1. Accident Prevention Manual
for Business & Industry:
Engineering & Technology
13th edition
National Safety Council
Compiled by
Dr. S.D. Allen Iske, Associate Professor
University of Central Missouri
3. Methods of Controlling Exposure
to Hazards Within the Workplace
• Engineering Controls - designed into the workplace
• Administrative Controls - worker rotation, proper
housekeeping and training
• Personal Protective Equipment (PPE)-Equipment, clothing
or materials which are used in the workplace, for the
purpose of reducing the risk of injury or illness due to
workplace hazards.
4. Introduction
• Personal protective equipment (PPE) refers to the use of
respirators, special clothing, safety glasses, hard hats, or
similar devices whose proper use reduces the risk of
personal injury or illness resulting from occupational
hazards.
• Least desirable method applied for protection.
• Engineering controls—eliminating toxic substances,
changing process design, using barriers or guards,
isolating or enclosing hazards.
• Administrative controls—worker rotation, implementing
proper housekeeping, proper worker training.
5. Programs and Policies
• When hazards cannot be removed through engineering or
administrative controls, the use of PPE becomes the best
method for protection.
• Creating a program to introduce PPE, both written policies
and enforcement measures are important.
• Management and the work force should embrace the use
of PPE.
6. Types of PPE and Coverage Area
• Head protection
• Eye and face protection
• Hearing protection
• Fall arrest protection
• Respiratory protection
• Hand and arm protection
• Protective footwear
• Special work clothing
7. Program to Introduce PPE
• Assessments of hazards in the workplace are conducted
to determine the need for PPE to protect workers.
• Management should complete the following:
1. Write a policy on usage of the PPE and communicate it to the
employees.
2. Select the proper equipment.
3. Implement a thorough training program to make certain
employees know the correct use and maintenance of their
equipment.
4. Enforce the use of PPE.
8. Policy
• The written program should include a policy, hazard
assessment or PPE-needs assessment, selection of PPE
to be used, worker training and motivation in use of PPE,
and enforcement of company PPE policy.
• The policy should clearly state the need for and use of
PPE.
• It also should identify any exceptions and limitations to the
use of PPE.
• Details of the specific work conditions are often stated.
• Management must follow the same safety rules.
9. Selection of Proper Equipment
• Except for respiratory protection devices, few items of
PPE are tested according to performance specifications
and approved by impartial or third-party examiners.
• ANSI standards
• National Institute for Occupational Safety and Health (NIOSH)
Certified Equipment List
• SEI (Safety Equipment Institute)
• developed policies for third-party certification of safety equipment
• existing certification programs include eye and face protection,
emergency eyewash and shower equipment, firefighters’ helmets,
protective headwear, protective footwear, and personal fall protection
10. Proper Training
• PPE training programs should include:
• description of what hazards and/or conditions exist in the
workplace environment
• explanation of what has been done, can/cannot be done about
hazards
• explanation of why a certain type of PPE has been selected
• discuss the capabilities and/or limitations of PPE
• demonstrate the use, adjust, or fit of the PPE
11. Proper Training (Cont.)
• Practice use of the PPE.
• Explain the company policy and its enforcement.
• Discuss how to deal with emergencies.
• Discuss how PPE will be paid for, maintained, repaired,
cleaned, and any other details.
• Use of PPE must be enforced including disciplinary
measures.
• 29 CFR 1910.132-138
• establishes the employer’s obligation to provide PPE to employees
12. Head Protection (Safety Helmets)
• Used to protect the head from:
• impacts caused by falling objects
• to protect from electrical shock and burns
• to prevent entanglement of hair or the head in machinery
• ANSI standard Z89.1-2003
• A helmet is a device that is worn to provide protection for the head
from, impact, flying particles, electrical shock, and must contain a
suitable harness.
13. Helmet Classifications
• Type 1—helmet with full brim not < 1¼ inches wide to
reduce the force of impact to top of head
• Type 2—helmets intended to reduce the force of impact
from a blow to the sides or top of head
• Class G (general)—general service, limited voltage
protection (impact hazards, heavy industrial settings—
manufacturing and construction)
• Class E (electrical)—utility service, high-voltage protection
—falling or flying objects, and high-voltage shock and
burns
• Class C (conductive)—special service, no voltage
protection—comfort, bump of head, no electrical
protection
14. Head Protection (Cont.)
• Bump caps—not a helmet or hard hat; no standards
except manufacturer’s specification; impact from bumping
into stationary objects or from cleaning in tight spaces,
and not from overhead operations; risk of potential injury
is limited. Not to replace helmets required by Z89.1.
