Contents:OSHA - Standards........................................2All About OSHA...............................3OSHA - View on Training ..............................9Personal Protective Equipment............11Hearing Conservation Strategies...................13

Volume TwoNovember 2004

3

Frequently CitedOSHA Standards

This article is the first in a series that will identify andsuggest ways to correct the hazards related to the mostfrequently cited OSHA standards in the industries withSIC codes of 3271–Concrete Block and Brick,3272–Concrete Products Except Block and Brick and3273–Ready-Mix. Using weighted average methodology,it was determined that the top five most frequently citedstandards within these three SIC codes are:

1. Control of Hazardous Energy–Lockout/Tagout2. Hazard Communication3. Respiratory Protection4. Permit Required–Confined Spaces5. Electrical Wiring Methods–Components &

EquipmentA total of 1247 citations were issued in these three SIC

codes during 2002. Fines approaching US$750,000 werelevied. Each inspection conducted, citation issued andfine imposed is contained within the OSHA IntegratedManagement Information System (IMIS) database, whichcan be accessed on the osha.gov web site. Employers canuse this information to educate employees about whichhazards commonly cause accidents, while OSHA fieldpersonnel use this information to identify violationscommonly found in certain types of facilities.

The three pie charts on the right indicate the mostfrequently cited OSHA standards in Concrete Block andBrick, Concrete Products Except Block and Brick andReady-Mix. Reviewing the information on these chartswill guide producers to the first areas to address withsafety efforts.

In all three industry segments Hazard Communicationwas a frequently violated OSHA standard. This topic willbe addressed in the next issue of Concrete Impressions.Articles about Respiratory Protection and ElectricalWiring Methods—Components and Equipment willfollow. Articles about Lockout/Tagout and PermitRequired Confined Spaces have previously beenaddressedine, and can be accessed online at besser.com.

An ongoing commitment to established safetyprograms, equipment guarding and engineering controlswill help ensure that your facility is an all-around safeworkplace. Consult the OSHA web site or your state-sponsored plan web site for specific guidelines onestablishing and maintaining a safety program.

By Duane A. RondeauEngineering Manager

Besser Company, Alpena,Michigan

www.OSHA.gov

Reference

2

All About OSHAby Amy E. Essex

Besser Company Tax and Risk Manager

What is OSHA?A force to be

reckoned withand avoided at

all costs? Notnecessarily. You

need not fear a knockon your door from OSHA.

OSHA is the OccupationalSafety & Health Administration.

Founded in 1970, OSHA works tosave lives and prevent accidents in

the workplace. Since the founding ofOSHA, the workplace death rate hasbeen cut in half and occupational injuryand illness rates have declined 40percent. During the same time,employment in the United States nearlydoubled from 56 million workers at 3.5million work sites to 105 millionworkers at 6.9 million sites.

OSHA StructureIn 1999, federal OSHA operated with

a staff of more than 2,200 including1,200 inspectors and a budget of $382million. In addition, OSHA-approvedprograms operate in 25 states including:Alaska, Arizona, California, Connecticut(state and municipal employees only),Hawaii, Indiana, Iowa, Kentucky,Maryland, Michigan, Minnesota,Nevada, New Mexico, New York (stateand municipal employees only), NorthCarolina, Oregon, Puerto Rico, SouthCarolina, Tennessee, Utah, Vermont,Virgin Islands, Virginia, Washington andWyoming.

At work sites under OSHAjurisdiction, compliance to standards is

Part 1 of 3

• Requesting information from theemployer on safety and healthhazards in the workplace.

• Observing any monitoring ormeasuring of hazardous materials andseeing the resulting records.

• Being informed, by posting, of anycitation issued by OSHA as part of aninspection.

Although OSHA does not citeemployees for violations of theirresponsibilities, OSHA states thatemployees “shall comply with alloccupational safety and health standardsand all rules, regulations and ordersissued under the Act.”

Employees’ responsibilities include:• Reading the OSHA posters at the

work site.• Complying with applicable OSHA

standards.• Following all employer safety and

health regulations and wearing orusing prescribed protectiveequipment while working.

• Reporting hazardous conditions tothe employer.

• Reporting a job-related injury orillness to the employer and seekingtreatment promptly.

• Cooperating with the OSHAcompliance officer conducting aninspection if he or she inquires aboutsafety and health conditions in theworkplace.

OSHA’s Hazard CommunicationStandard

More than 30 million workers arepotentially exposed to one or morechemical hazards. There are anestimated 650,000 hazardous chemicalproducts in existence today andhundreds of new ones are introducedannually. This poses a serious problemfor exposed workers and theiremployers.

The OSHA Hazard CommunicationStandard (HCS) includes protection forall workers exposed to hazardouschemicals in all industrial sectors. Thisstandard is based on a simple concept -that employees have both a need andright to know the hazards and theidentities of the chemicals they areexposed too. Consequently, the OSHAHazard Communication Standard iscommonly referred to as “Right to

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enforced through unannouncedinspections. Top priorities for OSHA arelife-threatening situations, accidentsinvolving deaths, or three or moreworkers injured severely enough torequire hospitalization. Also, high onthe list for inspections are employeecomplaints. Inspections of high hazardindustries and work sites with a record ofmany injuries or illnesses come next.OSHA will also conduct follow-upinspections at companies previouslycited for violations.

Employers’ Responsibilities underthe OSHA Act• Providing a safe workplace for

employees (the General Duty Clause).• Preparing and maintaining records of

work related injuries and illnesses.• Communicating information about

workplace hazards to employees.• Complying with all OSHA rules and

standards.• Posting all applicable notices (job

safety posters, OSHA workplaceinjury and illness log).

• Providing personal protectiveequipment to your employees, whereapplicable.

Employees’ Rights andResponsibilities under the OSHAAct

• Reviewing copies of appropriatestandards, rules, regulations andrequirements that the employershould make available at theworkplace.

3

Resources

References

State or regional OSHA offices - contactOSHA at (202) 693-1999 for help findingthe correct office to contact.

Occupational Safety and HealthAdministration (OSHA) web site:www.osha.gov.

The front of the card showsboth the NFPA and HMISlabeling systems. The backof the card explains thehazard numbering system(which is the same foreither system). Cards likethese are available frommost safety supply catalogs.

Know.” Workers also need to know whatprotective measures are available toprevent adverse effects from occurring.OSHA predicts that properimplementation of the HCS will result ina reduction of illnesses and injuriescaused by chemicals.

The HCS establishes uniformrequirements to ensure that the hazardsof all chemicals imported into, producedor used in the United States’ workplacesare evaluated. This hazard informationmust be transmitted to affectedemployers and exposed employees.Chemical manufacturers and importersmust convey hazard information toemployees through container labels andmaterial safety data sheets (MSDSs). Inaddition, all covered employers musthave a hazard communication programto inform employees.

Labels contain information relatingto the health hazards, fire hazards andreactivity hazards associated with achemical substance. Labels can alsoindicate what personal protectiveequipment is appropriate to use when incontact with the substance.

There are two types of labelingsystems in common use. The NationalFire Protection Association (NFPA) usesa “diamond” system to show the healthhazard, fire hazard, reactivity hazard andany specific hazard inherent in aproduct. The Hazard MaterialIdentification System (HMIS) also showsthe health, fire and reactivity hazard of aproduct, but instead of showing otherspecific hazards, it includes a spot toshow what personal protectiveequipment (PPE) should be used whenhandling the product. Either system canbe used, but it is best to choose one anduse it consistently.

MSDSs include information on themanufacturer, the hazardous ingredients,physical/chemical characteristics, fireand explosion hazard data, reactivitydata, health hazard data, precautions forsafe handling and use and hazardcontrol measures.

Training, Training, TrainingWhat is the most common theme at

OSHA these days? You guessed it:TRAINING. Training is the commonthread running through most of theOSHA standards.

Determining what training is requiredcan be a mind-boggling task. OSHAoffers some guidelines in this area in theform of a seven-step process:

1. Determine if training is needed.2. Identify training needs.3. Identify goals and objectives.4. Develop learning activities.5. Conduct training.6. Evaluate program effectiveness.7. Improve the program.

Part 2 of this OSHA series of safetyarticles will address the topic of trainingin depth.

The OSHA General Duty ClauseOnce an employer has reviewed and

complied with all OSHA standards,common sense says that employersshould be safe from any inspection-related penalties. However, OSHA hasthrown a catch-all into the mix. Underthe General Duty Clause, “Eachemployer shall furnish to each of hisemployees employment and a place ofemployment which are free fromrecognized hazards that are causing orare likely to cause death or seriousphysical harm to his employees.” OSHAinspectors have applied the GeneralDuty Clause to issues such as (but notlimited to) workplace violence,ergonomics (soon to be a standard of itsown) and indoor air quality.

In general, you must keep theworkplace safe from hazards, even if thehazards are not specifically spelled outin an OSHA standard.

What is OSHA up to today?The proposed new ergonomics

standard is a top priority.

Musculoskeletal disorders account forone-third of all serious injuries andone-third of workers’ compensationcosts. Preventing these injuries is a toppriority for OSHA. The standard has notbeen released yet but it is expectedsoon. What does this new standard meanfor you as an employer? It willundoubtedly mean reevaluating theconditions under which employees workand how job functions are performed. Itmay mean changing work stations andthe way employees do their jobs.

Three other serious safety and healthproblems that OSHA is currentlyfocusing on are: Silicosis, amputationsand lead poisoning. In the concreteproducts industry, Silicosis andamputations are common problems.

ConclusionThe primary goal of OSHA is to

ensure safe and healthful conditions forevery American worker. All of theagency’s enforcement, educational andpartnership efforts seek to reduce thenumber of occupational injuries,illnesses and deaths.

OSHA prides itself on being “the newOSHA.” They claim their emphasis is onresults - not red tape. Inevitably, youwill have some interface with OSHA atsome point. Keep an open mind, takesteps to protect your company, but mostimportantly, work to make the OSHAinterface a beneficial experience foryour company.

Front Back

Editor’s Note: Amy Essex has expanded herresponsibilities to include risk management forthe Besser Family of Companies and corporate-wide tax planning.

4

OSSAF

All About OSHA - The OSHA Inspectionby Amy E. Essex

Besser Company Tax and Risk Manager

Part 2 of 3

Editor’s Note - In this article “OSHA” and“OSHA Compliance Officer” refer to theFederal OSHA. Your state may have its ownstate-approved OSHA programs and theseguidelines may vary slightly.

The best way to be prepared for anOSHA inspection is to continually stressthe importance of safety in theworkplace. Management and employeesmust be committed to safety. Aneffective safety program must be inplace that holds one person responsiblefor implementing and monitoring theprogram.

The following guidelines will helpyou through an inspection.

Authority to InspectOSHA is authorized under the

Occupational Safety & Health Act toconduct workplace inspections. Everyestablishment covered by the Act issubject to inspection by OSHAcompliance safety and health officers.Similarly, states with their ownoccupational safety and health programsconduct inspections using qualifiedcompliance officers.

