FOREWORD

ELEVATOR WORLD, the National Elevator Industry, Inc.

(NEII) and the members of the NEII Field Employee Safety
Committee assume no responsibility for either safety condi-
tions or compliance with legal requirements at any particular
jobsite. The safety practices and procedures spelled out within
this Elevator Industry Field Employees Safety Handbook are
based upon experiences of field personnel and research
conducted by many safety specialists. These practices and
procedures are not only common-sense precautions to
eliminate hazards, prevent incidents and avoid injuries; they
are also the recommended methods by which to carry out
and complete a job safely. This handbook should be carried
and consulted in order for safety to become a way of life
on every construction or maintenance job. Because elevator
and escalator components vary from company to company,
and because unique or unusual jobsite conditions may exist,
it is not possible for a handbook on general safety methods
and practices to deal with every possible hazard which may
be present at every jobsite. For that reason, each user of this
handbook must carefully observe the safety conditions at
each jobsite to make certain there are no conditions which
would require safety precautions beyond those described in
this handbook. Although it does not purport to encompass or
override the laws or regulations of any government body,
however, changes in law, regulations and/or interpretations
may invalidate certain portions. It is the responsibility of the
employer to be familiar with all appropriate State and Federal
regulations. Written and edited by the NEII Safety Committee
in cooperation with Elevator World, Inc. Published by and
available from Elevator World, Inc., P.O. Box 6507, Mobile,
Alabama 36660. This handbook is also available online at
[Link] Revisions are kept current
online. Copyright 2015. All rights reserved by Elevator
World, Inc.

2015 Safety Handbook 1

 PREFACE

This Handbook is designed to provide a resource for

safety information that the elevator industry field employees
shall use to help prevent injuries and illnesses resulting from
unsafe acts and/or conditions.
The intent of this Handbook is to promote jobsite safety
through adherence to OSHA safety regulations and by defin-
ing recommended safe work practices affecting the elevator
industry and other trades working with us. Directions to field
personnel affecting the general public are incidental
to the purpose of the Handbook and therefore should not be
construed to be complete as to the proper way to safeguard
the public. This Handbook is also not intended to be used as
a guide, standard or code on the installation, repair or servic-
ing of building transportation systems.
This Handbook is intended to augment a company
safety program. It is not intended to be used as the total
company safety program (policy).
All elevator industry employees should familiarize them-
selves with the contents of this Handbook. The safety proce-
dures apply to all persons working on elevator, escalator,
moving walk, material lift and dumbwaiter equipment directly
employed by elevator companies, inspection companies and
AHJs who qualify with proper training.

2 2015 Safety Handbook

 NEII FIELD EMPLOYEE
SAFETY COMMITTEE
May 2015

Corey Ward, Chair NEII Field Employee Safety

Committee
Vice President of EHS KONE Americas

Kevin Brinkman, Secretary NEII Field Employee Safety

Committee
Code and Safety Director to NEII

Fred Wilt, Safety Manager, Technical Compliance

Schindler Elevator Corporation

Bob Rodriguez, Environmental Health & Safety

Otis Elevator Corp

Ivan Andrews, Manager, Quality Assurance & Field

Development
Mitsubishi Electric U.S., Inc.

Larry Leadingham, Director of Safety

ThyssenKrupp Elevator Corporation

Kent Lloyd, Owner

Abell Elevator International, Inc

L.J. Fleetwood, National Safety Coordinator

Fujitec America, Inc.

Tim Daly
Liaison from the National Elevator Industry Education
Program (NEIEP)

Raymond Downs
Liaison from the National Association of Elevator
Contractors (NAEC)

Ricia Hendrick, Liaison from Elevator World, Inc.

2015 Safety Handbook 3

 TABLE OF CONTENTS
Section 1 General Safety . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Employee Responsibilities . . . . . . . . . . . . . . . . . 8
1.2 Additional Safety Responsibilities of the
Mechanic/Mechanic-in-Charge . . . . . . . . . . . . . 13
1.3 Emergency Evacuation Procedures . . . . . . . . . 16
Section 2 Safety Inspections . . . . . . . . . . . . . . . . . . 17
2.1 Need for Routine Safety Inspections . . . . . . . . 17
2.2 Inspecting for Hazards . . . . . . . . . . . . . . . . . . . 17
2.3 Pre-startup Safety Survey . . . . . . . . . . . . . . . . 19
Section 3 Personal Protective Equipment (PPE) . . . . 22
3.1 Proper Clothing . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 Eye and Face Protection . . . . . . . . . . . . . . . . . 23
3.3 Occupational Head Protection . . . . . . . . . . . . . 25
3.4 Occupational Foot Protection . . . . . . . . . . . . . . 25
3.5 Hearing Protection . . . . . . . . . . . . . . . . . . . . . . 26
3.6 Personal Fall Arrest Equipment . . . . . . . . . . . . 26
3.7 Hand Protection (Gloves) . . . . . . . . . . . . . . . . . 27
3.8 Respiratory Protection . . . . . . . . . . . . . . . . . . . 27
Section 4 Fall Protection . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Personal Fall-Arrest System . . . . . . . . . . . . . . . 29
4.2 Guardrail Systems . . . . . . . . . . . . . . . . . . . . . . 33
4.3 Escalator/Moving Walk Barricades . . . . . . . . . . 38
4.4 Elevator Maintenance Barricades . . . . . . . . . . . 39
Section 5 Electrical Safety . . . . . . . . . . . . . . . . . . . . 40
5.1 General Precautions . . . . . . . . . . . . . . . . . . . . . 40
5.2 Meter Usage Safety Checklist . . . . . . . . . . . . . 42
5.3 Energized Circuit Troubleshooting Checklist . . 43
Section 6 Proper Use of Jumpers . . . . . . . . . . . . . . 45
6.1 Maintenance and Troubleshooting . . . . . . . . . . 46
6.2 Modernization and New Construction . . . . . . . 47
6.3 Door Bypass Procedure . . . . . . . . . . . . . . . . . . 48
Section 7 Lockout and Tagout . . . . . . . . . . . . . . . . . 49
7.1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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 7.2 Supervisory/Emergency Removal
of Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . 53
7.3 Lockout/Tagout Procedures for
Escalators and Moving Walks . . . . . . . . . . . . . 54
7.4 MRL Car Movement Locking Devices . . . . . . . 54
Section 8 Hoistways and Machine Rooms . . . . . . . 56
8.1 Hoistway Access Safety . . . . . . . . . . . . . . . . . . 56
8.2 Pit Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.3 Hoistway Screening . . . . . . . . . . . . . . . . . . . . . 67
8.4 Overhead Protection . . . . . . . . . . . . . . . . . . . . . 68
8.5 Machine Room Safety . . . . . . . . . . . . . . . . . . . 69
Section 9 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.1 Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
9.2 Portable Electric Tools and Lights . . . . . . . . . . 71
9.3 Powder Actuated Tools . . . . . . . . . . . . . . . . . . . 73
Section 10 Portable Ladders/Scaffolds/Stationary
Work Platforms . . . . . . . . . . . . . . . . . . . . . . . . 74
10.1 Scaffolds/Stationary Work Platforms . . . . . . . . 74
10.2 Portable Ladders . . . . . . . . . . . . . . . . . . . . . . . 75
Section 11 Moving Work Platforms . . . . . . . . . . . . . 78
11.1 Running Platforms . . . . . . . . . . . . . . . . . . . . . . 78
11.2 Temporary Cars . . . . . . . . . . . . . . . . . . . . . . . . 79
11.3 False Cars and Other Devices
Used in the Hoistway . . . . . . . . . . . . . . . . . . . . 79
Section 12 Material Handling . . . . . . . . . . . . . . . . . . 85
12.1 Manual Handling Lifting of Material . . . . . . . . . 85
12.2 Ramping and Blocking of Material . . . . . . . . . . 89
12.3 Hoisting and Rigging . . . . . . . . . . . . . . . . . . . . 89
12.4 Wire Rope Fastenings . . . . . . . . . . . . . . . . . . . 95
12.5 Chain Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
12.6 Slings and Hitches . . . . . . . . . . . . . . . . . . . . . . 96
12.7 Crosby Lifting Guide . . . . . . . . . . . . . . . . . . . . . 97
12.8 Synthetic Webbing Slings -
Selection, Use and Maintenance . . . . . . . . . . . 119

2015 Safety Handbook 5

 12.9 Beam Clamps . . . . . . . . . . . . . . . . . . . . . . . . . 124
12.10 Manila Rope . . . . . . . . . . . . . . . . . . . . . . . . . . 127
12.11 Synthetic Rope . . . . . . . . . . . . . . . . . . . . . . . . 127
12.12 Knots are Weak . . . . . . . . . . . . . . . . . . . . . . . 129
Section 13 Welding, Cutting and Soldering . . . . . 135
13.1 General Precautions . . . . . . . . . . . . . . . . . . . . 135
13.2 Acetylene, Oxygen and Other
Pressurized Fuel Cylinders . . . . . . . . . . . . . . . 137
13.3 Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Section 14 Hazard Communications (HAZCOM) . . . 139
14.1 Working with Chemicals . . . . . . . . . . . . . . . . . 139
14.2 Oils and Grease . . . . . . . . . . . . . . . . . . . . . . . 141
14.3 Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
14.4 Babbiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
14.5 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
14.6 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
14.7 Asbestos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
14.8 Flammable Liquids and Solvents . . . . . . . . . . 146
14.9 Carbon Dust . . . . . . . . . . . . . . . . . . . . . . . . . . 147
14.10 Sulfuric Acid Type Batteries . . . . . . . . . . . . . . 147
14.11 Radio Frequency (RF) Awareness . . . . . . . . . 150
Section 15 Inclined Elevators . . . . . . . . . . . . . . . . . 151
Section 16 Escalators and Moving Walks . . . . . . . 152
Section 17 Dumbwaiters . . . . . . . . . . . . . . . . . . . . . 155
Section 18 Job Hazard Assessment . . . . . . . . . . . . 157
18.1 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
18.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
18.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
18.4 Foot and Leg Protection . . . . . . . . . . . . . . . . . 158
18.5 Head Protection . . . . . . . . . . . . . . . . . . . . . . . 158
18.6 Hearing Protection . . . . . . . . . . . . . . . . . . . . . 158
18.7 Eye and Face Protection . . . . . . . . . . . . . . . . 159
18.8 Respiratory Protection . . . . . . . . . . . . . . . . . . 159
18.9 Personal Fall Arrest System . . . . . . . . . . . . . 159

6 2015 Safety Handbook

 18.10 Hand Protection . . . . . . . . . . . . . . . . . . . . . . 160
18.11 OSHA Regulations . . . . . . . . . . . . . . . . . . . . 160
18.12 Assessing Workplace Hazards . . . . . . . . . . . 160
18.13 Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Section 19 Driving and Vehicle Safety . . . . . . . . . 164
19.1 Recognizing Hazards . . . . . . . . . . . . . . . . . . 164
19.2 Alcohol/Drug Use . . . . . . . . . . . . . . . . . . . . . 164
19.3 Safety Belts are for Everyone . . . . . . . . . . . . 164
19.4 Vehicle Maintenance . . . . . . . . . . . . . . . . . . . 165
19.5 Communication Devices . . . . . . . . . . . . . . . . 165
Section 20 Substance Abuse . . . . . . . . . . . . . . . . 166
Section 21 Glossary of Terms . . . . . . . . . . . . . . . . 167
Section 22 Appendices . . . . . . . . . . . . . . . . . . . . . 173
22.1 Metric Conversion . . . . . . . . . . . . . . . . . . . . . 173
22.2 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
22.3 Timber, Beams andPlanks . . . . . . . . . . . . . . 181

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

2015 Safety Handbook 7

Section 1
GENERAL SAFETY

1.1 Employee Responsibilities

You shall familiarize yourself with the safety proceduresout-
lined throughout this safety handbook. The following safety
rules shall receive special attention and are not necessarily
all inclusive:
(a) In all operations, when removing or moving any compo-
nent or equipment, make sure that the effect of that
activity on the entire elevator or escalator system is
taken into consideration.
(b) Employees shall not work when their ability or alertness
is impaired by fatigue, intoxicating beverages, illegal or
prescription or over-the-counter drugs, or any other
physical or emotional cause that might expose the
employee or others to injury. (See Section 20)
(c) Practical jokes, horseplay, throwing of tools or fighting
on the job are forbidden.
(d) Weapons, explosives and illegal substances on the job
are forbidden.
(e) Mechanics arriving at a location to perform service or
repairs shall alert the owner or building management
and resident/route mechanic and place Company-
approved Out of Service signs on a single unit landing
call buttons before any work begins. (Building manage-
ment may require signature in log.)
(f) Secure the equipment (elevators, escalators, dumbwaiters,
moving walks, platform lifts and chair lifts) from the riding
public when performing any adjustments or work. Ensure
no one is in the car, close the doors and prevent the
doors from operating while working on the elevator.
(g) Before working on equipment, tuck loose-fitting clothing
and confine long hair. Remove all jewelry.

8 2015 Safety Handbook

(h) When unexpected movement of the equipment presents a
safety hazard while performing tasks on any parts that
move, the equipment shall be made inoperative by use
of lockout and tagout. See Lockout and Tagout
Procedure, Section 7.
(i) The use of personal entertainment devices (radios, tape
or CD players, etc.) are prohibited on all jobsites.
(j) Communication devices should be used with caution
around controllers because they may affect the opera-
tion of the elevator.
(k) If two-way radios are used, ensure your communication
channels are clear so they are not interfered with by
other trades. Be aware of potential delays in communi-
cations when using certain communication devices.
(l) Do not wear tool belts or carry tools in pockets.
(m) Keep the work area clean. Notify the General Contractor
or Building Manager of problems in common areas.
(n) Never use wiping cloths on or near moving and/or rotat-
ing equipment.
(o) Oily or chemically-soaked rags shall be kept in company-
approved containers, removed from the jobsite periodi-
cally and disposed of properly.
(p) If you are required to clean the pit, car top, machine
room floor or other apparatus, take precautions to avoid
lacerations or punctures from sharp objects by wearing
suitable work gloves and using a broom and shovel, or
dust pan, to pick up debris.
(q) Remove or bend all protruding nails.
(r) Work areas, ramps, runways, corridors, stairwells, offices,
shops and storage areas must be well-lit. Notify the
responsible party and your Superintendent/Manager if
lighting is inadequate.
(s) Do not work without adequate light. If there is inadequate
light, use a grounded portable light with a suitable,
non-conductive or grounded lamp guard and reflector.

2015 Safety Handbook 9

(t) Do not walk up or down stairways with hands in pockets.
Never run on stairs. Handrails must be provided and
used. Filler boards shall be in place on unfinished stairs.
Be alert for tripping hazards, especially if carrying tools or
materials.
(u) Do not run extension cords in stairwells if they will cause a
tripping hazard.
(v) Open-flame heaters shall not be used for space heating
of shanties, machine rooms or pits unless proper and approved
venting is provided and local codes are adhered to.
(w) When uncoiling rope, cable or wire, do not stand within the coil.
(x) Never slide, swing or climb on cables, ropes or
guiderails.
(y) Never drop objects down the hoistway. A rope shall be
used to safely lower objects.
(z) Observe and obey all safety signs. Every sign serves a
purpose. They are for your safety and the safety of others.
If a sign is no longer necessary, it shall be removed.
(aa) Administer first-aid only if you have been trained to do
so, and never exceed your level of training.
(ab) Do not cleanup spilled body fluids (blood, vomit, etc.) or
material with body fluids unless you have received the
appropriate training and vaccinations as required by
OSHA (29 CFR 1910.1030), or any applicable local
regulations. If you have received training and have been
offered the applicable vaccinations and personal protec-
tive equipment, then assume contamination in handling
any body fluids or material potentially contaminated with
body fluids. All cleanup activities shall be conducted in
accordance with your company Exposure Control Plan.
If you have been accidentally exposed to body fluids that
may contain bloodborne pathogens, contact your appli-
cable company medical provider as soon as possible.

10 2015 Safety Handbook

(ac) Report every injury to your Supervisor immediately (no matter
how trivial) in accordance with company policy and procedure.
(ad) The employee shall know the hazards and safe-use
procedures associated with the materials and/or chemi-
cals the employee is using. This information is available
on the Safety Data Sheets (SDS) provided by the
Company. See Section 14 Hazard Communications for
additional information. All materials and chemicals used
shall be company-approved with MSDSs sheets.
Improper use could result in injury or illness.
(ae) Some elevators may be located near operations with
process hazards or work environments that may be
potentially hazardous in an emergency, or as part of the
customers day-to-day operation. Such elevators may
be located in petrochemical plants, oil refineries, paper
mills, nuclear plants and similar facilities. In such facili-
ties the elevator pit/hoistway may be classified and/or
labeled as a permit-required confined space. Do not
enter the pit/hoistway until you have consulted your
Superintendent/ Manager.
(af) On modernization, when removing old material from
elevator platforms, make sure counter balance is properly
adjusted before proceeding.
(ag) Rotating equipment can be dangerous. Be aware of
your surroundings and be prepared for sudden start-
up of the equipment. (See Section 7)
(ai) Hydraulic oil may be hot and can cause severe burns.
(aj) Safety tests shall be performed in accordance with the
procedures specified in the ASME A17.2 Guide for
Inspection of Elevators, Escalators and Moving Walks,
(formerly Inspector Manual for Elevators).
(ak) Before equipment is placed back in service, be sure all
locks and tags have been removed and account for any

2015 Safety Handbook 11

 jumpers used. All door and safety circuits shall be tested
to ensure they are operating.
(al) Before leaving the building, if the car is returned to ser-
vice, remove all Out of Service signs. Checkout with
building management.
(am) Do not ride or permit anyone else to ride in or on top of
the car during safety and buffer tests.
(an) Do not allow other trades to work in the hoistway above
and below you.
(ao) Never look at an electric welding arc without proper eye
protection. See Section 3.2.
(ap) Never work in the hoistway below welding or cutting opera-
tions.
(aq) Dont work in an area where a gasoline engine is run-
ning unless properly vented. A gasoline engine gives off
deadly carbon monoxide gas.
(ar) Dont work in an area where propane heaters are used
unless properly vented.
(as) Never leave an open hoistway door unguarded. Before
working on an elevator with the hoistway door open
place a barrier in front of the entrance. See Section 8.
(at) If you have to get at something that is higher than you
can reach, use a ladder. See Section 10. Do not stand
on overturned buckets, crates, chairs, etc.
(au) Be careful of tripping and head bumping hazards.
(av) Never clean or lubricate ropes with a hand held rag.
(aw) Never work from a hoistway divider beam.
(ax) Where exposed to imminent danger, vacate the area
immediately and contact your supervisor.
(ay) Whenever accessing the hoistway, cab or cartop, verify
that the elevator is there prior to access. Follow 6 inch
rule See Section 8.1.

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1.2 Additional Safety Responsibilities
of the Mechanic/Mechanic-in-Charge

The Mechanic/Mechanic-In-Charge is the principal inter-

face with Company Management to ensure that the work is
performed in accordance with the company safety policy. In
fulfilling this responsibility, the Mechanic/Mechanic-In-Charge
shall take all practical steps to be sure that the work is per-
formed with due regard for safety. Unsafe acts, unsafe condi-
tions, accidents or injuries should be reported to a
Superintendent or other member of management immediately.
To keep operations safe, the following are some examples of
the principle job requirements of the Mechanic/ Mechanic-In-
Charge:
(a) Determine that their Apprentice(s)/Helper(s) fully
understand the safety requirements and that they
accept responsibility for the safety of themselves, their
fellow workers, the jobsite, and equipment.
(b) Ensure that all equipment, work areas, and access to
work areas where Elevator Company work is per-
formed are inspected for any unsafe conditions which
could cause injuries or property damage before com-
mencement of work.
(c) Take steps to correct all unsafe conditions or practices
that are under the control of the Company.
R - Recognize Hazards
E - Evaluate Hazards
C - Control Hazards
(d) When it is the responsibility of others to correct unsafe
conditions, notify those responsible, (i.e., Building
Owner, Project Manager, General Contractor) verbally
and/or in writing per company policy. Also notify your
Superintendent/Manager that such unsafe conditions
exist. Avoid the area until hazard(s) is removed.
(e) Whenever unsafe practices by workers of other trades are
observed that could effect personal safety or property

2015 Safety Handbook 13

 damage, immediately notify your supervisor and report
such practices, verbally and in writing, maintaining a
copy, to:
(1) the Responsible person at the jobsite and
(2) the Elevator Company Superintendent/Manager.
(f) When work must be performed or materials stored in
areas accessible to the public, install proper barricades,
warning signs, lights, etc.
(g) Keep unauthorized persons out of areas where work is
being performed, or where Company material is stored.
(h) Be sure all employees know the hazards of the type of
work to be performed.
(i) Do not work or allow any employee to work when their
ability or alertness is impaired by fatigue, intoxicating
beverages, illegal or prescription drugs, or any other
physical cause that might expose the employee or oth-
ers to injury and notify your Superintendent/ Manager
immediately.
(j) Maintain the Company Hazard Communication (HAZCOM)
program and Safety Data Sheets (SDSs) as appropriate.
(See Section 14.)
(k) Before leaving the jobsite for meals, at quitting time, or
for any other reason, determine the whereabouts of
each person on the crew(s) present on the jobsite.
(l) Never allow Company equipment to be loaned to, bor-
rowed or used by anyone other than Company personnel
unless authorized by your Superintendent/ Manager.
(m) Never allow non-Company personnel or non-Company
material to be carried on false cars or incomplete ele-
vators, escalators, or moving walks unless your
Superintendent/Managers approval has been obtained.
(n) Make sure that all tools, ladders, hoists, personal pro-
tective equipment, etc. are inspected for defects. Tag

14 2015 Safety Handbook

 defective equipment and remove from use and from
jobsite. Return for repair or replacement. Maintain com-
pany log when required.
(o) Conduct and document jobsite Safety Meetings (Toolbox
Talks) in compliance with Company policy.
(p) Ensure the following items are posted as required:
(1) OSHA material i.e., Federal & State posters, includ-
ing copies of any citations issued at that jobsite.
(2) Location of first aid station and telephone for medical
treatment, ambulance, fire department and police in
aconspicuous place.
(3) Evacuation, fire and other emergency procedures
are posted and meeting areas outside buildings are
designated when evacuation is required.
(q) A company-approved first-aid kit shall be on every job
(construction, modernization and major repair) and kits
shall be periodically checked and refilled as required.
(r) All employees are responsible for their own safety and the
safety of co-workers. Report violations of the Companys
Safety policies to your Supervisor/Manager.
(s) Notify your Superintendent/Manager or Safety
Department before proceeding with any inspection
by local, state or federal government agency.

1.3 Emergency Evacuation Procedures

(a) Upon entering any jobsite or building familiarize your-

self with the emergency exit route and evacuation pro-
cedure established by management of the facility.
(b) React immediately and do not assume any alarm is
false or a test.
1. Remain Calm;
2. Secure equipment to protect the public if necessary;

2015 Safety Handbook 15

 3. Do not retrieve tools or personal belongings; and
4. Proceed to the designated assembly area.
(c) Upon evacuation of the facility immediately contact
your supervisor or branch office for further instruction
or follow your companys defined safety program.

16 2015 Safety Handbook

Section 2
SAFETY INSPECTIONS

2.1 Need for Routine Safety Inspections

Safety inspections are a must in the elevator industry and
required by OSHA regulations. Such inspections shall be
conducted periodically to identify unsafe work practices and
conditions that could injure company employees and/or the
employees of others. Reasons for normal inspections
include, but are not limited to:
(a) Normal wear and tear on such items as ropes, slings,
scaffold planks, hand tools and PPE.
(b) Defects, damage and weather conditions.
(c) Changing conditions and other trades on site.
(d) Unsafe conditions created by others.

2.2 Inspecting for Hazards

The Competent Person on the jobsite must be aware of all

potential hazards on the jobsite and take immediate correc-
tive action. The following is a list of items to consider:
o Is Company-provided information posted at jobsite (OSHA,
emergency phone numbers, warning signs, etc.)?
o Is the site clean and free of debris? Are materials stored or
stacked neatly and a safe distance away from your work area?
o Are Company-approved first-aid kits on the job? Are they
periodically checked and refilled as required?
o Are emergency first-aid responders readily available or
first-aid trained people on the job?
o Is drinking water available and container plainly marked?
o Are personnel properly wearing Company-approved personal
protective equipment when exposed to possible danger (i.e.,
gloves, work boots/shoes, hard hats, safety harnesses, safety
glasses, goggles, welding hoods, etc.)?

2015 Safety Handbook 17

o Are company fire extinguishers inspected monthly, readily
accessible and annual maintenance certificates up-to-date?
o Are ground fault circuit interrupters (GFCIs) available and
in proper use?
o Are copies of your Companys Hazard Communication
(HAZCOM) Program and MSDSs on the site?
o Are hazardous materials used (i.e., welding and cutting
equipment, etc.) stored properly?
o Are required locks and tags for locking out equipment
available and used properly?
o Are open decks, scaffolds, planking, etc., enclosed with
approved guardrails and toeboards or are employees
using approved personal fall-arrest systems?
o Are all elevator hoistways, entrances and escalator well-
ways properly barricaded with removable guardrails?
o Are floor openings covered or protected by OSHA com
pliant guardrails?
o Are all hand and power tools in safe condition and grounded
or double insulated?
o Are defective tools and equipment tagged with company-
approved tags and removed from use?
o Is hoisting and rigging equipment in good condition and
properly rated?
o Is material handling equipment in good condition and
properly rated?
o Are ladders and scaffolding in good condition and being
properly used?
o Are company-approved warning signs posted where
necessary?
o Do work and common areas have adequate lighting?
o Are there any site specific hazards i.e., chemical plants,
refineries, etc.
o Are disconnects and controllers properly labeled?

18 2015 Safety Handbook

o Does the pit have adequate guards (i.e., counterweight
guards, etc.), covers, is dry, and is there safe access and
egress?
2.3 Pre-startup Safety Survey
A safety survey should be conducted on all construction,
modernization and major repair projects prior to starting
work. The responsibility for conducting a pre-startup survey
shall be determined by the company. The following is a
sample of the items that should be included on a pre-startup
checklist.
2.3.1 Asbestos
o Customer has identified all areas containing asbestos
o Sampling has been conducted to ensure safe atmo-
sphere
o Precautions have been taken to avoid asbestos contain-
ing material
o Employees have been properly trained, according to level
of exposure
2.3.2 Lead Paint
o Customer has identified all areas containing lead paint
o Sampling has been conducted to ensure safe atmo-
sphere
o Precautions have been taken to avoid lead paint
o Employees have been properly trained, depending on
level of exposure
2.3.3 Document Requirements
o EEO, OSHA & State Posters
o Emergency phone numbers identified (i.e. fire, hospital)
o OSHA 300 log available (if required)
2.3.4 Electrical
o Wiring labeled and grounded
o Adequate power provided in areas where needed
o High voltage adequately identified and covered
o Ground Fault Circuit Interrupters (GFCI) available

2015 Safety Handbook 19

2.3.5 Fall Protection
o Type of fall protection to be used is identified
o Anchor points identified
o Barricades installed properly per handbook (removable)
2.3.6 Fire Prevention
o Fire extinguishers available
o Wood/paper products or rubbish not in pit or machine
room
o Smoking/No-smoking areas identified
2.3.7 First Aid
o Location of first aid station (or kit) identified
o Trained personnel identified
2.3.8 General
o Evaluate the location of work by other trades and
determine impact
2.3.9 Hazard Communication
o Chemical inventory list
o Containers properly labeled
o MSDSs readily available
2.3.10 Hoisting & Rigging
o Adequate equipment for job
o Equipment inspected and certified per manufacturer
recommendations
o Capacities identified (equipment and load), ensure
equipment will meet expected lifting requirements
2.3.11 Housekeeping
o General condition of work area
o Walkways clear
o Regular waste disposal schedule
o Adequate lighting
2.3.12 Ladders/Stairwells
o Access stairwells have guardrails installed

20 2015 Safety Handbook

o Stairwells properly lit
o Serviceable ladders of sufficient height are available
o Extension ladders have safety feet and extend 3 ft (914
mm) above landings
o Safe access to work areas provided
2.3.13 Material Handling
o Employees are trained to operate forklifts safely and suf-
ficient equipment is available to move material safely
(forklifts, dollies, handcarts, etc.)
o Equipment in good working condition
o Staging area for material and equipment identified
2.3.14 Scaffolds
o Proper erection is supervised and inspected by Com
petent Person
o Locking pins installed
o Equipped with baseplates
o Tied to the structure when required
o Proper planking
2.3.15 Welding
o Adequate equipment provided (if needed)
o Area identified for proper cylinder storage
o Adequate shielding is available (if needed)
o Well ventilated area identified for welding
o Properly inspected extinguisher available

2015 Safety Handbook 21

Section 3
PERSONAL PROTECTIVE EQUIPMENT (PPE)
General Requirements
Employers shall ensure that personal protective equip-
ment (for eyes, face, head, and extremities), protective cloth-
ing, respiratory devices, protective shields and barricades,
are provided, used and maintained in a sanitary and reliable
condition. All employees shall have necessary OSHA
compliant personal protective equipment with them at
all times.
Employees shall properly maintain, store, and inspect
PPE each time before use to ensure that it is in good working
order and replace as necessary (if damaged or per manufac-
turers recommendation).
To assist in evaluating required PPE for individual jobsites,
the Job Hazard Assessment Form is to be used. See Section 18.

Employee-Owned Equipment
Where employees provide their own protective equipment,
the employer shall be responsible to assure its adequacy,
including proper maintenance, and sanitation of such equipment.

3.1 Proper Clothing

(a) Do not wear shorts, tank tops or trousers with cuffs.
Long-sleeve shirts are recommended.
(b) Hand tools and other objects shall not be placed in the
pockets of trousers due to the possibility of snagging on
moving objects or contacting energized equipment.
(c) Finger rings, loose jewelry and torn clothing are hazard-
ous and shall not be worn.
(d) When working around energized equipment, conductive
jewelry, metal-framed glasses, and large belt buckles
shall be removed or protected to prevent contacting
live components.
(e) Personal protective equipment shall not be traded or
exchanged unless sanitized.

22 2015 Safety Handbook

(f) Oil free clothing shall be worn when performing welding
or cutting operations.
(g) Always wear appropriate clothing when welding, grind-
ing or working around an open flame.
3.2 Eye and Face Protection
OSHA standards require employers to provide suitable
eye and face protection based on anticipated hazards.
(a) Types of protection
(1) Safety glasses with side protection (used for most
situations).
(2) Goggles (used when dust or chemical splash haz-
ards exist).
(A) Welders Goggles
Used for gas cutting and welding operations.
(See filter lens chart for proper shade and num-
ber in Figure 3a.)
(B) Welders Shield
Used for electric arc-welding work. Lens shade
chosen as above and protected by a clear cover
glass.
(C) Face Shields
Shall be worn when entire face needs protection,
(i.e.: flying sparks; chemical splash; etc.)
(b) Employees shall wear eye and face protection equipment
when machines or operations present potential eye or
face injury from physical, chemical, or radiant agents, (i.e.:
grinding; drilling; chiseling; babbitting; welding; dusty
and windy atmosphere; etc.)
(c) Eye and face protection shall meet the requirements
specified in American National Standards Institute,
ANSI Z87.1-1989 (R1998), Practice for Occupational
and Educational Eye and Face Protection.

