DEPARTMENT OF THE ARMY EM 385-1-1 U.S. Army Corps of Engineers CESO-ZA Washington, D.C. 20314-1000 Manual No. 385-1-1 15 September 2008 Safety SAFETY AND HEALTH REQUIREMENTS 1. Purpose. This manual prescribes the safety and health requirements for all Corps of Engineers activities and operations. 2. Applicability. This manual applies to Headquarters, US Army Corps of Engineers (HQUSACE) elements, major subordinate commands, districts, centers, laboratories, and field operating activities (FOA), as well as USACE contracts and those administered on behalf of USACE. Applicability extends to occupational exposure for missions under the command of the Chief of Engineers, whether accomplished by military, civilian, or contractor personnel. 3. References. a. 29 Code of Federal Regulation (CFR) 1910 b. 29 CFR 1926 c. 29 CFR 1960 d. Executive Order (EO) 12196 e. Federal Acquisition Regulation (FAR) Clause 52.236-13 This manual supersedes EM 385-1-1, 3 November 2003 f. Department of Defense Instruction (DODI) 6055.1 g. Army Regulation (AR) 40-5 h. AR 385-10. 4. General. a. The provisions of this manual implement and supplement the safety and health standards and requirements referenced above. Where more stringent safety and occupational health standards are set forth in these requirements and regulations, the more stringent standards shall apply. b. Mission applicability introduced in paragraph 2 above shall include the following: (1) Construction contract work under the provisions of FAR Clause 52.236-13. Contractors shall comply with the latest version of EM 385-1-1 (including interim changes) that is in effect on the date of solicitation. Prior to making an offer, bidders should check the HQUSACE Safety and Occupational Health web site (see paragraph c) for the latest changes. No separate payment will be made for compliance with this paragraph or for compliance with other safety and health requirements of this contract. Note: Existing contracts will continue to apply the provisions of the previous edition of this manual until contract completion. (2) Service, supply, and research and development contracting actions. Compliance with this manual shall be a contract requirement for such activities unless technical representatives (in coordination with safety and health professionals) advise that special precautions are not appropriate due to extremely limited scope of services or similar. However, it is understood that this manual in its entirety may be too complex for the type of work being performed under these contracts. These contractors may reference Appendix A, paragraph 11 for limited scope Accident Prevention Plan (APP). (3) Contracting actions for hazardous, toxic, and radioactive waste site investigation, design, or remediation activities. Compliance with this manual shall be a contract requirement. c. Changes. All interim changes (changes made between publication of new editions) to this manual, and the effective date of change, will be posted on the Safety and Occupational Health Office web site: http://www.usace.army.mil/CESO/Pages/Home.aspx and in USACE Electronic bid Sets. Hard copies of this manual are available from the local contracting official. d. Interpretations. Within the Corps of Engineers, interpretations to the requirements contained within this manual shall be executed in accordance with the process contained in Appendix M. Interpretations will apply only to the specific situation in question and may not be used as a precedent to determine the meaning of a requirement as it may apply to another circumstance. e. Variances and Waivers. Within the Corps of Engineers, variances and waivers to provisions of this manual require the approval of the Chief of Safety and Occupational Health, HQUSACE. Variances or waivers shall provide an equal or greater level of protection, shall be substantiated with a hazard analysis of the activity and shall be documented and forwarded through channels to Chief of Safety and Occupational Health, HQUSACE. The process for requesting variances or waivers is contained in Appendix N. f. Activities performed OCONUS. Some of the technical requirements of this manual may not be applicable to overseas activities due to conflicting circumstances, practices, and laws or regulations of the locality or the unavailability of equipment. In such instances, means other than the ones specified in this manual may be used to achieve the required protection. In such instances, a hazard analysis must be developed to document that the required protection will be achieved by the alternate means. h. The use of underlining in this manual indicates new or changed text from the 2003 version. i. Supplementation of this manual is not authorized except as published by the Safety and Occupational Health Office, HQUSACE. ( 1) Local USACE organizations may develop Standard Operating Procedures (SOPs) to implement the provisions contained within this manual, but may not implement new requirements without the specific approval of HQUSACE. (2) Locally developed Safety and Health Requirements will not be included in contract requirements without the approval of HQUSACE. FOR THE COMMANDER: AE~lijMILL Colonel, Corps of Engineers Chief of Staff EM 385-1-1 05 Jul 11 TABLE OF CONTENTS Section Page 1. Program Management ............................................................ 