Under the Act, “upon presentingappropriate credentials to the owner,operator or agent in charge,” an OSHAcompliance officer is authorized to:

1. “Enter without delay and atreasonable times any factory, plant,establishment, construction site orother areas, workplace, orenvironment where work isperformed by an employee or anemployer” and to

2. “Inspect and investigate duringregular working hours, and at otherreasonable times, and withinreasonable limits and in a reasonablemanner, any such place ofemployment and all pertinentconditions, structures, machines,apparatus, devices, equipment andmaterials therein, and to questionprivately any such employer,employee, owner, operator or agent.”

What to Do When OSHAComes Knocking

Common questions asked by manyemployers are, “What rights does OSHAhave when entering my business?” andconversely, “What rights andresponsibilities do I have as a businessowner when OSHA comes knocking atmy door?”

In general you will not receiveadvance notification of an OSHAinspection. Employers should alwaysinsist upon seeing the OSHAcompliance officer’s credentials, whoshould readily agree to this request. Inextreme cases you may wish to request asearch warrant from the complianceofficer before allowing entrance intoyour facility. By law, OSHA is requiredto have a search warrant to enter yourpremises; however, requiring OSHA tosecure a search warrant could create anadversarial relationship between yourcompany and OSHA. You may want torequest this only in the case where afatality or serious injury occurred thatcan result in criminal actions.

The Inspection ProcessArrival of the Compliance Officer

A designated individual fromthe company should greet the

compliance officer and check thecredentials. In rare cases when a searchwarrant seems necessary or prudent,verify that the search warrant is valid.

Opening ConferenceThis conference is your chance

to get more informationregarding the inspection. The

compliance officer should explain thepurpose of the visit, the scope of theinspection and the standards that apply.If the inspection is the result of anemployee complaint, you have a right tosee a copy of the complaint, althoughyou will probably not be shown thename of the complaining employee.

An authorized employeerepresentative is also given theopportunity to attend the opening

conference and to accompany thecompliance officer during theinspection. An employee union or aplant safety committee (in the absenceof a union) can designate the authorizedemployee. Where neither employeegroup exists, the employeerepresentative may be selected by theemployees themselves, or thecompliance officer will determine if anyemployee suitably represents theinterests of the other employees. Underno circumstances may the employerselect the employee representative forthe walk-around.

The Act does not require that there bean employee representative at eachinspection. When there is no authorizedemployee representative, however, thecompliance officer must consult with areasonable number of employeesconcerning safety and health mattersin the workplace; such consultationsmay be held privately.

Ways to protect yourrights and maintain a cordial

relationship withthe OSHA inspector

The OSHA compliance officer mayask to see reports of work-relatedaccidents or injuries (your OSHA log).Also, be prepared to show thecompliance officer your hazardcommunication program, lockout/tagoutprogram, a general safety program andother records relating to the safety ofyour employees.

Walk-throughThe compliance officer

determines the route andduration of the inspection. While

talking with employees, the complianceofficer should make every effort tominimize work interruptions. Thecompliance officer will observeconditions, consult with employees, takephotos (for record purposes), takeinstrument readings if necessary andexamine records.

An OSHA inspection is an evidencegathering process. Prepare to documentthe entire inspection.

Closing Conference During the closing conference

the compliance officer andthe employee representative will

discuss with the employer all unsafe or

can speak privately, but stay in sightrange of the the compliance officer.

Taking still photos is acceptable, butas a general rule, do not allow thecompliance officer to take videofootage. If the compliance officertakes a photo of something, youshould take your own photo.

If the compliance officer requestsdocuments, get the copies for him/her.Do not let the compliance officerbrowse through documents at will.Also, keep a file that contains a copyof all documents provided to thecompliance officer during the courseof an inspection.

Resources

References

State or regional OSHA offices - contactOSHA at (202) 693-1999 for help findingthe correct office to contact.

Occupational Safety and HealthAdministration (OSHA) web site:www.osha.gov.

unhealthful conditions observed duringthe inspection. The compliance officerwill indicate all apparent violations forwhich a citation may be issued orrecommended. At this time, theemployer is also told of appeal rights.The compliance officer will not indicateany proposed penalties since only theOSHA area director has that authority.

As the employer, you should be givena chance to discuss these violations andpresent your side of the case. You maywish to produce records whichdocument compliance efforts andprovide information which can helpOSHA determine how much time may beneeded to abate an alleged violation.

A closing conference may also beheld with the employees or theirrepresentative, if requested, to discussmatters of direct interest to employees.

Post InspectionGather your notes and photos

into a file. Follow-up with anyemployees who were interviewed

by the OSHA compliance officer. If theemployee has signed a statement,you are entitled to receive a copy of thatstatement for your file.

Listen carefully to questions asked bythe OSHA compliance officer. Answerhonestly, but answer only thequestion asked – do not volunteeradditional information.

Never try to guess, surmise orpresume what the OSHA complianceofficer is asking, if you are unsure askfor clarification. Make sure that youhave a clear understanding of what isbeing asked before you answer thequestion.

If the compliance officer takes notes -ask what he/she is writing and takeyour own notes.

ConclusionAbove all, remember that the

compliance officer is at your facilitybecause there is a question (whetherunfounded or not) about the safety ofyour employees. Cooperation betweenyou and the officer will result in a safeworking environment for employees.The goal is to rectify unsafe conditionswith minimal or no penalty imposed onyour company.

Ask the compliance officer thepurpose of the visit. Is this a wall-to-wall inspection or the result of acomplaint against the company? Ifthe inspection is the result of acomplaint, the compliance officershould only inspect the specificmachine or process involved in thecomplaint.

Never leave the compliance officeralone in the plant. Stay with him/herduring the entire visit.

The compliance officer is allowed tospeak privately to your employees.Allow enough space between youand the compliance officer so he/she

6

All About OSHA - Post Inspectionby Amy E. Essex

Besser Company Director, Corporate Tax and Risk

Part 3 of 3

OSTypes of Violations andPotential Penalties

failure to correct violations.

A copy of the Notice of Contest mustbe given to the employeerepresentative. If affected employeesare not represented by a recognizedbargaining agent, a copy of thenotice must be posted in a prominentlocation in the workplace or givenpersonally to each unrepresentedemployee.

OSHA Review ProcedureIf the written Notice of Contest has

been filed within the required 15working days, the OSHA area directorforwards the case to the OccupationalSafety and Health Review Commission(OSHRC). The commission is anindependent agency not associated withOSHA or the Department of Labor. TheCommission assigns the case to anadministrative law judge.

The judge may disallow the contest ifit is found to be legally invalid or ahearing may be scheduled at a public

SAF

Editor’s Note - In this article “OSHA”and “OSHA Compliance Officer” referto the Federal OSHA. Your state mayhave its own state-approved OSHAprograms and these guidelines may varyslightly.

Previous issues of Besser Blockdiscussed OSHA in general and whatoccurs during an OSHA inspection. Thisissue discusses the OSHA citation,appeal and settlement processes.

OSHA CitationsAfter the compliance officer reports

the findings from his/her visit to yourfacility, the OSHA area directordetermines if citations will be issued andif penalties will be proposed.

Citations indicate the allegedregulations and standards violated andthe proposed length of time set forabatement. The employer receivescitations and notices of proposedpenalties by certified mail. Theemployer must post a copy of eachcitation at or near the place where aviolation occurred, for three days oruntil the violation is abated, whicheveris longer.

The Appeal Process1. Abatement Period - When a

citation is issued, a date is set bywhich the OSHA violation must becorrected. The citation specifiesthe abatement date.

2. Appeals by Employees - If aninspection was initiated due to anemployee complaint, the employeeor an authorized employeerepresentative may request aninformal review of an OSHAdecision NOT to issue a citation.However, employees MAY NOTcontest citations, amendments tocitation, penalties or lack ofpenalties. Also, employees mayrequest an informal conferencewith OSHA to discuss issues raisedby an inspection, citation, noticeof proposed penalty or employer’sNotice of Contest.

3. Appeals by Employers

a. Request for Informal Hearing -When issued a citation, notice or

proposed penalty, an employer mayrequest an informal meeting with theOSHA area director to discuss thecase. The informal hearing shouldtake place within the 15 working daycontest period discussed later in thisarticle. Employee representativesmay be invited to attend the meeting.The OSHA area director is authorizedto enter into settlement agreementsthat revise citations and penalties toavoid prolonged legal disputes.

b. Petition for Modification ofAbatement - Upon receiving acitation, the employer must correctthe cited hazard by the prescribeddate unless he or she contests thecitation or abatement date. If theabatement cannot be accomplishedwithin the prescribed time, anemployer can file a Petition forModification of Abatement (PMA).The PMA must be filed in writingwith the OSHA area director whooriginally issued the citation by theworking day following theabatement date.

A PMA should specify all stepstaken to achieve compliance to date,the additional time needed toachieve complete compliance, thereason(s) additional time is needed,and steps being taken to safeguardemployees against the cited hazardduring the intervening period. Also,the employer must state that a copyof the PMA was posted in aconspicuous place at or near eachplace where a violation has occurredand that the employee representative(if there is one) has received a copyof the petition.

c. Notice of Contest - If an employerdecides to contest either the citation,the time set for abatement, or theproposed penalty, he/she has 15working days from the time thecitation and proposed penalty arereceived in which to notify theOSHA area director. The Notice ofContest MUST be in writing. Thereis no special format for the Notice ofContest however, it must identify theemployer’s reason for contesting thecitation, notice of proposed penalty,abatement period, or notification of

7

Resources

References

State or regional OSHA offices - contactOSHA at (202) 693-1999 for help findingthe correct office to contact.

Occupational Safety and HealthAdministration (OSHA) web site:www.osha.gov.

4. Corporate-Wide Settlements can beentered into under specialcircumstances. In these settlements,the employer formally recognizescited hazards and accepts theobligation to seek out and abatethose hazards throughout allworkplaces under the employer’scontrol.

ConclusionAbove all, remember that the

compliance officer is at your facilitybecause there is a question (whetherunfounded or not) about the safety ofyour employees. The objective is tocooperate with the compliance officer tocreate a safe place for your employees towork. If unsafe conditions exist, theideal goal is to rectify the unsafeconditions with minimal or no penaltyimposed on your company.

place near the employer’s location. Theemployer and the employees have theright to participate in the hearing.Although not required, having anattorney present may be advisable.

Once the administrative law judge hasruled, any party to the case may requestfurther review by OSHRC. An OSHRCcommissioner may also bring a case forreview.

Appeals in State PlansStates with their own occupational

safety and health programs have asystem to review and appeal citations,penalties and abatement periods. Theprocedures are generally similar to thoseof the Federal OSHA. However, a statereview board or equivalent authorityhears cases. If you are located in a statewith a state plan, familiarize yourselfwith the appeal process in that state.

Settlement of Cases1. OSHA area directors have guidelines

to negotiate settlement agreements,except for in extreme cases, or caseswhich affect other jurisdictions:

a. The area director can enter into aFormal Settlement Agreement afterthe employer has filed a writtenNotice of Contest.

b. Area directors are authorized tochange abatement dates, to reclassifyviolations (e.g. willful to serious,serious to other-than-serious) and tomodify or withdraw a penalty, acitation or citation item if theemployer presents evidence duringthe informal conference whichconvinces the area director that thechanges are justified.

