANCE: The vertical distance between the belt or harness
attachment point (at the time of an unrestrained fall) and any obstruction of
grade level or the activation of fall arrest equipment.
FULL BODY HARNESS: The design of single or multiple straps that can be
secured around the body to which a lanyard or device can be attached. The
design distributes the arresting forces over the buttocks, thighs, chest and
shoulders.
GATE: Snap hook closure that swings closed to secure.
38
ARCOR� EHS.Hand.07.99.1
HARDWARE: Snap hooks, D-Rings, buckles, carabiners, adjuster, O-rings, etc,
used to attach the components of a fall protection system together.
HAZARD: The potential to incur harm, an agent, energy or characteristic that
can cause physical damage to personnel or property.
HORIZONTAL LIFELINE: A rail, wire, or synthetic cable that is installed in a
horizontal plane and used for attachment of a worker’s lanyard or lifeline device
while moving horizontally. Used to control dangerous pendulum like swing falls.
INDEPENDENT ANCHORAGE: A point of attachment that is not part of the
working or walking surface or equipment rigging points.
LANYARD: A flexible line of webbing, rope or cable 2, 4, or 6 feet long, used to
secure a body belt or full body harness to a lifeline or on anchorage point.
LIFELINE: A vertical line from a fixed anchorage or between two horizontal
anchorages, independent or walking or working surfaces, to which a lanyard or
device is secured. Part of a fall protection system used a back-up safety for an
elevated worker.
LOCKING SNAP HOOKS: A connecting snap hook that requires two (2)
separate forces t open the gate; one to deactivate the gate keeper, and one to
depress and open the gate which automatically closes when released, used to
minimize roll-out or accidental disengagement.
PROCEDURAL CHANGE: A different method of doing the job to prevent
employee exposure to fall hazards.
RETRACTING LIFELINE: A fall arrestor whose integral line extends as a worker
moves downward and atomically removes slack as the worker moves up towards
the unit. Can have a centrifugal locking mechanism or alternatively centrifugal
braking mechanism for controlled descent.
ROLL OUT: Unintentional disengagement of a snap hook caused by the gate
being depressed under torque or contact with single action snap hooks that do
not have a locking gate keeper.
ROPE: Wire or synthetic rope used for lifelines.
ROPE GRAB: A fall arrestor that is designed to move up and down a lifeline
suspended from a fixed overhead anchorage point to which the belt or harness is
attached. In the event of a fall, the rope grab locks onto the compatible rope
through compression to arrest the fall.
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SAFETY BELT: A generic term for body support.
SAME LEVEL FALL: An accident in which you fall to the same level you were
standing or on (e.g. you fall to foot level).
SHOCK ABSORBER: A component of a fall protection system that dissipates
energy by creating or extending the deceleration distance.
SHOCK ABSORBING LANYARD: A flexible line of webbing, cable or rope with
an integral shock absorber, used to secure a body belt or harness to a lifeline or
anchorage point.
SINGLE-ACTION SNAP HOOK: A connecting snap hook that requires a single
force to open the gate which automatically closes when released.
SNAP HOOK: A self closing connecting device with a gatekeeper latch or
similar arrangement that remains closed until manually released. Includes
single action snap hooks that open when the gatekeeper is depressed and
double action snap hooks that require a second action on a gate keeper before
the gate can be opened.
SUSPENDED SCAFFOLD: A single point or multiple point work platform used
for powered or unpowered access up or down the side of a structure.
SYNTHETIC FIBERS: A manufactured fiber such as nylon, polyester or
polypropylene.
TIE-OFF: The act of securing the end of a lanyard to an anchorage point. The
term tied-off, and tying-off, are related to tie-off. An anchorage point is
sometimes referred to as a tie-off point.
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E. Manlifts
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Any Contractor wishing to use ARCOR�s manlifts are required to make an
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agreement with their ARCOR� Representative. The Contractor’s personnel
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must be trained by a qualified ARCOR� Representative.
F. Mobile Equipment Safety Policy
Definitions
Mobile Equipment: forklifts, raymonds, tuggers, sweepers, automobiles, trucks,
vans, lawn tractors and semi-tractors and semi-tractors, excavation equipment,
etc.
Certification & Training
The following items describe the medical and training guidelines necessary for
employees applying for certification or re-certification of a mobile equipment
license. Employees are only authorized to operate equipment for which they are
licensed and trained for.
Procedures
The following procedures and safety rules shall be followed at all times:
* Mobile equipment shall be operated only by licensed operators.
* Seat belts shall be worn at all times.
* No mobile equipment shall be operated unless it is in safe operating condition.