1-1 A. General ....................................................................... 1-1 B. Indoctrination and Training ........................................ 1-13 C. Physical Qualification of Employees ......................... 1-16 D. Accident Reporting and Recordkeeping .................... 1-18 E. Emergency Planning ................................................ 1-20 F. Emergency Operations ............................................. 1-21 2. Sanitation ................................................................................ 2-1 A. General Requirements ................................................ 2-1 B. Housekeeping ............................................................. 2-1 C. Drinking Water ............................................................ 2-1 D. Non-Potable Water...................................................... 2-4 E. Toilets .......................................................................... 2-4 F. Washing Facilities........................................................ 2-8 G. Showers ...................................................................... 2-8 H. Change Rooms ........................................................... 2-9 I. Clothes Drying Facilities .............................................. 2-9 J. Food Service ................................................................ 2-9 K. Waste Disposal ......................................................... 2-10 L. Vermin Control ........................................................... 2-11 3. Medical and First-Aid Requirements ....................................... 3-1 A. General ....................................................................... 3-1 B. First-Aid Kits ................................................................ 3-4 C. First-Aid Stations and Infirmaries ................................ 3-7 D. Personnel Requirements and Qualifications ............... 3-8 4. Temporary Facilities ............................................................... 4-1 A. General ....................................................................... 4-1 B. Access/Haul Roads ..................................................... 4-4 5. Personal Protective and Safety Equipment............................. 5-1 A. General ....................................................................... 5-1 i EM 385-1-1 05 Jul 11 B. Eye and Face Protection ............................................. 5-3 C. Hearing Protection and Noise Control ....................... 5-12 D. Head Protection ........................................................ 5-15 E. Protective Footwear ................................................. .5-17 F. High-Visibility Apparel ................................................ 5-18 G. Respiratory Protection .............................................. 5-19 H. Personal Fall Arrest Equipment Including Lineman’s Equipment Including Linemen’s Equipment (Electrically Rated Harnesses). .................................................... 5-24 I. Electrical Protective Equipment ................................ 5-24 J. Personal Flotation Devices ....................................... 5-29 K. Lifesaving and Safety Skiffs ..................................... 5-33 6. Hazardous or Toxic Agents and Environments ....................... 6-1 A. General ....................................................................... 6-1 B. Hazardous or Toxic Agents ......................................... 6-3 C. Hot Substances ......................................................... 6-11 D. Harmful Plants, Animals, and Insects........................ 6-14 E. Ionizing Radiation ...................................................... 6-15 F. Non-ionizing Radiation and Magnetic and Electric Fields ............................................................ 6-26 G. Ventilation and Exhaust Systems ............................. 6-29 H. Abrasive Blasting ...................................................... 6-31 I. Inclement Weather and Heat/Cold Stress Management ............................................................. 6-38 J. Cumulative Trauma Prevention ................................ 6-44 K. Indoor Air Quality (IAQ) Management ....................... 6-45 L. Control of Chromium (VI) Exposure .......................... 6-48 M. Crystalline Silica ....................................................... 6-49 7. Lighting ................................................................................... 7-1 A. General ....................................................................... 7-1 8. Accident Prevention Signs, Tags, Labels, Signals, Piping System Identification, and Traffic Control .................... 8-1 A. Signs, Tags, Labels, and Piping Systems ................... 8-1 B. Signal Systems, Personnel, and Procedures ............ 8-11 C. Traffic Control ........................................................... 8-12 ii EM 385-1-1 05 Jul 11 9. Fire Prevention and Protection ............................................... 9-1 A. General ....................................................................... 