2. Pre-Contest Settlements (InformalSettlement Agreements) occur duringor immediately following theinformal conference and prior to thecompletion of the 15 working daycontest period. If a settlement isreached during the informalconference, an Informal SettlementAgreement is prepared and theemployer representative is invited tosign it. The settlement becomeseffective once signed by the areadirector and the employerrepresentative.

3. Post-Contest Settlements (FormalSettlement Agreements) occur beforethe complaint is filed with theReview Commission. After anemployer files a Notice of Contest,the area director notifies the regionalsolicitor if a settlement with theemployer is forthcoming.

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Other than Serious ViolationA violation that has a directrelationship to job safety and health,but probably would not cause deathor serious physical harm. OSHA canimpose a penalty of up to US $7,000for this category of violation, whichcan be adjusted downward by as muchas 95% based on the employer’s goodfaith efforts to comply with standards,history of previous violations and sizeof business.

Serious ViolationA violation where there is asubstantial probability that death orserious physical harm could result andthat the employer knew, or shouldhave known, of the hazard. Amandatory penalty of up to US $7,000for each violation is proposed, whichcan be adjusted as described above.

Willful ViolationA violation that the employerknowingly commits or commits withplain indifference to the law. Theemployer either knows that what he orshe is doing constitutes a violation oris aware that a hazardous conditionexisted and made no reasonable effortto eliminate it. Penalties of up to US$70,000 may be proposed for eachwillful violation with a minimumpenalty of US $5,000 for eachviolation. A proposed penalty for thistype of violation can be adjusteddownward depending on the size ofthe business and the history ofprevious violations. Typically nocredit is given for good faith.

Repeated ViolationA violation that is substantiallysimilar to a violation for which theemployer has previously been issueda citation. The fine for this type ofviolation can be up to US $70,000and will not normally be adjusted.

Failure to Abate Prior ViolationFailure to abate a prior violation maybring a civil penalty of up toUS $7,000 for each day the violationcontinues beyond the prescribedabatement date.

De Minimis ViolationA violation of a standard which hasno direct or immediate relationship tosafety or health. These violations aredocumented the same way as otherviolations, but no citation is issued.

8

Determining if Training is NecessaryIf a problem exists in the workplace,

the first step is to determine whether theproblem can be remedied throughtraining. Problems that can be remediedinclude those that arise from lack ofknowledge of a work process,unfamiliarity with equipment orincorrect execution of a task. Anemployee’s lack of motivation or lack ofattention to the job can also beaddressed through training.

Sometimes, the problem is not anissue of a lack of knowledge or skilllevel, but rather an inherent hazard inthe workplace. These hazards should becorrected through other avenues.

Identifying Training NeedsIf the problem in the workplace can

be remedied through training, the nextstep is determining the type of trainingthat is needed. The question to ask is,“What is the employee expected to doand in what ways, if any, is theemployee’s performance deficient?” Ajob analysis can be used to determinethe answer and the goal of the training.OSHA Publication 3071 includesinformation on “How to Conduct a JobHazard Analysis.” This is a process thatrecords each step of a job, identifiesexisting or potential hazards anddetermines the best way to perform thejob in order to reduce or eliminate therisks inherent in the job. Employees areoften an excellent source of determiningwhat problems exist and how to solvethem.

Identifying Goals and ObjectivesAfter determining what kind of

training is needed, the goals andobjectives for the training need to beaddressed. Objectives do notnecessarily have to be written but theymust be clear, measurable and wellcommunicated. The objectives shouldtell the employee what the employerwants him/her to do, to do better or tostop doing.

Developing Learning ActivitiesThe next step is identifying and

describing the learning activities tomeet the training objectives. Theseactivities will provide skills needed bythe employee to perform jobassignments properly. The activitiesshould, as closely as possible, simulatethe employee’s actual job and caninclude lecture, role-play,demonstrations or self-instruction.

Conducting the TrainingPrior to conducting the training, the

employee should be convinced of theimportance and relevance of thematerials. Providing specific examplesor demonstrations that are relative to anemployee’s specific job function arehelpful. Since hands-on learning can bevery effective, employee involvement iscrucial in the training process.Employees should be allowed andencouraged to ask questions, contributetheir knowledge and expertise andbecome involved in demonstrations androle-playing.

Evaluating Program EffectivenessWhen creating a training program, a

method for measuring and evaluatingthe effectiveness of the program shouldalso be developed. Once the traininghas been conducted, this evaluationshould take place to ensure that theprogram met the goals and objectives.The evaluation can be a combination ofthe employee’s opinions of the program,supervisor observations of theemployee’s post-training performanceand demonstrated workplaceimprovements.

Improving the ProgramIf the program did not give the

employee the level of skill andknowledge anticipated, it should berevised. It may be helpful to survey theemployee trained to get input as to whythe training may have failed to meet theobjectives. All aspects of the design andimplementation of the program shouldbe reviewed, beginning with the jobanalysis, to determine where theprogram is deficient.

Specific Training Requiredby OSHA Standards

As mentioned earlier, OSHAadvocates but does not mandate trainingfor employees. OSHA does, however,require training in specific areas. Asample of some of the areas that mayapply to concrete products productionfacilities is shown in Figure 1. The listrefers to OSHA standards that containspecific training requirements. Eachproducer must determine which OSHAstandards apply to his or her plant.

The Occupational Safety and HealthAdministration (OSHA) does not have ageneral standard mandating safety andhealth training. However, OSHA doesrecognize that a general trainingprogram is essential to the workplace.Training can make employees morecompetent and better qualified toperform job assignments.

It is important to teach employeesabout job specific safety hazards and

proper work practices. Trainedemployees are less likely to be injuredon the job, which results in fewerworkplace injuries. Many OSHAstandards make it the employer’sresponsibility to limit certain jobassignments to employees who are“certified”, “competent” or “qualified”by means of completing specialtraining.

OSHA has developed a trainingmodel that employers can follow fordesigning, conducting, evaluating andrevising training programs. Theseguidelines are not currently mandatorybut are a good source of information.Remember safety and health programsare not “one size fits all.” OSHAencourages employers to personalizetraining to best suit their needs.

The OSHA Training Model

OSHA’s View on Trainingby Amy E. Essex, Director, Tax and Risk

Besser Company

9

Employee Emergency Plans and Fire Prevention Plans 1910.38

Hearing Protection 1910.95

Flammable and Combustible Liquids 1910.106

Personal Protective Equipment 1910.132

Respiratory Protection 1910.143

Specifications for Accident Prevention Signs and Tags 1910.145

Permit Required Confined Spaces 1910.146

The Control Of Hazardous Energy (lockout/tagout) 1910.147

Medical Services and First-Aid 1910.151

Fire Protection 1910.155

Fire Brigades 1910.156

Portable Fire Extinguishers 1910.157

Fixed Extinguishing Systems 1910.160

Fire Detection Systems 1910.164

Employee Alarm Systems 1910.165

Powered Industrial Trucks 1910.178

Bloodborne Pathogens 1910.1030

Hazard Communication 1910.1200

Sources of Training InformationAre you ready to take the next step,

but not sure how to proceed? Aneffective training program does notrequire a professional trainer orexpensive training materials. There aremany sources of training materialsavailable. A good place to start is theOSHA web site, www.osha.gov. TheOSHA web site allows you to downloadand print “Training Requirements inOSHA Standards and Training

Reference Herman, Alexis M., and Jeffress, Charles N.(1998). Training Requirements in OSHAStandards and Training Guidelines, U.S.Department of Labor, Occupational Safetyand Health Administration. OSHAPublication 2254. Available:www.osha-slc.gov/OshDoc/Additional.html.

OSHA Standard Title

Cita

tion

Nu

mb

er

Guidelines,” which is the referencesource for this article. Some of theinformation contained in the guidelinesis industry specific (e.g. a sectionrelating specifically to ShipyardEmployment), but most of thepublication relates to general industrytraining issues. Other sources fortraining assistance:

1. Your state OSHA (if you are in astate with a State Approved Plan).

2. Your workers’ compensationinsurance carrier. Many times theywill be able to provide orrecommend training to improve theskill of your workforce and reducethe number of work-related injuries.

3. The internet is a great place tosearch. There are many safetyprograms that can be purchasedinexpensively and then modified tofit your specific needs.

Figure 1

10

APersonal protective equipment (PPE)is an integral part of any safety program.Every program should include anin-depth evaluation of the PPE neededto guard against workplace hazards. Astandard operating procedure should bedeveloped which includes the propertraining of employees on the limitations,correct use and maintenance of PPE.

Identify HazardsThe first step is to determine the need

for PPE. Walk through the workplaceand identify potential sources ofhazards:

• Motion – machinery or processeswhere any movement of equipmentor particles could exist, or movementof employees could result in

collision with stationary objects• High temperatures that could result

in burns, eye injury or ignition of PPE• Chemical exposure• Harmful dust• Light radiation• Falling objects or potential for

dropping objects• Sharp objects which might pierce• Rolling or pinching objects• Electrical hazards

Organize and Analyze DataAfter the walk-through is completed,

organize and analyze your findings andinclude any injury/accident data. This willassist you in selecting the proper PPE.

• Compare the hazards found in theworkplace and the tasks performedby employees with the capabilities ofvarious PPE.

– The durability of PPE materials,such as tear and seam strength,should be considered in relationto the hazard and the task.– Keep in mind that certain PPEwill protect against some hazardsbut not against others.

• Choose PPE that provides moreprotection than the minimumrequired.

• Match the user with the appropriatePPE and make sure the equipmentfits properly.

• Provide instructions on the use,maintenance and limitations of thePPE.

• Reassess the workplace on a regularbasis to determine if the chosen PPEstill protects from the hazard.

Levels of ProtectionThere are four categories of PPE based

on the degree of protection. Level Arequires the most protection while LevelD requires the least.

Safety:Personal Protective Equipment

SAF

Level A protection should be used when:• The hazardous substance has been

identified and requires the highestlevel of protection for skin, eyesand the respiratory system basedon whether the measured (orpotential for) high concentrationof atmospheric vapors, gases, orparticulates exists; or theoperations and work functionsinvolve a high potential for splash,immersion, or exposure tounexpected vapors, gases, ormaterials that are harmful to skinor capable of being absorbedthrough the skin.

• Substances with a high degree ofhazard to the skin are known orsuspected and skin contact ispossible.

• Operations must be conducted inconfined, poorly ventilated areasand the absence of conditionsrequiring Level A protection havenot yet been determined.

Level A protection includes (whenappropriate):

• Positive pressure, full-face pieceself-contained breathing apparatus(SCBA), or positive pressuresupplied air respirator with escapeSCBA, approved by the NationalInstitute for Occupational Safety andHealth (NIOSH).

• Totally encapsulating chemical-protective suit

• Coveralls• Long underwear• Gloves, outer, chemical-resistant• Gloves, inner, chemical-resistant• Boots, chemical-resistant, steel toe

and shank• Hard hat (under suit)• Disposable protective suit, gloves

and boots (depending on suitconstruction, may be worn overtotally encapsulating suit)

11

DCB

by Amy E. Essex, Director, Tax and RiskBesser Company

Level C protection should be used when:• Atmospheric contaminants, liquid

splashes, or other direct contact willnot adversely affect or be absorbedthrough the skin.

• Air contaminants have beenidentified, concentrations measured,and an air-purifying respirator isavailable that can remove thecontaminants.