2015 Safety Handbook 23

(d) Eye and face protection equipment shall be kept clean
and in good repair. The use of this type equipment with
structural or optical defects shall be prohibited.
(e) Protection shall meet the following minimum require-
ments:
(1) Be adequate for the hazard.
(2) Fit snugly.
(3) Not interfere with the wearers movements.
(4) Be durable, easy to clean, and capable of
being disinfected.
(5) Be kept in good repair.
(f) The user shall be instructed regarding any limitations or
precautions indicated by the manufacturer.
(g) Non-metallic eye protection shall be worn while working
on or near electrical circuits or electrical apparatus.
Figure 3a

Filter lens shade numbers for protection

against Radiant Energy
Shade
Welding Operation
Number
Shielded metal-arc welding 1/16-, 3/32-, 1/8-,
5/32-inch diameter electrodes . . . . . . . . . . . . . . . . . 10
Gas-shielded arc welding (nonferrous) 1/16-, 3/32-, 1/8-,
5/32-inch diameter electrodes . . . . . . . . . . . . . . . . . 11
Gas-shielded arc welding (ferrous) 1/16-, 3/32-, 1/8-,
5/32-inch diameter electrodes . . . . . . . . . . . . . . . . . 12
Shielded metal arc welding (ferrous) 3/16-, 7/32-,
1/4-inch diameter electrodes . . . . . . . . . . . . . . . . . . 12
5/16-, 3/8-inch diameter electrodes . . . . . . . . . . . . . . 14
Atomic hydrogen welding . . . . . . . . . . . . . . . . . . . . . . 10-14
Carbon-arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torch brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 or 4
Light cutting, up to 1 inch . . . . . . . . . . . . . . . . . . . . . . 3 or 4
Medium cutting, 1 inch to 6 inches . . . . . . . . . . . . . . . 4 or 5
Heavy cutting, over 6 inches . . . . . . . . . . . . . . . . . . . . 5 or 6
Gas welding (light), up to 1/8-inch . . . . . . . . . . . . . . . 4 or 5
Gas welding (medium), 1/8-inch to 1/2-inch . . . . . . . . 5 or 6
Gas welding (heavy), over 1/2-inch . . . . . . . . . . . . . . 6 or 8
*General Note: 1 in. = 25.4 mm

24 2015 Safety Handbook

(h) Tinted (except yellow) and shaded eye protection
shall not be worn indoors except for welding and
cutting operations.
(i) Contact lenses are not recommended at work.

3.3 Occupational Head Protection

OSHA standards require employers to provide suitable

head protection.
(a) Employees working in areas where there is a possible
danger of head injury from impact, falling or flying
objects, or from electric shock and burns shall be pro-
tected by hard hats.
(b) Hard hats are to be worn at all times during all phases
of construction. For modernization and repair tasks in
the hoistway, hard hats are required (unless in a finished car).
(c) Hard hats shall be worn with the suspension properly fitted.
(d) Before using your hard hat, inspect it for cracks, etc.
(e) Dont store hard hat where it is exposed to direct sunlight.
(f) The application of decals, stickers, etc. is not recommended
unless required by the jobsite General Contractor. Painting
of hard hats is not permitted.

3.4 Occupational Foot Protection

Employers shall assess their employees needs based on

the type of work they perform to determine the proper work
shoe/boot for each employee. Work shoes purchased after
June 1, 2006, shall meet ASTM F2412-05 and ASTM F2413-05.
In addition Personal Protection-Protective Footwear shall con-
form to the following requirements:
(a) Leather uppers
(b) Oil resistant soles

2015 Safety Handbook 25

(c) Class 75 for impact and compression protection; where
protective toe caps are required.
(d) Employees working around live electrical equipment
shall have electrically rated soles (EHrating).

3.5 Hearing Protection

OSHA standards require employers to provide suitable

hearing protection. Hearing protection will be provided and
used whenever it is not feasible to reduce the noise levels or
duration of exposure below 85 dB on a time-weighted average.
(a) There is no cure for noise-induced hearing loss.
(b) Clean non-disposable earplugs after each use.
(c) Earmuffs need to make a perfect seal around the ear to
be effective.
(d) For extremely noisy situations, wear earplugs and earmuffs.
As a rule of thumb if you must raise your voice to
speak to others at a distance of 5 ft (1.5 m)or less -
hearing protection should be worn.

3.6 Personal Fall Arrest Equipment

OSHA standards require employers to provide suitable fall

arrest equipment.
(a) Personal fall arrest equipment shall be worn and lan-
yards attached to lifelines at all times when working in or
within 6 ft (1.8 m) of an open hoistway where there is the
potential to fall more than 6 ft (1.8 m).
(b) Personal fall arrest equipment shall be used only for
employee safeguarding.
(c) Any lifeline, harness, anchor, or lanyard actually subject-
ed to shock loading (disengages), as distinguished from
static loading, shall be immediately removed from service
and shall not be used again for employee safeguarding.

26 2015 Safety Handbook

(d) Lifelines shall be secured above the point of operation
to an anchorage or structural member capable of sup-
porting a minimum dead weight of 5,000 lb (2268 kg).
(e) Each employee is to be properly trained on the proper
use, maintenance and inspection of personal fall arrest
systems.
(f) Lanyards shall be attached to lifeline or suitable anchorage
such that an employee cannot free fall more than 6 ft (1.8
m), exceed calculated forces, nor contact any lower level.
(g) See Section 4 on Fall Protection.

3.7 Hand Protection (Gloves)

(a) Gloves shall be worn when potential hazards exist that
could cause injuries to the hands, (i.e.: cuts; abrasions;
burns; hazardous chemical exposure; etc.).
(b) Gloves SHALL NOT be worn in close proximity to mov-
ing machinery.

3.8 Respiratory Protection

In general, elevator, industry work environments do not
pose a health risk from breathing contaminated air. However,
respiratory protection may occasionally be required by job site
conditions or building owner requirements. Contact your
supervisor for more information if needed.
To control those occupational diseases caused by breath-
ing air contaminated with harmful dusts, fogs, fumes, mists,
gases, smokes, sprays, or vapors, the primary objective shall
be to eliminate the atmospheric contamination. This shall be
accomplished as far as feasible by accepted engineering
control measures (for example, enclosure or confinement of
the operation, general and local ventilation, and substitution
of less toxic materials). When effective engineering controls
are not feasible, appropriate respirators shall be used or
completely avoid area depending on company policy.

2015 Safety Handbook 27

 If approved by the company, NIOSH approved dust respi-
rators (non-sealing) can be used without the following
requirements as long as the employee has no known medical
condition which would put them at risk (i.e., heart condition,
respiratory difficulties, etc.) and the mask is discarded when
contaminated.
(a) Only physically qualified employees will be trained and
authorized to use respirators. A pre-authorization and
annual certification by a physician will be required and
maintained.
(b) Any changes in an employees health or physical char-
acteristics which may affect their ability to wear a respi-
rator (i.e., 20% weight gain or loss, heart condition,
respiratory problems, etc.) shall be reported to their
supervisor and will be evaluated by a physician.
(c) Only authorized and trained employees shall use respi
rators. Those employees may use only the respirator
that they have been trained on and properly fitted to use.
The training is required initially and shall reoccur annu-
ally. This training shall include:
(1) How to select the proper type of respirator and/or
cartridge.
(2) How to inspect and maintain the respirator.
(3) How and when to use the respirator.
(4) Limitations and capabilities of the respirator.
(d) Before an employee is required to use any respirator,
the employee shall be clean shaven where the respira-
tor meets the face, fit tested with the same make, model,
style, and size of respirator that will be used on the job.
The fit testing is required initially and shall reoccur annually.

28 2015 Safety Handbook

Section 4
FALL PROTECTION
General Requirements
Fall protection is required when a worker is exposed to a
fall hazard (working more than 6 ft. (1.8 m) above a lower
level and an opening more than 12 in. by 12 in. (305 mm by 305
mm) and the work activity is within 6 ft. of the opening.
There are three ways of controlling fall hazards. Elimination
of the fall hazard should be the first consideration. The second
consideration is a guard rail system, and the third is a personal
fall arrest system.

4.1 Personal Fall-Arrest System

Figure 4a Figure 4b (next page) shows the

attachment of the body harness and
shock-absorbing lanyard to the lifeline
while working in the hoistway/wellway,
and an example of typical top anchorage
of the lifeline is shown in Figure 4a.
BEAM

PAD

(a) Only company-approved lifelines, shock-

absorbing lanyards and body harnesses
shall be used.
(b) All fall protection components shall
be compatible.
(c) Lifelines shall be protected against
being cut or abraded. Only synthetic
Clevis or wire rope shall be used for lifelines.
(d) Lifelines shall be installed before
Typical Top working in the hoistway/wellway and
Anchorage shall run the full length of the hoist
of Lifeline way/wellway and be so arranged to

2015 Safety Handbook 29

Figure 4b

Full-Body Harness

30 2015 Safety Handbook

 permit tying off before entering the hoistway/wellway.
Prior to use the personal fall-arrest system shall be
approved by a Competent Person.
(e) Only one worker is permitted on a vertical lifeline, and
that lifeline shall have a breaking strength greater than
5000 lbs (2268 kg) after it has been attached to the
anchorage point.
(f) Shock-absorbing lanyards shall be anchored to the life-
line and shall be above shoulder height so that any fall
shall not exceed 6 ft (1.8 m). When determining fall
heights be sure to use proper fall clearance distances
(refer to figure 4b). Lanyards shall be connected to a
vertical lifeline by means of a rope grab; the lanyard
shall not be attached directly to the lifeline.
(g) Lifelines, harnesses and shock-absorbing lanyards sub-
jected to impact loading shall be immediately removed
from service. They shall be eliminated and destroyed for
employee safeguarding.
(h) Tying to the hoist line is prohibited. Proper rope grab
shall be used.
(i) Fall protection shall be used on top of a completed eleva-
tor car where there is a fall hazard and the car is secured
from movement.
(j) On a completed car secured from movement, tie off
when exposed to a fall hazard. Do not position yourself
where there is fall hazard.
(k) Replace personal fall protection equipment at intervals
recommended by the manufacturer.
(l) Before using a body harness, shock-absorbing lanyard
and lifeline, inspect them carefully each time for signs of
wear or damage.

2015 Safety Handbook 31

4.1.1 Inspection and Maintenance Checklist
To maintain service life and high performance, personal
fall arrest systems shall be inspected before each use.
Replace the personal fall arrest system if any defective condi-
tions are found.
(a) Webbing. Grasp the webbing with your hands 6 in. (150
mm) to 8 in. (200 mm) apart. Bend the webbing in an
inverted U. The resulting surface tension makes dam-
aged fibers or cuts easier to see. Follow this procedure
the entire length of the webbing, inspecting both sides of
each strap. Watch for frayed edges, broken fibers,
pulled stitches, cuts, burns and chemical damage.
(b) D-Rings/Back Pads. Check D-rings for distortion,
cracks, breaks, and rough or sharp edges. The D-ring
should pivot freely. D-ring back pads should also be
inspected for damage.
(c) Attachment of Buckles. Attachments of buckles and
D-rings should be given special attention. Note any
unusual wear frayed or cut fibers or distortion the buck-
les or D-rings.
(d) Tongue/Grommets. The tongue receives heavy wear
from repeated buckling and unbuckling. Inspect for loose,
distorted or broken grommets. Webbing shall not have
additional punched holes.
(e) Tongue Buckle. Buckle tongues shall be free of distor-
tion in shape and motion. They should overlap the
buckle frame and move freely back and forth in their
socket. The roller shall turn freely on the frame. Check
for distortion, sharp edges or grip failure.
(f) Friction and Mating Buckles. Inspect the buckle for dis-
tortion. The outer bars and center bars must be straight.
Pay special attention to corners and attachment points
of the center bar.
Visual Indications of Damage to Webbing and Rope. The
following indications refer to nylon and polyester webbing:

32 2015 Safety Handbook

(a) Heat. In excessive heat, webbing becomes brittle and
has a shriveled brownish appearance. Fibers will break
when flexed. Harnesses made of these materials should
not be used at temperatures above 180 degrees
Fahrenheit.
(b) Chemical. Changes in color usually appearing as a
brownish smear or smudge. Transverse cracks appear
when bent over a mandrel. Loss of elasticity.
(c) Molten Metal or Flame. Webbing strands fuse together.
Hard shiny spots appear. Hard and brittle feel.
(d) Paint and Solvents. Paint that penetrates and dries
restricts movement of fibers. Drying agents and solvents
in some paints cause chemical damage.

4.2 Guardrail Systems

General

OSHA compliant guardrail systems for car tops, open

hoistways or escalator wellways shall have a top rail 42 in.
3 in. (1067 mm 76 mm) high, with a mid-rail 21 in. (533
mm) high at centerline and toeboards. 3-1/2 in. (90 mm)
high, with no greater than 8 ft (2.4 m) between uprights and
shall be capable of sustaining a force equal to 200 lbs (890
N) at the toprail, 150 lbs (667 N) at the midrail, and 50 lbs
(222 N) at the toeboard. When 200 lbf (890 N) is applied,
the top rail shall not deflect lower than 39 in. (991 mm) (See
Figures c, d and e)
(a) OSHA compliant removable guardrail systems with toe-
boards shall be installed at elevator hoistways or escala-
tor wellways typically by the General Contractor, after
either rough or finished floors are in place.
(b) Signs shall be installed warning against removal. It is also
recommended that a sign indicate Caution: Workers in
Hoistway.

2015 Safety Handbook 33

(c) After hoistways are enclosed, and before permanent
doors are installed, openings shall be protected by remov-
able guardrail systems (including toeboards).
(d) If it is necessary to remove the guardrails, be sure to
replace them before leaving the area. When a guardrail is
removed to perform a job, a personal fall-arrest system
must be utilized when a fall hazard is present.
(e) Wire-rope guardrail systems are not recommended for
guarding hoistways. Where used, post spacing shall not
be greater than 8 ft (2.4 m) and they shall not deflect to
a height less than 39 in. above the walking/ working
level when a force of 200 lbf (890 N) is applied. Warning
flags shall be attached every 6 ft (1.8 m), toeboards
shall be provided and they must be easily removable for
access to the hoistway at the terminal landings.
(f) If guardrails are not properly maintained in place, notify
your Superintendent/Manager and the General
Contractor immediately.
(g) On new installation, modernization, or major repair jobs
where the general public is present, solid barricades at
least 8 ft (2.4 m) high shall be used to fully enclose the
work areas, open hoistways and escalator wellways.
They shall be properly secured to avoid unauthorized
access.
(h) Some cartops are equipped with guardrail systems.
Never climb over or stand on guardrails. Be aware of
pinch hazards and the risk of being caught between a
guardrail and hoistway equipment.
NOTE: The methods shown in Figures 4d and 4e are
recommended as a means of providing maximum pro-
tection and flexibility during construction. Do not use
during modernization or major repair jobs where the
general public is present use only solid barricades.

34 2015 Safety Handbook

Figure 4c
OSHA compliant cartop guardrail system

2015 Safety Handbook 35

 Figure 4d

SUGGESTED
GUARDRAIL SYSTEMS
42"

DO NOT REMO
21"

VE
2x4
2x4
2x4

DO
NO
BET TE
WE XC

2x4
EED
EN 8' 12"
SU 2x4

2x4
PPO
2x4

2x4
RT
POS
T

NOTE: Guardrails located 12" in front 1x4

1x4
of hoistway/escalator wellways open-
ing and flush with side walls. One
part should be removable for access.

2x4
2x4
42"

2x4

2x4
21"

DO N
OT R
EMO
12" VE
2x4
DO
2x4

NO
BET TE 1x4
XC
WE EED
EN 8'
SU
PPO
RT
P OS
1x4 Guardrails for single
T
hoistway/escalator well-
ways opening located
12" from opening

36 2015 Safety Handbook

 Figure 4e
SUGGESTED GUARDRAIL
SYSTEMS

DO NOT
REMOVE 2X4

42
12"

21
2X4
2X4

DO
NO
B TE
ETW X
NOTE: EEN
CEE
SUP
D8

1X4
GUARDRAILS POR
TP
LOCATED 12" IN OST NOTE: SUPPORT BRACES
FRONT OF HOISTWAY/ TO BE MOUNTED AT EACH
ESCALATOR WELLWAY SUPPORT POST
OPENING
SHADED AREA ABOVE REPRESENTS CLEAR
HOISTWAY/ESCALATOR WELLWAY OPENING

Top

3" 42" Blocking (spacing) as Needed

and Cleated to prevent
movement in any direction

CL Mid Rail
21"

Toe Board
Min. 3-1/2"
Removable Guardrails:
Space out from walls to permit Entrance Frame Installation.

2015 Safety Handbook 37

4.3 Escalator/Moving Walk Barricades
(a) Barricades shall be positioned to completely surround
the escalator/moving walk from public access.
(b) Barricades shall be positioned to surround, from public
access, floor opening created when equipment access
plate(s) are removed.
(c) Barricades shall be a minimum of 42 in. (1067 mm) high.
(d) Barricades shall be securely attached to the balus-
trades, handrails and/or floor.
(e) All sections shall be connected.
(f) A system shall be in place to keep the barricade rigid.
(g) See figure 4f.

Figure 4f

42"
Attach
securely to
escalator
balustrade
with adjustable
EZ Grip
attachment. Keep Rigid

38 2015 Safety Handbook

4.4 Elevator Maintenance Barricades
(a) Barricade shall be positioned to restrict public access to
the hoistway where doors are open greater than 5 in. (125
mm).
(b) Barricade shall be a minimum of 42 in. (1067 mm) high.
(c) Barricade shall cover entire entrance area.
(d) All sections shall be connected.
(e) A system shall be in place to keep the barricade rigid.
(f) See Figure 4g.

Figure 4g

Barricade

2015 Safety Handbook 39

Section 5
ELECTRICAL SAFETY
5.1 General Precautions
(a) When power is not required to perform the task, lockout/
tagout procedures must be followed. Testing and trouble
shooting may be done live, but repairs can only be done
when the system has been properly de-energized or
circuits isolated, preventing the release of harmful energy.
(b) The following steps should be considered:
a. Whenever possible, de-energize the circuit
b. Guard the energized circuit with effective insulation
c. Use safe electrical work practices
(c) THE FOLLOWING PERSONAL PROTECTIVE EQUIP-
MENT SHALL BE WORN WHEN TROUBLE- SHOOTING
(PERFORMING DIAGNOSTICS AND TESTING) ON
LIVE ELECTRICAL CIRCUITS:
For arc-flash protection long-sleeved natural-fiber or
FR-rated shirts and pants, or long-sleeved FR-rated coveralls
or other company-approved arc-flash-hazard protection
For arc-flash protection, clean leather gloves or arc
rated gloves when working on or near energized elec-
trical components.
Voltage rated gloves with leather protectors may be
required when working on energized components when
there is a risk of contact with energized components above
150V and if safe-working practices cannot abate the risk.
Nonconductive safety glasses
EH-rated footwear or rubber mats
(d) Always use a test instrument on each circuit to confirm
the circuit is de-energized. Test instruments should be
tested prior to use.
(e) All circuits shall always be treated as LIVE unless tests
prove otherwise.

40 2015 Safety Handbook

(f) Before troubleshooting any electrical circuits or appara-
tus, remove all jewelry, keyrings, cell phones, radios,
pagers and other metal objects, etc.
(g) Never troubleshoot circuits when standing or kneeling
on metal, wet surfaces or in water. This includes situa-
tions where your body comes into contact with another
grounded surface during the test and verify step of lock-
out tagout.
(h) When troubleshooting live circuits, take care to be safely
isolated (i.e., rubber mats, isolated tools, EH rated shoes, etc.).
(i) To prevent shocks, take precautions to:
(1) Keep metal objects from touching or being exposed
to any parts that are known to be live or have not yet
been confirmed to be dead, moving machine parts or
connections.
(2) Do not wear tool belts and do not carry tools in your
pockets.
(j) Use only insulated tools when troubleshooting on circuits
that may not be de-energized.
(k) While troubleshooting on MG Sets, elevator motors and
solid-state motor drives, take extreme precaution,
because the armature voltage present may be as high as
600 volts.
(l) Exercise caution (Be cognizant and prepared to test
other circuits that may be LIVE) when troubleshooting
on multi-car operations especially in group systems,
which may have circuits that are LIVE. Even when the
mainline disconnect switch is OFF, other circuits may be
powered from other sources (group controls, cab light-
ing, etc.)
(m) Always use fuse pullers to remove and install fuses.
Fuses and fuse holders should be marked for proper
size and type. Never use a higher amperage fuse, a
fuse of a different type or bridge a fuse.
(n) Use nonconductive flashlights.

2015 Safety Handbook 41

(o) All temporary wiring shall comply with the NEC and
OSHA 29 CFR 1910.305 for the general industry stan-
dard (and for construction where most temporary wiring
is found, 29 CFR 1926 403 and 404) and company
policy. When temporary wiring is used, locate wiring
in such a manner that no one can trip over it. Take pre-
cautions to protect temporary wiring from sharp edges
and mechanical damage and do not support it with nails
or wires.
(p) All 110-volt, 15- or 20-amp circuits shall be grounded.
Do not wire outlet receptacles into lighting circuits
unless they are grounded.
(q) Always replace covers on electrical equipment after
troubleshooting is completed.
(r) DO NOT OPEN THE MAINLINE DISCONNECT
SWITCH COVER. If power is not being supplied to the
elevator controller (e.g. open mainline fuses, etc.),
advise the building owner to correct the condition. This
is not the elevator companys responsibility.
(s) Keep electric cabinet doors closed when system is ener-
gized, whenever possible.
(t) A ground fault circuit interrupter (GFCI) is required when
using portable power tools and drop lights. GFCIs
should be tested prior to each use.
(u) Do not cut live wires. Verify zero energy and be aware
that there may be voltage due to interconnections from
other elevator units and/or the building.
(v) Before working on circuits containing capacitors, always
be sure to discharge or take precautions by installing
guard(s) to protect against accidental contact.

5.2 Meter Usage Safety Checklist

o Use Category III, 1000V multimeters.
o Follow the manufacturers safety procedures for the
meter used.

42 2015 Safety Handbook

o Be certain the meter is in good operating condition. Notify
your supervisor immediately if the meter is damaged.
o The meter used must meet accepted safety standards for
the environment in which it will be used.
o Inspect test leads for physical damage before making mea-
surements. If damaged, replace them before proceeding.
o Use the meter to check continuity of the test leads.
o Use only test leads that have shrouded connectors and
finger guards.
o Use only meters with recessed input jacks.
o Select the proper function and range for your measure-
ment and double check before proceeding.
o Be aware of high-current and high-voltage situations and
use the appropriate equipment, such as high-voltage
probes and high-current clamps.
o Use a meter that has overload protection on the ohm function.
o When measuring current without a current clamp, turn the
power off before connecting into the circuit.
o Where work is performed on electrical circuits located in
dark areas, use adequate, non-conducting auxiliary lighting.

5.3 Energized Circuit Troubleshooting Checklist

Work on de-energized circuits and use lockout/tagout proce-

dures whenever possible.

(a) On live circuits, use personal protective equipment (PPE).

o Use insulated tools.
o Wear nonconductive safety glasses.
o For arc-flash protection, clean leather gloves or arc rated
gloves when working on or near energized electrical
components.
o Voltage rated gloves with leather protectors may be
required when working within 12 inches of energized
components above 150V when there is a risk of contact
and if safe working practices cannot abate the risk.

2015 Safety Handbook 43

o Remove watches, jewelry or other metal objects.
o Stand on an insulated mat or use safety shoes with elec-
trically rated soles.
o For arc-flash protection long-sleeved natural-fiber or
FR-rated shirts and pants, or long-sleeved FR-rated cover-
alls or other company-approved arc-flash-hazard protection.
(b) When taking measurements on live circuits:
o Hook on the ground clip first, and then make contact with
the hot lead. Remove the hot lead first and the ground
lead last.
o Hang or rest the meter if possible. Try to avoid holding
it in your hands to minimize personal exposure to the
effects of transients.
o Use the three-point test method, especially when check-
ing to see if a circuit is dead. First, test a known live
circuit. Second, test the target circuit. Third, test the live
circuit again. This verifies that your meter worked prop-
erly before and after the measurement.
o Use the old electricians trick of keeping one hand in
your pocket. This lessens the chance of a closed circuit
across your chest and through your heart.

44 2015 Safety Handbook

Section 6
PROPER USE OF JUMPERS

(a) It is recognized that temporary circuit jumpers or clips

(jumpers) may be required for conducting some service
work on elevators, escalators or moving walks. All field
personnel shall be trained in the proper use of jumpers
for defeating safety circuits. When jumpers are used
they shall have the following characteristics:
(1) Extra-long, tied in knots, and brightly colored
wires or clips.
(2) Jumpers shall be numbered in sequence.
(3) The ends of jumper wires shall be affixed with insu-
lated alligator clips.
(4) Each employee shall have his/her name or personnel
number marked in indelible ink on a label permanently
attached to each jumper.
(b) Make sure you understand what effect using or remov-
ing a jumper will have on the entire elevator or escalator
system prior to use.
(c) Jumper wires shall never be placed or configured to
resemble permanent wiring.
(d) The number of jumpers carried shall be limited so that
all jumpers can be accounted for at all times (number-
ing jumpers in sequence will help). Jumpers shall be
removed and accounted for when returning equipment
to service.
(e) Equipment shall never be returned to service with jumpers
left on. Equipment found in this condition shall be
reported to your Superintendent/Manager immediately.

2015 Safety Handbook 45

6.1 Maintenance and Troubleshooting

6.1.1 Rules
(a) Jumpers shall not be used as a diagnostic tool. Always
use a meter to troubleshoot circuits.
(b) Temporary bridging (e.g., tomahawk) devices shall not
be used to short out hall door contacts.
(c) Do not jump out door and gate at the same time.
NOTE: You may deviate from this requirement only
when a second qualified person is on site and in direct
communication. USE EXTREME CAUTION WHEN
THESE CIRCUITS ARE JUMPED OUT.
(d) Ensure that elevator is on inspection before placing jumpers
on door, gate, or safety circuits. Make a visual inspection
that all hoistway doors are mechanically closed.
(e) Ensure all jumpers are removed before placing
equipment back in service.

6.1.2 Procedures for Jumper Use

(a) Remove elevator from public use and ensure no pas-
sengers are in the elevator.
(b) Place jumper kit on machine room door handle or other
conspicuous place.
(c) Verbally communicate to all other elevator personnel on
the jobsite when jumper(s) are to be used. This com-
munication provides needed information on circuits
bypassed and equipment affected.
(d) When work is complete, all jumpers shall be removed,
counted and returned to the jumper kit.
(e) Never leave jumpers on equipment or in the machine
room.

46 2015 Safety Handbook

6.2 Modernization and New Construction

On modernization and construction many jumpers are

used to operate elevators.
(a) Jumpers shall be brightly colored, easily identifiable and
shall be long and conspicuous.
(b) A Jumper Log shall be established to ensure that affect-
ed personnel are aware of the safety circuits which are
not functioning. It is the responsibility of the mechanic/
mechanic in charge to ensure that the Jumper Log is
completed. The Jumper Log shall be kept with the con-
troller and shall not be removed until all jumpers are
removed.
(c) Door, gate, or other safety circuits shall never be jumped
out unless car is on inspection in the controller.
(d) Jumpers shall be removed as soon as they are no longer
needed, maintenance and troubleshooting procedures
outlined above shall be followed.
In addition to the above, stickers shall be placed in the con-
troller cabinet, in close proximity to the inspection/automatic
switches, which read as follows:
DOOR, GATE OR SAFETY CIRCUITS SHALL NEVER
BE JUMPED OUT UNLESS CAR IS ON INSPECTION
IN THE CONTROLLER.

Before moving car with open doors, verify car is on inspection.

2015 Safety Handbook 47

6.3 Door Bypass Procedure
(a) Inspection operation with open door circuits (ASME
A17.1, Requirement [Link]) shall only be utilized
when it is necessary to move an elevator when the car
gate and/or door lock circuit is electrically open. Before
utilizing this, steps shall be taken to identify the problem
circuit (car gate or door lock) and bypass only that
circuit. Once a decision is made to utilize door bypass
circuitry, the elevator shall be placed on inspection
operation via the car top or the in-car inspection switches.
Once on inspection operation, the pertinent switch(es)
can be switched to bypass position. Then, whenever
possible, the elevator shall always be operated from the
top of the car.
(b) Extreme caution shall be taken prior to and while
moving the elevator to ensure the safety of the public
and elevator personnel, i.e., unprotected openings, body
parts clear of moving equipment, equipment unobstruct-
ed, etc.
(c) Once the purpose for using the door bypass circuitry
has been met, the switch(es) are to be switched to the
open position. A thorough check of the car gate/door
lock circuitry shall then be performed to ensure proper
operation. Once this is confirmed, the elevator shall be
placed back on automatic operation and returned to
service.

48 2015 Safety Handbook

Section 7
LOCKOUT AND TAGOUT

General Requirements
The procedures outlined below are intended to prevent
injury or death to employees by requiring certain procedures
be taken before working on equipment. Unless it is not fea-
sible (i.e., inspecting, troubleshooting, observing, etc.),
employees shall not perform any work on equipment where
there is a potential to be exposed to energized mechanical or
electrical hazards until all sources of energy have been de-
energized, grounded or guarded.
Equipment variations require the mechanic to know what car
controls are available and operating; the mechanic must
know what safety methods will be employed to gain control of
the car. Never access the hoistway unless you have control of
the car.
All forms of potential energy including electrical, mechani-
cal, hydraulic, pneumatic, kinetic, gravity, etc. shall be con-
trolled to prevent inadvertent movement of a unit or piece of
equipment being worked on.

7.1 Procedures

(a) Understand the equipment; be aware of its potential

hazards. If it is not understood, or if you have a question,
contact your Superintendent/Manager immediately before
proceeding.
(b) Where the accidental starting of the equipment would
create a hazard deactivate mainline disconnect
switch to shut off the power. CAUTION: Do not stand
directly in front of the mainline disconnect when operat-
ing (stand off to the side of the disconnect). Each
employee shall apply to the disconnect switch a personal
lock and a Do Not Start tag with the employees name
(Section 5.3).

2015 Safety Handbook 49

(c) Some components (capacitors, MG sets, etc.) often store
residual energy, even though power is shut off. The
stored energy can result in electrical shock or unintended
movement of equipment. Before working on equipment
with these components, discharge the stored energy to
ground.
(d) When it is impossible to lock the switch, assurances shall
be made that the circuit is deactivated and tagged out.

Figure 7a

50 2015 Safety Handbook

(e) CAUTION: It is likely to have electrical energy on a
controller that has had the mainline-disconnect switch
deactivated. After initiating lockout and tagout, the light-
ing circuit may still be energized, battery backup may still
be energized, and group controller cross connects may
still be live.
(f) Once the system has been locked out, verify with the
appropriate test equipment that the system has been
de-energized. (see Section 5.3)
(g) Before working on mechanical systems, make sure the
system is understood. If there are any questions, get
answers before proceeding. Such systems often store
energy, even though the electrical power is shut off. The
stored energy can result in violent movement of a machine
part, such as a plunger or piston rod, when work is done
on another portion of the equipment. If the portion of the
system to be worked on can be isolated and the pressure
in that portion of the system released by bleeding, it is not
necessary to shut down the entire system. However, the
valves and controls which could readmit pressure to the
system being worked on shall be identified with Do Not
Start tags and locked out. If a lockout is not possible, other
positive action shall be taken to ensure that the equipment
will not be energized. Check flanged connections, cylinder
heads or plate-mounted components. The sticking of a gas-
ket can hold the parts together, while bolts are removed,
and then can come apart violently due to stored pressure.
(h) When working under a hydraulic elevator, devices such
as jacks, pipe stands, etc. shall be installed to prevent
the elevator from injuring workers in the pit.
(i) Each employee who performs duties described above
will be provided with an individually keyed or combination
lockout device and tags. If more than one employee is
assigned to a task, each employee shall be responsible
for placing their own lock and Do Not Start tag, so the
controls cannot be operated.