� Operators shall inspect their mobile equipment at the beginning of their
shift.
� Problems with their equipment will be reported to their supervisor
immediately.
* Whenever a mobile equipment operator dismounts, the equipment shall be
restricted from movement by:
� Setting the parking brake.
� Placing the transmission in neutral. “Park� shall be used in place of
neutral on automobiles and pickups.
� Lowering loading engaging device completely (i.e. Fork Lifts)
* Twenty-Five Foot Rule:
� If the operator is required to be twenty-five (25) or more feet from the
piece of equipment or out of visual contact with it, the vehicle must
also be shut off.
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ARCOR� EHS.Hand.07.99.1
� If a piece of equipment is not equipped with a parking brake or the
parking brake is not working properly, the equipment must also be shut
off.
� Vehicle drivers are responsible for passengers and shall haul no more
than allowed.
� Operators and passengers should keep feet, legs and arms inside the
outer perimeter of the mobile equipment at all times.
� ALL accidents or incidents involving mobile equipment with personnel,
building structures, etc., shall immediately be reported to supervisor.
� Extreme care shall be taken when using LP fueled mobile equipment
around high temperatures. Exposure to high temperature devices
should be minimized. Never leave the equipment unattended or
parked in such areas. Never smoke while operating or sitting on the
equipment or when standing by the equipments� fuel tank area.
� Never make repairs on a vehicle unless specifically authorized to do
so.
� Never operate a vehicle with a fuel leak.
� Handle only load within the rated capacity of the mobile equipment.
Be sure the load is stable and safely arranged.
� Mobile equipment operators shall obey all traffic regulations and traffic
control signs, especially SPEED LIMITS.
� All mobile equipment shall be completely stopped and horn shall be
sounded before entering a building. Horns shall be sounded before
rounding a corner.
� Mobile equipment operators shall at all times be on the look out for
pedestrians and other mobile equipment.
� Stunt driving and “horseplay� shall not be permitted. Operator shall
not use equipment for any purpose other than that for which it is
designed.
� Do not drive equipment over loose objects.
� Mobile equipment operators shall be responsible for the stability and
safe transporting of a load.
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ARCOR� EHS.Hand.07.99.1
G. Storage & Handling of Flammable/Combustible Liquids
Definitions
Flammable Liquids: Those liquids having a flash point at or above 100 degrees
Fahrenheit (37.8 degrees Celsius).
Combustible Liquids: Those liquids having a flash point at or above 100 degrees
Fahrenheit (37.8 degrees Celsius).
Storage Cabinets: Metal cabinets that are UL or FM approved, limited to the
storage of 50 gallons or less.
Storage
* All bulk storage of flammable liquids will be in approved storage areas outside
the buildings. Flammable liquids may be kept in approved safety can outside the
flammable liquid storage cabinets, as long as they do not exceed ten (10)
gallons. Safety cans shall be metal, with a spring closing lid, flame arrestor, and
a spout cover so designed to relieve internal pressure when exposed to fire.
* Flammable liquid storage cabinets shall be commercially available approved
cabinets and shall be maintained so that all safety features are operational. All
cabinets used for such storage shall be labeled in red letters “FLAMMABLE -
KEEP AWAY FROM FIRE�. A maximum limit of three (3) storage cabinets may
be kept in on fire area. A distance of 100 feet or more must be maintained
between storage areas.
* Cabinets shall be kept free of combustible materials such as paper, rags,
packing materials, friction spark producing items, and incompatible materials
such as oxidizers and acids.
* Storage areas must be kept free of nonessential combustible materials such
as paper, rags, packing materials and vegetation.
* Containers shall be palletized in storage areas to prevent corrosion or
deterioration from moisture accumulations under the containers.
* Drums shall be transported on wood pallets or approved drum clamps between
storage buildings. Bare forks on fork lifts shall not be used on the sides for
transporting.
* Less than drum size quantities may be stored in original shipping containers.
* Unopened drums need not be grounded.
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ARCOR� EHS.Hand.07.99.1
* All storage areas shall be approved in advance by the Environmental and
Safety Managers.
Handling & Use
* Flammable liquids may be used only where there are no open flames of other
sources of ignition within the possible path of vapor travel up to a 20 foot radius.