• All criteria for the use of air-purifying respirators are met.

Level C protection includes (whenappropriate):

• Full-face or half-mask, air purifyingrespirators (NIOSH approved)

• Hooded chemical-resistant clothing(overalls, two-piece chemical-splashsuit, disposable chemical-resistantoveralls)

• Coveralls• Gloves, outer, chemical-resistant• Gloves, inner, chemical-resistant• Boots (outer), chemical-resistant steel

toe and shank• Boot covers, outer, chemical-resistant

(disposable)• Hard hat• Escape mask• Face shield

Level D protection should be used when:• The atmosphere contains no known

hazards.• Work functions preclude splashes,

immersion, or the potential forunexpected inhalation of or contactwith hazardous level of anychemicals.

Level D protection includes (whenappropriate):

• Coveralls• Gloves• Boots/shoes, chemical-resistant steel

toe and shank• Boots, outer, chemical-resistant

(disposable)• Safety glasses or chemical splash

goggles• Hard hat• Escape mask• Face shield

The use of PPE alone cannot protectemployees from harm. PPE must be usedin conjunction with establishedworkplace safety programs, equipment,guarding and engineering controls toensure that your facility is an all-aroundsafe workplace.

ReferenceOSHA - “Non-mandatory ComplianceGuidelines for Hazard Assessment andPersonal Protective Equipment Selection”(1910 Subpart I, Appendix B).

Level B protection should be used when:• The type and atmospheric

concentration of substances havebeen identified and require a highlevel of respiratory protection, butless skin protection.

• The atmosphere contains less than19.5 percent oxygen.

• The presence of unidentified vaporsor gases is indicated by a vapordetection instrument, but are notsuspected of containing high levelsof chemicals harmful to skin orcapable of being absorbed throughthe skin.

Level B involves atmospheres withIDLH (“Immediately Dangerous to Lifeand Health”) concentrations of specificsubstances that present severe inhalationhazards and that do not represent asevere skin hazard; or that do not meetthe criteria for use of air-purifyingrespirators.

Level B protection includes (whenappropriate):

• Positive pressure, full-face piece self-contained breathing apparatus(SCBA), or positive pressuresupplied air respirator with escapeSCBA (NIOSH approved)

• Hooded chemical-resistant clothing(overalls and long-sleeved jacket,coveralls, or one or two-piecechemical-splash suit, disposablechemical-resistant overalls)

• Coveralls• Gloves, outer, chemical-resistant• Gloves, inner, chemical-resistant• Boots, outer, chemical-resistant steel

toe and shank• Boot covers, outer, chemical-resistant

(disposable)• Hard hat• Face shield

12

Hearing ConservationStrategies

Work-related hearing loss is one of themost critical occupational healthproblems according to the OccupationalSafety and Health Administration(OSHA). Prolonged exposure to highlevels of noise can cause temporary orpermanent hearing loss.

OSHA has established a hearingconservation program to assist incombating this occupational healthproblem. The program is designed toprotect workers with significantoccupational noise exposures fromsuffering material hearing impairmenteven if they are subject to such noiseexposure over their entire workinglifetime.

The OSHA hearing conservationprogram contains the followingcomponents:

Monitoring• Employers are required to monitor

noise levels and identify employeesexposed to noise at or above 85decibels (dB) averaged over 8working hours or an 8 hour time-weighted average (TWA)

• The exposure measurement mustinclude all noise within an 80 dB to130 dB range

• Instruments that are used for noisemeasurement must be calibrated toensure accuracy

• Noise monitoring must be repeated ifthere is a change in noise levels

Audiometric Testing• Employers must develop and

maintain a program that includes abaseline hearing test (audiogram),annual audiograms, training andfollow-up

• The testing must be performed at nocost to employees who are exposedto a minimum level of 80 dB over an8 hour period or 8 hour TWA (actionlevel)

• A licensed or certified technicianmust perform the actual testing

• The baseline audiogram must beperformed within 6 months of anemployee’s first exposure at or abovean 8 hour TWA of 85 dB

• Employees should have 14 hours ofnon-exposure to workplace noiseprior to the baseline testing

• Annual audiograms must beconducted for employees at or abovethe action level

Audiogram Evaluation• Annual audiograms must be

compared to the baseline results todetermine if the employee must befitted or refitted with hearingprotectors

• Employees must be shown how toproperly wear the hearing protectionand must be required to wear them atwork

Hearing Protectors• Hearing protectors must be made

available to all employees exposedto an 8 hour TWA noise level of 85dB or above

• A person trained in fitting hearingprotectors should assist the employerin selecting appropriate hearingprotection

• Hearing protection should becomfortable to wear and should alsobe effective in preventing hearingloss

Training• Employees need to understand the

effects that prolonged exposure tohigh levels of workplace noise canhave on their hearing and generalhealth

8 ....................................................... 85 dB6 ....................................................... 87 dB4 ....................................................... 90 dB3 ....................................................... 92 dB2 ....................................................... 95 dB1.5 .................................................... 97 dB1 ...................................................... 100 dB0.5 ................................................... 105 dB

Duration (hours) Noise Level

The typical block plant employee is exposedto a variety of noise levels, as shown below:

Concrete Products Machine Operator .............. 102 dBMixer Operator .................................................... 99 dBCuber Operator ................................................... 98 dBFork Lift Operator ................................................ 94 dB

13

by Amy Essex, Director, Tax and RiskDuane Rondeau, Alpena Engineering Manager

Besser Company

• Employees exposed to an 8 hourTWA of 85 dB and above must betrained annually in the following:

- Effects of noise - Purpose, advantages, and

disadvantages of various types ofhearing protectors

- Selection, fit and care of hearingprotectors

- Purpose and procedures foraudiometric testing

Recordkeeping• Employers must keep noise exposure

measurement records for a minimumof two years

• Records of audiometric testing mustbe kept for the duration ofemployment of the affectedemployee

Removing hazardous noises from theworkplace through engineering controlsis the most effective way to preventnoise induced hearing loss. Hearingprotectors such as ear muffs and earplugs should be used when workplacenoise is above a safe level. Effectivenoise control strategies for block plantsinclude:• Hearing Protectors

- Ear muffs- Ear plugs

• Sound absorbing materials on the wallsor ceiling of the block plant

• Operator location- Position the operators in designated

areas throughout the plant to bestprotect them from prolonged noiseexposure, while still allowing themto perform job functions

- Reduce the number of operators byautomating block plant equipment

Whisper 30 dB

Normal Conversation 60 dB

Ringing Telephone 80 dB

(Exposures at or above 85 dB may cause hearing loss)

Hair Dryer 90 dB

Power Lawn Mower 90 dB

Belt Sander 93 dB

Tractor 96 dB

Hand Drill 98 dB

Impact Wrench 103 dB

Bulldozer 105 dB

Spray Painter 105 dB

Continuous Miner 108 dB

Chain Saw 110 dB

Pneumatic Percussion Drill 119 dB

Ambulance Siren 120 dB

Jet Engine Takeoff 140 dB

12-Gauge Shotgun 165 dB

Rocket Launch 180 dB

Loudest Tone Possible 194 dB

• Quieter equipment- SmartPac® vibration is quieter

than standard vibration byapproximately 5 dB

- Electro-mechanical devices arequieter than hydraulic power units

- Vibration isolators- Pallet receiver rubbers- Rubber covered pallet placing

fingers- Non-metallic mold locks

• Proper machine maintenance to avoidunnecessary noises

• Compartmentalize the followingfunctions:- Raw material handling- Production- Curing- Packaging- Maintenance

• Sound Enclosures- Concrete masonry walls- Insulated plywood partitions- Pre-manufactured insulated panels

Consult the OSHA web site or yourstate-sponsored plan web site forspecific guidelines on establishing andmaintaining a hearing conservationprogram.

SOURCE: National Institute forOccupational Safety and Health(NIOSH) General Estimates of WorkRelated Noises

ReferencesOSHA Regulation 1910.95

“Occupational Noise Exposure”OSHA Publication 3074

“Hearing Conservation”National Institute for Occupational

Safety and Health (NIOSH)

14

Conten t s :Safety Basics .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Pictorial Warnings... . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Confined Spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Reducing Lost Time A ccidents.. . . . . . . . . . .7Lockout/Tagout Revisited ... . . . . . . . . . . . . . . . .9Corporate Safety Programs ... . . . . . . . . . . .11Improve Plant Safety .. . . . . . . . . . . . . . . . . . . . . . .13Safety Decals .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-15

V olume OneSeptember 2000

The importance of safety in thedesign, operation, maintenance

and repair of equipment is in thepublic eye now more than everbefore. In the last decade Federal,State and International Safety andHealth Standards have becomeincreasingly stringent. For instance,during this time the adoption of the Occupational Safety and Health Administration (OSHA)Lockout/Tagout Standard, theANSI-Z535.4 Standard for safetysigns and decals, and EuropeanUnion requirements for equipment sold in Europe and theUnited Kingdom have beeninstituted.

Safety is important not onlybecause governmental agenciesare imposing harsherrequirements and stricterpenalties for failure to meet thoserequirements, but becauseemployees are a company’s most important asset and deserve tobe protected from hazards. Thereare numerous ways to protectemployees. This article will addressthe following necessary componentsof a plant safety program:

1) The Safe Work Environment;2) The OSHA Lockout/Tagout

Standard; and3) Pictorial Warnings.

The Safe Work EnvironmentThe most important benefit an

employer can provide to employeesis a safe work environment, which,in fact, is required by law. The mostimportant measure that employeescan do for themselves and for thecompany is to follow the safe workpractices and procedures each plant develops.

EL E M E N T S O F ASA F E WO R K EN V I R O N M E N T:• Proper guarding is in place for all

pinch, shear, crush and nip points.• A written lockout/tagout procedure

is in place.• Employees are trained in safety.• The work area is free from slipping

and tripping hazards.

• Equipment is not modified withoutwritten approval of themanufacturer.

• Proper maintenance is performedon the equipment.

• The operation or repair ofequipment by untrained personnelis never allowed.

SA F E WO R K PR A C T I C E SA N D PR O C E D U R E S:• Follow the written lockout /

tagout procedure.• Make sure your fellow workers

are clear of equipment beforestarting it.

• Be sure you use the appropriatesafety devices when providingmaintenance and repairs to anypiece of equipment.

• Always be sure equipment isproperly grounded.

• Always wear appropriate protectiveequipment like safety glasses,safety shoes, hearing protection,hard hats, etc.

• Never operate any equipmentwhile any part of your body is inthe proximity of potentiallyhazardous areas.

• Never climb or stand on any equipment while it is operational.• Never exceed the ratedcapacity of a machine or tool.• Never operate any equipment if unusual or excessivenoise or vibration occurs.

OSHA Lockout/Tagout Standard (29 CFR 1910.147)Lockout/tagout is one of the

least expensive and least complicatedOSHA standards with which tocomply, yet in many industries it is the most cited OSHA violation.Violation of the lockout/tagoutstandard usually involves theemployer not having a formalwritten lockout/tagout program in place or not conducting trainingfor employees. Recently, a Bessercustomer was visited by the OSHAdepartment in their state, resultingin the assessment of several fines,one of which related to failure to“develop, document, and utilizeprocedures for the control ofpotentially hazardous energy whenemployees are engaged in service or maintenance of machines orequipment where unexpectedenergization, start-up or release ofstored energy could occur and causeinjury.” This particular company wasfined US $600 for this violation, butthe fines can be as high as US $10,000.