2015 Safety Handbook 51

(j) If controls are so located that only one lock can be
accommodated, a multiple lockout device shall be used.
(k) Lockout devices shall be made available for locking out
additional equipment.
(l) Where special devices are required to lockout circuit
breakers, they shall be available and used.
(m) Lockout devices shall be returned to the Company when
an employee transfers to other assignments or terminates.
(n) When switches are deactivated for service, repairs or
alterations, they shall be locked out and tagged out.
(o) Before starting work on any equipment that is out of ser-
vice, make a thorough check of all electrical control and
starting devices. When any part of such equipment is
remotely controlled, lockout and tagout the mainline
disconnect and confirm that the system is de-energized
[Section 7.1(f)].

7.1.1 Shift Changes

(a) When employees are ending their shift and/or other
employees will continue work on the machine or equip-
ment, the employees shall attach the company locks
and tags and then shall remove their personal locks
and tags.
(b) The new shift employees shall apply their personal
locks and tags before beginning work on the machine or
equipment. After the employees have placed their per-
sonal lockout mechanism and tag, and have verified
that the system is de-energized the company locks and
tags shall be removed.

7.1.2 Restoring Equipment and

Machines to Normal Service
(a) All tools shall be removed, all guards and covers
shall be reinstalled and the area shall be checked to
insure that no personnel are exposed to the equipment
or machine.

52 2015 Safety Handbook

(b) The mechanic, after checking to make sure that no one
is exposed to the equipment or machine, shall restore
energy to it.
(c) After each portion of the work is completed, the individual
who places the lockout mechanism shall be responsible
for its removal. If more than one operation is performed
on a piece of equipment, machine or system, it will be
necessary for each individual to remove their lockout
mechanism immediately after their work task has ended.
The last individual to remove their lockout mechanism
shall notify the customer that all work has ended.
(d) The unit shall be operated in the normal mode before
returning it to service.
(e) Remove out of service tags.
(f) Notify the customer that the unit is back in service.

7.2 Supervisory/Emergency
Removal of Lockout/Tagout

(a) If it is necessary to operate a piece of equipment which

is locked out, every effort shall be made to locate the
employee whose lock is on the equipment. If the employee
cannot be located, and after positive assurance is made
that no one is working on the locked out equipment, your
Superintendent/Manager may personally remove the lock.
The Superintendent/ Manager must remember that there
is danger of the employee involved returning, thinking
the machine is still locked out, when actually it has been
reactivated. The Superintendent/Manager shall ensure
that the equipment is, once again, locked out before the
employee resumes work.

2015 Safety Handbook 53

(b) If a machine is locked out and it becomes necessary to
leave, recheck upon returning to make sure the machine
is still locked out. While supervisors will make every effort
to avoid removing locks, there may be situations when it
must be done. The recheck is for your protection.

7.3 Lockout/Tagout Procedures

for Escalators and Moving Walks
(a) The applicable procedures in Sections 7.1 and 7.2 apply
to all employees who work on escalators and moving
walks. Anytime work is to be performed within the inte-
rior plane of the steps/ pallets, it shall be locked out and
tagged out to prevent the unit from starting unexpectedly.
(b) In addition to lockout/tagout, whenever working within
the truss where 10% or more of the escalator steps are
removed, a mechanical blocking device shall be activated
to prevent the escalator from moving. If the unit is not
equipped with a mechanical blocking device, the drive
chain and/or step axles must be secured to the truss
braces to prevent movement in either direction.
(c) Whenever steps are removed and the unit is going to be
left out-of-service, the steps/pallets should be moved to
cover the openings (whenever possible).

7.4 MRL Car Movement Locking Devices

(a) Some machine-room-less elevators are equipped with

special car movement locking devices that provide an
independent method of securing the car. The cartop can
then safely be used for performing maintenance, inspec-
tion, adjustments, or repairs to overhead equipment.
Elevator suspension must be in place
The device is typically located on the crosshead

54 2015 Safety Handbook

 It shall have a sign stating WARNING! Engage
before maintaining on inspecting brake, emergency
brake or controller.
(b) Some MRLs with controllers in the hoistway have multiple
lockout locations. Prior to performing lockout/tagout,
determine the best location to de-energize the equipment
you will be working on. Refer to manufacturers docu-
mentation for further information.

2015 Safety Handbook 55

Section 8
HOISTWAYS AND MACHINE ROOMS
8.1 Hoistway Access Safety
When arriving on the site, notify owner, place out of service
signage and place barricades to protect public as applicable.
Prior to gaining access to the hoistway, determine whether
power is needed to perform the required task. If not, the appro-
priate lockout/ tagout procedure shall be used. (See Section
7.) Do not open the hoistway door more than 6 in. (152 mm) until
you determine the car or car top is located in a safe position
to access.

8.1.1 Top-of-Car Access/Egress Procedure

CAUTION: Besides examination, inspection, maintenance

and adjustment work that must be done on the car top, there
is a considerable amount of work in the hoistway which must
be done from the top of the car and, at times with the car in
motion. Examples of safe access/egress procedures are
outlined below.

[Link] Accessing Top-of-Car

Prior to accessing the hoistway always verify that the eleva-
tor has arrived before stepping into or on the car.

(a) Hoistway Access Switch Provided:

Capture the elevator, and take it to the top access landing.
Activate the means to disable the operating devices,
(in car inspection service) located in the COP. Verify
that the elevator is not on automatic operation by
attempting to register multiple car calls.
Insert proper door wedge tool to mechanically hold the
door(s) in the open position, bump the car down and then
up using the key switch to test the brake, stay clear from
the entrance and lower the car to a safe height by using

56 2015 Safety Handbook

 the hoistway access switch to run the car in the down
direction. Note: Be aware of car door clearances.
Remove key from hallway access switch.
Reach into the hoistway and place the top-of-car stop
switch in the STOP position and turn the car top work
light ON. (Note: If the switch cannot be accessed
from the landing, lockout/tagout procedure must be
followed prior to accessing the car top.)
Insert key into the hall access switch and try to move
elevator in both directions. It should not move. Remove key.
Place the car top inspection switch in the INSPECT
position and the car top STOP switch to RUN.
Reinsert the access key switch and try to run the car
in both directions. It should not move. Remove key.
Before stepping onto the car top, activate STOP switch
to STOP, locate a safe refuge area and access the car
top. Be aware of fall hazard.
Remove door wedge tool and allow doors to close.
Verify cartop inspection station switches work properly
by first running down, then up, then proceed with neces-
sary tasks in hoistway ensuring car top station remains
on INSPECT and stop switch is in the STOP position
when work is being performed.
CAUTION: Be sure you have a surface to stand on that will
support your weight. Dont stand on the car top emergency exit
or the fan unit and use special care where the car tops are
curved or domed

(b) Without Hoistway Access Switch:

Capture the elevator, and take it to the top access landing.
Establish down demand by activating 2 in-car car calls.
Using an approved door unlocking device, stop the
elevator in flight to verify the door interlock by
opening the hoistway no more than 6 inches. Be
sure to stop the elevator in a safe position to safely
reach the car top inspection run box.

2015 Safety Handbook 57

 Insert proper door wedge tool and place the top-of-
car stop switch in the STOP position, turn on light,
remove your door wedge tool and allow the doors to
close (Note: If the switch cannot be accessed from
the landing, lockout/tagout procedure must be fol-
lowed prior to accessing the car top.)
Wait ten seconds and open the hoistway door no
more than 6 inches to verify the top-of-car stop
switch is working. Car should not move.
Insert proper door wedge tool and place the car top
inspection switch in the INSPECT position and the
car top STOP switch to RUN. Remove your door
wedge tool and allow the doors to close.
Wait ten seconds and open the hoistway door no
more than 6 inches to verify the top-of-car inspection
switch is working. Car should not move.
Insert proper door wedge tool and activate car top
STOP switch to STOP position.
Locate a safe refuge area and access the car top.
Remove door wedge tool and allow doors to close.
Proceed with necessary tasks in hoistway ensuring
car top station remains on INSPECT and stop switch
is in the STOP position when work is being performed.
CAUTION: Be sure you have a surface to stand on that
will support your weight. Dont stand on the car top
emergency exit or the fan unit and use special care
where the car tops are curved or domed.

(c) When in a multiple hoistway, never place any part of

your body in the runway of an adjacent operational
elevator.
NOTE: On elevators without top-of-car inspection stations,
use the proper procedures in Section 8.1.2 (j).

[Link] Exiting Top-of-Car

(a) Position top-of-car level with the egress landing. When
a hoistway access switch is provided, position the top-of-
car at the landing where the top access switch is located.

58 2015 Safety Handbook

(b) Place the top-of-car stop switch in the STOP position.
(c) Check for tools, keys, rags or any other equipment.
(d) Slowly open hoistway door and place door wedge tool
into the sill.
(e) Step off top-of-car onto landing.
(f) Place the inspection switch in the NORMAL position.
(g) Place the top-of-car stop switch in the RUN position
and turn off the car top work light.
(h) When a hoistway access switch is provided, with the
hoistway door(s) in the open position, activate hoistway
access switch to run the car up. Stay clear of moving
car. Deactivate the means to disable operating devices.
(i) Remove door wedge tool and close hoistway door to
engage pickup rollers with door clutch.
(j) Inside cab return Access-Enable to NORMAL or OFF
position disabling access switch.
(k) Verify elevator is operational by placing a hall call.

8.1.2 Safety precautions when working on car tops:

(a) Familiarize yourself with the position of the car and
counterweights of the car being accessed as well as any
other cars/counterweights in the vicinity and take appro-
priate measures to keep yourself and others away from
hazards.
(b) If movement of the car is needed while on top of the car,
be sure to have a firm hold on the crosshead, or other
part of the car structure.
(c) Never stand or sit on the crosshead when the car
is moving.
(d) Never hold onto the ropes, sheaves or sheave guard.
(e) If the car top is not clean (i.e., oil, grease), clean it prior
to performing any activities.
(f) Verify proper operation of top-of-car inspection operat-
ing buttons.

2015 Safety Handbook 59

(g) Where outlets are provided, use a grounded portable
light with a suitable, non-conductive or grounded lamp
guard and reflector.
(h) Electrical cords are not to be hung on car or counter-
weight ropes.
(i) When a top-of-car operating device is available and
operational, use it to operate the car instead of depend-
ing on an operator in the car.
(j) If top-of-car operating device is not available and you
must ride on top of the car ensure:
(1) The person on the car top shall identify and be posi-
tioned in a safe refuge space. Do not enter areas
marked with Red and White strips.
(2) The operator in the car is briefed on the signals to
be used.
(3) The operator in the car repeats instructions each
time before moving the car.
(4) That hall buttons cannot control the car.
(5) The operator shall only run the car on the slowest
possible speed and only in the specified direction.
(6) In the case of single and collective-operation eleva-
tors or any elevator whose reversal at the terminals
is automatically controlled, instruct the operator to
reverse the direction of the car before the terminals
by means of the reversal switch in the car.
(k) When a fall hazard exists, fall protection shall be used.
(See Section 4.)
(l) Wire ropes shall only be inspected or lubricated when the
car is stopped. Avoid pinch points.
(m) When opening hoistway doors from the car top, do so
slowly so that no one steps in from the landing thinking
a car has arrived.
(n) Observe overhead clearances.
(o) Use extra care when working on car tops that are curved,
domed, or located in unenclosed hoistways.

60 2015 Safety Handbook

(p) Do not leave parts, lubricants, etc on the top of elevator
cars. This is a violation of the ASME A17.1 Code.
(q) The car top emergency exit shall remain in the closed
position except when passing through same.
(r) Before performing repairs from top-of-car, with the car at
or above the top landing, place a ladder in car under top
emergency exit to provide means of exiting from car top.

8.2 Pit Safety

8.2.1 General
(a) Many serious injuries occur every year, entering and exit-
ing pits. Every employee must be aware of the hazards
before entering a pit. Some of the more common hazards
are:
(1) Inadequate refuge space
(2) Inadequate lighting
(3) Improper access
(4) Tripping hazards
(5) Unsafe or lack of pit ladders
(6) Moisture/water/oil
(7) Moving equipment
Take appropriate steps to minimize these hazards and any
others that are identified.
(b) Before entering a pit, familiarize yourself with the position
of the car and counterweights for the car being worked
on as well as any other cars/counterweights in the vicinity.
(c) Control of the car shall be obtained prior to entry into the pit.
(d) If notified by the building owner or representative that the
pit and/or hoistway has been classified as a permit required
confined space (this notification could be verbal or the pit/
hoistway may be labeled), immediately notify your
Superintendent /Manager for further instructions. In either
case, DO NOT enter the pit/hoistway until consulting your
Superintendent/Manager and receiving authorization.

2015 Safety Handbook 61

8.2.2 Elevator Pit Access/Egress Procedure

NOTE: These procedures do not apply to walk-in pits. See

Section 8.2.3 for Walk-in Pit procedures.
[Link] Accessing Pits

(a) When the movement of the elevator is required, the

follow
ing procedure shall be followed in lieu of the
Lockout/ Tagout procedure in Section 7.
(b) Lockout/Tagout procedures are required if movement of
the elevator is not needed to complete the work being
performed. (See Section 7.)
(c) Before entering the pit, notify the building manager/
owner that you will be servicing the elevator. Tag the
elevator out of service by placing a sign on the controller
stating ELEVATOR IS UNDER THE CONTROL OF A
SERVICE PERSON - DO NOT OPERATE.
(d) Install barricades if the hoistway door is going to be
open more than 5 in. (125 mm) while performing your
work. (See Section 4.4)
(e) When a hoistway access switch is provided capture the
elevator at the lower access landing and activate the
Access-Enable to disable operating devices located at
the car-operating panel. Verify elevator is not on auto-
matic by registering multiple car calls. With the hoistway
door(s) held in the half-open position, activate hoistway
access switch to run the car up until toe guard clears
opening. Confirm the car stops.
(f) When a hoistway access switch is not provided, capture
the elevator and place two car calls to upper floors to
establish an up demand. As the elevator moves away
from the landing, open the hoistway door with a hoist-
way door unlocking device key to insure interlock stops
the elevator.

62 2015 Safety Handbook

CAUTION: When using hoistway door unlocking device keys be
aware of pinch hazard when the hoistway door opens under power.
(g) If hoistway access switches or hoistway door unlocking
devices are not provided follow your company safety
procedures for accessing the hoistway.
(h) Before accessing the elevator pit, place a door wedge
tool in the sill to ensure that the hoistway door(s) will not
shut, turn the pit light on and place the pit stop switch in
the STOP position.
(i) Insert access key. Try to move elevator in both direc-
tions. It should not move. Remove key from switch.
(j) Where an access ladder exposes a person to a fall
hazard of 6 ft (1.8 m) or greater; and
(1) The ladder is further than 29.5 in. (750 mm) from
the interior edge of the door frame; or
(2) The ladder or handhold extends less than 42 in.
(1067 mm) above the access landing,
(3) The clearance between the ladder rungs and side wall
is less than 4.5 in., a hazard assessment shall be
conducted to identify the necessary safety precautions.
(k) If the pit does not have a pit stop switch, the lockout/
tagout procedure is to be implemented before entering
the elevator pit. (See Section 7.)
(l) Standing outside the hoistway, remove door wedge tool
and close the hoistway door. Enter a hall call and wait
10 seconds to verify the elevator will not run and to verify
that the pit stop switch is working. When working on a
multiple bank of elevators wait for a minimum of 20 seconds
to verify the elevator you are working on will not run.
(m) Once verification of the pit stop switch operation is com-
plete, open the hoistway door, place a door wedge tool
back into the sill, do a mental and visual job hazard
assessment and locate a safe refuge space. Do not
enter areas marked with Red and White strips. Carefully
enter the pit. Close doors to about 6" and use door
wedge to block.

2015 Safety Handbook 63

(n) In deep pits a second stop switch is typically installed 4
ft above the pit floor. After descending the pit ladder
place the lower pit stop switch in the STOP position. The
second stop switch must be tested and verified by two
independent means. Methods may vary across organi-
zations.
(o) If operation of the elevator is necessary:
(1) The car is only to be operated on inspection opera-
tion from either the car top with top-of-car inspection
operation or inside the car with in-car inspection
operation, if provided, by a qualified elevator per-
son. The person operating the car and the person in
the pit shall establish and maintain two-way com-
munications.
(2) Install pipe stands (hydraulic elevators).
(3) Remove the door wedge tool and allow the hoistway
door to close.
(4) Place the upper pit stop switch in the RUN position.
(5) Stand on the pit floor and be prepared to stop the
movement of the elevator with the pit stop switch.
CAUTION:
(p) Never stand on the pit ladder when the pit stop switch at the
access landing is in the RUN position, unless two pit
stop switches are provided and the lower switch is in the
STOP position.
(q) When work is to be done on a hydraulic system, the car
shall be landed on pipe stands, hydraulic pressure
relieved and appropriate lockout/tagout procedures
implemented. (See Section 7.)
(r) When in multiple hoistways, never place any part of
your body in the runway of an adjacent opera
tional elevator.

[Link] Exiting Pits

(a) Verify lower pit stop switch, where provided, is in the
STOP position.

64 2015 Safety Handbook

(b) Verify pit stop switch at access door is in the STOP position.
(c) Place lower pit stop switch in the RUN position.
(d) Remove pipe stands (hydraulic elevators).
(e) Slowly open hoistway door and place a door wedge tool
into the sill. Exit the pit.
(f) Turn the pit light off.
(g) Place the pit stop switch at access door in the RUN position.
(h) When a hoistway access switch is provided, with the
hoistway door(s) in the open position, activate hoistway
access switch to run the car down. Stay clear of moving
car. Deactivate the means to disable operating devices.
(i) Remove door wedge tool and close hoistway door.
(j) Place the car back into service.

8.2.3 Walk-in Pits

NOTE: See Section 8.2.2 for pit access procedure through

lowest hoistway door

[Link] General guidance

(a) Every walk-in pit is different. Therefore it is difficult to
make one set of requirements that applies to all situa-
tions. For each situation that may be encountered, site
specific requirements and procedures shall be estab-
lished. Formulated requirements and procedures will
depend on the height of the pit (7 ft. [2.1 m] or more of
overhead clearance) and the guarding or location of relat-
ed components such as; tapes, governors, counter
weights, traveling cables, etc.
(b) Always wear a hard hat in walk-in pits where cars are
operating.

[Link] General Rules that apply

to the majority of walk-in pits.
(a) For walk-in pits where there is no risk of being stuck by
the car or related equipment:

2015 Safety Handbook 65

 (1) With elevators operating, it is generally safe to enter
the pit to perform brief visual inspections, to walk
from one pit to another to make observations, or to
retrieve dropped items at the front side of the hoist-
way (e.g. keys, money, jewelry, small tools, etc.).
(2) For brief work activities such as minor adjustments
or adding oil to buffers, the unit to be serviced must
have two circuits tested and verified that the elevator
will not run to ensure sufficient safe control.
(3) For repair work, the unit shall be locked and
tagged out.
(b) When working on elevated buffer stands (more than 6 ft.
[1.8 m] off the pit floor) fall protection (guardrails or
Personal Fall Protection) is required.

8.2.4 Safety precautions when working in pits:

(a) Locate a safe refuge area and be prepared to enter
same at a moments notice.
(b) Ensure that all portable lights and tools are connected
through a Ground Fault (GFCI).
(c) Take care to protect all lighting from damage.
(d) Do not work in a pit with standing water.
(e) Never jump into a pit always use the access ladder
or a portable ladder.
(f) Always check your shoes for oil/grease prior to climbing.
(g) Use both hands when using ladders entering or exiting
the pit.
(h) Be aware of moving equipment (i.e., counterweights,
pumps, motors, belts, and sheaves) and ensure that
clothing and hands cant get caught in them.
(i) Avoid smoking or open flames while in the pit.
(j) Use proper hand protection while cleaning pit.
(k) Never place your body under the car and have the car
lowered to or below the bottom landing. This does not
apply to walk-in pits.

66 2015 Safety Handbook

(l) Never stand in counterweight runway, under compensat-
ing chains or straddle over the traveling cable(s) loop.
(m) Never use wooden timbers to support car or counter-
weights.
(n) Do not leave parts, lubricants, cleaning equipment, etc
in the pit. This is a violation of the ASME A17.1/CSA B44
Code. Pipe stands may be properly stored in the pit, not
on the floor (hydraulic elevators).

8.2.5 Additional safety precautions to be taken

when working under hydraulic units:
(a) DO NOT stand on the hydraulic piping.
(b) DO NOT work on the hydraulic system (i.e., repacking a
jack, work on oil supply lines, pipe fittings or any portion
of system that may be under pressure) unless the eleva-
tor is landed on pipe supports.
(c) Avoid pinch points that a plunger or piston may present.
The plunger or piston may not react normally, especially
after repacking.

8.3 Hoistway Screening

Where an elevator is operating in a multiple hoistway, and

construction or modernization work is to be performed in an
adjacent portion of that multiple hoistway, that portion of the
elevators hoistway where the work is to be performed shall
be fully separated. The material used for this separation
shall:
(a) be equal to or stronger than 0.0437 in. (1.118 mm) dia. wire;
(b) have openings not exceeding 1 in. (25 mm);
(c) be so supported and braced so as to not deflect into the
code required running clearance of the adjacent car; and
(d) be in accordance with local code.

2015 Safety Handbook 67

8.4 Overhead Protection
(a) Overhead protection shall be provided in the hoistway
and in any other work area where there is exposure to
falling objects. This protection is to prevent all parts of
the body from being struck by falling tools, debris,
small parts, etc.
(b) In general, overhead protection can be achieved by one
or a combination of the following examples:
(1) False cars with roofs/netting designed and selected
by the company.
(2) Installation of an overhead barrier directly above the
work area which covers all areas where field personnel
have to stand or reach to install hoistway components
(3) Protection of all hoistway openings above the work
area (e.g.: installation of hoistway doors or protective
screening)
(4) Sealing off corridors to prevent other trades from
working near or passing by wall openings
(5) Walls are in place and all hoistway doors closed
(6) Guarding all holes in the machine room and secondary
levels
(7) Prohibiting simultaneous work in hoistway and
machine room with unguarded holes
(8) Prohibiting simultaneous work in common hoistways
where no hoistway screening exists between hoistways
(9) Prohibiting storage of materials within 6ft. (1.8m) of
hoistway openings.
(c) All cases where objects have fallen down the hoistway
must be immediately investigated and reported by the
mechanic in charge. Once the cause for this occurrence
has been identified, it will be mitigated by the company
or the MIC.

68 2015 Safety Handbook

8.5 Machine Room Safety

Access to machine rooms, as well as working in the

machine room itself, can be hazardous if proper precautions
are not taken. It is very important that you have the ability to
recognize potential hazards and are aware of the proper
precautions to take when they exist. Machine rooms shall be
secured from unauthorized access.

8.5.1 Access to the machine room

Just getting to a machine room can be hazardous, so recog-
nizing potential hazards and taking steps to correct or avoid them
is very important. Some of the more common hazards are:
(a) Lighting
(1) If the stairwell or hallway area is not well lit, use a
flashlight or other temporary lighting until the situa-
tion can be corrected Dont just feel your way in
the dark.
(b) Unsafe ladders
(1) Many machine rooms can only be accessed through
the use of fixed ladders. Always check the condition
of the ladder before climbing.
(2) Never climb a ladder with tools in your hands. Use
a rope to pull tools up.
(c) Machine room doors are typically self-closing and/or
self-locking. The ASME A17.1 requires the door to be
operable from inside the machine room without the need
to use a key.

2015 Safety Handbook 69

Section 9
TOOLS

9.1 Hand Tools

(a) Employees shall maintain hand tools in good condition
at all times.
(b) Do not use tool belts and never carry tools in your pockets.
(c) Never use tools that are worn, cracked or broken.
(d) Pliers and pipe wrenches shall not be used on nuts and
bolts.
(e) Crescent wrenches shall never be used in place of the
proper-type wrench.
(f) Do not use makeshift tools such as pipe, iron bars or
extensions for leverage (cheaters).
(g) Use the correct size crowbar for each job. Place a block
of wood under the head of the crowbar for leverage.
(h) Never strike hardened steel surfaces with a steel hammer.
Use a soft metal hammer or one with a plastic, wooden
or rawhide head.
(i) Cold-chisels, center-punches, etc., shall be dressed to
eliminate mushrooming.
(j) Keep a knife sharp and in a sheath or holder when car-
rying it on a job. Do not use it for stripping traveling
cable; use traveling cable strippers instead. When using
a knife, always cut away from your body.
(k) Avoid placing a tool box where another person may trip
over it.
(l) Split or loose handles in hammers or sledges shall be
replaced with new and properly fitted handles before
being used. Handles shall never be wired or taped.
(m) Always keep screwdrivers properly dressed and their
handles in good condition.

70 2015 Safety Handbook

(n) Never use a screwdriver as a punch, wedge, pinch bar,
pry or chisel.
(o) Files shall never be used unless they have a proper han-
dle, and never as a pry.
(p) Always use the proper tool for the job it was intended.
Figure 9a
Use only properly dressed chisels

Wrong Wrong Right

9.2 Portable Electric Tools and Lights

(a) Electrically powered tools cause the same types of inci-
dents as hand tools, but the injuries can be more severe.
(b) Power tools, portable lights or cord sets shall be pro-
tected by GFCIs.
(c) If the insulation on an electric tool or cord is broken,
cracked, missing or damaged, destroy and discard the
tool or cord.

2015 Safety Handbook 71

(d) Never tamper with or remove three-prong grounding
plugs or pins. This defeats the grounding protection.
When grounded outlets are not available as may be
found in older buildings adapter plugs shall be used
with the grounding wire secured to a positive ground.
(Note: The cover plate screw may not give a positive ground,
use your meter or GFCI tester to test for positive ground.)
(e) Always use a GFCI when plugged in even when using
double insulated tools. Figure 9b
(f) Double-insulated tools may be used if they are
distinctively marked with the words Double
Insulated, or the symbol shown in Figure 9b.
(g) When using extension cords, make sure the cord is
plugged into a grounded outlet of correct voltage and
the cord is capable of carrying the expected load.
Extension cords shall conform to OSHA Standards and
be Company-approved. 110-volt extension cords shall
be durably marked with the size (12-3 or 14-3 AWG) and
type as noted in the chart below:
Figure 9c Approved Markings for Extension Cords

Hard Service Junior Hard Service
S SO ST SE SJ SJE SJT
SOO STO SEO SJO SJEO SJTO
STOO SEOO SJOO SJEOO SJTOO
(h) Flexible cords shall be used in continuous lengths with-
out splice or tape.
(i) Electric cords shall not be run through holes in walls,
ceilings or floors. If run through doorways, windows, or
similar openings, they shall be protected from damage.
(j) Metal or plastic electrical boxes, commonly referred to
as handy boxes, shall not be used to make extension
cords and multipliers. Do not field engineer electrical
components.

72 2015 Safety Handbook

(k) Portable lights shall be equipped with guards to prevent
accidental contact with the bulb. Unless guards and
handles are properly grounded, they shall be made from
nonconductive materials.
(l) Portable lights shall not be suspended by their electric
cords, unless cords and lights are designed for this
means of suspension.
(m) Work areas, walkways and similar locations shall be
kept clear of all cords so as not to create a hazard to
employees or subject cords to damage.
(n) Do not lift or lower portable electric tools by the power
cord; use a handline. Never throw tools, equipment or
material from one work level to another.
(o) Keep all cords coiled when not in use. To prevent cord
damage do not wrap cords tightly around tools.
(p) Hand-held power tools shall not be equipped with a
dead man control. It may have a lock-on control provided
turn off can be accomplished by a single motion of the
same finger or fingers that turn it on.
(q) Power operated cutting tools shall have a functional brake.
(r) Avoid forcing tools; let the tool do the work.
(s) Unplug power when adjusting or cleaning the tool.
(t) Never use electrical tools for purposes other than intended.
(u) Keep guards in place and properly adjusted.
(v) Have a firm footing and be properly braced when using
power tools.
9.3 Powder Actuated Tools
Powder actuated tools are prohibited on all worksites.

2015 Safety Handbook 73

Section 10
PORTABLE LADDERS / SCAFFOLDS /
STATIONARY WORK PLATFORMS

10.1 Scaffolds and Stationary Work Platforms

(a) Scaffolds and stationary work platforms shall be erected
in accordance with approved safety standards under the
supervision of a Competent Person (see Section 21).
(b) When used, wooden or synthetic planks shall be
marked as scaffold-grade.
(c) The assembly and disassembly of scaffolds and stationary
work platforms shall be done using a safety harness and
lifeline anytime there is more than a 6 ft (1.8 m) fall exposure.
(d) Ladders are required to reach working surfaces more
than 2 ft (610 mm) above or below the point of access.
(e) In hoistways, at least two 2 in. (51 mm) by 10 in. (254
mm) planks must be used with a minimum of 6 in. (152
mm) of bearing and a maximum of 12 in. (305 mm) of
overhang beyond the bearing surface. The span shall
not exceed 10 ft (3.05 m) for a single plank. The planks
shall be cleated to prevent movement.
(f) No planks shall be of such length as to extend into pas-
sageways where there is a possibility of planking being
bumped by the movement of people, materials or equip-
ment through the area.
(g) Under no circumstances shall others be permitted to
use the Elevator Companys scaffolds, scaffolding
materials or stationary work platforms unless approved
by your Supervisor/Manager. Under no circumstances
shall the elevator company use other trade scaffolds or
stationary work platforms unless approved by your
Supervisor/ Manager.

74 2015 Safety Handbook

(h) If it is necessary to have workers below the work area,
make sure cover protection is provided. A minimum of 3/4 in.
(19 mm) plywood on 2 in. (51 mm) planking shall be used.
(i) Never erect scaffolding or stationary work platforms in
an active hoistway, unless the car has been completely
shut down and the mainline disconnect switch locked
out and tagged. (See Section 7.)
(j) Do not climb cross braces on scaffolds.
(k) When using tubular welded frame scaffold, the sections
shall be joined together using the lock pins provided for
that purpose.
(l) Spacing between ladder rungs shall meet OSHA standards.
(m) Scaffolds shall be equipped with baseplates.
(n) Scaffolds and stationary work platforms shall be tied into
the building with rigid connectors spaced 4 times the
minimum width at intervals not exceeding 26 ft (7.9 m).
(o) Unless the scaffold is fully planked and equipped with
proper guardrails and toeboards, the employee shall be
tied off using a personal fall-arrest system.
(p) Scaffolding shall be inspected for damage and proper
assembly each day before use.

10.2 Portable Ladders

(a) Only OSHA-compliant ladders shall be used.

(b) Use type 1-A ladders (300-lb rating) as a minimum.
(c) Because metal ladders are conductors of electricity,
they shall not be used.
(d) Extension ladders shall be equipped with safety feet.
(e) Ladders shall be examined for defects before every use.
Those found to be defective shall be tagged Defective
Do Not Use and removed from the jobsite.
(f) Ladders shall never be painted.