* Flammable liquids shall be drawn from or transferred into vessels, containers
or portable tanks within a building only from 1) original shipping containers with a
capacity of five (5) gallon or less, or 2) from safety cans, or 3) through a closed
piping system or 4) from a portable tank or container by means of a device
drawing through an opening in the top of the tank or container.
a) Flammable liquids shall not be dispensed from metal containers unless the
nozzle or fill pipe is in direct contact with the container. This can be
accomplished either by maintaining metallic contact during filling or by a bond
wire between them. Bonding is not required where a container is filled through a
closed system, or the container is made of glass or other non-conducting
material. Flammable liquid dispensed from original approved containers shall be
done outside of buildings or inside of an approved fume hood.
b) Drums shall not be emptied by air pressure except as produced by a hand
pump or approved dispensing pump.
c) Drums must be grounded whenever they are opened and especially during
transfer of liquids. An electrostatic bond that will bond the dispensing and
receiving container shall be used. Smaller metal containers must be bonded to
main supply container prior to transfer of flammable liquids.
d) Only Underwriters Laboratories (UL) or Factory Mutual (FM) tested and
approved metal safety containers will be used for less than drum quantities of
flammable liquids in work areas. Maximum safety container capacity is five (5)
gallons.
e) Polyethylene type safety containers shall not be used for storage or
dispensing of flammable liquids.
f) Laboratories are permitted to utilize glass containers of one gallon maximum
capacity.
g) All containers shall be properly labeled.
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ARCOR� EHS.Hand.07.99.1
H. Respiratory Program
This program ensures that employees who are exposed to excessive levels of air
contaminants such as dusts, mists or gases are properly trained in the hazards
of these contaminants, the use and limitations of proper respiratory protection
and are medically approved to use the equipment.
I. Welding, Burning and Cutting Program
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ARCOR� contains a significant amount of flammable and combustible materials
in locations throughout the plant. Whenever activities such as welding, cutting or
other maintenance or production work occurs near these materials, specific
precautions must be taken. This program ensures that all welding and cutting is
conducted in a safe manner and that area specific hazards (such as flammable
materials) are recognized before the work begins so that appropriate action can
be taken to ensure that the work does not create a hazardous situation.
A Welding, Burning and Cutting Permit must be obtained from the
Maintenance Supervisor before performing any of the above.
J. Barricade Tape
General Instructions
* Yellow Barricade Tape shall be used to communicate CAUTION:
HAZARDOUS CONDITIONS! Personnel may enter areas barricaded with yellow
barricade tape, provided they understand the hazardous present.
* Red Barricade Tape or red barricade fencing (four or six foot) shall be used to
communicate DANGER: DO NOT ENTER! Only authorized employees may
enter and work in areas so barricaded. The decision to use red barricade
fencing should be based upon the hazard circumstances.
* Any information tag should be placed in a conspicuous place on the barricade
tape providing the following information:
* Who is authorizing the barricade
* What is barricaded and
* How long the area will be barricaded.
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ARCOR� EHS.Hand.07.99.1
TSCA (Toxic Substance Control Act)
TSCA is a law which was created by the EPA (Environmental Protection Agency)
that requires the review of new chemicals before being introduced into the USA,
as well as, collect information on chemicals which are already in use. By
collecting information, the EPA is preventing unreasonable risk to human health
or the environment.
If you believe that a chemical you are working with has caused a significant
harmful effect to you or the environment, contact the plant TSCA coordinator. In
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the event that the coordinator is not available, contact your ARCOR� supervisor.
The harmful effect may be recognized hazard of the substance, at which time
appropriate control measures will be implemented. If the observed harmful
effects have not been previously recognized for the substance, our TSCA
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coordinator will file appropriate reports with ARCOR�. Based on corporate
evaluation, the EPA may have to be contacted regarding these previously
unrecognized hazards.
Environmental Information
This section of the handbook will provide you with some basic information about
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environmental matters at ARCOR�. This information can help you do your part
to protect the environment while working for here.
Spill Response
If a spill of hazardous or unknown materials occurs, the following action should
be taken to stop or contain the hazard:
1) Determine the chemical and the use of appropriate protective equipment.
2) Obtain information from the MSDS (Material Safety Data Sheet).
3) Once the material has been identified and proper personal protective
equipment issued, stop the container from leaking (stop the container form
leaking only if it can be accomplished in a safe manner).
4) Contain the material with some type of absorbent so that it will not leak further.
5) If the spill is near a storm drain, block the storm drain before discharge.
6) If necessary, evacuate the area.
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If a spill has occurred that involves a hazardous material, the following actions
should be taken:
1) Contact should be made with PDC response team.
2) Evacuate personnel from around the area.
3) Try to contain the material as much as possible so it doesn’t go down a drain.
4) Try to identify the material.
5) Try to find the appropriate MSDS for the PDC response team when they get
there.
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6) Immediately, if not sooner, notify an ARCOR� supervisor. If you are unable
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to contact your ARCOR� supervisor, notify someone on the emergency contact
list.
-END-
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