The OSHA Lockout/TagoutStandard was developed in 1990 to prevent the accidental release ofenergy from equipment. The OSHA standard establishes the minimum requirements forlockout of energy isolating deviceswhenever maintenance or servicingis done on machines or equipment.The procedure should be used to ensure that the machine orequipment is stopped, isolated fromall potentially hazardous energysources and locked out beforeemployees perform any servicing ormaintenance where the unexpectedenergization or start-up of themachine or equipment or release of stored energy could cause injury.If the lockout procedure is notfollowed, severe injury or death canresult. Representatives of OSHAhave stated that compliance with thestandard could prevent as many as120 deaths and 60,000 accidents yearly.

Shown above is a suggestedlockout procedure decal available

Safety Basicsby

Amy E. Essex

Tax & Risk Manager

1

from Besser Company. This decalshould be placed on all machines andelectrical panels. The decal will enableemployees to refer to the lockoutprocedure rather than having tomemorize the procedure. However,do not substitute the decal for a writ-ten lockout/tagout procedure andtraining program. The decal is meantto be an aid to a formal procedure,

and a reminder to employees of thesteps which should be followed.

When you review these resourcesplease keep in mind that ultimatelyit is the responsibility of theemployer to ensure that a formalwritten lockout/tagout procedure isin place and that employees aretrained in the application of thelockout/tagout procedure. TheOSHA Lockout/Tagout Standard is not only required by law, butfollowing it makes good sense.

Pictorial WarningsPrior to the approval of the

American National StandardsInstitute (ANSI) Z535 Standards inJune 1991, product manufacturers

did not have a uniform standard or guideline for designing productsafety signs and decals. Mostmanufacturers either developedtheir own warning designs,borrowed the OSHA designs forenvironmental and facility safetysigns, or purchased generic warningsigns from safety sign companies.The result was a multitude of

product safety sign designs, colors,and messages in use.

The ANSI Z535.4 Standard wasspecifically designed to correct thisproblem. It establishes definitionsfor the layout, content, and color ofa product safety sign. The result forplant owners and employees is asystem of safety signs and decalsthat are easily recognizable andunderstandable, resulting in fewerproduct-related injuries and deaths.

In 1990 Besser Companyinstituted a pictorial warningprogram. All Besser customers weremailed notification of the availabilityof pictorial type warning decals forall Besser machines, conveyors,motors and electrical panels. In our

mailing, Besser customers wereurged to retrofit their equipmentwith these labels. These pictorialwarning decals are designed inaccordance with the ANSI Z535.4Standard. The decals are shown onpages five through eight of the 2000Besser Parts and AccessoriesCatalog, and can be ordered fromthe Besser Central Order departmentor through your local Besserrepresentative. Prints are alsoavailable showing the suggestedplacement of the decals.

Besser had a good response to the 1990 mailing, but that was along time ago. Please check thestatus of the pictorial warnings onyour equipment. If they are missingor unreadable, now is the time toreplace them.

Developing A Plant Safety ProgramUse of the safety practices and

procedures detailed above areminimum guidelines for thedevelopment of a plant safetyprogram. These guidelines shouldbe tailored to fit the specifics of each plant, including the types ofequipment used, the types ofoperations which will be performedon each piece of equipment, and anyspecific guidelines issued by theOSHA department in each state.Remember, ultimately it is theresponsibility of the employer toensure that employees have safework conditions. ■

References:1. OSHA Compliance Manual for General

Industry, Appendix A to 1910.147 – Typical Minimum Lockout Procedure,1995, The Merritt Company.

2. 29 CFR §1910.147, The Control ofHazardous Energy (Lockout/Tagout).

3. The ANSI Z535.4 Standard and theProduct Safety Design Process, 1996,Geoffrey Peckham, HazardCommunications Systems, Inc.

In 1990 Besser Company instituted a pictorial warning program. All Besser customers were mailed notificationof the availability of pictorial type warning decals for all Besser machines, conveyors, motors and electricalpanels. These pictorial warning decals are designed in accordance with the ANSI Z535.4 Standard.

2

Have you everwondered why

there are pictoriallabels on Bessercapital equipment?The labels are thereto communicatevaluable infor-mation regardingsafe operation of

the equipment. If thesewarnings are followed by everyonewho operates, maintains or repairsthe equipment, the labels mayprevent a serious injury, or even save a life.

Pictorial warning labels arecarefully designed and worded to beeasily understood, even by peoplewho speak other languages. A plantowner, manager or supervisor canbenefit from understanding theimportance of these labels and theprocess behind their formulation and design.

The Construction of PictorialWarning Labels:There are strict guidelines (ANSIZ535.4) which address the design ofsafety signs. A good safety signcontains all of the following elements:

Signal Words: CAUTION,WARNING or DANGERIt is important that the warning labelbegins with the correct signal word.

CAUTION indicates a potentiallyhazardous situation which, if notavoided, MAY result in minor ormoderate injury.

WARNING indicates a potentiallyhazardous situation which, if notavoided, COULD result in death orserious injury.

DANGER indicates an imminentlyhazardous situation which, if notavoided WILL result in death orserious injury. This signal word is tobe limited to the most extremesituations.

You may wonder, why not be“safe” and use the DANGER signalword for all potentially hazardoussituations? The answer is simple:because people tend to become“immune” to warnings whenoverused. If all the equipment in

your plant was plastered withDANGER signs workers couldbecome used to the signs and beginto ignore the signals, or they may notrecognize situations where trueDANGER is present.

Safety Alert Symbol.The safety alertsymbol indicates apotential personalsafety hazard. It ismade up of atriangle surroundingan exclamation point. If the hazardcould result in personal injury thesafety alert symbol should be presenton the pictorial warning label.

Colors - Yellow, Orange and Red

Caution- should be in black letters ona yellow background

Warning- should be in black letters onan orange background

Danger- should be in white letters ona red background

These colors were carefully selectedby the ANSI committee and areintended to serve as visual codes toreinforce the meaning of the signalwords. By using these colorsconsistently, workers will recognize thelevel of hazard seriousness at a glance.

The Word MessageThe signal word and the color asdescribed above unite to communicatethe serious-ness of the hazard.The wordmessage andthe pictorialitself combineto communi-cate the threeother

elements of the sign:* the nature of the hazard,* how to avoid the hazard, and * the consequence of involvementwith the hazard.

The word message should beconcise and readily understood.However, when detailed instructions,precautions or consequences become lengthy, the pictorial sign may refer the user to the properinstruction manual.

The PictorialThe pictorial is agraphic represen-tation intended toconvey a messagewithout the use ofwords. The pictorialcan represent ahazard, a hazardous situation, aprecaution to avoid a hazard, a resultof not avoiding a hazard, or anycombination of these messages.Pictorials can be used as a supplementto or in place of a worded message ona safety sign or label.

Foreign LanguagesThe ANSI Z535.4standard does notaddress the issueof bilingualformats forproduct safetylabels. However,Besser hasdesigned labels to show the signalword in both English and Spanish.Also, because many Besser customershave employees with variouslanguage backgrounds, safety labelshave recently been introduced whichshow both the signal word and theword message in one of fivelanguages: Spanish, French, Italian,Russian and Chinese (see Besser Block,Third Quarter 1997, Vol. 22, No.3).

Pulling it TogetherWhen all of these elements (signalword, color code, word message andpictorial) are combined, the result is apictorial warning label that isintended to show staff at a glancewhat hazard is present, how to avoidthe hazard and what the consequencesare if the hazard is not avoided.

The Importance of Pictorial Warningsby Amy E. Essex

Besser Company Tax & Risk Manager

CAUTION

WARNING

DANGER

3

In 1990 Besser enhanced itswarning labels by adding pictorials.At that time, customers were notified of the availability of theselabels. For the safety of your staff, iflabels for your pre-1990 equipmenthave not been obtained or if any ofyour equipment has missing ordamaged labels, please take the timeto order TODAY.

These labels can be ordered frompages three through eight of the 2000Besser Parts and Accessories catalog.If you do not know which labels you

need, please contact a Besser representativefor assistance.

References: ANSIZ535.4 Standard

The ANSI Z535.4Standard and theProduct Safety DesignProcess, GeoffreyPeckham, HazardCommunicationsSystems, Inc.,September 1996

Nip hazard.

lockout procedureconveyor. Follow

before servicing.

stay clear of

WARNINGMUCHOCUIDADO

This notice is issued to advise you that some previously accepted shop practices may not bekeeping up w ith changing Federal and State Safety and Health Standards. Your current shoppractices may not emphasize the need for proper precautions to insure safe operation and useof machines, tools, automatic loaders and allied equipment and/or w arn against the use ofcertain solvents or other cleaning substances that are now considered unsafe or prohibited bylaw. Since many of your shop practices may not reflect current safety practices and procedures,particularly w ith regard to the safe operation of equipment, it is important that you reviewyour practices to ensure compliance w ith Federal and State Safety and Health Standards.

IMPORTANTThe operation of any machine or power-operated device can be extremely hazardous unless propersafety precautions are strictly observed. Observe the following safety precautions.

• A lways be sure proper guarding is in place for all pinch, catch, shear, crush and nip points.• A lways make sure that all personnel are clear of the equipment before starting it.• A lways be sure the equipment is properly grounded.• A lways turn the main electrical panel off and lock it out in accordance with published

lockout/tagout procedures prior to making adjustments,repair, and maintenance.• A lways wear appropriate protective equipment like safety glasses, safety shoes, hearing

protection and hard hats.• A lways keep chemical and flammable material away from electrical or operating equipment.• A lways maintain a safe work area that is free from slipping and tripping hazards.• A lways be sure appropriate safety devices are used when providing maintenance and repairs to

all equipment.• Never exceed the rated capacity of a machine or tool.• Never operate equipment if unusual or excessive noise or vibration occurs.• Never use any toxic flammable substance as a solvent cleaner.• Never allow the operation or repair of equipment by untrained personnel.• Never climb or stand on equipment when it is operational.

It is important that you review Federal and State Safety and Health Standards on a continualbasis. All shop supervisors, maintenance personnel, machine operators, tool operators, and anyother persons involved in the setup, operation, maintenance, repair or adjustment of Besser-builtequipment should read and understand this bulletin and all Federal and State Safety and HealthStandards on w hich this bulletin is based. For additional copies of this bulletin see page three ofthe 2000 Besser Parts and Accessories Catalog or contact Julie DeYoung at 517-354-1170.

4

Background

In October 1993, OSHA issuedgeneral industry safety standards

relating to confined space entry.OSHA initially directed its effortsat certain high-risk industrieswhere every entry into a confinedspace was potentially fatal.Through informational articles andcrack downs by state OSHAdepartments, employers in otherindustries are gradually becomingaware of the responsibility toprotect and educate theiremployees about confined spaces and the potential hazards.This article is intended to make youaware of the OSHA Confined SpaceSafety Standard by providingbackground information. Contactyour OSHA area representative toget more specific guidance on thestandards in your state.