2015 Safety Handbook 75

(g) No more than one person is allowed on a ladder.
(h) Avoid reaching more than an arms length while working
on a ladder.
(i) Do not work from the top 3 rungs of any straight or
extension ladder or top 2 steps of an A-frame ladder.
(j) Only ladders of sufficient length shall be used. Adding
makeshift extensions is dangerous and prohibited.
(k) When ladders are used for ascending or descending
from one level to another, extend the ladder top at least
3 ft (914 mm) above the landing served and tie it off, with
feet secured against slippage.
(l) Extension ladders shall be placed so that the space
between the bottom of the ladder and the supporting
structure is 1/4 the supported length of the ladder (see
Figure 10a).
(m) When placing and using extension ladders, care shall
be taken to avoid overhead obstructions and hazards
(electrical, low ceilings, pipes, etc.).
(n) When a ladder is being used in a location where it may
be struck by others in the area, there shall be a second
person at the bottom of the ladder at all times. Ladders
shall never be left in such locations when not in use.
Whenever it is necessary to place a ladder in front of a
door opening, the door shall be blocked, locked or
guarded by a second person. When ladders are placed
in an aisle or corridor, the area shall be barricaded or
roped off.
(o) Be aware of the potential hazard of other trades working
on ladders in your immediate area.
(p) Lift and lower large articles with a handline.
(q) When climbing up and down, always face the ladder and
maintain 3-point contact at all times.
(r) Extension ladders shall not be taken apart to make two
ladders.

76 2015 Safety Handbook

(s) Step ladders shall only be used in their fully open posi-
tion with spreader or locking device engaged to prevent
accidental fold-up of the ladder.
(t) Remove tools, tool bucket and equipment from ladder
before moving.
(u) When working on a ladder, maintain three points of
contact, with center of body within the rails at all times or
fall protection shall be used when 6 ft. (1.8 m) or greater
above the ground.

Figure 10a

3'0" min
Illustration shows proper Secured
placement of ladder

L Length

On firm Safety
level sur- Feet
face

1/4 of L

2015 Safety Handbook 77

Section 11
MOVING WORK PLATFORMS

11.1 Running Platforms

(a) The running platform is not an elevator and shall not
be used to haul other personnel or material. Any other
use of a running platform shall be approved by your
Superintendent/Manager. In the event that work done
by another trade must be done on a running platform,
it shall be done only with the permission of your
Superintendent/Manager. Any movement of a running
platform shall be done by Elevator Company Personnel only.
(b) Before hoisting or roping of a platform, the governor
shall be installed and roped to the safety releasing arm
and tested to ensure that the safety is operational.
(c) Fall protection should always be utilized - However, if a
personal fall protection system is not utilized, the run-
ning platform shall be equipped with guardrails and
toeboards. The front of the platform shall be equipped
with removable guardrails until the front of the hoistway
is completely enclosed.
(d) When required the running platform shall be counter-
weighted for the weight of the car platform assembly
and its expected load. Counterweights shall be secured
from bouncing or being lifted out of the frame.
(e) Temporary run controls and cords shall be inspected
daily. Damaged cord shall be destroyed and discarded.
(f) Temporary run controls shall be three button control
(UP,DOWN, SAFETY) so that it takes activation of
two buttons to run any direction, plus an emergency
stop switch on a stand-alone circuit. Cords shall be fitted
with strain relief and insulation shall be intact. All buttons
shall function as intended.

78 2015 Safety Handbook

(g) The operating station shall have a means for locking it out of
service or disconnecting it to prevent unauthorized use.
(h) Buffers shall be in place before using a running platform.
(i) Running platform for hydraulic elevators shall never be
hoisted with a chain fall or winch.
11.2 Temporary Cars
(a) When an elevator is to be turned over to the building owner
or general contractor for temporary use during construc-
tion, it shall meet all the requirements of Section 5.10 of
the ASME A17.1 Safety Code for Elevators and Escalators
and/or applicable local code. Post proper signs showing
capacity in pounds (kilograms) and number of people.
(b) The signed Temporary Acceptance Form shall show
allowable capacity in pounds (kilograms) and number of
passengers. If counterweight, setting of governor, or
area of car platform have been altered, coordinate with
your office to provide proper documentation for opera-
tion of the temporary elevator.
11.3 False Cars And Other Devices
Used In The Hoistway
(a) There are a variety of false cars and similar devices
used in the hoistway to stack rails, set brackets, set
hoistway entrances, run hoistway wiring, etc. Remember
the following very important points at all times:
(1) In the event that work done by another trade must
be done from a false car, it shall be done only with
the permission of your Superintendent/Manager.
(2) Any movement of a false car shall be by Elevator
Company Personnel only.
(b) This equipment is designed to move Company workers,
equipment and supplies only. The maximum load on a

2015 Safety Handbook 79

 Figure 11a

FALSE CAR

Foot Safety Release

(Install opposite motor-side
of cable climbing device.)

Detail

80 2015 Safety Handbook

Figure 11b

see 11.3(f)

FALSE CAR
WITH OPTIONAL
DEBRIS NET

Typical arrangement of safety equipped

working platform with optional overhead
protection, hoist and wire rope safety.

NOTE: Net to be attached so it will

break away in a fall. Hanging but not
secured to the uprights.

2015 Safety Handbook 81

 false car shall not exceed the manufacturers rated load. The
manufacturers rated load shall be posted on the equipment.
(c) The assembly and disassembly of a false car shall be
done using body harnesses, shock-absorbing lanyards
and lifelines anytime there is more than a 6 ft (1.8 m) fall
exposure. (See Section 3.6.)
(d) When a false car is first placed in use on a job or moved
from one hoistway to another, a safety test as detailed by
Company Policy shall be performed to ensure the safeties
hold the load. This test shall be documented and a file
maintained as long as the false car is in use in that hoist-
way. A daily test shall be done on a static basis before
using the car each day. The overhead supports and rig-
ging shall be checked on a daily basis also. The safety
test shall be performed at or as close as possible to the
lowest landing. It is equally important that the false car
safeties be properly adjusted for the size rails on which
they are being used. Never disable the safeties by tying
back the safety cables.
(e) The two sides and rear of the false car shall be provided
with a guard rail system 42 in. 3 in. (1067 mm 76 mm)
high with a midrail 21 in. (533 mm) high and toe board
3-1/2 in. (90 mm) high, conforming to OSHA require-
ments. Warning chains shall be installed across the front
of the false car. Where working conditions are such that
overhead protection is required on the car, the use of a
debris net with 1/4 in. (6.4 mm) openings is recommended.
(f) An alternative to the optional safety net is a plywood struc-
ture mounted overhead on an angle slanting to the back of
the hoistway. If required, this protective structure should be
hinged with a heavy grade hinge and hardware. In the case
of front and rear openings the overhead protection shall be
slanted to the side of any non-opposing equipment.
(g) There are two recommended methods of moving a false
car in the hoistway. The first is a cable-climbing-type

82 2015 Safety Handbook

 device. These are available under a variety of names,
such as Power Climber, Sky Climber, and Cable Climbers,
etc. Each unit has some minor differences, but basically,
they operate in the same manner. They climb a wire
rope that has been located in the hoistway and securely
fastened to the overhead support structure. The excess
wire rope is normally coiled up and hung in the pit to
prevent damage to it.
(h) There shall be a safety line (block stop) or other second-
ary safety device installed to hold the unit in case of
failure of the main hoist rope. This safety line can either
be installed in the motor of the climber or it can run
through the cable-climbing device itself.
(i) In the event a false car is operated in the upper part of a
high-rise hoistway without enough wire rope to travel the
distance, sufficient safeguards shall be taken to prevent the
false car from traveling beyond the length of the wire rope.
(j) The cable-climbing device is attached to the false car by
bolting it to the lifting angle attached to the false-car
safety plank. Always use case-hardened bolts with lock
nuts for attachments. Some important things to watch out
for are:
(1) Fist grips shall be used on the wire ropes of the
climber. U-bolt-type clips shall not be used .
(2) Adequate padding shall be placed around the entire
support members; and
(3) All bolts shall be tightened and checked on a daily
basis.
(k) Another method of positioning a false car is to use a drum
hoist outside of the hoistway. No personnel shall ride the
platform as it is being positioned. The drum hoist is
rigged with overhead sheaves at the top of the hoist-
way to properly guide the hoist rope from the hoisting
machine to the false car. The hoisting machine shall be

2015 Safety Handbook 83

 equipped with a slack rope switch. There shall be an
operator at the hoist, and there shall be a positive two-
way communication between the hoist operator and the
workers on the false car. This is required any time a
hoisting machine is being used from a remote location.
A proper guardrail system shall be provided at the land-
ing where the hoist is located.
(l) Shafters and other similar-type pieces of equipment are
operated in the same manner as false cars and require
periodic safety tests and inspections according to the
manufacturers specifications. Shafters also have an
independent safety line (block stop) to arrest the fall of
the unit in the event the hoist rope fails, and shall be
installed on all jobs where shafters are used.

84 2015 Safety Handbook

Section 12
MATERIAL HANDLING

12.1 Manual Handling Lifting of Material

(a) When any heavy object is to be lifted and carried to
another point, first inspect and clear the area and route
over which the object is to be carried. Be sure nothing
is in the way that might cause slipping or tripping.
(b) Inspect the object to be lifted to determine how it will be
grasped. Make sure it is free of sharp edges, protruding
nail points, slivers or other hazards that might cause
injury to the hands or body. Wear appropriate gloves to
protect hands. (See Section 3.)
(c) Do not permit material storage within 6 ft (1.8 m) of
escalator wellways or elevator hoistways.
Lifting Loads
(a) Incorrect lifting methods require unnecessary effort and
often cause strain or other types of injuries. When it is
necessary to lift any object which is difficult for one
person to handle, ask for help.
(b) The safest way to lift is actually the easiest way to lift
(see Figure 12a):
Figure 12a

1 2-3-4 5

2015 Safety Handbook 85

 (1) Get a secure footing.
(2) Bend at knees to grasp the object.
(3) Keep a natural curve in back and as nearly upright
as possible.
(4) Get a firm hold.
(5) Lift gradually by straightening legs, keeping the
back as nearly straight as possible.
The same procedure must be observed when setting
loads down.
(c) A common injury that occurs in our industry is back
sprain or strain. Low-back pain is the most common
ailment. The misconception that back injuries are only
caused by improper lifting lulls us into a false sense of
security. Overexertion, overextending, overreaching
and improper bending are some of the many causes of
low-back pain. Most of the low-back ailments are nor-
mally not of a serious nature, until we choose to ignore
the warning signs. When this happens, the backaches
become chronic.
Figure 12b Position for Lifting

Right
Straighten legs

Legs Weight
bent close
to body

All the load is on the back

86 2015 Safety Handbook

Figure 12c

HELPFUL HINTS FOR ON AND OFF THE JOB

Walk with good posture. Keep

head high chin tucked in. Dont
slouch. Dont wear improper
shoes.

DOS DON'TS

Stay close to your work and Dont overextend your reach

keep feet flat on floor. by being on tip-toes.

2015 Safety Handbook 87

Figure 12d

DOS DON'TS

Dont Slump. Keep chair

Keep feet flat on thefloor
close to your work. Avoid
when sitting. Your
excessive leaning and
back should be
arching your back.
firmly against the
back of the chair.

Bend with your knees keep a Dont bend with your legs
natural curve in your back. Lift straight. Avoid lifting above
objects only chest high. shoulder level.

Sleep on firm mattress. Sleep on Dont sleep on soft, sagging

your side with your knees bent. mattresses. Sleeping on your
stomach will cause sway back.

88 2015 Safety Handbook

12.2 Ramping and Blocking of Material
(a) Handling of all heavy materials requires considerable
care. Never use short cuts.
(b) Pay particular attention to the position of fingers and feet
when using rollers, pinchbars, jacks and blocking to
move heavy materials and equipment.
(c) Before trying to lift a load with a pinchbar, be sure to
take an ample bite.
(d) Jacks shall always be placed on a solid footing and so located
that a good bite is provided on the object being moved.
(e) Timber used for blocking and cribbing shall be of ade-
quate size to carry and distribute loads being supported.
(f) When placing blocking and cribbing, be sure to have
ample bearing surface. Never stack the timber in such a
manner that maneuvering the load could cause it to tip.
(g) Whenever more than two tiers of timber are used, be
sure to cross-rib.
(h) Secure skid-boards to eliminate the possibility of their
shifting, and block or crib them to prevent excessive or
uneven deflection.
(i) Passageways for the movement of materials and equip-
ment shall be cleared of debris and obstacles to afford
needed working space and ease of movement.
(j) Before moving extremely heavy loads (machines,
escalator trusses, etc.) check with your Superintendent/
Manager that the floor will support the load.

12.3 Hoisting and Rigging

(a) The cardinal rules of hoisting are: stay clear of the load
at all times, never stand under the load, know the weight
of the load, capacity of your equipment, the structure
to which you are rigging and the overall condition

2015 Safety Handbook 89

 of these items. Stand uphill or to the side of a load
thats on a ramp.
(b) Do not allow non-Company personnel to use Elevator
Company hoisting and rigging.
(c) Elevator personnel must be aware of all hoisting being
done in or around their work area. Always take necessary
safety precautions.
(d) When elevator personnel are conducting hoisting opera-
tions, access to hoisting areas, especially hoistways
and wellways, shall be restricted to elevator personnel
involved in the lift. Warning signs shall be posted.
(e) Elevator personnel shall avoid areas where other
trades are hoisting.
(f) Before making the first hoist, and at the start of each
day thereafter, when the hoist is to be used, the rigging,
overhead supports, blocking, etc., shall be inspected
by the mechanic/MIC. The hoist shall be inspected
visually prior to each use. It shall be tested by raising
the load several inches and holding it there prior to
making an actual lift.
(g) Power operated rigging equipment shall be tested to
ensure the machine stalls prior to rigging breaking or
coming loose (i.e., tie to major support structure activate
motor to ensure integrity of rigging system).
(h) The safe working load of a hoist, or any part of the rigging
system, as determined by the manufacturer, shall be
clearly marked on the hoist or other equipment, and
this safe working load shall not be exceeded. If the
hoist or other equipment is not marked with the safe
working load do not use it.
(i) Only company approved hoisting and rigging equipment
shall be used.

90 2015 Safety Handbook

(j) No alterations to any hoisting and rigging equipment
shall be made without the manufacturers written
approval. Annual or manufacturers recommended test-
ing to certify the safe working load of the hoist shall be
done by a qualified testing facility and the hoist shall be
tagged or identified certifying test and date.
(k) The supporting structure to which the hoist is attached
shall have sufficient strength to support the load. (Refer
to Allowable Concentrated Loads on American Standard
Beams in Figure 22i).
(l) The support shall be arranged so as to provide for free
movement of the hoist and shall not restrict the hoist
from lining itself up with the load.
(m) The hoist shall be installed only in locations that permit
the operator to stand clear of the load at all times.
(n) The overhead structure shall be padded where any
choke or assembly is passed over steel. This padding is
essential to keeping the rigging in good condition.
(o) Only properly made wire rope or nylon slings and chok-
ers shall be used for rigging.
(p) Do not use the hoist chain as a choker.
(q) Do not use a jack wrench as a lifting block. These are
not designed for these uses.
(r) The use of two or more chain hoists for hoisting a single
load is not permitted, unless any one of them will handle
the entire load by itself.
(s) Whenever a load cannot be lifted by one person pulling on
the chain, investigate for overload or a defect in the chain fall.
(t) To prevent hooks from being disengaged from the load
or overhead support, it is recommended that only hooks
with safety latches be used. Hooks which do not have
safety latches shall be moused as a temporary measure.

2015 Safety Handbook 91

(u) A clevis-type shackle, with locking device or through
bolt with jam nut, or nut with cotter pin, shall be used to
hoist rails, brackets, etc.
(v) Use only manufacturer recommended wire rope of the
proper size for powered hoists. Always examine such wire
rope for defects. Wire ropes found to be defective shall not
be used.
(w) Always wear gloves when handling wire rope.
(x) When using a capstan hoist, do not stand in the coil of
rope.
(y) Do not rig the capstan hoist so as to overload it.

Figure 12e
VERTICAL PULL ONLY

Choker or
Beam Clamp

Load Line Choker

To Winch

ad
Lo

Snatch Block
ad
Lo
Lift Line

Do not pull so that bending stress is put on beam clamp.

92 2015 Safety Handbook

(aa) Do not drill additional holes in the capstan hoists mounting
brackets, as this could weaken the hoist.
(ab) Rated load divided by the number of parts of the rope
shall not exceed 20% of the nominal breaking strength
of the rope (i.e., safety factor of 5).
(ac) Wire rope used for supporting the top block hoist rig
shall have, as a minimum, one more turn than the
number of sheaves used in the traveling hoist rope,
and shall be well padded where it goes around the
support beam. Remember: Wire rope strength deterio-
rates 25% when it is wrapped around supports and is
secured with fist grip type clips.
(ad) Hoist machines shall be substantially secured so that
they will not shift under a load.
(ae) When starting a lift, gradually take slack out of slings
and make sure that no ones hands are in a position to
be caught between the load and sling hook.
(af) Never attempt to make a lift or move equipment when
anyone is in a position to be injured should the load shift
or fall.
(ag) Do not drag sling, chains, etc., along the floor or across
equipment.
(ah) When hoisting rails into a hoistway, and the guardrail
system must be removed to allow access, if there is
more than a 6 ft (1.8 m) fall exposure, the employee
feeding the rails into the hoistway shall be protected
from falling into the hoistway by a personal fall arrest
system attached to a lifeline. Remember to keep the
guardrail system up on the unused portions of the hoist-
way and keep others out of your hoisting area.
(ai) Clear communications are required. All verbal commands
shall be repeated by the receiving party and reconfirmed
by the directing party.

2015 Safety Handbook 93

Figure 12f

Allowable Number of Broken Strands

for Wire Ropes used in Hoisting Equipment
1. Six randomly distributed broken wires in one lay.
2. Three broken wires in one strand on one lay.
3. If one-third of the outside wires show wear or
disintegrate at any place on the rope.
Causes Of Wire Rope Failure
1. Using wire rope of insufficient strength for the job.
2. Improper rigging.
[Link].
4. Improper lubrication, storage and care, allowing
rusting, corrosion or internal abrasion.
5. Exposure to extreme heat.
6. Crushing on winch drum.
7. Using drums or sheaves of insufficient diameter
of incorrect tread.
8. Permitting ropes to abrade over sharp corners
or other fixed objects.
9. Contact with electrical current.
Signs Of Wire Rope Deterioration
1. Reduction of rope diameter below nominal
diameter due to loss of core support, internal/
external corrosion, or wear of outside wire.
2. Broken outside wires and degree of distribution
or concentration of broken wires.
3. Worn outside wires.
4. Corroded, rusty or broken wires at end connections.
5. Severe kinking, crushing, cutting and/or unstranding.

94 2015 Safety Handbook

12.4 Wire Rope Fastenings
(a) When it is necessary to make a short bend, as in attach-
ing wire rope or when it is to be looped, thimbles shall
always be used.
(b) Fist grips are preferred fasteners because the wire rope
does not become damaged.
(c) In forming an eye, the loose or dead end is clamped
against the main part of the rope, with the wire-rope
clips spaced a distance equal to six times the diameter
of the rope.
(d) Wire-rope clip fastenings seldom develop more than
80% of rope strength, at best.
(e) The point of greatest fatigue and/or wear in a rope usually
develops at or near the end where it is attached to the becket
on the block. Clips shall be inspected at least daily, and
tightened if they show signs of loosening. All connections
shall be periodically disassembled and the wire rope
inspected for damage on a regular basis.

Figure 12g

Double Saddle Clips (Fist Grip and J Clips)

2015 Safety Handbook 95

12.5 Chain Hoists
(a) Generally chain hoists are more durable, more adapt-
able and stronger than block and tackle.
(b) All chain hoists shall be visually inspected for defects
prior to first use, and daily when in use.
(c) The lower hook on all chain hoists is designed to be the
weakest part and will spread when overloaded. When
this occurs, the entire hoist shall be inspected.
(d) Damaged hoists shall be removed from service.
(e) Repairs shall only be made by an authorized representative
of the manufacturer. This includes the replacement of a chain.
(f) The unit shall be returned to the vendor for testing,
maintenance and internal inspection as recommended
by the manufacturer.
(g) Always use proper hand signals when hoisting. See
Figures 12i and 12j.
(h) Discard hooks that spread beyond allowable spread,
see Figure 12y.

12.6 Slings and Hitches

(a) Chain slings shall not be used when hoisting material.
(b) Nylon slings are to be used for hoisting equipment within
their rated load. Label with rating shall be attached to sling.
(c) Nylon slings shall be inspected for cuts or tears before
using and damaged slings discarded.
(d) The type of sling or hitch to be used shall be deter-
mined from the shape of the load and by the flexibility
and condition of the rope. In lifting multiple objects,
such as a load of lumber or steel sheathing, the sling
must bind on the load sufficiently to prevent slipping of
the individual pieces. In handling single pieces, such

96 2015 Safety Handbook

 as timbers, posts or piles, a timber hitch with two half-
hitches (or a similar hitch) shall be used.
(e) Only approved slings of proper size shall be used for
slinging loads.
(f) In using wire rope as straps for hooking onto tackle
blocks, there shall be the same number of parts of rope
in the strap as there are moving parts in the tackle. For
instance, if triple-block tackle is used, there shall be six
parts of rope for the strap.
(g) Endless wire slings shall be made using a minimum of
six fist grip rope clips as shown in Figure 12h. If the
rope is greater than 5/8 in. (16 mm) additional fist grip
rope clips are required, see Figure 12ac.
Figure 12h
ENDLESS SLING ASSEMBLY

D D D D
D = 6 times diameter of rope

(Also see Section 12.7 Crosby Lifting Guide)

12.7 Crosby Lifting Guide
The following pages of information in this section have
been printed with permission of The Crosby Group Inc. The
strengths of the slings, shackles and other rigging equipment
identified within these pages are to be used in conjunction
with the referenced Crosby products. When using rigging
equipment not manufactured by Crosby, obtain appropriate
strength and capacity information from the manufacturer of
the products that are being used.

2015 Safety Handbook 97

Figure 12i
HAND HOISTING SIGNALS

HOIST.
With forearm vertical, forefinger
pointing up move hand in
small horizontal circle.

EMERGENCY STOP.
Arms extended palms down,
move hands rapidly right and left.

MOVE SLOWLY.
Use one hand to give any
motion signal and place other
hand motionless in front of
hand giving the motion signal.
(Hoist Slowly shown in example.)

98 2015 Safety Handbook

Figure 12j

HAND HOISTING SIGNALS

LOWER.
With arm extended downward,
forefinger pointing down, move
hand in small horizontal circles.

STOP.
Arm extended, palm down,
move hand rapidly right and left.

DOG EVERYTHING.
Clasp hands in front of body.

2015 Safety Handbook 99

 Figure 12k
RIGHT AND WRONG RIGGING PRACTICES
Use of Chokers

RIGHT: WRONG:
No cutting action Right, because of cutting action of
on running lines. eye splice on running lines. Left,
bolt on running line can work loose.
Suspending Needle Beams or Scaffolds

WRONG:
Steel can
cut rope.

RIGHT: Sharp
(Also see Section 12.7 Crosby Lifting Guide)

corners padded.

Eye Bolts
RIGHT: Vertical
lift on eye bolt.

WRONG:
Lifting on eye
bolts from an
angle reduces
safe loads as
much as 90%.

100 2015 Safety Handbook

Figure 12l

RIGHT AND WRONG RIGGING PRACTICES

Hoisting Structural Steel
RIGHT: Use space
blocks and pad corners.

WRONG:
Can bend flanges
and cut rope.

Hook Slings

RIGHT: WRONG: Hook openings

(Also see Section 12.7 Crosby Lifting Guide)

Hooks are turned out. should be turned out.

NOTE: When hoisting 2 or more pieces of material

over 12 ft long, double slings hall be used.

RIGHT:
Load
over 12 ft
long
WRONG:
Load over 12 ft long

2015 Safety Handbook 101

 Figure 12m

1
USERS GUIDE LIFTING VERSION (4/02)

RISK MANAGEMENT TERMINOLOGY FOR ADDITIONAL

DEFINITION WORKING LOAD LIMIT (WLL) SUPPORT
COMPREHENSIVE SET OF ACTIONS THAT THE MAXIMUM MASS OR FORCE WHICH THE
REDUCES THE RISK OF A PROBLEM, A PRODUCT IS AUTHORIZED TO SUPPORT IN A
FAILURE, AN ACCIDENT PARTICULAR SERVICE.

PROOF TEST

102 2015 Safety Handbook

P.O. Box 3128
Quality Continuum A TEST APPLIED TO A PRODUCT SOLELY TO Tulsa Oklahoma 74101
DETERMINE INJURIOUS MATERIAL OR
MANUFACTURING DEFECTS. Phone: (918) 834-4611
Fax: (918) 832-0940
ULTIMATE STRENGTH 1-800-777-1555
THE AVERAGE LOAD OR FORCE AT WHICH Web:
THE PRODUCT FAILS OR NO LONGER
SUPPORTS THE LOAD.
[Link]
E-Mail:
DESIGN FACTOR crosbygroup@[Link]
AN INDUSTRIAL TERM DENOTING A
PRODUCTS THEORETICAL RESERVE
CAPABILITY; USUALLY COMPUTED BY
BLOCKS & FITTINGS
DIVIDING THE CATALOG ULTIMATE LOAD BY FOR WIRE ROPE & CHAIN
THE WORKING LOAD LIMIT. GENERALLY
EXPRESSED AS A RATIO,
e.g. 5 TO 1. CROSBY FITTINGS
LEBUS McKISSICK
WESTERN NATIONAL
 Figure 12n

THE BASIC RIGGING PLAN RESPONSIBILITY 2

1. WHO IS RESPONSIBLE (COMPETENT) FOR THE USER RESPONSIBILITY

RIGGING? COMMUNICATION ESTABLISHED?
2. IS THE EQUIPMENT IN ACCEPTABLE CONDITION? 1. UTILIZE APPROPRIATE RIGGING GEAR SUITABLE FOR
APPROPRIATE TYPE, PROPER IDENTIFICATION? OVERHEAD LIFTING.
3. ARE THE WORKING LOAD LIMITS ADEQUATE? 2. UTILIZE THE RIGGING GEAR WITHIN INDUSTRY
CAPACITY OF GEAR KNOWN? STANDARDS AND THE MANUFACTURERS
WHAT IS THE WEIGHT OF LOAD? RECOMMENDATIONS.
WHERE IS THE CENTER OF GRAVITY? 3. CONDUCT REGULAR INSPECTION AND
WHAT IS THE SLING ANGLE? MAINTENANCE OF THE RIGGING GEAR.
WILL THERE BE ANY ANGULAR OR SIDE LOADING?
ARE THE SLINGS PADDED AGAINST SHARP MANUFACTURERS RESPONSIBILITY
CORNERS? 1. PRODUCT AND APPLICATION INFORMATION
4. WILL THE LOAD BE UNDER CONTROL? 2. PRODUCT THAT IS CLEARLY IDENTIFIED
IS THE LOAD RIGGED TO THE CENTER NAME OR LOGO
OF GRAVITY? LOAD RATING AND SIZE
IS THE HITCH APPROPRIATE? TRACEABILITY
TAG LINE NEEDED? 3. PRODUCT PERFORMANCE
IS THERE ANY POSSIBILITY OF FOULING? WORKING LOAD LIMIT
CLEAR OF PERSONNEL? DUCTILITY
5. ARE THERE ANY UNUSUAL FATIGUE PROPERTIES
LOADING OR ENVIRONMENTAL IMPACT PROPERTIES
CONDITIONS?
WIND, TEMPERATURE, OTHER?
6. SPECIAL REQUIREMENTS?

2015 Safety Handbook 103

 Figure 12o

INSPECTION OF HARDWARE INSPECTION OF WIRE ROPE SLINGS 3

DEFORMATION PER ANSI B30.9
REMOVE FROM SERVICE IF ANY SIGNIFICANT ALL SLINGS AND ATTACHMENTS SHALL BE VISUALLY
DEFORMATION. CHECK THROAT OPENING OF HOOKS. INSPECTED BY THE PERSON HANDLING THE SLING EACH
DAY THEY ARE USED. IN ADDITION, A PERIODIC
WEAR INSPECTION SHALL BE PERFORMED BY A DESIGNATED
PERSON, AT LEAST ANNUALLY, AND SHALL INCLUDE A
REMOVE FROM SERVICE IF EXCESSIVE WEAR. WEAR IS RECORD OF THE INSPECTION.
EXCESSIVE IF:
MORE THAN 5% WEAR IN THROAT OR EYE OF HOOK INSPECTION CRITERIA
AND OTHER CRITICAL AREAS OF HARDWARE.

104 2015 Safety Handbook

MORE THAN 10% WEAR IN OTHER AREAS. KINKING CORE PROTRUSION
CRUSHING CORROSION
CRACKS, NICKS, GOUGES UNSTRANDING BIRDCAGING
BROKEN OR CUT STRANDS BROKEN WIRES
REMOVE FROM SERVICE IF CRACKS, NICKS, OR GOUGES STRANDING DISPLACEMENT
ARE DETECTED.