9-1 B. Flammable and Combustible Liquids .......................... 9-6 C. Liquefied Petroleum Gas (LP-Gas) ........................... 9-13 D. Temporary Heating Devices ...................................... 9-18 E. First Response Fire Protection .................................. 9-24 F. Fixed Fire Suppression Systems ............................... 9-29 G. Firefighting Equipment .............................................. 9-30 H. Fire Detection and Employee Fire Alarm Systems .... 9-31 I. Fire Fighting Organizations - Training and Drilling .... 9-32 J. Fire Patrols ............................................................... 9-33 K. USACE Wild Land Fire Control ................................. 9-33 10. Welding and Cutting ........................................................... 10-1 A. General ..................................................................... 10-1 B. Respiratory Protection ............................................... 10-3 C. Fire Protection ........................................................... 10-5 D. Oxyfuel Gas Welding and Cutting ............................. 10-7 E. Arc Welding and Cutting .......................................... 10-10 F. Gas Metal Arc Welding ............................................ 10-12 11. Electrical ............................................................................. 11-1 A. General ..................................................................... 11-1 B. Arc Flash ................................................................... 11-5 C. Overcurrent Protection, Disconnects, and Switches . 11-7 D. Grounding ................................................................. 11-8 E. Temporary Wiring and Lighting ............................... 11-13 F. Operations Adjacent to Overhead Lines .................. 11-15 G. Batteries and Battery Charging ............................... 11-19 H. Hazardous (Classified) Locations ........................... 11-20 I. Power Transmission and Distribution ..................... 11-23 J. Underground Electrical Installations ....................... 11-40 K. Work in Energized Substations ............................... 11-41 L. Communication Facilities ......................................... 11-42 12. Control of Hazardous Energy .............................................. 12-1 A. General ..................................................................... 12-1 B. Training ..................................................................... 12-5 iii EM 385-1-1 05 Jul 11 C. Periodic Inspections .................................................. 12-6 D. Locks and Tags ......................................................... 12-6 E. Application and Removal of Locks and Tags ............ 12-7 13. Hand and Power Tools ....................................................... 13-1 A. General ..................................................................... 13-1 B. Grinding and Abrasive Machinery ............................. 13-3 C. Power Saws and Woodworking Machinery ............... 13-5 D. Pneumatic Tools ....................................................... 13-7 E. Explosive-Actuated Tools .......................................... 13-8 F. Chain Saws ............................................................. 13-10 G. Abrasive Blasting Machinery ................................... 13-10 H. Power-Driven Nailers and Staplers ......................... 13-11 14. Material Handling, Storage, and Disposal ........................... 14-1 A. Material Handling ...................................................... 14-1 B. Material Storage ........................................................ 14-2 C. Housekeeping ........................................................... 14-5 D. Debris Nets ............................................................... 14-6 E. Material Disposal ....................................................... 14-7 15. Rigging................................................................................ 15-1 A. General ..................................................................... 15-1 B. Personnel Qualifications ............................................ 15-2 C. Multiple Lift Rigging (MLR) ........................................ 15-3 D. Wire Rope ................................................................. 15-5 E. Chain ......................................................................... 15-8 F. Synthetic Rope Slings ............................................. 15-10 G. Slings ...................................................................... 15-12 H. Rigging Hardware ................................................... 15-14 16. Cranes and Hoisting Equipment ......................................... 16-1 A. General ...................................................................... 16-1 B. Personnel Qualifications ............................................. 16-6 C. Classification of USACE Equipment and Training of USACE Operators ...................... …………………….16-16 D. Inspection Criteria for Cranes and Hosting Equipment……………………………………………....16-18 E. Safety Devices and Operational Aids ...................... 16-29 iv EM 385-1-1 05 Jul 11 F. Testing .................................................................... 