• Hair protection—employees with long hair or beards must
be protected from contact with moving parts. Caps should
cover the entire head of hair. Modifications per job and
hazards.
15. Head Protection (Cont.)
• Maintenance:
• Inspect helmets for cracks, signs of impact or rough treatment,
and wear that might reduce the degree of safety originally
provided.
• Exposure to ultraviolet light, chemicals, or welding may decrease
the life expectancy.
• Discard and replace all helmets which show signs of deterioration.
• Check product service life and replace as necessary.
• DO NOT PAINT OR ALTER HARD HATS WITH LABELS AND
STICKERS—potential to cover cracks or defects.
• Clean and store helmets appropriately after use.
16. Eye Protection
• Use to protect the eyes from exposures caused by:
• physical agents
• chemical agents
• radiation
17. Eye and Face Protection
• About 70% of all eye injuries result from flying or falling
foreign objects.
• Contact with harmful substances, chemicals, and so forth
causes more than 20% of injuries.
• Foreign bodies in the eye occurred in about 60% of the
cases.
• Eye and Face Protection Standard, ANSI z87.1-1989 sets
comprehensive standards to be used for protective eye
and face devices in OSHA regulations.
• Most current standard is ANSI Z87.1-2003.
18. Eye Protection (Cont.)
• Selection of impact-resistant eyewear includes:
• level of protection afforded
• comfort with which they can be worn
• ease of repair
• Proper eye protection devices should be selected and
their use enforced to provide maximum protection for the
degree of hazard involved.
• Face shields are not recommended as eye protection
from impact (ANSI Z87.1).
• Goggles should protect the eye socket.
19. Eye Protection (Cont.)
• Contact lenses
• Prevent Blindness America
• …Contact lens wearers must conform to the prerogatives and directions
of management regarding contact lens use. When the work environment
entails exposures to chemicals, vapors, splashes, radiant or intense
heat, molten metals or a highly particulate atmosphere, contact lens use
should be restricted accordingly.
• American Optometric Association
• Contact lenses may be worn in some hazardous environments with
appropriate covering safety eyewear. Contact lenses themselves do not
provide eye protection in the industrial sense.
20. Face Protection
• Face shields should be worn over suitable basic eye
protection.
• A variety of face shields will protect the face and neck
from flying particles, sprays of hazardous liquids, splashes
of molten metal, and other hot solutions.
• Provide antiglare protection where required.
• Materials should combine:
• mechanical strength
• light weight
• non-irritation to skin
• withstand frequent disinfecting operations
21. Face Protection (Cont.)
• Used to protect the face and neck from:
• flying particles
• sprays of hazardous liquids
• splashes of molten metal
• hot solutions
22. Face Protection (Cont.)
• Acid hoods and chemical goggles:
• Protection from acids, alkalis, or other hazardous liquids
• Chemical hood may be worn with and without ventilation in addition
to protective eyewear.
• Laser beam protection
• Lasers produce monochromatic, high-intensity light beams,
frequently capable of causing significant eye damage.
• Laser goggles, spectacles, or eye shield are used.
• Welding
• Radiant energies of ultraviolet, visible and infrared bands require
worker protection.
23. Hearing Protection
• Used to protect the ear from damaging sounds which may
cause temporary or permanent hearing loss
• NIHL (noise-induced hearing loss)—slowly developing
hearing loss over a long period (years) resulting from
exposure to continuous or intermittent loud noise
• Occupational acoustic trauma results from single
exposure to sudden burst of sound
• Hearing conservation programs for employees exposed to
excessive noise mandated by OSHA
24. Hearing Protection (Cont.)
• Occupational noise-induced hearing loss characteristics:
• always sensorineural, affecting the hair cells in the inner ear
• low-frequency limits: about 40 db
• high frequency limits: about 75 db
• if noise is discontinued, no significant further loss
• as hearing threshold increases, rate of loss decreases
• earliest damage to inner ears reflects a loss at 3000, 4000 and
6000 hz and less at 500, 1000, and 2000 hz.