MODIFICATION BROKEN WIRES

REMOVE FROM SERVICE STRAND LAID AND SINGLE PART
DO NOT WELD, DO NOT SUBSTITUTE SHACKLE PINS OR SLINGS IF TEN OR MORE RANDOMLY DISTRIBUTED WIRES
OTHER COMPONENTS, DO NOT HEAT, BEND OR MODIFY IN ONE ROPE LAY, OR FIVE BROKEN WIRES IN ONE ROPE
IN ANY MANNER. STRAND IN ONE ROPE LAY.
PROPER FUNCTION DISTORTION OF WIRE ROPE
IMPROPERLY INSTALLED HARDWARE OR MALFUNCTION REMOVE FROM SERVICE WIRE ROPE SLINGS THAT HAVE
IS CAUSE FOR REMOVAL. CHECK FOR LATCHES, SWIVEL ANY DAMAGE RESULTING IN DISTORTION OF THE WIRE
BEARINGS, LOCKING DEVICES, AND INSTALLATION OF ROPE STRUCTURE SUCH AS KINKING, CRUSHING,
WIRE ROPE CLIPS AND WEDGE SOCKETS. UNSTRANDING, BIRDCAGING, STRAND DISPLACEMENT
OR CORE PROTRUSION.
 Figure 12p

INSPECTION OF CHAIN SLINGS INSPECTION OF SYNTHETIC SLINGS 4

PER ANSI B30.9 PER ANSI B30.9
ALL SLINGS AND ATTACHMENTS SHALL BE VISUALLY ALL SLINGS AND ATTACHMENTS SHALL BE VISUALLY
INSPECTED BY THE PERSON HANDLING THE SLING EACH INSPECTED BY THE PERSON HANDLING THE SLING EACH
DAY THEY ARE USED. IN ADDITION, A PERIODIC DAY THEY ARE USED. IN ADDITION, A PERIODIC
INSPECTION (NORMAL SERVICE: YEARLY, SEVERE INSPECTION SHALL BE PERFORMED BY A DESIGNATED
SERVICE: MONTHLY) SHALL BE PERFORMED BY A PERSON, AT LEAST ANNUALLY, AND SHALL INCLUDE A
DESIGNATED PERSON, AT LEAST ANNUALLY, AND SHALL RECORD OF THE INSPECTION.
INCLUDE A RECORD OF THE INSPECTION.
INSPECTION CRITERIA
INSPECTION CRITERIA ACID OR CAUSTIC BURNS BROKEN STITCHES
WEAR WELD SPLATTER MELTING OR CHARRING WORN STITCHES
NICK, CRACKS, BREAKS EXCESSIVE TEMPERATURE HOLES, CUTS EXCESSIVE ABRASION
GOUGES, STRETCH, BENDS THROAT OPENING OF HOOK TEARS, SNAGS KNOTS

CHAIN LINKS ROUND SLING NOTES

REMOVE SLING FROM SERVICE IF LINKS ARE WORN REMOVE FROM SERVICE ROUND SLINGS THAT HAVE
EXCESSIVELY (MORE THAN 10% OR REFER TO CORE FIBER EXPOSED BY HOLES, TEARS, CUTS,
MANUFACTURERS INFORMATION), SHARP TRANSVERSE EMBEDDED PARTICLES, WEAR OR SNAGS.
NICKS AND GOUGES SHOULD BE ROUNDED OUT BY REMOVE FROM SERVICE ROUND SLINGS THAT HAVE
GRINDING (DO NOT EXCEED WEAR ALLOWANCE). CHAIN MELTING, CHARRING OR WELD SPLATTER ON ANY PART
LINKS AND ATTACHMENTS SHOULD HINGE FREELY TO OF SLING.
ADJACENT LINKS.
IDENTIFICATION
IDENTIFICATION WEB SLINGS AND ROUND SLINGS SHALL BE
CHAIN SLINGS SHALL HAVE PERMANENTLY AFFIXED PERMANENTLY MARKED INDICATING: MANUFACTURERS
IDENTIFICATION STATING: SIZE, GRADE, RATED LOAD, TRADEMARK AND CODE (OR STOCK NUMBER), RATED
NUMBER OF LEGS AND MANUFACTURER. LOADS FOR THE THREE HITCHES AND MATERIAL.

2015 Safety Handbook 105

 Figure 12q

WIRE ROPE SLING CAPACITIES (LBS.) - FLEMISH EYE - ANSI B30.9 5

6 X 19 AND 6 X 37 IMPROVED PLOW STEEL - IWRC 5/1 DESIGN FACTOR

Q & T CARBON ANGLE

SHACKLE 120
MINIMUM
SHACKLE SIZE 90 45
60 30
WIRE FOR A D/d>1
ROPE AT LOAD
SIZE CONNECTION

106 2015 Safety Handbook

SHACKLE VERTICAL TWO LEG 60 DEGREE 45 DEGREE 30 DEGREE
SIZE (SINGLE LEG) CHOKER OR BASKET HITCH SLING ANGLE SLING ANGLE SLING ANGLE
1/4 5/16 1120 820 2200 1940 1500 1120
5/16 3/8 1740 1280 3400 3000 2400 1740
3/8 7/16 2400 1840 4800 4200 3400 2400
7/16 1/2 3400 2400 6800 5800 4800 3400
1/2 5/8 4400 3200 8800 7600 6200 4400
9/16 5/8 5600 4000 11200 9600 7900 5600
5/8 3/4 6800 5000 13600 11800 9600 6800
3/4 7/8 9800 7200 19600 16900 13800 9800
7/8 1 13200 9600 26400 22800 18600 13200
1 1-1/8 17000 12600 34000 30000 24000 17000
1-1/8 1-1/4 20000 15800 40000 34600 28300 20000
1-1/4 1-3/8 26000 19400 52000 45000 36700 26000
1-3/8 1-1/2 30000 24000 60000 52000 42400 30000
RATED CAPACITIES BASED ON PIN DIAMETER OR HOOK NO LONGER THAN THE NATURAL EYE WIDTH (1/2 X EYE LENGTH) OR LESS THAN
THE NOMINAL SLING DIAMETER
REFER TO ANSI B30.9 FOR FULL DETAILS
HORIZONTAL SLING ANGLES OF LESS THAN 30 DEGREES ARE NOT RECOMMENDED
 Figure 12r

WIRE ROPE SLING CAPACITIES - TONS (2000 LBS.) - FLEMISH EYE - ASME B30.9 5A
6 X 19 AND 6 X 37 EXTRA IMPROVED PLOW STEEL - IWRC 5/1 DESIGN FACTOR
HORIZONTAL SLING ANGLES OF LESS THAN 30 DEGREES ARE NOT RECOMMENDED
WIRE
ROPE
SIZE
INCHES

SINGLE SINGLE TWO LEG SLING TWO LEG SLING TWO LEG CHOKER
LEG CHOKER VERTICAL 60 45 60
(VERTICAL) HORIZONTAL HORIZONTAL HORIZONTAL
SLING ANGLE SLING ANGLE SLING ANGLE
1/4 0.65 0.48 1.3 1.1 0.9 0.8
3/8 1.4 1.1 2.9 2.5 2.0 1.8
7/16 1.9 1.4 3.9 3.4 2.7 2.5
1/2 2.5 1.9 5.1 4.4 3.6 3.2
9/16 3.2 2.4 6.4 5.5 4.5 4.1
5/8 3.9 2.9 7.8 6.8 5.5 5.0
3/4 5.6 4.1 11.0 9.7 7.9 7.1
7/8 7.6 5.6 15.0 13.0 11.0 9.7
1 9.8 7.2 20.0 17.0 14.0 13.0
1-1/8 12.0 9.1 24.0 21.0 17.0 16.0
1-1/4 15.0 11.0 30.0 26.0 21.0 19.0

2015 Safety Handbook 107

 Figure 12s

WIRE ROPE SLINGS AND WIRE ROPE SLINGS AND 6

CONNECTIONS TO FITTINGS CONNECTIONS TO FITTINGS
USE A THIMBLE TO NEVER PLACE A A CHOKER HITCH HAS
PROTECT SLING AND SLING EYE OVER A 75% OF THE CAPACITY
INCREASE D/d FITTING WITH A OF A SINGLE LEG ONLY
DIAMETER OR IF THE CORNERS ARE
NEVER PLACE EYE WIDTH GREATER SOFTENED AND THE
OVER A FITTING THAN ONE HALF HORIZONTAL ANGLE IS
SMALLER DIAMETER THE NATURAL GREATER THAN 30
OR WIDTH THAN THE LENGTH DEGREES. USE A
ROPES DIAMETER. OF THE BLOCK OF WOOD

108 2015 Safety Handbook

EYE. UNDER CHOKE TO
INSURE ANGLE IS
PROPER.

60 45 30

TRIPLE LEG SLINGS HAVE 50% MORE CAPACITY

CAPACITY % OF THAN DOUBLE LEG ONLY IF THE CENTER OF
GRAVITY IS IN CENTER OF CONNECTION POINT
ANGLE SINGLE LEG AND LEGS ARE ADJUSTED PROPERLY (EQUAL
90 200 % SHARE OF THE LOAD)
A BASKET HITCH HAS TWICE 60 170 % QUAD LEG SLINGS OFFER IMPROVED
THE CAPACITY OF A SINGLE STABILITY BUT DO NOT PROVIDE INCREASED
45 140 % LIFTING CAPACITY.
LEG ONLY IF D/d RATIO IS 25/1
AND THE LEGS ARE VERTICAL. 30 100 %
 Figure 12t

CHAIN SLING CAPACITIES (LBS.) - CHAIN GR-8 - ASME B30.9 DESIGN FACTOR 4/1 7

CHAIN
60
SIZE 45 30
(IN.) 90
QT
ALLOY
CHAIN GR - 8 SINGLE LEG DOUBLE LEG
DESIGN VERTICAL TWO LEG OR 60 DEGREE 45 DEGREE 30 DEGREE MASTER LINK MASTER LINK
FACTOR 4/1 (SINGLE LEG) BASKET HITCH SLING ANGLE SLING ANGLE SLING ANGLE SIZE (IN.) SIZE (IN.)
1/4 - (9/32) 3500 7000 6050 4900 3500 1/2 1/2
3/8 7100 14200 12200 10000 7100 3/4 3/4
1/2 12000 24000 20750 16950 12000 7/8 1
5/8 18100 36200 31350 25500 18100 1 1-1/4
3/4 28300 56600 49000 40000 28300 1-1/4 1-1/2
7/8 34200 68400 59200 48350 34200 1-1/2 1-3/4
1 47700 95400 82600 67450 47700
1-1/4 72300 144600 125200 102200 72300

A CHAIN GRAB HOOK

APPLICATION WILL 60
RESULT IN A 20% 45
30
REDUCTION OF CHAIN
CAPACITY OF A SINGLE
LEG. THE HORIZONTAL
HORIZONTAL CAPACITY % OF ANGLE MUST BE TRIPLE LEG SLINGS HAVE 50% MORE CAPACITY THAN
ANGLE SINGLE LEG DOUBLE LEG ONLY IF THE CENTER OF GRAVITY IS IN
GREATER THAN 30
90 200% DEGREES. CENTER OF CONNECTION POINT AND LEGS ARE
60 170% ADJUSTED PROPERLY (EQUAL SHARE OF THE LOAD).
45 140% QUAD LEG SLINGS OFFER IMPROVED STABILITY BUT
30 100% DO NOT PROVIDE INCREASED LIFTING CAPACITY.

2015 Safety Handbook 109

 Figure 12u

CHAIN SLING CAPACITIES (LBS.) - CHAIN GR-10 - ASME B30.9 DESIGN FACTOR 4/1 7A

CHAIN
60
SIZE 45 30
(IN.) 90
QT
ALLOY
CHAIN GR - 10 SINGLE LEG DOUBLE LEG
4 TO 1 DESIGN VERTICAL TWO LEG OR 60 DEGREE 45 DEGREE 30 DEGREE MASTER LINK MASTER LINK
FACTOR (SINGLE LEG) BASKET HITCH SLING ANGLE SLING ANGLE SLING ANGLE SIZE (IN.) SIZE (IN.)
1/4 - (9/32) 4300 8600 7400 6100 4300 1/4-5/16 in. 3/8 in.

110 2015 Safety Handbook

5/16 5700 11400 9900 8100 5700 1/4-5/16 in. 3/8 in.
3/8 8800 17600 15200 12400 8800 3/8 in. 1/2 in.
1/2 15000 30000 26000 21200 15000 1/2 in. 5/8 in.
5/8 22600 45200 39100 32000 22600 5/8 in. 3/4 in.

Crosby Spectrum 10 System Makes Assembly Easy

A-1342
Master Link
 Figure 12v

WEB SLING CAPACITIES - ANSI B30.9 - DESIGN FACTOR 5/1 9

ANGLE
120

30
90 60 45

VERTICAL TWO LEG 60 DEGREE 45 DEGREE 30 DEGREE

(SINGLE LEG) CHOKER OR BASKET SLING ANGLE SLING ANGLE SLING ANGLE
100% OF 80% OF 200% OF 170% OF 140% OF SAME AS
SINGLE LEG SINGLE LEG SINGLE LEG SINGLE LEG SINGLE LEG SINGLE LEG

SYNTHETIC SLINGS A CHOKER HITCH HAS 80% OF

60
THE CAPACITY
RATED LOAD 45
OF A SINGLE 30
LEG IF THE
FOLDING, BUNCHING OR CORNERS ARE
PINCHING OF SYNTHETIC SOFTENED AND
SLINGS, WHICH OCCURS WHEN THE TRIPLE LEG SLINGS HAVE 50% MORE
USED WITH SHACKLES, HOOKS HORIZONTAL CAPACITY THAN DOUBLE LEG ONLY IF THE
OR OTHER APPLICATION WILL ANGLE IS CENTER OF GRAVITY IS IN CENTER OF
REDUCE THE RATED LOAD. GREATER THAN CONNECTION POINT AND LEGS ARE
30 DEGREES. ADJUSTED PROPERLY (EQUAL SHARE OF
USE A BLOCK OF THE LOAD).
WOOD UNDER
CHOKE TO QUAD LEG SLINGS OFFER IMPROVED
INSURE ANGLE STABILITY BUT DO NOT PROVIDE
BUNCHING PINCHING IS PROPER. INCREASED LIFTING CAPACITY.

2015 Safety Handbook 111

 Figure 12w

CENTER OF GRAVITY AND SLING LOADING WEIGHT = VOLUME X UNIT WEIGHT OF MATERIAL 10
3
WHEN LIFTING VERTICALLY, UNIT WEIGHT STEEL = 490 LBS/FT
3
THE LOAD WILL BE SHARED UNIT WEIGHT ALUMINUM = 165 LBS/FT
3
EQUALLY IF THE CENTER OF CENTER OF GRAVITY AND UNIT WEIGHT CONCRETE = 150 LBS/FT
3
GRAVITY IS PLACED EQUALLY SLING LOADING
UNIT WEIGHT WOOD = 50 LBS/FT
3
BETWEEN THE PICK POINTS. UNIT WEIGHT WATER = 62 LBS/FT
3
SLING 1 SLING 2 UNIT WEIGHT SAND AND GRAVEL = 120 LBS/FT
IF THE WEIGHT OF THE LOAD
IS 10,000 LBS., THEN EACH 10,000 LBS.
SLING WILL HAVE A LOAD VOLUME OF CUBE =
OF 5,000 LBS. AND EACH HEIGHT x WIDTH x LENGTH
D1=5 FT D2=5 FT

112 2015 Safety Handbook

SHACKLE AND EYEBOLT WILL
ALSO HAVE A LOAD OF 5,000 LBS. HEIGHT
WIDTH

CENTER OF GRAVITY AND SLING LOADING WEIGHT = VOLUME X UNIT WEIGHT OF MATERIAL
WHEN THE CENTER OF GRAVITY
CENTER OF GRAVITY AND
IS NOT EQUALLY SPACED BETWEEN SLING LOADING VOLUME OF SPHERE =
THE PICK POINTS, THE SLING AND
3.14 x (DIAM. x DIAM. x DIAM.) / 6
FITTINGS WILL NOT CARRY AN EQUAL SLING 1 SLING 2
SHARE OF THE LOAD. THE SLING
VOLUME OF CYLINDER =
CONNECTED TO THE PICK POINT 10,000 LBS.
3.14 x (DIAM. x DIAM. x LENGTH) / 4
CLOSEST TO THE CENTER OF GRAVITY
WILL CARRY THE GREATEST SHARE
D1=8 FT D2=2 FT
OF THE LOAD.
SLING 2 IS CLOSEST TO COG. IT WILL HAVE THE GREATEST SHARE
OF THE LOAD. DIAMETER
SLING 2 = 10,000 X 8 / (8+2) = 8,000 LBS.
SLING 1 = 10,000 X 2 / (8+2) = 2,000 LBS.
 Figure 12x

SLING ANGLES 11
TWO LEGGED SLING - WIRE ROPE, CHAIN, SYNTHETICS
LOAD = LOAD IN EACH HORIZONTAL SLING LOAD ANGLE
500 X LOAD SLING = L/H X 500 ANGLE (A) DEGREE FACTOR = L/H
ANGLE 90 1.000
FACTOR
60 1.155
A A 50 1.305
A=
HORIZONTAL 45 1.414
SLING 30 2.000
ANGLE LOAD ON EACH LEG OF SLING =
VERTICAL LOAD X LOAD ANGLE FACTOR

HORIZONTAL SLING
ANGLES OF LESS THAN
30 DEGREES
ARE NOT
RECOMMENDED
REFER TO ANSI B30.9
FOR FULL
INFORMATION

LOAD ON SLING CALCULATED LOAD ON SLING CALCULATED

TENSION 1 = LOAD X D2 X S1/(H(D1+D2)) TENSION 1 = LOAD X D2 X S1/(H(D1+D2))
TENSION 2 = LOAD X D1 X S2/(H(D1+D2)) TENSION 2 = LOAD X D1 X S2/(H(D1+D2))

2015 Safety Handbook 113

 Figure 12y

RIGGING HARDWARE 12
SHACKLES QUENCHED & TEMPERED HOOKS QUENCHED & TEMPERED
IN METRIC TONS DESIGN FACTOR IN METRIC TONS
SCREW PIN CARBON SHACKLE ALLOY SHACKLE QUIC-CHECK SHANK HOOK EYEHOOKS - 5/1 (EXCEPT ALLOY QUIC-CHECK
AND DESIGN FACTOR DESIGN FACTOR SWIVEL HOOK 30 TON AND LARGER ARE 4-1/2 TO 1)
BOLT TYPE 6/1 5/1 EYE HOOK SHANK AND SWIVELS ARE 4-1/2 TO 1.
CARBON ALLOY CARBON ALLOY
NOMINAL MAXIMUM MAXIMUM MAXIMUM MAXIMUM
SIZE (IN) WORKING WORKING INSIDE WIDTH WORKING WORKING THROAT DEFORMATION
DIAMETER LOAD LOAD AT PIN DIAMETER LOAD LOAD OPENING INDICATOR
OF BOW TONS TONS (INCHES) OF PIN TONS CODE TONS CODE (INCHES) A-A
3/16 1/3 1.38 1.25 3/4 DC 1 DA 1.89 11.50

114 2015 Safety Handbook

1/4 1/2 1.47 1.31 1 FC 1-1/2 FA 1.91 12.00
5/16 3/4 1.53 1.38 1-1/2 GC 2 GA 1.00 12.00
3/8 1 2 1.66 1.44 2 HC 3 HA 1.09 12.00
7/16 1-1/2 2.6 1.75 1.50 3 IC *4-1/2 /5 IA 1.36 12.50
1/2 2 3.3 1.81 1.63 5 JC 7 JA 1.61 13.00
5/8 3-1/4 5 1.06 1.75 7-1/2 KC 11 KA 2.08 14.00
3/4 4-3/4 7 1.25 1.88 10 LC 15 LA 2.27 14.00
7/8 6-1/2 9.5 1.44 1.00 15 NC 22 NA 3.02 15.00
1 8-1/2 12.5 1.69 1.13 20 OC 30 OA 3.25 16.50
1-1/8 9-1/2 15 1.81 1.25 25 PC 37 PA 3.00 17.00
1-1/4 12 18 2.03 1.38 30 SC 45 SA 3.38 18.00
1-3/8 13-1/2 21 2.25 1.50 40 TC 60 TA 4.12 10.00
1-1/2 17 30 2.38 1.63 * 320 EYE HOOK IS NOW RATED AT 5 TONS

INSURE SCREW PIN IS DO NOT SIDE LOAD ROUND

MAXIMUM
TIGHT BEFORE EACH LIFT PIN SHACKLE DO NOT SIDELOAD
INCLUDED
USE BOLT TYPE USE SCREW PIN OR BOLT ANGLE 90 DO NOT TIP LOAD
SHACKLE FOR TYPE TO COLLECT SLINGS.
DEGREES DO NOT BACKLOAD
PERMANENT
MAXIMUM INCLUDED ANGLE EYE HOOK
INSTALLATION INCLUDED
INCLUDED
HUNG ANGLE 120 DEGREES HUNG ANGLE

FOR ADDITIONAL INFORMATION REFER TO THE PRODUCT WARNINGS

 Figure 12z

RIGGING HARDWARE 13

LINKS AND RINGS WITH TURNBUCKLES

WIRE ROPE AND SYNTHETIC G-341 A-341 A-342
SLINGS 5/1 DESIGN FACTOR CARBON ALLOY ALLOY
WORKING LOAD LIMIT POUNDS WORKING LOAD LIMIT WORKING LOAD LIMIT
SIZE JAW AND EYE HOOK END FITTING
INCHES G-341 A-341 A-342 SIZE 5/1 DESIGN FACTOR 5/1 DESIGN FACTOR
1/2 2900 7000 7000 1/4 500 400
5/8 4200 9000 9000 5/16 800 700
3/4 6000 12300 12300 3/8 1200 1000
7/8 8300 14000 14000 1/2 2200 1500
1 10800 24360 24360 5/8 3500 2250
1-1/8 N/A 30600 N/A 3/4 5200 3000
1-1/4 16750 36000 36000 7/8 7200 4000
1-3/8 20500 43000 N/A 1 10000 5000
1-1/2 N/A 54300 54300 1-1/4 15200 6500
1-5/8 N/A 62600 N/A 1-1/2 21400 7500
1-3/4 N/A 84900 84900
2 N/A 102600 102600 THE USE OF LOCKNUTS
WORKING LOAD LIMITS ARE FOR USE WITH WIRE ROPE AND OR MOUSING IS AN
SYNTHETIC SLINGS, NOT FOR CHAIN SLINGS. WORKING LOAD EFFECTIVE METHOD OF
LIMITS ARE BASED ON SINGLE LEG (IN-LINE), OR RESULTANT PREVENTING TURNBUCKLES
LOAD ON MULTIPLE LEGS WITH AN INCLUDED ANGLE LESS THAN FROM ROTATING.
OR EQUAL TO 120 DEGREES.

FOR ADDITIONAL INFORMATION REFER TO THE PRODUCT WARNING

2015 Safety Handbook 115

 Figure 12aa

RIGGING HARDWARE 14
QUENCHED &
TEMPERED DESIGN
SHOULDER DESIGN FACTOR SWIVEL FACTOR 5/1
EYE BOLTS 5/1 HOIST RINGS
WORKING WORKING WORKING LOAD WORKING LOAD
WORKING LOAD LIMIT LOAD LIMIT LIMIT ANGLE LESS LIMIT FULL
LOAD LIMIT 60 DEGREES 45 DEGREES THAN 180 DEGREE THREAD
SHANK IN LINEPULL SLING ANGLE SLING ANGLE 45 DEGREES PIVOT SHANK TORQUE
DIAMETER (LBS.) (LBS.) (LBS.) (LBS.) (LBS.) SIZE U.N.C. FT - (LBS)

116 2015 Safety Handbook

1/4 650 420 195 160 800 5/16 7
5/16 1200 780 360 300 1000 3/8 12
3/8 1550 1000 465 380 2500 1/2 28
1/2 2600 1690 780 650 4000 5/8 60
5/8 5200 3380 1560 1300 7000 3/4 100
3/4 7200 4680 2160 1800 8000 7/8 160
7/8 10600 6890 3180 2650 10000 1 230
1 13300 8645 3990 3325 15000 1-1/4 470
1-1/4 21000 13600 6300 5250 24000 1-1/2 800
1-1/2 24000 15600 7200 6000 30000 2 1100
SHOULDER EYE BOLTS SWIVEL HOIST RINGS
WHEN USING LIFTING SLINGS OF TWO OR MORE LEGS
NEVER EXCEED WORKING LOAD LIMITS.
MAKE SURE THE FORCES IN THE LEG ARE CALCULATED.
NEVER USE REGULAR NUT EYE BOLTS FOR ANGULAR LIFTS.
SELECT THE PROPER SIZE SWIVEL HOIST RING TO ALLOW
ALWAYS USE SHOULDER NUT EYE BOLTS FOR ANGULAR LIFTS.
FOR LOAD IN SLING LEG. ALWAYS INSURE
FOR ANGULAR LIFTS, ADJUST WORKING LOAD AS SHOWN ABOVE.
ALWAYS INSURE HOIST HOIST RING IS
ALWAYS TIGHTEN NUTS SECURELY AGAINST THE LOAD.
RING IS FREE TO ALIGN PROPERLY TORQUED
ALWAYS APPLY LOAD TO EYE BOLT IN THE PLANE OF THE EYE.
ITSELF WITH SLING. TO REQUIRED VALUE.

FOR ADDITIONAL INFORMATION REFER TO THE PRODUCT WARNING

 Figure 12ab

OPERATING PRACTICES - ANSI B30.9 LOAD CONTROL 15

WHENEVER ANY SLING IS USED, THE FOLLOWING PRACTICES SHALL BE
OBSERVED. POSITIVE LOAD
1. SLINGS THAT ARE DAMAGED OR DEFECTIVE SHALL NOT BE USED. CONTROL
2. SLINGS SHALL NOT BE SHORTENED WITH KNOTS OR BOLTS OR
OTHER MAKESHIFT DEVICES.
3. SLING LEGS SHALL NOT BE KINKED.
4. SLINGS SHALL NOT BE LOADED IN EXCESS OF THEIR RATED
CAPACITIES.
5. SLINGS USED IN A BASKET HITCH SHALL HAVE THE LOADS
BALANCED TO PREVENT SLIPPAGE.
6. SLINGS SHALL BE SECURELY ATTACHED TO THEIR LOAD.
7. SLINGS SHALL BE PADDED OR PROTECTED FROM THE SHARP EDGES
OF THEIR LOADS.
8. SUSPENDED LOADS SHALL BE KEPT CLEAR OF ALL OBSTRUCTION.
9. ALL EMPLOYEES SHALL BE KEPT CLEAR OF LOADS ABOUT TO BE
LIFTED AND OF SUSPENDED LOADS.
10. HANDS OR FINGERS SHALL NOT BE PLACED BETWEEN THE SLING
AND ITS LOAD WHILE THE SLING IS BEING TIGHTENED AROUND THE
LOAD.
11. SHOCK LOADING IS PROHIBITED!
12. A SLING SHALL NOT BE PULLED FROM UNDER A LOAD WHEN THE
LOAD IS RESTING ON THE SLING.

INSPECTION: EACH DAY BEFORE BEING USED, THE SLING AND ALL
FASTENINGS AND ATTACHMENTS SHALL BE INSPECTED FOR DAMAGE OR REEVING THROUGH CONNECTIONS TO LOAD
DEFECTS BY A COMPETENT PERSON DESIGNATED BY THE EMPLOYER. INCREASES LOAD ON CONNECTION FITTINGS BY AS
ADDITIONAL INSPECTIONS SHALL BE PERFORMED DURING SLING USE
WHERE SERVICE CONDITIONS WARRANT. DAMAGED OR DEFECTIVE
MUCH AS TWICE.
SLINGS SHALL BE IMMEDIATELY REMOVED FROM SERVICE. DO NOT REEVE!

2015 Safety Handbook 117

 Figure 12ac

RIGGING HARDWARE 16

CLIPS 80% EFFICIENT CLIPS 80% EFFICIENT G-429

G-450 UNDER 1", 90% 1" UNDER 1", 90% 1" Fist Grip
WIRE ROPE U-Bolt Clip AND ABOVE AND ABOVE Clip
CLIPS
NUMBER OF TURNBACK TORQUE NUMBER OF TURNBACK TORQUE
SIZE CLIPS LENGTH (IN.) FT-LBS. SIZE CLIPS LENGTH (IN.) FT-LBS.
1/8 2 3-1/4 4.5 3/16 2 4 30
3/16 2 3-3/4 7.5 1/4 2 4 30
1/4 2 4-3/4 15 5/16 2 5 30

118 2015 Safety Handbook

5/16 2 5-1/4 30 3/8 2 5-1/4 45
3/8 2 6-1/2 45 7/16 2 6-1/2 65
7/16 2 7 65 1/2 3 11 65
1/2 3 11 -12 65 9/16 3 12-3/4 130
9/16 3 12 95 5/8 3 13-1/2 130
5/8 3 12 95 3/4 4 16 225
3/4 4 18 130 1 5 37 225
1 5 26 225
THE NUMBER OF CLIPS SHOWN IS BASED ON USING RRL OR
APPLY U-BOLT OVER DEAD END OF THE WIRE ROPE. LIVE END OF RLL WIRE ROPE, 6X19 OR 6X37 CLASS, FC OR IWRC: IPS OR XIP.
THE ROPE RESTS IN THE SADDLE. A TERMINATION IS NOT COMPLETE IT ALSO APPLIES TO ROTATION RESISTANT RRL WIRE ROPE,
UNTIL IT HAS BEEN RETORQUED A SECOND TIME. NEVER SADDLE A 8X19 CLASS, IPS, XIP, SIZES 1-1/2 INCH AND SMALLER, AND TO
DEAD HORSE! ROTATION RESISTANT RRL WIRE ROPE, 19X7 CLASS, IPS, XIP,
2 SIZES 1-3/4 INCH AND SMALLER. FOR ELEVATOR, PERSONNEL
1 TURNBACK HOIST, AND SMALLER, FOR ELEVATOR, PERSONNEL HOIST, AND
3 SCAFFOLD APPLICATIONS REFER TO ANSI A17.1 AND ANSI
A10.4. THESE STANDARDS DO NOT RECOMMEND THE USE OF
U-BOLT STYLE WIRE ROPE CLIPS.

FOR ADDITIONAL INFORMATION REFER TO THE PRODUCT WARNING

Do not use U-Bolts

12.8 Synthetic Webbing Slings
Selection, Use and Maintenance
This section applies to slings fabricated by sewing of woven
synthetic webbing of nylon or polyester type yarns, for the
purpose of hoisting, lifting, and general material handling.

12.8.1 Construction

[Link] Webbing
Webbing should be of fabric woven of high tenacity syn-
thetic yarns, offering suitable characteristics for use in the
fabrication of web slings. Webbing shall have the following
characteristics.
(a) Sufficient certified tensile strength to meet the sling
manufacturers requirements.
(b) Uniform thickness and width.
(c) Full woven width, including selvage edges.
(d) Webbing ends shall be sealed by heat, or other suitable
means, to prevent raveling.

[Link] Thread
The thread used in the manufacture of synthetic web slings
shall be of the same generic type yarn as the sling webbing.

[Link] Stitching
(a) Stitching shall be the only method used to fabricate
synthetic web slings within the scope of this standard.
(b) The stitching pattern and length of stitching shall be in
accordance with the manufacturers standard practice.

2015 Safety Handbook 119

[Link] Fittings
(a) The material selected shall be compatible with the
mechanical and environmental requirements imposed
on the fitting. Material selected should be carbon steel,
alloy steel, aluminum, or other suitable material.
(b) Fitting shall have sufficient strength to sustain twice the
rated load of the sling without permanent deformation
and a minimum breaking strength equal to five times
the rated load of the sling.
(c) All surfaces shall be cleanly finished and sharp edges
removed so as not to cause damage to the webbing.
(d) Slings incorporating aluminum fittings shall not be used
where fumes, vapors, sprays, mists or liquids of caustic, or
acids are present.
(e) The eye opening in the fitting shall be the proper shape
and size to insure that the fitting will seat properly in the
hook or other attachment.
[Link] Marking (Sling identification)
Each sling shall be permanently marked to show.
(a) Name of trademark or manufacturer.
(b) Manufacturers code or stock number.
(c) Rated loads for types of hitches used.
(d) Type of synthetic web material.
12.8.2 Design Factor
The design factor for synthetic web slings shall be a
minimum of 5.

120 2015 Safety Handbook

12.8.3. Rated Load
(a) A sling shall not be used at a load greater than that
shown on its tags. Slings shall be used in accordance
with the manufacturers recommendations.
(b) Each manufacturer shall make available on request test
data to justify these recommended rated loads.
12.8.4 Proof Test
When specified by the purchaser, web slings of all types
shall be proof loaded:
(a) The proof load for single leg slings and endless slings
shall be two times the vertical rated load.
(b) The proof load for multiple leg bridle slings shall be
applied to the individual legs and shall be two times the
vertical rated load of a single leg sling.
12.8.5 Effects of Environment
(a) Chemically active environments, such as acids and
caustics, can affect the strength of slings the manufac-
turer should be consulted before slings are used in
chemically active environments.
(b) Nylon and polyester slings shall not be used at tem-
peratures in excess of 194(F) 90(C).
12.8.6 Inspection
(a) Initial Inspection. Before using any new or repaired
sling, it shall be inspected to insure that the correct sling
is being used as well as to determine that the sling
meets the requirements of this standard.
(b) Frequent Inspection. This inspection should be made by
the person handling the sling each day the sling is used.