16-34 G. Operation ................................................................. 16-37 H. Critical Lifts .............................................................. 16-52 I. Environmental Considerations ................................ 16-54 J. Lattice, Hydraulic, Crawler-, Truck-, Wheel-, and Ringer-Mounted Cranes ......................................... 16-55 K. Portal, Tower, and Pillar Cranes ............................. 16-57 L. Floating Cranes, Floating Derricks, Crane Barges, and Auxiliary Shipboard Mounted Cranes .............. 16-60 M. Overhead and Gantry Cranes ................................. 16-67 N. Monorails and Underhung Cranes .......................... 16-68 O. Derricks ................................................................... 16-69 P. Handling Loads Suspended from Rotorcraft .......... 16-70 Q. Material Hoists ........................................................ 16-74 R. Pile Drivers ............................................................. 16-77 S. Hydraulic Excavators, Wheel/Track/Backhoe Loaders Used to Transport/Hoist Loads w/Rigging . 16-80 T. Crane-Supported Personnel (Work) Platforms ...... .16-84 U. Base-Mounted Drum Hoists Used To Hoist Personnel, Guided And Non-Guided Worker’s Hoists [Whether Powered By Internal Combustion Engine, Electric Motor Or Other Prime Mover (Air Tuggers)]…………..……16-92 V. Powered Industrial Trucks (PITs)/Telehandlers…….16-94 17. Conveyors ........................................................................... 17-1 A. General ..................................................................... 17-1 B. Operation .................................................................. 17-7 18. Motor Vehicles, Machinery and Mechanized Equipment, All Terrain Vehicles, Utility Vehicles and other Specialty Vehicles ............................................................................... 18-1 A. General ..................................................................... 18-1 B. Guarding and Safety Devices .................................... 18-3 C. Operating Rules ...................................................... 18-10 D. Transportation of Personnel .................................... 18-13 E. Motor Vehicles (for Public Roadway Use ................ 18-14 F. Trailers .................................................................... 18-16 G. Machinery and Mechanized Equipment .................. 18-16 H. Drilling Equipment ................................................... 18-25 v EM 385-1-1 05 Jul 11 I. All Terrain Vehicles (ATVs) and Off-Road Vehicles (ORVs) .................................................................... 18-30 J. Utility Vehicles ......................................................... 18-32 K. Specialty Vehicles ................................................... 18-34 19. Floating Plant and Marine Activities .................................... 19-1 A. General ..................................................................... 19-1 B. Access ..................................................................... 19-14 C. Marine Fall Protection Systems .............................. 19-17 D. Main Deck Perimeter Protection ............................. 19-17 E. Marine Railing Types............................................... 19-20 F. Launches, Motorboats, and Skiffs ........................... 19-24 G. Dredging ................................................................. 19-27 H. Scows and Barges .................................................. 19-29 I. Navigation Locks and Vessel Locking ...................... 19-30 20. Pressurized Equipment and Systems ................................. 20-1 A. General ..................................................................... 20-2 B. Compressed Air and Gas Systems ........................... 20-5 C. Boilers and Systems ................................................. 20-9 D. Compressed Gas Cylinders .................................... 20-11 21. Fall Protection ..................................................................... 21-1 A. General ..................................................................... 21-1 B. Training ..................................................................... 21-3 C. Fall Protection Program ............................................ 21-4 D. Controlled Access Zones .......................................... 21-6 E. Fall Protection Systems ............................................. 21-6 F. Covers ..................................................................... 21-10 G. Safety Net Systems ................................................ 21-10 H. Personal Fall Protection Systems ........................... 21-12 I. Ladder-Climbing Devices (LCDS) ........................... 21-21 J. Scaffolds, Aerial Lift Equipment and Moveable Work Platforms................................................................. 21-21 K. Warning Line Systems (WLS) ................................. 21-22 L. Safety Monitoring Systems (SMS) ........................... 21-24 M. Rescue Plan and Procedures… .............................. 21-24 N. Working Over or Near Water .................................. 21-24 vi