• stable exposure conditions will reach a maximal level in 10–15
years
25. Hearing Protection (Cont.)
OSHA Hearing Conservation Standard (29 CFR 1910.95,
Occupational Noise Exposure) requires a hearing
conservation program for employees exposed to
excessive noise (85 dBA for an 8-hour time-weighted
average).
OSHA Permissible Limit of 90 dBA for an 8-hour time-
weighted average.
Exposure to 115 dBA is permitted for 15 minutes for 8-
hour day. No exposure above 115 dBA per 1926.52.
Must have an accurate knowledge of the noise levels that
pose a hazard to workers before mandating a hearing
protection program.
26. Hearing Protection (Cont.)
U.S. Environmental Protection Agency (EPA) provides
noise reduction ratings (NRR) for protective devices.
Four types of hearing protection
enclosure (helmets)
aural (ear inserts)
most commonly used and cheapest
include formable, custom molded, and molded types
superaural (canal caps)
circumaural (earmuffs)
27. Fall Arrest Systems
• Means of preventing workers from experiencing
disastrous falls from elevations
• Classifications:
• Passive: requires no action on worker’s part (personnel and debris nets)
• Active: requires some manipulation on worker’s part (harnesses,
lanyards, anchor points, fall arresters, shock absorbers)
• Systems needed:
• over 4 ft guardrail or midrail, per 29 CFR 1910.23
• over 6 ft guardrail per 29 CFR 1926.500
• over 25 ft overwater per 29 CFR 1926.105
• assess vertical versus horizontal work requirements
• consider rescue methods, backup systems, dry or wet, number of
workers, and environmental factors
28. Fall Arrest Systems (Cont.)
• Elements of a successful fall arrest program:
• policy and enforcement of fall protection
• worker qualification at elevated conditions
• training on fall arrest system
• selection of equipment
• installation of equipment
• equipment maintenance and inspection
• rescue procedures
• job survey analysis
30. Fall Protection
• Components of the active fall arrest systems:
• anchor/anchorage points
• lanyard
• body belts
• harnesses
• retracting lifeline devices
• lifelines
• lifeline (“dropline”)
• hardware connectors
• fall arresters and shock absorbers
• fall arresting system and work positioning system
• restraint system
31. Fall Protection (Cont.)
• Equipment inspection and maintenance
• Utilize the manufacturer’s instructions per preventive maintenance
and inspection.
• Check for damage before each use.
• Equipment must be removed from service after exposure to the
forces of arresting a fall or equivalent forces.
• Clean arrest equipment regularly to keep it in good condition and
top working order.
• Store away from bright light and UV light and maintain in a cool dry
place. Check for fading of colors, which may indicate damage or
potential failure.
32. Respiratory Protection
• Employers are required to use engineering and work
practice controls as a primary means to protect an
employee’s health from contaminated or oxygen-
deficient air.
• If controls are not technologically or economically
feasible, an employer may rely upon a respiratory
protection program to protect employees.
33. Respiratory Protection Program
• written respiratory protection program containing workplace-
specific hazard to protect worker (29 cfr 1910.134)
• procedures for selecting respirators
• medical evaluations of employees required to use
respirators
• fit-testing procedures for tight-fitting respirators
• use of respirators in routine and emergency situations
• procedures and schedules for cleaning, disinfecting, storing,
inspecting, repairing, and maintenance
• procedures to ensure adequate air quality and quantity
• training for respiratory hazards, limitations, use and
maintenance
• audit program for effectiveness
34. Selecting Proper Respiratory
Protection
• The selection involves three steps:
1. identify the hazard
2. evaluate the hazard
3. select appropriate, approved respiratory equipment based on the
first two steps
36. Respiratory Protection
• Engineering and administrative controls
• Fit, selection, training
• Identifying hazards—dust, fumes, mists, vapors, etc.
• Evaluation of hazard—walk-through, measurements,
physical/chemical nature, needed or not needed
• NIOSH along with Assigned Protection Factor (APF)
designate the level of effectiveness a respirator provides
to a wearer.