2015 Safety Handbook 121

(c) Periodic Inspection. This inspection should be conduct-
ed by the Competent Person. Frequency of inspection
should be based on:
(1) Frequency of sling use;
(2) Severity of service conditions; and
(3) Experience gained on the service life of slings used
in similar applications
(d) Periodic inspections should be conducted at least
annually.
12.8.7 Removal Criteria
A sling shall be removed from service if damage such as
the following is visible and shall only be returned to service
when approved by a Qualified Person.
(a) Acid or caustic burns
(b) Melting or charring of any part of the sling
(c) Holes, tears, cuts or snags
(d) Broken or worn stitching in load bearing splices
(e) Excessive abrasive wear
(f) Knots in any part of the sling
(g) Excessive pitting or corrosion, or cracked, distorted, or
broken fittings
(h) Other visible damage that causes doubt as to the
strength of the sling.

12.8.8 Repairs
(a) Slings shall be repaired only by a sling manufacturer or
a Qualified Person. When repaired, a sling shall be per-
manently marked to identify the repair agent.
(b) Temporary repairs of either webbing, fittings, or stitching
shall be not permitted.
(c) Repaired sling shall be proof tested to two times its
assigned rated load before being put back into service.

122 2015 Safety Handbook

12.8.9 Operating Practices
(a) The weight of load shall be within the rated load of the sling.
(b) Slings shall not be shortened or lengthened by knotting
or other methods not approved by the sling manufacturer.
(c) Slings that appear to be damaged shall not be used
unless inspected and accepted as usable under Section
12.7.6.
(d) Sling shall be hitched in a manner providing control of
the load.
(e) Sharp corners in contact with the sling should be padded
with material of sufficient strength to minimize damage
to the sling.
(f) Personnel should stand clear of the suspended load.
(g) Personnel shall not ride the sling.
(h) Shock loading should be avoided.
(i) Slings should not be pulled from under a load when the
load is resting on the sling.
(j) Slings should be stored in a cool dry, and dark place to
prevent environmental damage.
(k) Twisting and kinking the legs shall be avoided.
(l) Load applied to the hook should be centered in the base
(bowl) of hook to prevent point loading on the hook.
(m) During lifting, with or without load, personnel shall be
alert for possible snagging.
(n) In a basket hitch, the load should be balanced to prevent
slippage.
(o) The slings legs should contain or support the load from the
sides above center of gravity when using a basket hitch.
(p) Slings should be long enough so that the rated load is ade-
quate when the angle of the legs is taken into consideration.
(q) Slings should not be dragged on the floor or over an
abrasive surface.
(r) In a choker hitch, slings shall be long enough so the choker
fitting chokes on the webbing and never on the other fitting.

2015 Safety Handbook 123

(s) When extensive exposure to sunlight or ultraviolet light
is experienced by nylon or polyester web slings, the sling
manufacturer should be consulted for recommended
inspection procedure because of loss in strength.

12.9 Beam Clamps

(a) A beam clamp used for rigging shall be engineered to
properly support the expected load.
(b) Confirm with your Supervisor the hoisting beam is rated
to carry the maximum load to be hoisted. Do not load
the lower flange to more than 50% of the beams capacity.
(c) Do not use a choker through the eye
of the beam clamp while hoisting.
(d) Beam clamps shall be properly sized
for the beam to which it is attached.
(e) Use only case-hardened bolts with
lock nuts or nuts with lock washers
for the beam clamp assembly.
Figure 12ad

124 2015 Safety Handbook

Figure 12ae INSPECTING MANILA ROPE
Watch outer surface
and inner side of
strands for black or
rusty spots indicating
damage by acids or
Untwist strands to caustics.
examine for signs of
discoloration. New
manila rope should
be bright yellow.

Unwind a piece of
yarn 8 inches long
and test strength, if
it is easily broken,
the rope is unsafe.

Look for broken fibers and

abrasions in outer surface
as they may be the first
sign of weakness.

If rope is to be used
around electric installa-
tions, be sure there are
no metallic strands.

Safe Practice Rules

1. Frozen fiber rope shall not be used in load carrying service.
2. Fiber rope that has been subjected to acids or excessive heat shall
not be used for load carrying purposes.
3. Fiber rope shall be protected from abrasion by padding where it is
fastened or drawn over square corners or sharp or rough surfaces.

2015 Safety Handbook 125

Figure 12af

Five-Part Falls
A five-part reeve is accomplished using a two- and three-
sheave block as follows: Enter the lead line through the front of the
stationary block at sheave (B), then go down in back of traveling
block and through at sheave (E), up behind stationary block and
through at sheave (C), down in front of traveling block and through
at sheave (D), up in front of stationary block and through at sheave
(A), down to the traveling block and becket off. This reeving is more
widely used for rope falls (manila), but is also used for wire rope
(cable).

Six-Part Falls
Using a pair of three-sheave blocks, a six-part reeve is accom-
plished as follows: Enter the lead line through the front of the sta-
tionary block at sheave (B), then go down in front of traveling block
and through at sheave (E), up behind stationary block and through
at sheave (A), down behind traveling block and through at sheave
(D), up in front of stationary block and through at sheave (C), down
in front of traveling block and through at sheave (F), up to station-
ary block and becket off. This reeving is more widely used for rope
falls (manila), but is also used for wire rope (cable).

Seven-Part Falls
A seven-part reeve is accomplished using a three- and four-
sheave block as follows: Enter the lead line through the front of the
stationary block (four-sheave) at sheave (C), go down in front of
traveling block and through at sheave (F), up behind the stationary
block and through at sheave (A), down behind traveling block and
through at sheave (E), up in front of stationary block and through at
sheave (D), down in front of stationary block and through at sheave
(G), up behind stationary block and through at sheave (B), down to
the traveling block and becket off.

126 2015 Safety Handbook

 FIVE-PART FALLS SIX-PART FALLS SEVEN-PART FALLS

Stationary Stationary Stationary

Block Block Block

ABC A BC AB CD

3 2
2 6 5 3 2 6

5
Lead Line
4 1 Lead Line
Lead Line 7 4 1 5

3 4 1

E F G
D E DE F

Traveling Block Traveling Block Traveling Block

2015 Safety Handbook 127

Figure 12ae Continued

This theory applies to two-part, three-part and four-part falls.

12.10 Manila Rope
(a) Frozen manila rope shall not be used in load-carrying service.
(b) Manila rope shall be protected from abrasion by padding
where it is fastened or drawn over square corners, or sharp
or rough surfaces.
(c) Even the finest-quality rope deteriorates very rapidly
when not given the best of care. Kinking, overheating,
moisture and acid all cause deterioration, which is not
readily noticeable upon casual inspection.
(d) Manila rope shall be stored in a clean, dry location. Keep
off pit floor, coil into protective device such as a drum.
(e) Manila rope is not a substitute for wire rope. It shall only
be used for lashings, tackles, tag lines, straps on light
leads and temporary guy lines and light hoisting.
(f) Points to look for during manila rope inspection are:

Good Characteristics Poor Characteristics

Hard but pliant Brown spots weak, soft
Silvery or pearly luster Black or dark spots weak
Inner fibers bright & clean Abrasion of fibers
Individual yarn strong Loss of stretch
Uncut and unabraded Cuts Burns
outer & inner fibers Dirt between inner fibers
Stretch and spring good Freezing of rope

12.11 Synthetic Rope

(a) Synthetic fiber ropes are made from nylon, polypropylene,
or polyester. Synthetic fiber ropes consist of individual
threads and fibers that run the full length of the rope (natu-
ral fibers are not continuous in fact, they are short and
overlapped).
(b) Do not choose synthetic rope when burning and welding.
Synthetic rope is also more likely to be affected by chem-
icals and it tends to be slippery.
(c) Do not use clamps for splicing synthetic rope unless it is
specifically designed for this purpose.

128 2015 Safety Handbook

(d) Good practices when using synthetic rope:
(1) Keep rope dry and clean and away from chemicals
(2) Never overload a rope
(3) Never use a frozen rope
(4) Dont drag a rope on the ground. This will damage the
outside surface of the rope.
(5) Never allow the rope to bend over sharp edges
(6) Dont permit the rope to drag against itself
(7) Observe proper picking angles
(8) Pad all corners when lifting materials
(9) When coupling ropes, use thimbles
(10) Inspect rope often by twisting to expose the inside yarns
(e) Synthetic rope shall be removed from service if it shows
signs of:
(1) Abnormal wear
(2) Powder between strands
(3) Broken or cut fibers
(4) Variations in the size or roundness of strands
(5) Discoloration or rotting
(6) Distortion of hardware
(f) When rope is damaged and taken out of service, it shall be
completely destroyed to prevent others from using it.

12.12 Knots Are Weak

If a knot or hitch of any kind is tied in a rope, its failure

under stress is sure to occur at that place. Each fiber in the
straight part of the rope takes proper share of the load. In all
knots, the rope is cramped or has a short bend, which throws
an overload on those fibers that are on the outside of the
bend, and one fiber after another breaks until the rope is torn
apart. The shorter the bend in the standing rope, the weaker
the knot. The results given in Figure 12ag are approximate, but
are sufficient to cause caution in all rope fastenings employed
in important work.

2015 Safety Handbook 129

Figure 12ag Approximate Efficiency Comparison
of Rope Knots and Connections to Safe Load
Sheepshank Square or
Reef Knot

35% 43%

50% 53%
Timber Hitch
Bowline (outside) (inside) 72% & Half Hitch

Long Splice 68% Clove Hitch 75%

Short Splice 85% Eye Splice 85%

Source: Handbook for Riggers, 1977 Revised Edition
Note: Variations in test equipment, procedures, rope age, condition and con-
struction, etc. may impact test results. The efficiencies shown above are for
point of reference only. Rigging methods, rope capacity, etc. shall well
exceed the weight of the load to be hoisted. Knot efficiencies shall
not be factored into the lift too closely; err on the side of caution.

130 2015 Safety Handbook

Figure Eight Knot Figure 12ah

Used in the end of a rope to temporarily prevent

the strands from unraveling. Useful to prevent
the end of a rope from slipping through a
block or an eye, and does not jam as easily
as the overhand knot.

Figure 12ai
Catspaw
Used to secure the middle of a rope to a
hook. Take two bights (loops) in the rope,
twist in opposite directions and then bring
the loops together and pass over hook.

Timber Hitch Figure 12aj

B
(A) Used for hoisting planks, timbers A
and pipe. Holds without slipping and
does not jam. A half-hitch is added in
(B) This is done to keep a plank or
length of pipe on end, while lifting.

Reef Knot or Square Knot

Figure 12ak
Used to join two ropes or lines
of the same size - holds firmly
and is easily untied.

2015 Safety Handbook 131

 Figure 12al

Bowline on the Bight

Used in emergencies to lift an injured per-

son off a building or out of a hole. This is
accomplished by sitting in one loop, and
putting the other loop around the back
and under the arms. Also used to tie bow-
line in middle of line.

Figure 12am
Clove Hitch or Builders Hitch
Because of its wide use by construction workers in
fastening rope to upright posts on staging to act as a rail
or warning line, it is also known as a builders hitch.
Making a line fast is another common use.

Figure 12an
Running Bowline
This is merely a bowline knot made round the
standing part of a rope to form a running noose
or slip knot and is very reliable. Runs freely on the
standing part and is easily untied. This knot shall
not be used for securing lifelines.

132 2015 Safety Handbook

Figure 12ao Round Turn and Two Half Hitches

Used to secure a rope to a column

or post, and will stand heavy strain
without slipping. Easily tied and
does not jam.

Figure Eight on a Bight Figure 12ap

Provides a secure loop in the end of a rope.

Made by doubling a line back on itself and
then tying a Figure Eight knot in the dou-
ble line. This knot may reduce the
strength of a rope by 20%. This knot
shall not be used for securing a lifeline.
CAUTION: Be certain you tie a Figure Eight,
not an Overhand on a Bight.

(A) (B)

Figure 12aq Figure Eight Follow Through

Similar to Figure Eight on a Bight, but is tied
around the anchor point. Tie a simple Figure
Eight well back from the end of the rope.
Pass the end of the rope
around the anchor point then
follow back through parallel
to the first knot. Follow every
contour of the first knot with
both rope ends going in the
same direction. This knot shall not
be used for securing a lifeline.

2015 Safety Handbook 133

 Bowline
One of the best-known and most-widely used Figure 12ar
of all knots. A favorite knot with riggers, it is
easily constructed and used wherever a hitch
is required that will not slip, jam or fail. (Hint:
Leave a long tail and secure the tail with two
half-hitches.) This knot shall not be used
for securing a lifeline.

Figure 12as
Rolling Hitch
This knot is used for lifting round loads,
such as pipe or bar steel. For a more
efficient knot, add half-hitch, short end
around long end.

Carrick Bend Figure 12at

Used for joining large ropes together, and
easier to untie than most knots
after being subjected to strain.

Figure 12au

Sheepshank
This knot is used for shortening a rope.
The method shown is especially useful where
the ends of the rope are not free, as it can be
employed in the center of a tied rope. Taking the
strain off a damaged piece of rope when there is
not time to immediately replace with sound rope
is another use. When seized, as shown, it is
more secure.

134 2015 Safety Handbook

Section 13
WELDING, CUTTING AND SOLDERING
13.1 General Precautions
(a) Local regulations or contract requirements may require
a permit or license before using portable cutting or welding
equipment.
(b) Move combustible material to a safe area. If combustible
material cant be moved, cover completely with fire-
retardant material.
(c) Provide a fire watch to make sure fires do not start. Have
a fire extinguisher readily accessible where employees
are working. Extinguishers shall be of ABC type, minimum
2A:20BC rating.
(d) Never burn or weld over other workers.
(e) After completing a burning or welding operation, monitor
the scene of work for fires. Inspect adjacent areas as well.
(f) Use only non-flammable PVC glue to bond in-ground
PVC hydraulic jack liners to prevent explosion hazard
resulting from welding or burning operations. NEVER
WELD OR BURN IN OR OVER AREAS WHERE
FLAMMABLE AGENTS ARE PRESENT.
(g) Do not use cutting or welding equipment near flamma-
ble liquids. Do not cut or weld on closed tanks which
have held flammable liquids or other combustibles.
(h) Ensure there is sufficient ventilation to remove potentially
toxic fumes in areas of concern.

2015 Safety Handbook 135

(i) Never use empty containers such as drums as a work
station. They may contain potentially hazardous fumes.
Consideration should be given for air monitoring by
qualified personnel.
(j) Keep cutting and welding equipment in good operating
condition at all times. Equipment found to be defective
shall be tagged immediately and returned to the shop for
repair.
(k) Operators shall never wear oil-stained clothing.
(l) Always hold lighted acetylene and propane torches
do not lay them down or hang them on beams or
planks. A safe area shall be selected for resting a live
electrode holder before striking an arc.
(m) Do not burn or weld in hoistways, where rails or other
equipment are covered with oil or lint.
(n) Assure proper ventilation is provided for gas welders.
(o) Torch valves should be opened to vent pressure from
the line and shut again.
(p) Use proper eye protection when welding, cutting and
chipping. Reference Personal Protection Equipment
see Section 3.
(q) Wear a leather jacket or equivalent material to protect
your skin from burns due to metal splatter and UV
radiation.
(r) Use welding gloves to protect your hands
(s) Leather chaps are recommended to protect your legs
and vital parts.
(t) When welding and cutting be aware of other people in
the area. Advise them to look away when welding.
(u) Be aware of falling splatter, hot slag and sparks.

136 2015 Safety Handbook

13.2 Acetylene, Oxygen and
Other Pressurized Fuel Cylinders
Acetylene and oxygen cylinders are under high pressure
and shall be handled with extreme care. Cylinders shall be
kept in an upright position, either on a tank cart or tied to a
vertical building member, such as a building column. Never
lay cylinders down.
(a) Valve handles or valve wrenches shall be retained in
place while cylinders are in use.
(b) Check all connections for leaks.
(c) Keep hose in the clear so that it cannot be damaged.
(d) Protect gauges and torches from damage.
(e) Keep cylinders away from work areas so that sparks
cannot reach them.
(f) Oil and grease shall never be used on or around welding
and cutting equipment.
(g) The use of regulators and flash arrestors are mandatory.
(h) Do not use oxygen to blow out or clean equipment.
(i) Do not take cylinders into elevator pits; keep them in a
well-ventilated area.
(j) Do not lift cylinders by their protective caps.
(k) Propane and butane are heavier than air, and highly
explosive. Guard against leaks when using this equip-
ment. Use only in well-ventilated areas. Unburned gas
from even a small leak will settle in pockets such as
elevator pits, stairwells or other areas.
(l) Shut off valves and purge all hoses immediately after
each use.
(m) Cylinder caps shall be in place whenever cylinders are
not in use, being moved, or while they are in storage.
(n) Acetylene and oxygen cylinders can be temporarily kept in
a hand cart if they were used in the current 24 hour period.

2015 Safety Handbook 137

(o) When not in use, oxygen and acetylene cylinders shall
be stored at least 20 ft (6.1 m) apart, or separated by a
one-half-hour (30-minute) rated fire-resistive wall or
partition at least 5 ft (1.5 m) high, and shall be secured
to prevent tipping.
(p) Empty cylinders shall be marked MT.
(q) Cylinders shall never be stored in gang boxes.

13.3 Soldering
(a) Solder containing lead shall not be used.
(b) Be careful of splatter.
(c) Burns from hot solder are painful and may lead to infec-
tion. Treat all burns immediately.
(d) Wear a face shield, especially if you are soldering over-
head. See Section 3.2.
(e) Keep shirt collar buttoned.
(f) Wear a long sleeve shirt and button the cuffs.

138 2015 Safety Handbook

Section 14
HAZARD COMMUNICATIONS (HAZCOM)
14.1 Working With Chemicals
The OSHA Hazard Communication (HAZCOM) (Right-To-
Know) Standard requires all employees be given adequate
information and training on the long- and short-term health
effects of chemicals they work with. Your company has
established a Hazard Communication (HAZCOM) Program
to provide this information to you. You can take the steps
necessary to safeguard your health by following the proce-
dures established in this program.
A copy of this program along with a chemical inventory
list and corresponding Safety Data Sheets (SDSs) shall be
readily available for your review. This program may be made
available to others upon request to your Superintendent/
Manager.
Chemicals affect the human body differently. The physical
makeup of the chemical, the amount of exposure (time and
quantity), and the manner in which the chemical is absorbed
by the body all play a role in the resulting effects. As long as
exposures are not excessive, many potentially dangerous
substances are eliminated naturally from the body. It is
important to remember that most materials can be removed
this way, and their effects are usually not cumulative.
What is important is the dose or amount of a particular
chemical that is absorbed over a period of time. Too much of
a chemical, either all at once or over time, may be danger-
ous. Chemicals are absorbed into the body in three ways:
(a) Inhalation The chemical is taken in with the air we
breathe, either as a vapor, dust, gas, fume or mist.
(b) Ingestion The chemical is ingested either intentionally
or accidentally. It can be taken in with the food you eat (or

2015 Safety Handbook 139

 drink) especially if you fail to wash your hands before
eating or smoking.
(c) Absorption It is absorbed through the skin. This occurs
for only a limited number of chemicals.
Inhalation is by far the most common way in which chem-
icals enter the body. How much enters and is subsequently
absorbed through the lungs is a function of the chemical.
The human respiratory system is extremely effective at
removing dust from the air that is breathed. Only the smallest
particles reach the lungs. The majority are trapped in the
nose and throat, and later eliminated.
The amount of liquid chemicals entering the lung depends
on how fast the liquid evaporated into the air. This is a func-
tion of the surrounding (ambient) temperature and the vapor
pressure of the liquid (the higher the vapor pressure, the
faster the evaporation rate). How much is absorbed varies
with each chemical.
Industrial Hygienists are engaged in the science of pro-
tecting workers from the harmful effects of chemicals. They
are trained to recognize, evaluate and control potential expo-
sures to chemicals in the workplace. Today, many chemicals
have been studied, and as a result, their effects have been
identified. Levels of acceptable exposure for a normal work
day have been determined. These are known as threshold
limit values (TLV), or permissible exposure limits (PEL).
In general, there are two major types of effects which are
of concern when talking about chemical exposure the short
term or acute effects, and the long term or chronic effects.
Some chemicals have both, some one or the other.
Asbestos is an example of a substance that can result in
chronic health effects. Asbestos fibers enter the body
through inhalation of airborne asbestos particles and can
become embedded in the tissues of the respiratory or digestive
systems. Diseases associated with asbestos exposure often

140 2015 Safety Handbook

do not manifest themselves for 25-35 years following the start
of exposure. The risk of disease is significantly increased
when both asbestos exposure and smoking occurs.
Most acid gases exhibit only acute health effects. Exposure
to acid gases can be extremely irritating, causing a sore
throat, coughing and tearing of the eyes. However, once
exposure stops, the effects generally pass with no lasting
results. The exposure limits are designed to eliminate both
short- and long-term symptoms.
Information on a particular chemical (or mixture of chemicals)
can be found on the Safety Data Sheet (SDSs) for that
chemical. This gives the trade name, manufacturer, chemical
components, exposure limits, effects of exposure, precautions
to follow, as well as data on the vapor pressure, flammability,
etc., and other physical data.
If you wish to know about a specific chemical you work
with, talk to your Superintendent/Manager, review the SDSs
and discuss the procedures for handling the chemical estab-
lished by your Elevator Company. Fortunately, most chemicals
used in the elevator industry are of low toxicity, but like any
chemical, must be used correctly to avoid hazardous conditions.
14.2 Oils and Grease
OSHA has established an exposure limit of 5 milligrams
per cubic meter (mg/m3) for oil mist in air. In the elevator
industry, exposure results from physically handling the oil.
Airborne exposures are virtually nonexistent. The biggest potential
hazard results from contact with the oil (especially used oil) on
the skin. Use gloves where appropriate. Always wash your hands
when they become oily use soap and water.

2015 Safety Handbook 141

14.3 Cleaners
Check the label on the container or the SDS for the appro-
priate personal protective equipment to wear prior to working
with any chemicals.
Three main types of cleaners are found in the elevator industry.

14.3.1. Petroleum Naphthas

(a) These are petroleum distillates or naphtha-based clean-
ers commonly used for oil and grease removal. They
have a relatively low volatility (do not evaporate fast)
and low toxicity. They have an odor like gasoline or
kerosene and are generally used in a liquid form, but
may also be found in aerosol form.
(b) Petroleum naphtha cleaners and vapors are flammable.
They shall not be used around open flames, welding opera-
tions or other ignition sources. Exposure to high vapor
concentrations can cause irritation of the eyes, nose
and throat, nausea and headaches. Care should be
taken to avoid using these materials in areas with inad-
equate air movement where the vapors can accumulate;
ensure proper ventilation before, during and after use.
(c) Excessive skin contact can cause defatting of the skin,
which can lead to skin irritation. Good personal hygiene
practices and the use of personal protective equipment
(PPE), such as rubber or neoprene gloves and chemical
goggles, can minimize exposure.

14.3.2 Hydrocarbons
(a) These have been used for cleaning electrical components
such as controllers and motors. Due to the inherent safety
issues with hydrocarbons, water-based cleaners shall
be used. They are usually found in aerosol form. There
are two forms of hydrocarbon cleaner: halogenated and
non-halogenated.

142 2015 Safety Handbook

(b) Halogenated hydrocarbons contain a high percentage of
chlorofluorocarbons (CFCs), various combinations of fluorine
and chlorine. Examples of CFCs found in halogenated
hydrocarbon cleaners used in the elevator industry include
1,1,1-Trichloroethane (methyl chloroform), Trichloro-
trifluoroethane (Freon 113), and dichlorodifluoromethane
(Freon 12).

14.3.3 Water-Based Cleaners

(a) Water-based cleaners are being used as an effective
substitute for petroleum naphtha cleaners to remove oils
and grease, but without the potential fire and health
hazards posed by the chemical compounds found in the
petroleum naphthas. Water-based cleaners are generally
used in a liquid or semi-liquid (gel) form. They are also avail-
able for cleaning electric contacts (e.g. Simple Green, etc.).
(b) Although the most prevalent ingredient in these cleaners is
water, precautions are necessary. Repeated and pro-
longed skin contact can remove the oil from the skin,
leading to irritation and possible infection. Good personal
hygiene and the use of gloves and chemical goggles will
limit exposure.

14.4 Babbitting

Babbit contains lead, which is a highly toxic material and

shall be handled correctly. The primary route of exposure is
through the inhalation of fumes, though ingestion can be
significant if hands are not washed before eating or smoking.
Repeated overexposure can result in elevated concentra-
tions in the body, which is slowly eliminated when exposure
ceases. Significant lead fumes are only released when the
lead approaches its boiling point, over 1000F (537.8C) which
is well above the temperature used in babbitting operations,
around 400F (204.4C). Adequate ventilation shall also be

2015 Safety Handbook 143

provided. Chronic overexposure to lead may cause damage
to the blood-forming, nervous, urinary and reproductive systems
of the body. Symptoms include loss of appetite, metallic taste in
the mouth, excessive tiredness, constipation, nausea, nervous
irritability, joint pain, tremors, weakness and dizziness.
(a) Use wedge shackles when ever possible.
(b) Protective face shields and gloves shall be worn while
pouring babbit.
(c) Preheat the bearing housing or shackle to be poured to
be sure that it is dry. The presence of moisture will form
captured steam and the hot babbit will explode.
(d) Avoid breathing fumes. Melt and pour babbit in well-
ventilated areas.
(e) Wash hands prior to eating or smoking after handling babbit.
(f) Do not use cutting torches to melt babbit. An electric melting
pot shall be used, as it will not allow babbit temperatures
to exceed a safe level.
(g) Care shall be taken when using resins for socketing.
Use only Company-approved heaters for curing. Do not
allow the material to come into contact with exposed
skin. Do not store the material in direct sunlight.

14.5 Painting

(a) Some paints contain solvents that can be combustible

or flammable. Some spray containers have flammable
propellants. Some paints have undesirable odors.
(b) Use spray paint only in well ventilated areas.
(c) Field employees shall only use paints approved by their
company. Follow the training you have been given and
follow the instructions for use on the container label. If
you have concerns, contact your supervisor and review
the material safety data sheets to be certain no hazard
exists to yourself, fellow employees or the public.

144 2015 Safety Handbook

14.6 Welding
(a) Welding produces fumes from the metals being joined
and the welding rods being used. In addition, radiation
from the arc can damage the eyes, so appropriate goggles
or a welding mask or hood shall always be used.
(b) In the elevator industry, iron oxide fumes are the primary
exposure encountered. The recommended exposure
level is 5 mg/m3 (even in industrial environments where
welding operations are continuous this level is seldom
exceeded). Overexposure can cause welding fume fever
which causes flu-like symptoms. Welders exposure is
further reduced by the welding mask or hood.
(c) In cases where welding is to be performed on painted
surfaces, the paint shall first be removed, using your com-
panys approved method, in case the paint contains
lead, which can rapidly vaporize during the welding
process. Adequate ventilation must always be provided.
(See Section 13.)
(d) A MSDS is required for welding rods.

14.7 Asbestos

(a) The term asbestos refers to a number of naturally

occurring silicate materials. Asbestos in the forms of
sprayed-on fireproofing, pipe insulation and acoustical
plaster was used in commercial and residential buildings
until the mid-to-late 1970s, when its use was banned.
(b) The presence of asbestos-containing materials does
not, in itself, present a health risk. Only when asbestos
becomes airborne does it pose a potential hazard.
Asbestos, containing materials that are susceptible to
contact, water damage and/or air flow are more likely to
result in fibers being released. Only approved testing
methods can determine whether asbestos is present,
and at what levels.

2015 Safety Handbook 145

(c) Employees shall not perform any construction, maintenance
or repairs in areas where there is a potential exposure
to Presumed Asbestos Containing Material (PACM) or
Asbestos Containing Material (ACM) in excess of the
Personal Exposure Limits or in regulated areas in the
normal scope of their work without first receiving the
proper training and personal protective equipment for
the type or class of work to be performed. If any employee
is asked to enter such areas they shall first contact their
supervisor for instructions, before entering the areas.
Employees shall not, under any circumstances intention-
ally disturb, remove or clean up asbestos containing
material without first contacting their supervisor.
(d) CAUTION when drilling in doors that you suspect contain
asbestos, special training and work practices are required.
Contact your supervisor.

14.8 Flammable Liquids and Solvents

(a) ONLY NON-FLAMMABLE PVC GLUE SHALL BE USED

FOR BONDING SECTIONS OF IN-GROUND PVC
HYDRAULIC JACK LINERS.
(b) When using paints, solvents and chemicals, read the warn-
ing labels, appropriate MSDSs and follow instructions.
(c) Avoid getting solvent on clothing. If clothing becomes
contaminated, it shall be changed immediately.
(d) Flames, sparks or any other ignition source shall be kept
away from flammable liquids and their vapors. Smoking is
prohibited in areas where such materials are used or stored,
and No Smoking signs shall be posted in these areas.
(e) Flammable liquids shall not be transferred from one container
to another unless electrically interconnected.
(f) Store in properly labeled safety cans or in original container
if one gallon or less.

146 2015 Safety Handbook

(g) Flammable and combustible materials shall not be stored
in areas used for exits, stairways or areas normally used
for the safe passage of people.
(h) Be sure there is adequate ventilation when storing flam-
mable or combustible materials.
(i) No more than 25 gal. (90.84 L) of such materials shall
be stored in a room, unless an approved safety storage
cabinet is provided.

14.9 Carbon Dust

Most electrical brushes expel carbon dust onto machine

room equipment. When cleaning components, avoid irritation
to skin and breathing passageways. You may consider wear-
ing a dust mask and latex gloves or use a closed system
(bonnet). Safety glasses/goggles are also required if liquid
cleaning agents are being used.

14.10 Sulfuric Acid Type Batteries

(a) Batteries may contain sulfuric acid and as such shall be

handled with care. The acid is contained in a gel media
and is not subject to leaking (unless case is cracked),
however at high temperatures (greater than 140 F) the
gel may liquefy causing leakage. Similarly discharged
batteries may freeze at temperatures below 10 F which
can crack the case and cause subsequent leakage.
(b) Sulfuric acid is corrosive and can cause burns to the skin
and eyes. Fumes can cause eye, nose and throat irrita-
tion, but significant fumes would only be generated in
unusual circumstances if the battery were to become
overheated.
(c) Always use personal ground straps to dissipate static
discharge if you must handle hot batteries. Battery
cabinet shelves are to be lined with plastic to prevent
leaking batteries from eating the shelf which, if undetected,
may cause it to collapse.

2015 Safety Handbook 147

NOTE: Sixteen 12V batteries in a series can generate up to
192 volts. Remember disconnecting the main line switch
does not protect you. Use proper gloves and insulated tools
and follow safe electrical work practices.