What is a Confined Space?A confined space has ALL

of the followingcharacteristics:• The size and shape

of the space allowsa person to enter it;

• The space has limitedopenings for workersto enter and exit; and

• The space is notdesigned forcontinuous occupancy.Look around your

plant: which pieces ofequipment and areas inyour facility exhibit thecharacteristics describedabove? What about bins,hoppers, kilns, mixers, or pits?There is a good chance that yourstate OSHA department willconsider some or all of these to beconfined spaces. There may beother areas in your plant which arealso considered confined spaces. Soyou should never let youremployees enter these spaces,right? WRONG!! Mixers, bins,kilns, pits and other potentialconfined spaces unique to theconcrete industry need to becleaned and maintained on aregular basis. These activities

usually require that employeesaccess these spaces. What can youdo to protect your workers frompotential hazards? Just as you need a written policy for the OSHALockout/Tagout Standard, youmust also develop a written policyfor entering and working in con-fined spaces and you must educateyour employees about what couldconstitute a confined space.

Permit-Required Confined SpacesCertain confined spaces are

further characterized as “Permit-Required Confined Spaces.” Suchspaces require a permit before entryto the space can be allowed. Thepermit is issued by a supervisor orother company official and allowsan employee entry into theconfined space. The permit tellswhat hazards are present in thepermit space and how to

controlthem. Also included is a

checklist of necessary safetymeasures. Access to permit-required confined spaces should belimited by a barrier where feasible,or clearly marked. Permit-requiredconfined spaces include thosewhich could pose the followinghazards to your employees:• Hazardous atmosphere• Not enough oxygen• Flammable or toxic air• Engulfment – being trapped

in liquid or solid material• Danger from unexpected

movement of machinery• Electrocution• Heat stress• Becoming wedged into a narrow

part of the space and suffocating• Physical dangers such as falls,

debris, slipping ladders.All confined spaces should be

considered permit-required unlessthey are exempted by OSHA, orunless you can prove to OSHA,upon inspection, that the space isnot permit-required. This permitrequirement may be waived byyour area OSHA office for mixers,pits and other pieces of equipment.However, exemption from thepermit requirement does not freeyou from the obligation to institute procedures to keepemployees safe when entering

these spaces. In fact, theOSHA office will notwaive the permitrequirement unlessyou can show that youhave safety measuresin place such asatmosphericmonitoring data,lockout/tagoutprograms andadditional trainingprograms whichshow that the spaceshould not be apermit-requiredconfined space.

Establishing a Confined Space Program

What steps do you, as anemployer, need to take to establisha Confined Space Program? Thefirst step is to get information onthe applicable Confined SpaceStandards in your state. The generalsteps in establishing a program are:• Identify all permit spaces in

your facility.• Reduce employee risk around

permit spaces with signs like theone pictured on this page and with training.

Confined Spacesby Amy E. Essex

Besser Company Tax & Risk Manager

Permit required.

Confined space.

Always keep person

at door during entry.

DANGER

PELIGRO

5

• Prevent unauthorized employeeentry in permit spaces.

• Develop and implement awritten permit space program.

• Document proceduresestablishing a non-permit space.

• Re-evaluate spaces whenconditions change.

• Make special arrangements withcontractors who may enterpermit spaces.

• Supply safety and personalprotective equipment, if needed.

• Establish emergency/rescueprocedures in case someonebecomes trapped in a confined space.Remember, it is your duty

to keep your plant safe for youremployees. This can only beachieved through awareness,education, training and cooperationof both the plant owner and theemployees. �

Please contact your area OSHArepresentative for specific guidance onconfined space guidelines in your state.

References:1. “Common Confined Spaces,”

Bob Eckhardt, Concrete Products,January 1997.

2. “A Guide to Safety in… ConfinedSpaces,” National Institute forOccupational Safety and Health, published by Praxair, Inc., July 1987.

3. Department of Labor, General IndustrySafety Standards Commission, SafetyStandards, part 90: Confined Space Entry.

6

24-Hour OSHA Hotline: 1-800-321-OSHA(To report suspected fire hazards, imminentdanger safety and health hazards in theworkplace, or other job safety and healthemergencies.)

Region I - Boston, MA (617) 565-7164Region II - New York, NY (212) 337-2378Region Ill - Philadelphia, PA (215) 596-1201Region IV - Atlanta, GA (404) 347-3573Region V - Chicago, IL (312) 353-2220

Region VI - Dallas, TX (214) 767-4731Region VII - Kansas City, MO (816) 426-5861Region VIII - Denver, CO (303) 844-3061Region IX- San Francisco, CA (415) 744-6670Region X - Seattle, WA (206) 553-5930

U.S. Department of Labor

Robert B. Reich, Secretary

Occupational Safety and Health Administration

OSHA 3140

1993

Make sure you know all of the appropriate proceduresand precautions to take for entry into and exit from confinedspaces. If there are hazardous confined spaces where youmust work, your employer is required by law to have a permit-required confined space program, permit system, emergencyprocedures, appropriate engineering and work practice con-trols and to provide you with training and appropriate personalprotective equipment. See OSHA’s standard on confined spaces

in Title 29 of the Code of Federal Regulations, Part 1910.146.For related OSHA publications, contact your regional or areaoffice, or call (202) 219-4667, FAX (202) 219-9266.

ConfinedSpacesCan Kill!

How longhas it

been sinceyour plantexperienceda lost-timeaccident?1 year?

8 years?Chances are

you have hadseveral lost-time

accidents withinthese time frames. A lost-time

accident is one that results inoccupational injury or diseasewhich disables the worker beyondthe day of injury; i.e. the worker isunable to return to work for theirnext regularly scheduled shift.According to statistics published bythe Bureau of Labor Statistics, U.S.Department of Labor, the 1997 lost-time incident rate for concrete blockand brick manufacturers was 6.3days per 100 workers. Forequipment manufacturers (such as

Besser Company), the lost timeincident rate was 2.9 days per 100workers in 1997.

This article focuses on twocompanies: one just completed oneyear without a lost-time accidentand remarkably, the other has beenwithout a lost-time accident for overeight years. By comparing andcontrasting the safety programs ofthese two companies you will seethat these programs are not “onesize fits all.” A program that workswell for one company may not beappropriate for another. The key isto find what works for you andyour employees and set a programin action.

A Study of Conditions and People

Featherlite Building ProductsCorporation, with locationsthroughout Texas, recentlycompleted a year without a lost-time accident. How was thisaccomplished? According to

Eddie Pina, Safety Director forFeatherlite, the key was the SafetyTraining and Observation Program(STOP) by DuPont. “The main

objective of DuPont’s program is toeliminate incidents and injuries.This is done by modifying behaviorby observing people as they workand talking with them to encouragesafe work practices and eliminateat-risk behavior.”

STOP is based on the followingprinciples:

✓ All injuries and occupational illnesses can be prevented.

✓ Safety is everyone’s responsibility.

✓ Management is directly accountable for preventing injuries and occupational illnesses.

✓ Safety is a condition of employment.

✓ Training is an essential element for safe work practices.

✓ Safety audits must be conducted.✓ Safe work practices should

be reinforced and all unsafe acts and unsafe conditions must be corrected promptly.

✓ It is essential to investigate injuries and occupational illnesses as well as incidents with the potential for injury.

✓ Safety off the job is an important element of your overall safety effort.

✓Preventing injuries

Reducing Lost Time Accidentsby Amy E. Essex

Besser Company Tax & Risk Manager

According to statistics published

by the Bureau of Labor

Statistics, U.S.

Department of Labor,

the 1997 lost-time incident rate

for concrete block and brick

manufacturers was

6.3 days per 100 workers.

Mike Krom from the Besser International Pipe Machinery purchasing department updates the safety record sign.

7

and occupational illnesses is good business.

✓ People are the most critical element in the success of a safetyand health program.

STOP utilizes videos andworkbooks for training managers,safety coordinators, linesupervisors and key lead peoplein the principles of the program.

Why has this program workedfor Featherlite? “Featherlite hasbeen successful with thisprogram because it has taughtour supervisors how torecognize unsafe actions of ouremployees. It has taught oursupervisors how to talk with ouremployees and how to preventrecurrence of an unsafe act.STOP has also taught oursupervisors how to reinforcepositive behavior when anemployee is working safe,” stated Eddie.

For further information on STOP,contact DuPont at 1-800-532-SAFE

or access their website atwww.dupont.com/safety.

A Safety Record to EmulateIncredibly, Besser International PipeMachinery in Sioux City, Iowa, hascompleted eight years without alost-time accident. This safetyrecord was accomplished under theguidance of a six-person safetycommittee led by Don Groves,

production manager and safetymanager at Besser InternationalPipe Machinery.

The safety committee at BesserInternational Pipe Machineryconducts random plant inspectionson a monthly basis, looking forunsafe working conditions. Once aninspection has been completed, allshop employees meet to discuss thefindings. These meetings can take aslong as an hour and a half. Thecommittee then works to change theunsafe conditions. Besser Inter-national Pipe Machinery strives tomeet or exceed OSHA standards onall safety issues in the plant.

Do all employees need to meet foran hour and a half each month? Isthis excessive? You might say “Yes”,

but the safety record of BesserInternational Pipe Machinery says“No.” The cost of one lost-timeaccident can easily off-set the cost ofhalting production for one hourevery month or quarter so employeescan discuss unsafe conditions andpractices in the work environment.

According to Don, training andcommunication are the keys to thesafe working conditions at BesserInternational Pipe Machinery.“Employee involvement is critical,and to be committed to safety. Weare fortunate that our employees aresold on safety.”

Comparison and ContrastFeatherlite uses a structured,commercial program purchasedfrom a safety vendor while BesserInternational Pipe Machinery uses aless formal program consisting ofregular plant inspections and all-employee meetings.

The similarity between the twoprograms is SUCCESS. Bothprograms include a strongcomponent of communication andemployee involvement. Employeesdo not want to be injured on the job.Insight and input from employeesabout how to do their jobs safely isan invaluable resource informulating a safety program.

The key to safety:Do what works for your

company. Investigate resources andstudy what other companies aredoing, then develop and administera customized program suited toyour employees.

8

An article titled “Safety Basics” in a previous Besser Block issue(Volume 22, Number 1) touched onthe importance of a Lockout/TagoutProgram. The following articletakes a more in-depth look atlockout/tagout and discusses whereto go for additional resources andassistance in setting up a programand procedures.

Employees performing service ormaintenance on equipment can beexposed to injuries from theunexpected energization or start-upof the equipment or from the releaseof stored energy in the equipment.Many injuries can be prevented byfollowing a proper Lockout/TagoutProgram.

In January 1990, OSHA issuedStandard 29 CFR 1910.147, Controlof Hazardous Energy. The standardis known as the OSHA“Lockout/Tagout Standard” andcompliance is mandatory forproducers in the United States. Thestandard requires implementingprocedures to shut down theequipment, isolating it from theenergy source(s) and preventing therelease of potentially hazardousenergy while maintenance andservicing activities are beingperformed.