37. Types of Respirators
• Air supplying respirator—independent source of air (open
circuit or closed circuit) provides clean breathing air
• Air-purifying, can only be used in atmospheres that
contain adequate (19.5% or greater) oxygen.
• There are 3 kinds: those which remove contaminants from the air
via filter or cartridge for use with gases/vapors, particulate filters,
and gas masks
• Service Life Indicators for effective use—end-of-service-life-
indicators (ESLIs) or change out schedule
38. Air-Supplying Respirators
• Classified according to the way air is supplied and
regulated
• self-contained breathing apparatus (air or oxygen is carried in a
tank on the worker’s back)
• supplied-air respirators (compressed air from a stationary source is
supplied through a high-pressure hose connected to the respirator)
• combination self-contained and supplied-air respirators
39. Air Purifying
• These respirators can purify the air of gases, vapors, and
particulates but do not supply clean breathing air.
• They must not be used in oxygen-deficient atmospheres.
• The useful life is limited by:
• the concentration of the air contaminant
• the breathing demand of the wearer
• the removal capacity of the air-purifying medium
40. Fitting Respirators
• Fit tests must be performed prior to respirator use.
• Fit-testing is required for all employees when:
• using negative or positive pressure tight-fitting respirators
• respirators are required by OSHA
• employer requires the use of respirator
• Storage, maintenance, cleaning, medical
41. Fitting Respirators (Cont.)
• Fit tests must be repeated:
• at least annually
• whenever a different respirator facepiece is used
• whenever a change in the employee’s physical condition could
affect the use of the respirator
• Qualitative tests: wearer is challenged to ensure a tight fit
against irritant or odorous chemical.
• Pros: convenient, quick, easy, and low cost.
Con: not reliable
• Quantitative tests: wearer challenged in chamber to test
atmosphere during typical movements. Calculation of
safety factors to ensure no leakage.
• Pros: objective, provides protection in IDLH or toxic atmospheres
• Cons: costly, requires trained personnel to conduct test.
42. Respirator Storage and
Maintenance
• Respirators should be stored to protect from dust,
sunlight, heat, extreme cold, excessive moisture, and
damaging chemicals.
• Before storage, clean and wash per directions, and
sanitize.
• Maintain all respirators.
• Perform inspections of all components and parts prior to each use
as well as daily and weekly.
• Repair or remove from service any defective respirators.
43. Protective Clothing
• Gloves: consider tools used to perform assigned tasks
• cotton, leather: used primarily in construction and industrial
applications
• Latex, nitrile, neoprene, etc.: used for hazardous chemicals
• Hand/arm leathers: protect against hot, rough objects
• heavier and more flexible than gloves
• Impervious, natural rubbers, latex, olefin: protect against
dusts, vapors, and moisture of hazardous substances and
corrosive liquids
• Follow disposal/washing procedures
• Workers should shower or at a minimum wash hands
appropriately.
• Properly launder prior to reuse or dispose of contaminated PPE
equipment.
44. Protective Footwear
• Classified according to its ability to meet the
requirements for compression resistance and
impact resistance.
• Examples:
• metatarsal
• conductive
• electrical hazard
• static dissipative
• sole puncture resistant
• foundry
45. Footwear Standards
• ASTM F2413-05 Standard Specifications for Performance
Requirements for Foot Protection
• OSHA Standard 29 CFR 1910.132 General
Requirements for Personal Protective Equipment
• OSHA Standard 29 CFR 1910.136 Foot Protection
• OSHA standards contain hazard assessment and foot
protection requirements for employees whose work
presents hazards to their feet.
• Hazards include: objects falling onto or placed on foot,
objects rolling over foot, sharp objects penetrating sole of
footwear, static electricity, contact with energized
conductors.
46. Additional Protective
Footwear Features
• Additional features provided by many manufacturers which
are not required by standards:
• waterproofing
• chemical resistance
• insulation
47. Special Work Clothing
• Clothing which helps to minimize the effects of job
exposures to:
• heat
• molten metal
• corrosive chemicals
• cold temperatures
• body impact
• cuts
• other specialized hazards
48. Care and Use of
Personal Protective Devices
• Do not alter or change the device.
• Use the device for the purpose it was intended.
• Dispose of devices that show signs of wear and tear.
• Use the manufacturer’s suggestions for cleaning devices
that can be reused.