(d) When working on or in rooms with sulfuric acid batteries

the following items shall be kept onsite/inside the elevator
machine room:
(1) One (1) Pair of Rubber Gloves
(2) One (1) Pair of Safety Goggles
(3) One (1) Spill Kit
(4) One (1) Rubber Apron
(5) One (1) Face Shield
(6) One (1) Eye Wash Kit
(7) One (1) Bottle of Sterile Water
(8) One (1) Box of Baking Soda
(e) In addition, it is recommended that the proper warning
signage be posted on the machine room door.
(f) When handling or testing batteries, you shall wear
gloves, apron and full face shield (and goggles) to avoid
contact with acid which may leak from the battery.
(g) If acid gas/fumes are detected, immediately exit the
room and notify your supervisor.
(h) Acid gas/fumes are readily detected by an irritation in
the nose and throat.
(i) As charging produces hydrogen which readily burns,
machine rooms should be well ventilated to prevent hydro-
gen build up.
(j) Smoking, flames or sparks shall be kept away from bat-
teries. Use personal ground straps when handling hot
batteries to control static discharge.
(k) The following procedures should be followed in case of
contact with acid:
(1) Eyes: Flush with water for 15 minutes use eye
wash in safety kit and follow up with ordinary water
if necessary. Seek medical attention.

148 2015 Safety Handbook

 (2) Skin: Flush affected parts of the body with large
amounts of water, then neutralize with baking soda
or sodium bicarbonate and remove contaminated
clothing. If the burn is severe, go immediately to the
emergency room at the nearest hospital.
(3) Inhalation: Remove immediately to fresh air, if dizzy
or unconscious, transport immediately to the emer-
gency room at the nearest hospital.
(4) Ingestion: If sulfuric acid is swallowed, DO NOT
INDUCE VOMITING, wash out the mouth with water,
if milk is available drink as much as possible, if not,
then drink as much water as possible and go immedi-
ately to the emergency room at the nearest hospital.
(l) Before energizing equipment, ensure doors on battery
compartment are closed. There have been isolated
reports of batteries exploding when first put under load.
(m) Batteries shall not be stacked on each other as this may
crack the case.
(n) Do not clean battery cases with cleaning solvents.
(o) Return all used batteries to local office for proper disposal.
(p) Be aware that all bottles of eye wash and boxes of baking
soda are dated and shall be routinely checked and replaced
as necessary. Make certain that a currently dated eye
wash bottle and box of baking soda is available.

14.11 Radio Frequency (RF) Awareness

Radio frequency (RF) exposure may be encountered during
machine-room access. Be aware and obey the following
safety practices.
(a) Be aware that RF energy exists.
(b) Obey all posted signs.
(c) Never stop directly in front of an antenna.
(d) The maximum permissible exposures are set approximately

2015 Safety Handbook 149

 10 times lower than the levels that are known to cause
adverse effects. ANSI has guidelines for these limits.
(e) Never touch an antenna. Touching un-insulated anten-
nas or other un-insulated objects on an antenna may
cause burns. Most antennas are insulated by a fiber-
glass coating for your protection.
(f) Assume that all antennas are active and maintain a
minimum of 3-ft. safe distance per FCC guidelines.
Some communication providers recommend maintain-
ing a 7-ft. distance from the emitting source.
(g) As a precaution, if a pacemaker is worn, you should
consult your physician before entering an outlined area
around an antenna.
(h) Effects of RF exposure do not accumulate over time.
(i) Prolonged exposure to low levels of RF energy are not
considered to be a health risk.
(j) Prolonged exposure to sufficiently high levels of RF
energy can cause a buildup of heat.
(k) Contact your supervisor if you have concerns.

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Section 15
INCLINED ELEVATORS

You shall familiarize yourself with the safety procedures

outlined throughout this safety handbook. In addition, the follow-
ing safety requirements shall receive special attention when
working on Inclined Elevators.
(a) Inclined elevators operate at some degree from the
horizontal and present hazards not expected by persons
familiar with vertical electric elevators.
(b) The horizontal motion of the car and counterweight must
always be considered as well as the fact that most inclined
elevators have their counterweight operating directly below
the car chassis (frame), sometime within the same guide
rail. Counterweight pit guards are not required.
(c) Inclined elevator counterweights are commonly located
within the same guide rail assembly and below the car.
Be extremely cautious near the mid-point of travel.
(d) End loading inclined elevators have no runby and the
car door will be extremely close to the landing door at
the uphill terminal.
(1) There is no refuge in the direction of travel
beyond the terminals.
(2) Keep all parts of the body and any tools inside the
car when in motion.

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Section 16
ESCALATORS AND MOVING WALKS

You shall familiarize yourself with the safety procedures

outlined throughout this safety handbook. In addition, the fol-
lowing safety rules shall receive special attention when
working on escalators or moving walks:
(a) Mechanics arriving at a location shall alert the owner or
superintendent and place company-approved signs and
proper barricades at both ends of escalators and walks
to restrict all non-authorized persons from entering the
work area or stairways. (See Section 4.3)
(1) When step, step-treads, pallets, combplates, comb-
plate teeth, floor plates or trap doors have been
removed, and power is not required for the equip-
ment it shall be locked out, tagged out and secured
from movement with barricades in place at both ends.
(2) Unattended equipment shall always be locked and
tagged out. When steps/pallets are removed always
attach a note to the lockout and tagout indicating the
steps/pallets has been removed.
(b) Before work begins, the mechanic shall instruct all
employees inexperienced with escalator or moving walk
service on the location of the emergency STOP button
and safety switches.
(c) Communicate with all employees before moving an esca-
lator or walk. Repeat commands or direction signals. Make
sure their actions show they understand your message.
(d) NEVER start, or attempt to start, a unit while anyone is
on, or in, or about to step onto the unit.
(e) Whenever work must be performed within the interior plane
of the steps/pallets (truss) or machinery space that does
not require movement of the unit, lockout and tagout the

152 2015 Safety Handbook

 mainline power disconnect in the OFF position. See
Lockout and Tagout procedures, Section 7.3.
(f) Before you enter the unit or the pit, personally verify that
the unit will not start by testing all locations and possible
combinations of the run and speed key-start switches.
(g) Be aware that the power may still be live at the junction
box, even after the mainline power has been deactivated.
Use a circuit tester to test all circuits before working
on them.
(h) While working on escalators or moving walks, the per-
son in attendance shall have complete control of the
equipment.
(i) Separate your escalator- or moving-walk-start keys from
your key ring. The weight of a full ring of keys can hold
a key switch over in the ON or START position, which
overrides the safety circuit. If you try to stop the unit, the
key would re-start the unit immediately.
(j) Always remove the start key from the switch when you do
not need it, especially when you are leaving the area.
(k) When removing steps or pallets, use proper lifting techniques.
(l) When working on or around moving equipment, take
precautions to avoid getting yourself, or a tool, caught or
pulled into the equipment. Be aware of all pinch points.
Never attempt to remove a foreign object from an esca-
lator or moving walk with the unit in operation.
(m) When walking on a partially disassembled unit, avoid
walking on the step axles as much as possible. Always
hold the handrail. The unit shall be electrically locked
out and blocked ( See Section 7.3)
(n) Where possible, do not inch equipment unless the
holding circuit has been opened.

2015 Safety Handbook 153

(o) When any steps or pallets are removed, always work, or
if necessary, ride facing the opening.
(p) It is recognized that temporary circuit jumpers or clips
may be the only means available for conducting some
service work on escalators or moving walks. These
devices shall only be used as a last resort. (See Section 6.)
(q) Before leaving the building, if the unit is to be returned to
service, remove all Out of Service signs and barricades.
Checkout with the Building Superintendent/Manager.
(r) Should live testing on the controller be necessary:
(1) Place the mainline disconnect switch in the OFF
position;
(2) Remove the controller from the machinery space:
(3) Secure the controller in a vertical position prior to
moving the mainline disconnect to the ON position
(4) Before returning the control to the machinery space
place the mainline disconnect in the OFF position.

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Section 17
DUMBWAITERS

You shall familiarize yourself with the safety procedures

outlined throughout this safety handbook. In addition, the fol-
lowing safety rules shall receive special attention when
working on dumbwaiters.
(a) Never ride or stand on a dumbwaiter, unless the rated load
exceeds your weight, plus the weight of your tools. The cab
must also be structurally capable of holding your weight,
plus the weight of your tools before you access the top of
the car, even if the car is secured as described below.
(b) Before riding or standing on top of a dumbwaiter, ensure
the following safety precautions are in place:
(1) Ensure the dumbwaiter is equipped with a function-
ing top-of-car operating station.
(2) Ensure the top-of-car emergency stop switch is oper-
ating. (See Stop Switch Procedure Section 8.1.)
(3) Verify if the dumbwaiter is equipped with safeties.
(4) Always ride on top of the dumbwaiter and never
inside the car.
(5) Observe overhead clearance.
(c) If work must be performed on top of the car and any one
of the five safety precautions above are not present,
other methods of securing the car shall be employed.
Initiate the Lockout and Tagout Procedure in Section 7.2
and secure the car from the overhead, or block the car
from below in such a manner that the car will hold your
weight, plus the weight of your tools.
(d) When working from the car top, be extremely careful
that your body is within the confines of the car and clear
of all hoistway protrusions while running.

2015 Safety Handbook 155

(e) Make sure all operating devices are inactive (push buttons,
automatic-leveling and homing circuits, etc.), except
those under your immediate control.
(f) Check turnbuckles on car and counterweight ropes to
be sure they are double-nutted and cotter keyed. Wire
rope has a tendency to twist when operating over
sheaves and will spin nuts off turnbuckles if they are not
secured with a cotter key.
(g) Never leave a hoistway door open or unlocked at a land-
ing when the car is not there, level or under conditions
where the car can move, unless the opening is guarded
by a Competent Person.
(h) Check for adequate overhead and under-the-car clearance
before getting on top of car or in the pit.
(i) Do not enter pit unless mainline power switch has been
disconnected, locked out and tagged out. (See Section 7.2.)
(j) On dumbwaiters with automatic-transfer devices, be
sure all such units are within the car before running.
(k) When working through an open hoistway door or the
machine room door and the car is moved, be careful to
avoid contact with the car-gate spreader.
(l) When troubleshooting, be aware slack rope in the system
can cause unintended movement of the car.

156 2015 Safety Handbook

SECTION 18
JOB HAZARD ASSESSMENT

18.1 Instructions
OSHA requires each employer to assess the workplace to
determine if hazards are present, or likely to be present, which
necessitate the use of Personal Protective Equipment (PPE).
Currently, this regulation does not apply to construction.

18.2 Overview

PPE is designed to aid in the protection against work and

environmental hazards that cannot be eliminated. The
Occupational Safety and Health Administration (OSHA)
requires employers to conduct a hazard assessment for
the workplace. The survey results can serve as the basis for
establishing PPE requirements for all similar jobs.
In 1997, the NEII Safety Committee developed the Job Hazard
Assessment Form to help the industry facilitate compliance
with the OSHA regulations specified above. The Job Hazard
Assessment Form (NEII SC01) shall be utilized in conjunction
with the Elevator Industry Field Employees Safety Handbook
and is intended to help your company and you comply with the
OSHA PPE Standard.

18.3 General

All equipment shall be company approved and designed

for the work to be performed. All PPE equipment shall be used
and maintained in a sanitary and reliable condition. These
provisions apply to all field personnel, management personnel
and visitors.

2015 Safety Handbook 157

18.4 Foot and Leg Protection
(a) All footwear shall meet industry and company requirements
and protect the worker from falling, rolling or sharp objects,
wet slippery surfaces and potential electrical hazards.
(b) Leggings protect the lower leg and feet from welding
sparks. Safety snaps allow them to be removed quickly.
Knee guards may be required if the worker is exposed
to extended kneeling. (Also see Section 3.4)

18.5 Head Protection

(a) OSHA regulations mandate that all workers wear protective

helmets in areas where there is a possible danger of head
injury from impact, falling or flying objects, or electrical
shock and burns.
(b) Each worker is required to comply with both industry and
company standards on when, where and how to fit and
wear hard hats. Hard hats shall comply with the American
National Standards Safety Requirements for Industrial
Head Protection, ANSI Z89.1-1986, which shall be marked
on the helmets shell. (Also see Section 3.3)

18.6 Hearing Protection

(a) OSHA has established permissible noise levels and duration

of exposure for workers. When noise levels or exposure
cannot be reduced to below the permissible noise level,
ear protection devices shall be provided and worn.
(b) To be effective, the device used shall be properly fitted.
Some earplugs are disposable and should be discarded
after one use. Nondisposable earplugs shall be cleaned
after each use. (Also see Section 3.5)

158 2015 Safety Handbook

18.7 Eye and Face Protection
(a) Eye and face protective equipment shall be provided
when there is a potential for injury from flying particles,
liquid chemicals, gases, electrical shock/arcing and radi-
ant energy. Companies are required to provide a type of
eye protection suitable for the work to be performed.
(b) Eye and face protection can include goggles, glasses
and face shields. Eye protection devices shall comply
with the American National Standard Practice for
Occupational and Educational Eye and Face Protection,
ANSI Z87.1-1989. (Also see Section 3.2)

18.8 Respiratory Protection

(a) The company shall provide appropriate respiratory devices,

where required. They are to be used by all affected workers
in accordance with the companys respiratory program.
(b) All respiratory devices shall be approved by the
Department of Health and Human Services National
Institute for Occupational Safety and Health for the con-
taminant or situation to which the worker is exposed.
(Also see Section 3.8)

18.9 Personal Fall Arrest System

The company shall provide each worker an appropriate

personal fall arrest system to be used, where required.
Safety harnesses, lifelines and shock-absorbing lanyards
shall be used when guardrails and safety nets are not avail-
able or feasible, and there is a fall exposure over six feet.
(Also see Section 3.6 and 4.1)

2015 Safety Handbook 159

18.10 Hand Protection
If there is a potential for cuts, abrasions, burns and skin con-
tact with chemicals, gloves, suitable for the hazard, shall be
worn. (Also see Section 3.7)

18.11 OSHA Regulations

A job hazard assessment for PPE is required by 29 CFR

Subpart 1, Section 1910.132 through 138. Additional PPE
requirements can be located in 29 CFR Subpart E, Section
1926.95 through 107 and other regulations, such as Subpart
G, K and M. The Job Hazard Assessment establishes the
minimum PPE requirements for elevator industry personnel
performing service and repair work.

18.12 Assessing Workplace Hazards

The employer shall assess the workplace hazards to

determine where PPE is required. Use of the Job Hazard
Assessment Form (NEII SC01) is recommended to help the
elevator company comply with OSHA regulations. The
assessment process is outlined as follows:
(a) A Competent Person shall conduct a hazard assess-
ment to identify hazards which require PPE and/or to
verify the PPE used by the worker is sufficient. This
shall be noted and documented as written certification
of the assessment.
(b) Select, and have each affected employee use, the types
of PPE that will protect the affected employee from the
hazards identified in the hazard assessment.
(c) Issue and train each employee on the use and care of
the required PPE and insure that each employee has
properly fitted PPE.

160 2015 Safety Handbook

(d) Appropriate equipment shall be issued to the employee
prior to startup or at new-hire orientation by the employ-
er. The employee may be required to provide some
PPE.
18.13 Training

OSHA requires the company to provide training to each

employee who is required to have PPE and to know:
(a) when PPE is necessary;
(b) what PPE is necessary;
(c) how to properly wear, fit, adjust and remove PPE;
(d) the limitations of the PPE; and
(e) the proper care, maintenance, useful life and disposal of
the PPE.
If the company has reason to believe the trained worker
does not have the understanding and skill required by the
company to use the PPE, the company shall remove the
worker from the job until the worker is adequately trained.
Each company is required to certify that each worker has been
trained or retrained if there is a job assignment change which
presents a new hazard, or the need for retraining is identified.
Documentation on the date, type of training and workers

2015 Safety Handbook 161

 Page 1 of 2
Top of Car Outside of Car (Landing) SERVICE AND REPAIR Date: ___________
Pit Escalator/Moving Walk JOB HAZARD ASSESSMENT Job: ______________________________
Inside of Car Machine Room (MAY NOT BE ALL INCLUSIVE) Prepared By:_______________________
Personal Protective Equipment Control (CFR 1910) Additional Control
Work Location: Eyes Face Hands/Arms Head Feet/Legs Other* (Specify)
Figure 18a

Major Tasks: ____________________

______________________________
Steps:
1. ____________________________
2. ____________________________
3. ____________________________
4. ____________________________
5. ____________________________

CHECK IF APPLICABLE
SAFETY GLASSES W/SIDE SHIELDS
SAFETY GOGGLES
WELDING (GLASSES & GOGGLES)
RESPIRATOR
FACESHIELD
WELDERS HOOD (W/TINTED LENS)
HEARING PROTECTION
COTTON WORK GLOVES
CUT RESISTANT GLOVE
RUBBER GLOVE
NEOPRENE GLOVE
LEATHER GLOVE
HEAT RESISTANT GLOVE
SLEEVES
WELDERS JACKET
STANDARD HARDHAT
OTHER
SAFETY SHOES
PANTS/COVERALLS
KNEE GUARDS
PERSONAL FALL ARREST SYSTEM
LIFELINE
GUARDRAILS/BARRICADES
HOLE COVERINGS
LOCKOUT/TAGOUT
GFCI
STOP SWITCH PROCEDURE

Hazards

162 2015 Safety Handbook

Equipment Movement Car Escalator/Moving Walk
Electrical
- Energized High Voltage
- Energized Low Voltage
- De-energized
- Inspecting Controller
- Use of Meters
Overhead Clearances
Housekeeping
Hazardous Trash
Environmental
- Chemicals
- Solvents/Oils
- Temperature
- Space Constraints
- Dust/Carbon Dust
- Noise
- Paints
Site Conditions
- Stairways
- Ladders
- Projections
- Walking Surfaces
- Floor Openings
2004, NEII, Salem, NY Form: SC01 * May be required to comply with other regulatory and/or company standards
 Page 2 of 2
Top of Car Outside of Car (Landing) SERVICE AND REPAIR Date: ___________
Pit Escalator/Moving Walk JOB HAZARD ASSESSMENT Job: ______________________________
Inside of Car Machine Room (MAY NOT BE ALL INCLUSIVE) Prepared By:_______________________
Personal Protective Equipment Control (CFR 1910) Additional Control
Work Location: Eyes Face Hands/Arms Head Feet/Legs Other* (Specify)

Major Tasks: ____________________

Figure 18b

______________________________
Steps:
1. ____________________________
2. ____________________________
3. ____________________________
4. ____________________________
5. ____________________________

CHECK IF APPLICABLE
SAFETY GLASSES W/SIDE SHIELDS
SAFETY GOGGLES
WELDING (GLASSES & GOGGLES)
RESPIRATOR
FACESHIELD
WELDERS HOOD (W/TINTED LENS)
HEARING PROTECTION
COTTON WORK GLOVES
CUT RESISTANT GLOVE
RUBBER GLOVE
NEOPRENE GLOVE
LEATHER GLOVE
HEAT RESISTANT GLOVE
SLEEVES
WELDERS JACKET
STANDARD HARDHAT
OTHER
SAFETY SHOES
PANTS/COVERALLS
KNEE GUARDS
PERSONAL FALL ARREST SYSTEM
LIFELINE
GUARDRAILS/BARRICADES
HOLE COVERINGS
LOCKOUT/TAGOUT
GFCI
STOP SWITCH PROCEDURE

Hazards
Site Conditions cont
- Falling Objects

Mechanical Repairs
- Blowers
- Welding
- Soldering
- Cutting
- Hoisting
- Grinding
- Sanding/Chiseling
- Babbitting
- Drilling
- Power Accuated Tools
- Metal Working/Handling
- Sawing
- Roping
Moving Equipment
Other (Specify if not all inclusive)

2015 Safety Handbook 163

2004, NEII, Salem, NY Form: SC01 * May be required to comply with other regulatory and/or company standards
name should be retained as documentation.
Section 19
DRIVING AND VEHICLE SAFETY

Motor vehicle incidents are the number one cause of lost

work time and on-the-job fatalities. Consider this: approximately
40% of all occupational deaths are motor-vehicle related.

19.1 Recognizing Hazards

Recognizing traffic hazards requires being aware of vehicles
that are entering or exiting the roadway, going too fast or slow
for conditions, or changing lanes. Other skills include aware-
ness of weather conditions, traffic flow and road conditions. A
driver should know whats going on ahead at least one city
block, to each side, on the road behind, and inside the vehicle.
Hazards include pedestrians, school buses, animals, inter-
sections, school zones, vehicle breakdowns, cargo spills and
traffic lights.

19.2 Alcohol/Drug Use

More motor vehicle fatalities are linked to alcohol/drug use
than any other cause. It is a violation of law to operate any
vehicle while impaired. DO NOT DRINK AND DRIVE.

19.3 Safety Belts Are For Everyone

The safety belt enables you to take control of your life.
Sure, you may not be able to control that drunk driver who is
headed straight for your car, but you can control your chanc-
es of surviving the crash. As long as you wear your safety
belt, you are in control. Your chances of survival increase
about 50%. There is no question about it, safety belts reduce
fatalities and injuries. Safety belts shall be worn even if the
vehicle is equipped with an airbag. SEAT BELTS SHALL BE

164 2015 Safety Handbook

WORN AT ALL TIMES.
19.4 Vehicle Maintenance
Proper vehicle maintenance is vital for safe and efficient
operation. The driver of the vehicle will know best when non-
scheduled maintenance is necessary. Before each trip, the
driver shall check lights, mirrors, tires and brakes, and that the
load is secured. Remember, safe driving doesnt happen by
accident; you make it happen.
19.5 Communication Devices
Do not operate communication devices (unless hands free)
while operating a motor vehicle. Pull vehicle to the side of the road
and stop in a safe place before operating communication devices.

2015 Safety Handbook 165

Section 20
SUBSTANCE ABUSE

(a) No Elevator Industry employee may use or possess

unlawful drugs.
(b) Employees shall not bring prescription drugs on
Company property or job sites, unless a licensed physi-
cian has prescribed them. Only employees receiving
such prescriptions in the manner, combination and
quantity prescribed can utilize such drugs.
(c) Employees shall not use over-the-counter or prescription
drugs that may impair your performance.
(d) Employees shall not use alcoholic beverages during work-
ing hours and shall not be under the influence of alcohol
while at work.
(e) Employees shall not bring alcohol onto the job site for
the purpose of such use.
(f) Employees shall be subject to drug and/or alcohol test-
ing following an accident on Company property or on
Company business.
(g) Any employee whose conduct, appearance or behavior
may tend to suggest that the individual is impaired or
otherwise not fit to perform the tasks of his or her job
and is under the influence of drugs or alcohol, will be
required to submit to testing as specified in their
Company policy.
(h) Employees who have failed a previous test shall be subject
to unannounced follow-up testing for a period of one (1)
year after their return to duty.

166 2015 Safety Handbook

Section 21
GLOSSARY OF TERMS
This glossary defines various terms used in the Elevator
Industry Field Employees Safety Handbook.
Abatement Elimination of workplace hazards either imme-
diately or through a process.
Acute Injury or Illness caused by a one time exposure.
Acute Effect Adverse effect which has severe symptoms
developing rapidly and coming quickly to a crisis.
American National Standards Institute [ANSI] A voluntary
membership organization (run with private funding) that
coordinates the development of consensus standards
nationally and verifies that the principles of openness and
due process have been followed.
ASME A17.1 Code A code of safety standards covering
the design, construction, operation, inspection, testing,
maintenance, alteration and repair of elevators, escalators,
moving walks and dumbwaiters. AKA Safety Code for Elevators
and Escalators, ASME A17.1 an American National Standard.
Barricade A temporary structure to restrict access to an
escalator or elevator.
Bloodborne Pathogens An OSHA Standard, 29 CFR
1910.1030, requiring Companies whose employees are
exposed to human blood or other potentially infectious material
to have a program that is disseminated to all employees.
Carcinogen A substance or physical agent that may cause
cancer.
Chemical Manufactured substance used on the worksite
that requires an Material Safety Data Sheet.
Chronic Injury or Illness caused by a persistent, prolonged
or repeated exposure to a hazard or hazardous condition.

2015 Safety Handbook 167

Chronic Effect An adverse effect on a human body, with
symptoms which develop slowly over a long period of
time or which recur frequently.
Code of Federal Regulations [CFR] Federal codes that
address specific standards, including OSHA regulations.
Competent Person A person who is capable of identifying
existing and predictable hazards, on the job, in the surround-
ings or working conditions which are unsanitary, hazardous
or dangerous to employees and who has authorization to
take prompt corrective measures to eliminate them.
Confined Space An area that has adequate size and configura-
tion for employee entry; and has a limited means for entry
and exit; and is not designed for continuous occupancy.
Do-Not-Start Tag A company approved tag used in
conjunction with the company lockout/tagout program,
advising the equipment has been de-energized for
maintenance or repairs.
Emergency Response A plan to ensure employee
safety in the event of fire and other emergencies that is
not limited to, escape procedures and routes, employee
accounting and reporting.
Environmental Protection Agency [EPA] A Federal
agency responsible for the administration of laws to con-
trol and/or reduce pollution of the air, water and land.
Equipment elevators, escalators, dumbwaiters, moving
walks, platform lifts and chair lifts.
Explosive Range The range between the lower and upper
explosive limits, expressed in terms of percentage of
vapor or gas in air by volume, and is also often referred
to as the Flammable Range.
Fall Hazard exists when working more than 6 ft (1.8 m) above
a lower level and an opening greater than 12 in. (305 mm).

168 2015 Safety Handbook

Fall Protection The use of guardrails, floor hole covers or
personal fall arrest systems when a potential fall hazard exists.
False Car A temporary movable platform assembled or
built on the job-site for installing elevator equipment.
Flash Point The lowest temperature at which a liquid gives
off enough vapor to form an ignitable mixture with air and
burn when a source of ignition (sparks, open flames,
cigarettes, etc.) is present.
Foot Protection Work shoes or boots that meet the com-
pany, industry and/or ANSI Z41 standard.
Ground-Fault Circuit Interrupter [GFCI] A device
intended for the protection of personnel that functions to
de-energize a circuit or portion thereof within an estab-
lished period of time when a current to ground exceeds
4-6 milliamps (mA).
Guardrail System An OSHA compliant barrier installed at
the entrance of elevator hoistway or around a hoistway or
escalator/moving walk wellway at construction, moderni
zation or major repair site.
Hazard Communication [HAZCOM or Right-to-Know]
A formal process to alert employees about workplace
chemicals through a written program.
Incident An occurrence or event resulting in a serious
injury, illness (medical treatment beyond first aid), death,
environmental spill and/or near miss.
Job Hazard Assessment [JHA] Process of analyzing
each step of a task to identify hazards and corrective
actions to minimize/eliminate hazards.
Jumpers A temporary means of bypassing or shunting
an electrical circuit.

2015 Safety Handbook 169

Lockout/Tagout A procedure to identify all potential
energy sources and to ensure that they are completely
isolated (locks and tags are attached to primary energy
sources) prior to working on system.
Lower Explosive Limit [LEL] (AKA Lower Flammable
Limit). The lowest concentration of a substance that will
produce a fire or flash if an ignition source (flame, spark,
etc.) is present.
Material Safety Data Sheets [MSDS] A document that
identifies the hazards, safe handling and emergency pro
cedures for each individual hazardous chemical used in
the workplace.
National Institute for Occupational Safety & Health
[NIOSH] A federal agency that develops and periodi-
cally revises exposure limits for hazardous substances or
conditions. NIOSH also recommends appropriate preven-
tive measures to reduce or eliminate adverse health and
safety effects of these hazards.
Occupational Safety & Health Administration [OSHA]
Federal agency under the Department of Labor that pub-
lishes and enforces safety and health regulations for
most businesses and industries in the United States.
Permissible Exposure Limit [PEL] An exposure limit that
is specified in OSHA regulations. PEL may be a time-
weighted-average (TWA) exposure limit (8 hour), a
15-minute short-term exposure limit (STEL), or a ceiling (C).
Permit Written permission to proceed with an activity. A
customer may require a permit (permission) prior to per-
forming hot work (welding, grinding), entering a confined
space, etc. A legal document obtained from a government
agency to allow for the installation or modernization of an
elevator, etc.

170 2015 Safety Handbook

Permit Required Confined Space A confined space that
contains a hazardous atmosphere, mechanical or electrical
hazards, limited means of entry and egress and is a serious
safety or health hazard that requires air monitoring, specific
training, record keeping and permit for entry.
Personal Fall Arrest System A system used to arrest an
employee in a fall from a working level. It consists of an
anchorage, connectors, a body harness and may include
a lanyard, deceleration device, lifeline, or suitable combina-
tions of these. (As defined by OSHA).
Personal Protective Equipment (PPE) Protective equip-
ment for eyes, face, head and extremities. Including but
not limited to protective clothing, respiratory devices and
protective shields and barricades.
Polychlorinated Biphenyls [PCBs] A compound
derived from biphenyl and containing chlorine that is
used in electrical insulators, flame-retardants, and plas-
ticizers. PCB is a hazardous environmental pollutant
that is difficult to dispose of safely.
Professional Medical Treatment Medical treatment
beyond first aid administered by a medical professional.
Qualified Person One, who by possession of a recognized
degree, certificate, or professional standing, or by extensive
knowledge, training, and/or experience has successfully
demonstrated his/her ability to solve or resolve problems
related to the work.
Recognition of Hazards Ability to identify hazards that
have the potential to injure employees on the job.
Respiratory Protective Equipment Devices such as
respirators and masks used to protect employees from
inhalation of specific dust, chemicals and solvents.
Right-to-Know See Hazard Communication Program.

2015 Safety Handbook 171

Running Platform A temporary device installed in the
hoistway for elevator installation.
Scaffolds A temporary working platform supported by a
frame that is used for the erection or repair of an elevator.
Shafter (also referred to as Spider, Go-Devil, Sky
Climber or False Car) A moveable hoistway working
platform, generally built on the jobsite for installing eleva-
tor equipment.
Shall Indicates a mandatory requirement.
Short Term Exposure Limit [STEL] The maximum con-
centration to which workers can be exposed for a short
period of time (15 minutes).
Should Indicates a recommendation not a mandatory
requirement.
Stop Switch A manually operated device that removes
power from an elevator or escalator driving machine,
motor and brake.
Top of Car Inspection [TOCI] A device on top-of-the-car
required by ASME A17.1 Code that permits elevator per-
sonnel to operate the elevator from the car top.
Upper Explosive Limit [UEL] (AKA Upper Flammable
Limit) The highest concentration of a substance that will
burn or explode when an ignition source is present.