Lockout vs. Tagout

Lockout: A method of keepingequipment from being set in motion.It involves:

1. Putting a disconnect switch,circuit breaker, valve or otherenergy isolating mechanism inthe safe or off position.

2. Placing a device over the energy isolating mechanism to hold it in place.

3. Attaching a lock so that theequipment can’t be energized.

Tagout: A written warning attached toan energy isolating device which hasbeen placed in the safe or off position.

NOTE - Locks and tags alone do notde-energize equipment. Attach themonly after the equipment has beenisolated from its energy source.

Other Important Definitions

Affected Employee: An employeewho is required to use equipmenton which servicing or maintenanceis being performed under lockout ortagout, or who performs other jobresponsibilities in an area wheresuch servicing or maintenance isbeing performed.

Authorized Employee: A personwho locks or tags equipment inorder to perform service ormaintenance.

Energized: Connected to an energysource or containing residual orstored energy.

Energy Isolating Device: Amechanical device that physicallyprevents the transmission or releaseof energy.

Energy Source: Any source ofelectrical, mechanical, hydraulic,pneumatic, chemical, thermal orother energy.

What if equipment is not locked ortagged out?

• A person could be cut by a sharppart that starts moving suddenly.

• A person could be struck by apart that hasn’t stopped movingor starts moving accidentally.

• A person’s limbs could becrushed between moving parts.

• An equipment part that isn’tsecured could push a personaway with force.

• A person or his/her clothingcould become entangled in amoving part.

• A moving part could clampdown on a person from above.

When should equipment be lockedor tagged out?

• During set-ups

• Before performing maintenance

• During troubleshooting

• Before making repairs

In short - an employee shouldlock or tag any time a guard or other

safety device is removed or when an employee must place any part of his/her body where it could becaught by moving equipment.All mechanical equipment which is capable of sudden, unexpectedmovement should be locked ortagged out.

Employers’ Responsibility forLockout/Tagout

Employers must:

Develop an energy control program.

Use locks when equipment can belocked out.

Ensure that new equipment oroverhauled equipment canaccommodate locks.

Use an effective tagout program toensure safety when tags rather thanlocks are used.

Identify and implement specificprocedures (IN WRITING) for thecontrol of hazardous energyincluding preparation forshutdown, equipment isolation,lockout/tagout application, releaseof stored energy and verification ofisolation.

Institute procedures for release oflockout/tagout to includeequipment inspection, notificationand safe positioning of affectedemployees and removal oflockout/tagout devices.

Obtain standardized locks and tagswhich are of sufficient quality anddurability to ensure effectiveness.The locks and tags should alsoidentify the employees using them.

Train employees in specific energycontrol procedures.

Use training reminders.

Schedule annual inspections of thecontrol procedures.

Adopt procedures to ensure safetywhen equipment must be testedduring servicing, when outsidecontractors are working at the site,when a multiple lockout is neededfor a crew servicing equipment andwhen shifts or personnel change.

Lockout/Tagout Revisitedby Amy E. Essex

Besser Company Tax and Risk Manager

9

Summary of Lockout/TagoutProcedures

1. Notify others - authorized employeesshould notify affected employees.

2. Review the entire Lockout/TagoutProcedure before beginning.

3. Identify all energy sources, understand the hazards and knowhow to control the energy sources.

4. Shut down the machine or equipment.

5. Disconnect the power - isolate theequipment from the energy sources.

6. Lockout or tagout the equipment toprevent an accidental start.

Each member of a work crew shouldapply his/her own lock (can be doneusing a multiple-lock hasp). It is theemployer’s choice whether to uselockout or tagout.

7. Neutralize stored or potential energy.

8. Verify isolation - test to make sure theequipment can’t start.

9. Begin work activity.

Release from Lockout/Tagout Status

1. Ensure that the equipment is safe tooperate.

2. Safeguard all employees and removeany tools from the area.

3. Notify affected employees that theequipment is being put back intoservice.

4. Re-install guards and other safetydevices and ensure operability.

5. Remove the lockout/tagout device.Except in emergencies each devicemust be removed by the person whoput it on.

6. Re-energize the equipment followinga checklist.

Conclusion

Employers are responsible fordeveloping and implementing aLockout/Tagout Program and fortraining employees in the proper use ofLockout/Tagout Procedures. Employeesare responsible for adhering to theprogram to keep themselves and co-workers safe.

As with other OSHA Standards, manystate OSHA departments have developedtheir own standards and those should betaken into consideration whendeveloping a program.

QuizNow that you understand the basics - take the following quiz to see howmuch you’ve learned (answers can be found on page 12).

Indicate whether each of these statements is true or false:

1. In a lockout, an energy isolating device is locked in the safe or off position.

2. In a tagout, the energy isolating device is placed in a safeposition and a written warning is attached to it.

3. A worker may use any sturdy lock to apply a lockout.

4. Lockout/tagout should be used whenever you are performingservice or maintenance around any machine where you could beinjured by unexpected start-up or release of stored energy.

5. Each individual employee can decide whether to use lockout,tagout or both.

6. Applying locks or tags in the right places de-energizes theequipment.

7. Turning off the power switch removes all energy from poweredequipment.

8. Before lockout/tagout is applied, all workers in the affected areamust be notified.

9. Before you turn off equipment in order to lock or tag it out, youmust know the type of energy it uses, the hazards of that energyand how to control the energy.

10. Once you isolate a system from its main power source, you canbe sure no energy will reach the equipment.

11. In a lockout, one person is allowed to attach a single lock for anentire work crew.

12. After equipment has been isolated from its power sources, it’sstill necessary to control any energy stored in the system.

13. Before removing lockout/tagout devices, you must make surethe danger area is clear of tools and workers.

14. If a worker is not present to remove his/her own lock, any co-worker can remove it as long as he/she first makes sure it’s safe.

T F

Resources

Following are resources that may assist you in developing and implementinga Lockout/Tagout Program.

OSHA website - www.osha.govContains a lockout/tagout tutorial

that explains the OSHA Standard in“plain terms” and also contains a list ofstates which have adopted their ownOSHA approved state plans.

National Concrete MasonryAssociation - (703) 713-1900

NIOSH website -www.cdc.gov/niosh/homepage/html

Lists resources for orderinglockout/tagout videos which can beused for training purposes. The phonenumber for NIOSH is 1-800-35-NIOSH.

State or regional OSHA offices - contactOSHA at (202) 693-1999 for helpfinding the correct office to contact.

References

OSHA Standard 20 CFR 1910.147,Control of Hazardous Energy (Lockout/Tagout)

OSHA Lockout/Tagout (Loto)Tutorial, found at www.osha.gov

10

Does my company need a corporate safety program?

As a plant owner or supervisor/manager, you are no doubt

extremely busy with the day-to-daypressures of running a successfulbusiness. How can you also devote timeto ensure a safe work environment…because as an employer you must. It is a requirement that you protect workersfrom harm. But, equally important, it isto your benefit to institute a completesafety and risk control program in your facility.

FACT – 98% of all accidents andinjuries are caused by unsafe workingconditions, unsafe acts of personnel or a combination of both.

FACT – Employers that demonstrateto employees that they really do careabout safety are likely to have fewerworkplace accidents.

I carry worker’s compensationinsurance in case of an accident – isn’t that enough?

The cost of accidents fall into twocategories:

� Insured Costs – Worker’sCompensation will cover:• Medical costs• Compensation costs

� Uninsured Costs – Not covered byWorker’s Compensation:• Lost production time of injured

worker getting first aid or medicalattention

• Costs of time spent investigatingand reporting injuries, handlinginjured worker

• Costs of hiring and trainingreplacements for injured workers

• Interruptions and delays caused byaccidents

• Damage to machines and materialscaused by accidents

• Other indirect inefficiencies andhindrances

It has been estimated that uninsuredcosts are usually several times the insuredcosts. The amount paid for worker’scompensation insurance is only a smallpart of the total cost of accidents, eventhough this is the most obvious directoutlay of money. Preventing accidents pays doubly by reducing worker’scompensation premiums and by reducinguninsured costs as well.

Even if insurance paid all costs, you still have a responsibility to keepemployees safe from harm. If a workersuffers a fatal injury in your plant, all the insurance in the world won’t bring him/her back. An effective safetyand risk control program includes safety and injury prevention activities as well as post-accident loss controlmeasures. Every effort should be madeto identify and eliminate physicalhazards and educate employees as tothe most cautious and efficient methodof performing required tasks. If aninjury does occur, despite safety andinjury prevention measures, the riskcontrol program must have appropriatepost-incident follow-up activities in place to minimize the severity of the incident.

Whose responsibility is safety?Each employee in your facility isresponsible for certain aspects of safety.Safety responsibilities should be placedand accepted as follows:

� Management:• State and enforce a policy

on safety

• Provide a safe workplace• Prescribe safe work practices and

procedures• Provide adequate training and

competent supervision• Designate responsibility and

delegate authority to supervisors

� Supervisors:• Train personnel in proper and safe

work practices• See that proper practices are

followed• Investigate all injuries for causes• Take corrective action when unsafe

conditions or work methods areobserved

• Maintain safe equipment, tools,environment

� Employees:• Observe prescribed work practices• Report to supervisor any hazards

that exist• Report all injuries immediately• Use protective devices and

safety equipment

What are the elements of a complete corporate safety and risk control program?

� A Company Safety Policy

� A Safe Work Environment

• Eliminate Mechanical and PhysicalHazards• Keep guards on machinery• Maintain good housekeeping• Promote safe materials handling

methods• Properly maintain tools and

equipment• Ground and control electricity

Corporate Safety Programs:If You Can’t Afford Safety, You Can’t Afford To Be In Business

by Amy E. EssexBesser Company Tax and Risk Manager

FACT – 98% of all accidents and injuries are caused by unsafe working conditions, unsafe acts of personnel

or a combination of both.FACT – Employers that demonstrate to employees that they really

do care about safety are likely to have fewer workplace accidents.

11

� Eliminate Environmental andChemical Hazards

• Provide personal protectiveclothing and equipment

• Control air contaminants• Control temperature and

humidity (where feasible)• Control toxic substances and

chemicals• Provide adequate illumination• Provide noise control or

hearing protection• Provide radiation control

� Competent Supervision of Employees

• Delegate authority for safetydecisions to supervisors

• Train and educate supervisors and employees

• Lockout/Tagout program• Confined spaces• Safe and proper use of machines• Perform safety inspections• Measure safety performance• Maintain safety records• Form a safety committee

Why does my company need a safety committee?

Workers are more likely to beresponsive to a Safety Program if theyhelp develop the program and are able tomake suggestions and recommendationsregarding safe practices in their workenvironment.

Who should serve on the committee?� Supervisors� Machine operators� Maintenance workers� Plant owners? If practical –

and if their presence does not prevent workers from stating

opinions andmaking safetyrecommendations.

How oftenshouldthe committeemeet and for how long?� Will vary fromplant to plant.

� Will need to meet more oftenif you are juststarting up a safety

program, then less often whenmaintaining the program.

� If you have more than one shift or work crew – hold very short “safety briefings” each week –conducted by the supervisor or shift foreman. The meeting shouldcover one safety topic or subject and take no longer than 10-15 minutes.

Raising the level of safety awarenessamong workers through frequent butshort safety messages is critical.

What are good topics for the safetycommittee or briefings to address?

� Past injuries that have happened inthe plant.

� Proper lifting and material handlingtechniques.

� How to safely use a specific piece ofequipment. Discuss how to use it andwhy, including a discussion of whatcould happen if the equipment ismisused.

� Company Safety Rules. Pick one specificrule for each meeting. Describe injuriesthat could happen if the rule is broken.

� When, where and how to wearpersonal protective equipment.Explain why the equipment isnecessary and give examples ofinjuries which occurred because theequipment was not worn.

How can I ensure that the companysafety program will work?

� Be personally “sold” on the safetyprogram and the risk control activitiesof the company. Emphasize theimportance of plant safety.

� Enforce the company safety rules.� As a plant owner or supervisor, give

constructive suggestions and feedbackto the safety committee.

� Take seriously the responsibility of

conducting scheduled andunscheduled safety inspections.

� Use visual aids as part of the program: posters, bulletin boards,safety signs, videos/films.

� Commend employees who are safetyconscious. Let them know you noticed!

Where can I go for sources toestablish a safety program?

� Your insurance carrier� National Concrete Masonry

Association (NCMA) Recource Guide– Phone: (703) 713-1900

� Other Trade Organizations� Your State OSHA Department. How-

ever, if you call them for assistance, beprepared to make all changes theyrequire or possibly be subject to fines.This source is not recommended if youare just beginning a Safety Program –check other sources first.

� Other Concrete Products Plant Owners.

References:Elements of a Safety Program, Bureau of Safety

and Regulation, Michigan Department of Labor,

Safety Education & Training Division.

Business Insurance, 4 May 1998, Vol. 32, No. 18,

Crain Communication, Inc. ■

Crush hazard.

secure elevatorprocedure and

before servicing.

Follow lockout

DANGER

PELIGRO

12

1. True

2. True

3. False. Only

standardized locks

supplied by the

employer are to

be used.

4. True

5. False. The employer

decides whether to

use lockout, tagout

or both; individual

workers must follow

the company policy.

6. False. The

equipment must

first be isolated from

its energy sources

using energy

isolationg devices.

7. False. Whether the

switch is on or off,

energy of some sort

is always present.

8. True

9. True

10 False. You must

also isolate the

equipment from

any secondary

power sources.

11. False. Every

worker in the crew

must attach his/her

own personal lock.

12. True

13. True

14. False. An absent

worker’s lock can be

removed only in an

emergency, and

only under the

employer’s direction.

Answers to Quiz (from page 10):

Safety decals with text in Spanish,French, Italian, Russian, and

Chinese languages are now availablefrom Besser Company. These newsafety decals compliment the Englishlanguage safety decals which havebeen available since 1990.

If the operators of your equipmentspeak one of the languages listedabove as a first language, you shouldstrongly consider investing in thesenew decals. Providing more informa-tion to your employees about thepotential hazards of working withmachinery will improve the safety ofyour employees.

The new safety decals consist ofboth a signal word (caution, warn-ing or danger) and text in one of thefive languages. The signal wordindicates the potential severity of thehazard while the text describes thehazard and how to avoid it.

The Spanish, French, Italian,

Russian, and Chinese safety decalscontain only text and must be placednext to the English decal which carriesthe corresponding pictorial. Followingthis advice is critical since only theEnglish decals carry the pictorials.

Ordering the decals is simple. First,locate the correct part number(s) inthe column labeled English. Then,determine which additional partnumber(s) is/are necessary byscanning across the table to the rightuntil the column label matches theadditional language(s) you require.

Warning: Under no circumstanceshould Spanish, French, Italian,Russian or Chinese decals be usedwithout the English decal carrying the pictorial.

Contact your Besser sales repre-sentative or the Besser service partscenter at (800) 530-9991 or (517) 354-3166 to order safety decals. �

Improve Plant Safetyby Amy E. Essex

Besser Company Tax & Risk Manager!

Safety DecalsNOTE:All foreign language safetydecals are intended for use inconjunction with an Englishsafety decal with pictorial.Please determine the correctdecal for your needs using thefollowing directions.

Directions1. Determine which English

safety decals are requiredfor each piece of equipment.

2. Locate the correct partnumber(s) in the columnlabeled English Part #.

3. Determine whichadditional language decalis needed.

4. After locating the Englishpart number for the decalyou need, scan across thetable and locate thecorresponding partnumber for the languagethat you need.

In addition to English and Spanish, the safety decals are also available in French, Chinese, Italian and Russian languages.These safety decals compliment the English language safety decals, and must be used in conjunction with English decalswhich carry the pictoral. Refer to page eight of the 2000 Besser Parts and A ccessories catalog to order, or contact theBesser Company service parts center at 800-530-9991 or at 517-354-3166.

13

Decal Equipment That Decals English CorrespondingNumber Should Be Adhered To: Part # Spanish Part #

1 1 per Panel 113236F0409 113236F0404ES2 4 per Mixer 113237F0410 113237F0405ES3 1 per Concrete Products Machine 113240F0307 113240F0303ES

2 per Depalleter4 2 per Mixer 114692F1006 114692F0404ES5 4 per Skiploader 114688F0906 114688F0404ES6 8 per Skiploader/Mixer Platform 114689F0804 114689F0303ES7 8 per Skiploader/Mixer Platform 114690F0805 114690F0303ES8 2 per Vertical: Pallet Transport System 113244F0410 113244F0404ES

6 per Horizontal: LSC-40A /LSC-1004 per Pallet Transport System

9 4 per Besser-Matic 113242F0409 113242F0404ES10 4 per Besser-Matic 113243F0410 113243F0404ES11 4 per Skiploader 114691F1006 114691F0404ES12 1 per Electrical Panel 113249F0410 113249F0409ES13 4 per Overhead Block Transfer 113238F1005 113238F0405ES14 1 per Concrete Products Machine 113248F1006 113248F0405ES15 2 per Concrete Products Machine 113241F0605 113241F0303ES16 12 per Conveyor 113246F0704 113246F0303ES17 8 per Cuber 113247F1006 113247F0405ES18 3 per Cuber 113250F1006 113250F0405ES

2 per Block Turnover2 per Slat Conveyor

DANGER

PELIGRO

Mixer blade hazard.Close front paneland stay clearduring operation.Follow lockout procedure before servicing.

DANGER

PELIGRO

High voltage.Follow lockoutprocedure beforeservicing panel or machine.

DANGER

PELIGRO

Crush hazards.Stay clear ofmachine.Follow lockoutprocedurebefore servicing.

DANGER

PELIGRO

Crush hazard.Stay clear.Follow lockoutprocedure beforeservicing.

DANGER

PELIGRO

Nip points.Stay clear. Followlockout procedurebefore servicing.

WARNING

MUCHOCUIDADO

Fall hazard.Stay clear.

113237F0410Mixer Blade HazardWidth 4 1/2"Height 10 1/4"

Large: 113236F0409High VoltageWidth 4 1/2" Height 9 5/8"Small: 113236F0204High VoltageWidth 2" Height 4 1/8"

Vertical: 113240F0307Crush HazardWidth 3 1/2" Height 7 1/2"Horizontal: 113239F0604Crush HazardWidth 6 5/8" Height 4"

114688F0906Crush HazardWidth 6 1/4"Height 9 1/2"

114692F1006Nip PointsWidth 5 3/4"Height 9 1/2"

114689F0804Fall HazardWidth 4 1/2"Height 7 3/4"

WARNING

MUCHOCUIDADO

Falling objects.Hard hat area.

Falling objects.Stay clear oftransfer area.Follow lockoutprocedure beforeservicing.

DANGER

PELIGRO

114690F0805Falling ObjectsWidth 4 3/4"Height 8"

Crush hazard.Stay clear of carand crawler.Follow lockoutprocedure beforeservicing.

DANGER

PELIGRO

DANGER

PELIGRO

Crush hazard.Stay clear oftransfer area.Follow lockout procedure beforeservicing.

Vertical: 113244F0410Crush HazardWidth 4 1/2" Height 10"Horizontal: 113245F1005Crush HazardWidth 10" Height 5 3/4"

113242F0409Crush HazardWidth 4 1/2"Height 9 5/8"

DANGER

PELIGRO

Shear hazard.Fall hazard.Stay clear. Followlockout procedurebefore servicing.

SUGGESTEDLOCKOUTPROCEDURE1. Announce lockout to other employees.2. Turn power off at main panel.3. Lockout power in off position.4. Put key in pocket.

5. Clear machine of all personnel.

6. Test lockout by hitting run button.

7. Block, chain or release stored energy sources.

8. Clear machine of personnel before restarting machine.

114691F1006Shear and Fall HazardsWidth 5 3/4"Height 9 3/4"

113249F0410Safety Instructions Decal –Suggested Lock-out ProcedureWidth 4" Height 10"

113243F0410Falling ObjectsWidth 4 1/2"Height 10"

1 2 3 4

9 10 11 12

5 6 7 8

14 continued on back cover

WARNINGThe operation of any machine or power-operated device can be extremely hazardous unless you strictly observe

the correct safety precautions. Make sure you observe all safety precautions for operation of any machinery.

Improve Plant Safety continued . . .To order safety decals, contact your local Besser representative

or the Besser Service Parts Center at 800-530-9991

DANGER

PELIGROCrush hazard.Stay clear of machine. Follow lockout procedure before servicing.

Crush hazard. Stay

lockout procedurearea. Follow

before servicing.

clear of transfer

DANGER

PELIGRO

DANGER

PELIGROCrush and pinchpoints. Stay clearof machine. Followlockout procedurebefore servicing.

Nip hazard.

lockout procedureconveyor. Follow

before servicing.

stay clear of

WARNINGMUCHOCUIDADO

DANGER

PELIGROCrush and pinch-points. Stay off conveyor. Followlockout procedurebefore servicing.

113238F1005Crush HazardWidth 10 inchHeight 5 3/4 inch

113248F1006Crush Hazard

Width 10 inchHeight 6 inch

113241F0605Crush and Pinch PointsWidth 6 5/8 inchHeight 4 inch

113246F0704Nip Hazard

Width 7 inchHeight 4 1/2 inch

Crush hazard.

secure elevatorprocedure and

before servicing.

Follow lockout

DANGER

PELIGRO

113247F1006Crush HazardWidth 10 inchHeight 6 inch

113250F1006Crush and Pinch Hazard

Width 10 inchHeight 6 inch

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15

17

14

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Family of CompaniesVisit the Besser web site at www.besser.com

Besser Alpena Besser Appco Besser Baker801 Johnson Street 442 N. W.W. White Road 3380 US-23 NorthAlpena, Michigan 49707 San Antonio, Texas 78219 Alpena, Michigan 49707800-530-9980 800-330-5590 517-354-2189

Besser CMC Besser IPMC Besser Lithibar2121 Del Amo Boulevard 111 S. George Street 13521 Quailty DriveCompton, California 90220 Sioux City, Iowa 51103 Holland, Michigan 49424310-537-5171 800-621-7768 800-626-0415

Besser OEM Besser Proneq Besser Quinn5306 Pride Road 765 Bombardier 1518 E. 12th StreetOscoda, Michigan 48750 Mascouche, Quebec, Boone, Iowa 50036517-739-7105 Canada J7K 3L7 800-654-3127

800-363-2400

2000vp9/00