172 2015 Safety Handbook

 APPENDICES
Section 22

22.1 Metric Conversion

POUNDS TO KILOGRAMS FROM 0 TO 10.9 POUNDS

(1 pound = 0.45359265 of a kilogram)
Pounds 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
Kgs Kgs Kgs Kgs Kgs Kgs Kgs Kgs Kgs Kgs
0 0.00000 0.01536 0.09072 0.13508 0.18144 0.22680 0.27216 0.31751 0.36287 0.40823
1 .45359 .49895 .51431 .58967 .63503 .68039 .72575 .77111 .81647 .86183
2 .90719 .95254 .99790 1.01326 1.08862 1.13398 1.17931 1.22470 1.27006 1.31542
3 1.36078 1.40614 1.45150 1.49686 1.54222 1.58757 1.63293 1.67829 1.72365 1.76901
4 1.81437 1.85973 1.90509 1.95015 1.99581 2.04117 2.08653 2.13189 2.17724 2.22260
5 2.26796 2.31332 2.35868 2.40404 2.44910 2.49176 2.54012 2.58548 2.63084 2.67620
6 2.72156 2.76692 2.81227 2.85763 2.90299 2.94835 2.99371 3.03907 3.08443 3.12979
7 3.17515 3.22051 3.26587 3.31123 3.35659 3.40194 3.44730 3.49266 3.53802 3.58338
8 3.62874 3.67410 3.71946 3.76482 3.81018 3.85554 3.90090 3.94626 3.99162 4.03697
9 4.08233 4.12769 4.17305 4.21841 4.26377 4.30913 4.35449 4.39985 4.44521 4.49057
10 4.53593 4.58129 4.62664 4.67200 4.71736 4.76272 4.80808 4.85344 4.89880 4.94416
Figure 22a

2015 Safety Handbook 173

U.S. GALLONS TO LITERS FROM 0 TO 100 GALLONS
(1 gallon = 3.7853323 liters)
Gallons 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
 POUNDS TO KILOGRAMS FROM 0 TO 10.9 POUNDS
(1 pound = 0.45359265 of a kilogram)
Pounds 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
Kgs Kgs Kgs Kgs Kgs Kgs Kgs Kgs Kgs Kgs
0 0.00000 0.01536 0.09072 0.13508 0.18144 0.22680 0.27216 0.31751 0.36287 0.40823
1 .45359 .49895 .51431 .58967 .63503 .68039 .72575 .77111 .81647 .86183
Figure 22b
2 .90719 .95254 .99790 1.01326 1.08862 1.13398 1.17931 1.22470 1.27006 1.31542
3 1.36078 1.40614 1.45150 1.49686 1.54222 1.58757 1.63293 1.67829 1.72365 1.76901
4 1.81437 1.85973 1.90509 1.95015 1.99581 2.04117 2.08653 2.13189 2.17724 2.22260
5 2.26796 2.31332 2.35868 2.40404 2.44910 2.49176 2.54012 2.58548 2.63084 2.67620
6 2.72156 2.76692 2.81227 2.85763 2.90299 2.94835 2.99371 3.03907 3.08443 3.12979
7 3.17515 3.22051 3.26587 3.31123 3.35659 3.40194 3.44730 3.49266 3.53802 3.58338
8 3.62874 3.67410 3.71946 3.76482 3.81018 3.85554 3.90090 3.94626 3.99162 4.03697
9 4.08233 4.12769 4.17305 4.21841 4.26377 4.30913 4.35449 4.39985 4.44521 4.49057
10 4.53593 4.58129 4.62664 4.67200 4.71736 4.76272 4.80808 4.85344 4.89880 4.94416

174 2015 Safety Handbook

U.S. GALLONS TO LITERS FROM 0 TO 100 GALLONS
(1 gallon = 3.7853323 liters)
Gallons 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
Liters Liters Liters Liters Liters Liters Liters Liters Liters Liters
0 00.0000 3.7853 7.5707 11.3560 15.1413 18.9267 22.7120 26.4973 30.2827 34.0680
10 37.8533 41.6387 45.4240 49.2093 52.9947 56.7800 60.5653 64.3506 68.1360 71.9213
20 75.7066 79.4920 83.2773 87.0626 90.8480 94.6333 98.4186 102.2040 105.9893 109.7746
30 113.5600 117.3453 121.1306 124.9160 128.7013 132.4866 136.2720 140.0573 143.8426 147.6280
40 151.4133 155.1986 158.9840 162.7693 166.5546 170.3400 174.1253 177.9106 181.0960 185.4813
50 189.2666 193.0519 196.8373 200.6226 204.4079 208.1933 211.9786 215.7639 219.5493 223.3346
60 227.1199 230.9053 234.6906 238.4759 242.2613 246.0466 249.8319 253.6173 257.4026 261.1879
70 264.9733 268.7586 272.5439 276.3293 280.1146 283.8999 287.6853 291.4706 295.2559 299.0413
80 302.8266 306.6119 310.3972 314.1826 317.9679 321.7532 325.5386 329.3239 333.1092 336.8946
90 340.6799 344.4652 348.2506 352.0359 355.8212 359.6066 363.3919 367.1772 370.9626 374.7479
100 378.533
NOTE: This table may be read from 100 to 1000 gallons in steps of 10 gallons by moving decimal points one place to right.

Courtesy of ASME
 NOMINAL ELEVATOR CAR SPEEDS IN
Figure 22c

FEET PER MINUTE TO METERS PER MINUTE AND METERS PER SECOND
Feet Meters Meters Feet Meters Meters Feet Meters Meters Feet Meters Meters
per Min. per Min. per Sec. per Min. per Min. per Sec. per Min. per Min. per Sec. per Min. per Min. per Sec.
5 1.5 .03 105 32.0 .53 205 62.4 1.04 325 99.0 1.65
10 3.0 .05 110 33.0 .56 210 64.0 1.07 350 107.0 1.78
15 4.6 .03 115 35.0 .58 215 65.0 1.09 375 114.0 1.91
20 6.0 .10 120 36.0 .61 220 67.0 1.12 400 122.0 2.03
25 8.0 .13 125 38.0 .64 225 68.0 1.14 425 129.0 2.16
450 137.0 2.29
30 9.0 .15 130 40.0 .66 230 70.0 1.17 475 145.0 2.41
35 11.0 .18 135 41.0 .69 235 71.0 1.19 500 152.0 2.54
40 12.0 .20 140 43.0 .71 240 73.0 1.22 525 160.0 2.67
45 14.0 .23 145 44.0 .74 245 74.0 1.24 550 168.0 2.79
50 15.0 .25 150 46.0 .76 250 76.0 1.27 575 175.0 2.92
600 183.0 3.05
55 17.0 .28 155 47.0 .79 255 78.0 1.30 625 190.0 3.18
60 18.0 .30 160 49.0 .81 260 79.0 1.32 650 198.0 3.30
65 20.0 .33 165 50.0 .84 265 80.0 1.35 675 205.0 3.43
70 21.0 .36 170 52.0 .86 270 82.0 1.37 700 213.0 3.56
75 23.0 .38 175 53.0 .89 275 84.0 1.40 725 221.0 3.68
750 229.0 3.81
80 24.0 .41 180 55.0 .91 280 85.0 1.42 775 236.0 3.94
85 26.0 .43 185 56.0 .94 285 87.0 1.45 800 244.0 4.06
90 27.0 .46 190 58.0 .97 290 88.0 1.47 825 251.0 4.19
95 29.0 .48 195 59.0 .99 295 90.0 1.50 850 259.0 4.32
100 30.0 .51 200 60.0 1.02 300 91.0 1.52 875 267.0 4.45

2015 Safety Handbook 175

900 274.0 4.57
Courtesy of ASME
Figure 22d
FRACTIONS OF AN INCH (FOR EACH 64th) TO MILLIMETERS

Fractions 64ths
Decimals Millimeters
of Inch of Inch
1 .015625 0.397
1/32 2 .031250 0.791
3 .046875 1.191
1/16 4 .062500 1.588
5 .078125 1.984
3/32 6 .093750 2.381
7 .109375 2.778
1/8 8 .125000 3.175
9 .140625 3.572
5/32 10 .156250 3.969
11 .171875 4.366
3/16 12 .187500 4.763
13 .203125 5.159
7/32 14 .218750 5.556
15 .234375 5.953
1/4 16 .250000 6.350
17 .265625 6.747
9/32 18 .281250 7.144
19 .296875 7.541
5/16 20 .312500 7.938
21 .328125 8.334
11/32 22 .343750 8.731
23 .359375 9.128
3/8 24 .375000 9.525
25 .390625 9.922
13/32 26 .406250 10.319
27 .421875 10.716
7/16 28 .437500 11.113
29 .453125 11.509
15/32 30 .468750 11.906
31 .484375 12.303
1/2 32 .500000 12.700

176 2015 Safety Handbook

Figure 22d
FRACTIONS OF AN INCH (FOR EACH 64th) TO MILLIMETERS

Fractions 64ths
Decimals Millimeters
of Inch of Inch
33 .515625 13.097
17/32 34 .531250 13.494
35 .546875 13.891
9/16 36 .562500 14.288
37 .578125 14.684
19/32 38 .593750 15.081
39 .609375 15.478
5/8 40 .625000 15.875
41 .640625 16.272
21/32 42 .656250 16.669
43 .671875 17.066
11/16 44 .687500 17.463
45 .703125 17.859
23/32 46 .718750 18.256
47 .734375 18.653
3/4 48 .750000 19.050
49 .765625 19.447
25/32 50 .781250 19.844
51 .796875 20.241
13/16 52 .812500 20.638
53 .828125 21.034
27/32 54 .843750 21.431
55 .859375 21.828
7/8 56 .875000 22.225
57 .890625 22.622
29/32 58 .906250 23.019
59 .921875 23.416
15/16 60 .937500 23.813
61 .953125 24.209
31/32 62 .968750 24.606
63 .981375 25.003
1 64 1.000000 25.400

2015 Safety Handbook 177

Figure 22e FEET TO METERS FROM 0 T0 249 FEET
(1 foot = 0.3048004006 meter)
Feet Meters Feet Meters Feet Meters Feet Meters Feet Meters
0 0.00000 50 15.24003 100 30.48006 150 45.72009 200 60.96012
1 .30480 1 15.54483 1 30.78436 1 46.02489 1 61.26492
2 .60060 2 15.84963 2 31.08966 2 46.32969 2 61.56972
3 .91440 3 16.15443 3 31.39446 3 46.63449 3 61.87452
4 1.21920 4 16.45923 4 31.69926 4 46.93929 4 62.17932
5 1.52400 5 16.76403 5 32.00406 5 47.24409 5 62.48412
6 1.82880 6 17.06883 6 32.30886 6 47.54890 6 62.78893
7 2.13360 7 17.37363 4 32.61367 7 47.85370 7 63.09373
8 2.43840 8 17.67844 8 32.91847 8 48.15850 8 63.39853
9 2.74321 9 17.98234 9 33.22327 9 48.46330 9 63.70333
10 3.04801 60 18.28804 110 33.52807 160 48.76810 210 64.00813
1 3.35281 1 18.59284 1 33.83287 1 49.07290 1 64.31293
2 3.65761 2 18.89764 2 34.13767 2 49.37770 2 64.61773
3 3.96241 3 19.20244 3 34.44247 3 49.68250 3 64.92253
4 4.26721 4 19.50724 4 34.74727 4 49.98730 4 65.22733
5 4.57201 5 19.81204 5 35.05207 5 50.29210 5 65.53213
6 4.87681 6 20.11684 6 35.35687 6 50.59690 6 65.83693
7 5.18161 7 20.42164 7 35.66167 7 50.90170 7 66.14173
8 5.48641 8 20.72644 8 35.96647 8 51.20650 8 66.44653
9 5.79121 9 21.03124 9 36.27127 9 51.51130 9 66.75133
20 6.09601 70 21.33604 120 36.57607 170 51.81610 220 67.05613
1 6.40081 1 21.64084 1 36.88087 1 52.12090 1 67.36093
2 6.70561 2 21.94564 2 37.18567 2 52.42570 2 67.66574
3 7.01041 3 22.25044 3 37.49047 3 52.73051 3 67.97054
4 7.31521 4 22.55525 4 37.79528 4 53.03531 4 68.27534
5 7.62002 5 22.86005 5 38.10008 5 53.34011 5 68.58014
6 7.92482 6 23.16485 6 38.40488 6 53.64491 6 68.88494
7 8.22962 7 23.46965 7 38.70968 7 53.94971 7 69.18974
8 8.53442 8 23.77445 8 39.01448 8 54.25451 8 69.49454
9 8.83922 9 24.07925 9 39.31928 9 54.55931 9 69.79934
30 9.14402 80 24.38405 130 39.62408 180 54.86411 230 70.10414
1 9.44882 1 24.68885 1 39.92888 1 55.16891 1 70.40894
2 9.75362 2 24.99365 2 40.23368 2 55.47371 2 70.71374
3 10.05842 3 25.29845 3 40.53848 3 55.77851 3 71.01854
4 10.36322 4 25.60325 4 40.84328 4 56.08331 4 71.32334
5 10.66802 5 25.90805 5 41.14808 5 56.38811 5 71.62814
6 10.97282 6 26.21285 6 41.45288 6 56.69291 6 71.93294
7 11.27762 7 26.51765 7 41.75768 7 56.99771 7 72.23774
8 11.58242 8 26.82245 8 42.06248 8 57.30251 8 72.54255
9 11.88722 9 27.12725 9 42.36728 9 57.60732 9 72.84735
40 12.19202 90 27.43205 140 42.67209 190 57.91212 240 73.15215
1 12.49682 1 27.73686 1 42.97689 1 58.21692 1 73.45695
2 12.80163 2 28.04166 2 43.28169 2 58.52172 2 73.76175
3 13.10643 3 28.34646 3 43.58649 3 58.82652 3 74.06655
4 13.41123 4 28.65126 4 43.89129 4 59.13132 4 74.37135
5 13.71603 5 28.95606 5 44.19609 5 59.43612 5 74.67615
6 14.02083 6 29.26086 6 44.50089 6 59.74092 6 74.98095
7 14.32563 7 29.56566 7 44.80569 7 60.04572 7 75.28575
8 14.63043 8 29.87046 8 45.11049 8 60.35052 8 75.59055
9 14.93523 9 30.17526 9 45.41529 9 60.65532 9 75.89535

1 inch = 0.02540 meter 4 inches = 0.10460 meter 7 inches = 0.17780 meter 10 inches = 0.25400 meter
2 inches = 0.05080 meter 5 inches = 0.20320 meter 8 inches = 0.12700 meter 11 inches = 0.27960 meter
3 inches = 0.07620 meter 6 inches = 0.15240 meter 9 inches = 0.22860 meter 12 inches = 0.30480 meter

178 2015 Safety Handbook

22.2 Electrical Figure 22f

COLOR CODE FOR FIXED RESISTORS VALUES IN OHMS

Number
of Zeros
1st 2nd Tolerance 1st 2nd
Significant Figures Number of Zeros Tolerance Significant Figures

Resistor with axial wire leads. Resistor with radial wire leads.
BODY END DOT OR BAND END
1st Band 2nd Band 3rd Band End Band
Color Value Color Value Color Value Color Tolerance
Black . . . . . . 0 Black . . . . . . 0 Black . . . . . . . None Gold. . . . . . . . 5%
Brown . . . . . 1 Brown . . . . . 1 Brown. . . . . . . . . . 0 Silver . . . . . . 10%
Red . . . . . . . 2 Red . . . . . . . 2 Red . . . . . . . . . . 00 None . . . . . . 20%
Orange . . . . 3 Orange . . . . 3 Orange. . . . . . . 000
Yellow . . . . . 4 Yellow . . . . . 4 Yellow. . . . . . . 0000
Green . . . . . 5 Green . . . . . 5 Green. . . . . . 00000
Blue. . . . . . . 6 Blue . . . . . . . 6 Blue . . . . . . 000000
Violet . . . . . . 7 Violet . . . . . . 7 Violet . . . . 0000000
Grey . . . . . . 8 Grey. . . . . . . 8 Grey . . . . 00000000
White. . . . . . 9 White . . . . . . 9 White . 000000000

COLOR CODE FOR JAN FIXED MICA CAPACITORS

Black Dot Identifies Directional

MICA Capacitor Indicator CAPACITANCE

Signifi- Char-
Color cant Decimal Tolerance acter-
Figure Multipler istic
Black 0 1 20%(M) A
2nd Significant Brown 1 10 ....... B
1st Figures of Red 2 100 2%(G) C
Capacitance
Characteristics in nm
Orange 3 1,000 ....... D
Yellow 4 ....... ....... E
Capacitance Green 5 ....... ....... F
Number of Zeros in
Tolerance
Capacitance Value Blue 6 ....... ....... G
Violet 7 ....... ....... ..
Grey 8 ....... ....... ..
Color code scheme for JAN standard fixed mica White 9 ....... ....... ..
capacitors. The significance of the letters denot- Gold ... 0.1 5%(J) ..
ing characteristicwill be found in the joint Army- Silver
2015
...
Safety
0.01
Handbook
10%(K)
179
..
Navy Specification JAN-G-5.
 Blue. . . . . . . 6 Blue . . . . . . . 6 Blue . . . . . . 000000
Violet . . . . . . 7 Violet . . . . . . 7 Violet . . . . 0000000
Grey . . . . . . 8 Grey. . . . . . . 8 Grey . . . . 00000000
White. . . . . . 9 White . . . . . . 9 White . 000000000
Figure 22g

COLOR CODE FOR JAN FIXED MICA CAPACITORS

Black Dot Identifies Directional

MICA Capacitor Indicator CAPACITANCE

Signifi- Decimal Char-

Color cant Tolerance acter-
Figure Multipler istic
Black 0 1 20%(M) A
2nd Significant Brown 1 10 ....... B
1st Figures of Red 2 100 2%(G) C
Capacitance
Characteristics in nm
Orange 3 1,000 ....... D
Yellow 4 ....... ....... E
Capacitance Green 5 ....... ....... F
Number of Zeros in
Tolerance
Capacitance Value Blue 6 ....... ....... G
Violet 7 ....... ....... ..
Grey 8 ....... ....... ..
Color code scheme for JAN standard fixed mica White 9 ....... ....... ..
capacitors. The significance of the letters denot- Gold ... 0.1 5%(J) ..
ing characteristicwill be found in the joint Army- Silver ... 0.01 10%(K) ..
Navy Specification JAN-G-5.

180 2015 Safety Handbook

 TIMBER USED FOR HEADBEAMS
(THE LOADS GIVEN ARE FOR DRESSED BEAMS, WHICH
ARE SLIGHTLY SMALLER THAN NOMINAL SIZES LISTED)
Loads are in lbs concentrated at center of span.
VERTICAL Reduced listed loads to allow for beam weights. HORIZONTAL
BEAM SPAN (FEET)
SIZE (INCHES)
4 6 8 10 12 14 16 18 20 24
22.3 Timber, Beams and Planks

4x4 ................ 990 660 500 390 330 280

4 x 6 Hor . . . . . . . . . . . . . 1,530 1,000 750 600 500 430 370 330
4 x 6 Vert . . . . . . . . . . . . . 2,280 1,520 1,140 910 760 650 570 510 455 380
6x6 ................ 3,460 2,310 1,730 1,380 1,150 990 860 770 690 570
6 x 8 Hor . . . . . . . . . . . . . 4,710 3,140 2,360 1,880 1,570 1,340 1,170 1,040 940 780
6 x 8 Vert . . . . . . . . . . . . . 6,400 4,290 3,220 2,580 2,150 1,840 1,610 1,430 1,290 1,070
8x8 ................ 8,540 5,870 4,400 3,520 2,930 2,510 2,200 1,950 1,750 1,460
8 x 12 Vert . . . . . . . . . . . . 12,820 12,820 10,330 8,270 6,890 5,910 5,170 4,590 4,130 3,440
8 x 14 Vert . . . . . . . . . . . . 14,920 14,920 14,260 11,400 9,500 8,150 7,120 6,830 5,700 4,750
8 x 16 Vert . . . . . . . . . . . . 17,070 17,070 17,070 15,020 12,510 10,700 9,390 8,340 7,500 6,260
10 x 10 . . . . . . . . . . . . . . 13,330 11,900 8,930 7,140 5,950 5,100 4,470 3,970 3,570 2,970
10 x 12 Vert . . . . . . . . . . 16,000 16,000 13,080 10,470 8,720 7,480 6,540 5,820 5,230 4,360
10 x 14 Vert . . . . . . . . . . 18,660 18,660 18,020 14,420 12,020 10,300 9,020 8,010 7,210 6,010
Figure 22h

*General Note: 1 in. = 25.4 mm; 1 ft = 0.305 m; 1 lb = 0.454 kg

2015 Safety Handbook 181

 Figure 22i

ALLOWABLE CONCENTRATED LOADS ON AMERICAN STANDARD BEAMS

LOAD IN CENTER OF SPAN WITH BEAM FIXED AGAINST HORIZONTAL MOVEMENT
LOAD IN KIPS (1,000 LBS.)

NOMINAL DEPTH & WIDTH WEIGHT PER FEET

SPAN 10 x 4-3/4 8x4 7 x 3-3/4 6 x 3-3/8 5x3 4 x 2-3/4 3 x 2-3/8
(FEET)

182 2015 Safety Handbook

35 25.4 23 18.4 20 15.3 17.25 12.15 14.75 10 9.5 7.7 7.5 5.7
3 65 35 26 16 13 10 7 6 4 3
4 48 26 23 20 17 14 12 10 8 5 5 3 2
5 39 32 21 19 16 14 11 9 8 6 4 4 2 2
6 32 27 18 16 13 11 9 8 6 5 3 3 2 1
7 28 23 15 13 11 9 8 6 5 4 3 2 1 1
8 24 20 13 12 10 8 7 6 5 4 2 2
9 21 18 12 10 8 7 6 5 4 3 2 2
10 19 16 10 9 8 6 5 4 4 3
11 17 15 9 7
12 16
*General Note: 1 in. = 25.4 mm; 1 ft = 0.305 m; 1 lb = 0.454 kg
 ALLOWABLE LOADS FOR WOOD PLANKS
(Pounds)
Total allowable uniformly distributed loads for timber planks supported at ends. The allowable concentrated load shall be
one-half the distributed load.
Based on unit stress of 1,000 psi
PLANKS
Nom. Size 6x2 8x2 10 x 2 12 x 2 14 x 2 8x3 10 x 3 12 x 3
(Inches)
Actual Size 5-5/8 x 7-1/2 x 9-1/2 x 11-1/2 x 13-1/2 x 7-1/2 x 9-1/2 x 11-1/2 x
(Inches) 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 2-5/8 2-5/8 2-5/8
Area In.2 9.15 12.20 15.45 18.70 21.95 19.70 25.0 30.2
Span
(Feet)
4 410 550 700 850 990 1440 1820 2200
5 330 440 560 680 790 1150 1460 1770
6 280 370 470 560 660 960 1220 1470
7 240 320 400 480 570 820 1040 1260
8 210 280 350 420 500 720 910 1100
9 ....... 180 250 310 380 440 640 810 980
10 ....... ....... 220 280 340 400 580 730 880
11 ....... ....... 200 250 310 360 520 660 800
12 ....... ....... 180 230 280 330 480 610 740
13 ....... ....... ....... 220 260 310 440 560 680
14 ....... ....... ....... 200 240 280 410 520 630
15 ....... ....... ....... 180 230 270 380 490 590
16 ....... ....... ....... ....... 210 250 360 460 550
17 ....... ....... ....... ....... 200 240 340 430 520
18 ....... ....... ....... ....... 190 220 320 400 490
19 ....... ....... ....... ....... ....... 210 300 380 460
20 ....... ....... ....... ....... ....... 200 290 370 440

2015 Safety Handbook 183

Figure 22j

*General Note: 1 in. = 25.4 mm; 1 ft = 0.305 m; 1 psi = 6.89 kPa; 1 in.2 = 6.451 E-04 m2
 ALLOWABLE LOADS FOR BEAMS
(Pounds)
Allowable uniformly distributed loads for timber beams supported at ends. The allowable concentrated load shall be one-
half (1/2) the distributed load.
Based on unit stress of 1,000 psi
Figure 22k

BEAMS
Nom. Size 2x4 2x6 2x8 2 x 10 2 x 12 2 x 14 4x4 4x6 6x6
(Inches)
Actual Size 1-5/8 x 1-5/8 x 1-5/8 x 1-5/8 x 1-5/8 x 1-5/8 x 3-5/8 x 3-5/8 x 5-1/2 x
(Inches) 3-5/8 5-5/8 7-1/2 9-1/2 11-1/2 13-1/2 3-5/8 5-5/8 5-1/2
Area In.2 5.90 9.15 12.20 15.45 18.70 21.95 13.15 20.4 30.2
Span
(Feet)

184 2015 Safety Handbook

4 600 1430 2540 4070 5970 8230 1330 3190 4600
5 480 1140 2030 3260 4780 6580 1060 2550 3690
6 400 950 1700 2720 3980 5490 890 2120 3080
7 340 820 1450 2320 3410 4700 760 1820 2630
8 300 710 1270 2040 2990 4110 660 1590 2300
9 ....... 630 1130 1810 2650 3660 590 1420 2050
10 ....... 570 1010 1630 2390 3290 530 1270 1840
11 ....... 520 920 1480 2170 3000 480 1160 1670
12 ....... 470 840 1360 1990 2740 440 1060 1530
13 ....... ....... 780 1250 1840 2530 ....... 980 1410
14 ....... ....... 720 1160 1710 2350 ....... 910 1310
15 ....... ....... 670 1090 1590 2190 ....... 850 1220
16 ....... ....... 630 1020 1490 2060 ....... 800 1150
17 ....... ....... ....... 960 1400 1930 ....... 750 1080
18 ....... ....... ....... 900 1320 1820 ....... 710 1020
19 ....... ....... ....... 860 1260 1730 ....... 670 970
20 ....... ....... ....... 810 1200 1640 ....... 640 930
*Allowable
Load 800 1230 1640 2080 2520 2950 1770 2740 4050
for Shear at
100 lbs/in.2
*General Note: 1 in. = 25.4 mm; 1 ft = 0.305 m; 1 psi = 6.89 kPa; 1 in.2 = 6.451 E-04 m2
 INDEX
A
Acetylene Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Alcohol/Drug Use (Vehicle Safety) . . . . . . . . . . . . . . . . . 164
Allowable Concentrated Loads on
American Standard Beams (Chart) . . . . . . . . . . . . . . 182
Allowable Loads for Beams (Chart) . . . . . . . . . . . . . . . . 184
Allowable Loads for Wood Planks (Chart) . . . . . . . . . . . 183
Allowable Number of Broken Strands for
Wire Ropes Used in Hoisting Equipment. . . . . . . . . . . 94
Anchor, Safety Harness (Illustration). . . . . . . . . . . . . . . . . 30
Asbestos (HAZCOM). . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

B
Babbitting (HAZCOM). . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Barricade (Illustration). . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Batteries, Sulfuric Acid Type (HAZCOM) . . . . . . . . . . . . 147
Beam Clamps Vertical Pull Only (Illustration) . . . . . . . . 92
Beam Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Beams, Allowable Concentrated Loads
on American Standard (Chart). . . . . . . . . . . . . . . . . . 182
Beams, Allowable Loads for (Chart) . . . . . . . . . . . . . . . 184
Beams, Suspending Needle or Scaffolds (Illustration) . . . 100
Beams, Timber Used for. . . . . . . . . . . . . . . . . . . . . . . . . 181
Blocking and Ramping of Material . . . . . . . . . . . . . . . . . . 89
Body Harness, Full (Illustration) . . . . . . . . . . . . . . . . . . . . 30

2015 Safety Handbook 185

 C
Capacitors, Color Code for Jan Fixed MICA (Illustration). . 180
Carbon Dust (HAZCOM). . . . . . . . . . . . . . . . . . . . . . . . . 147
Cars, Temporary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Car-Top Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Chain Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Chain Sling Capacities Lbs (Illustration). . . . . . . . . 109, 110
Chain Slings, Inspection of. . . . . . . . . . . . . . . . . . . . . . . 105
Chemicals, Working With . . . . . . . . . . . . . . . . . . . . . . . . 139
Chisels, Use Only Properly Dressed (Illustration). . . . . . . 71
Chokers, Use of (Illustration) . . . . . . . . . . . . . . . . . . . . . 100
Clamps, Beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Cleaners (HAZCOM). . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Clothing, Proper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Color Code for Fixed Resistors Values in OHMS
(Illustration). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Communication Devices (Vehicle Safety) . . . . . . . . . . . 165
Competent Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Crosby Lifting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Cutting, Welding and. . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

D
Double Saddle Clips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Driving and Vehicle Safety . . . . . . . . . . . . . . . . . . . . . . . 164
Drug/Substance Abuse. . . . . . . . . . . . . . . . . . . . . . . . . . 164
Dumbwaiters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

E
Electric, Portable Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Electrical Safety General Precautions. . . . . . . . . . . . . . 40
Elevator Car Speeds in Ft/Min to M/M and M/S (Chart) . . . . 175

186 2015 Safety Handbook

Elevator Maintenance Barricades. . . . . . . . . . . . . . . . . . . 39
Employee Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . 8
Endless Sling Assembly (Illustration) . . . . . . . . . . . . . . . . 97
Escalator/Moving Walk Barricades. . . . . . . . . . . . . . . . . . 38
Escalators and Moving Walks . . . . . . . . . . . . . . . . . . . . 152
Escalators and Moving Walks, Lockout Procedures for . . . . 54
Extension Cords, Approved Markings for. . . . . . . . . . . . . 72
Eye and Face Protection. . . . . . . . . . . . . . . . . . . . . . 23, 159
Eye Bolts (Illustration). . . . . . . . . . . . . . . . . . . . . . . . . . . 100

F
Fall Arrest Equipment, Personal . . . . . . . . . . . . . . . . . . . 26
Fall Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fall-Arrest System, Personal. . . . . . . . . . . . . . . . . . . . . . 29
Falls, Five- Six- & Seven-Part (Illustration). . . . . . . 125,126
False Car (Illustration). . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
False Car with Optional Debris Net (Illustration). . . . . . . . 81
False Cars and Other Devices Used in the Hoistway. . . . 79
Fastenings, Wire Rope. . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Filter Lens Shade Number for
Protection Against Radiant Energy (Chart) . . . . . . . . . 24
Fire, Precautions Against (Welding and Cutting) . . . . . . 135
Five-Part Falls (Illustration). . . . . . . . . . . . . . . . . . . 125, 126
Fixed Resistors, Color Code for (Values in OHMS)
(Illustration). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Flammable Liquids and Solvents (HAZCOM). . . . . . . . . 146
Foot and Leg Protection. . . . . . . . . . . . . . . . . . . . . . . . . 158
Foot Protection, Occupational . . . . . . . . . . . . . . . . . . . . . 25
Fuel Gas Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Full-Body Harness (Illustration). . . . . . . . . . . . . . . . . . . . . 30

2015 Safety Handbook 187

 G
Gallons to Liters (Chart) . . . . . . . . . . . . . . . . . . . . . . . . . 174
Glossary of Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Grease, Oils and (HAZCOM) . . . . . . . . . . . . . . . . . . . . . 141
Guardrail Systems (Illustration). . . . . . . . . . . . . . . . . . 36, 37
Guardrail Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

H
Hand Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27, 160
Hand Signals, Hoisting (Illustration) . . . . . . . . . . . . . . 98, 99
Hand Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Hardware, Rigging (Illustration). . . . . . . . 114, 115, 116, 118
Harness, Full-Body (Illustration) . . . . . . . . . . . . . . . . . . . . 30
Hazard Communications (HAZCOM) . . . . . . . . . . . . . . . 139
Asbestos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Babbitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Carbon Dust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Chemicals, Working with . . . . . . . . . . . . . . . . . . . . . . 139
Cleaners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Flammable Liquids and Solvents. . . . . . . . . . . . . . . . 146
Oils and Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Painting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Sulfuric Acid Type Batteries. . . . . . . . . . . . . . . . . . . . 147
Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Head Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25, 158
Headbeams, Timber Used for (Chart). . . . . . . . . . . . . . . 181
Hearing Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 158
Helpful Hints for On and Off the Job (Illustration) . . . 87, 88
Hitches, Slings and. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Hoisting and Rigging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Hoisting Structural Steel (Illustration). . . . . . . . . . . . . . . 101
Hoisting, Hand Signals (Illustration) . . . . . . . . . . . . . . 98, 99

188 2015 Safety Handbook

Hoists, Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Hoistway Screening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Hoistway, False Cars and Other Devices
Used in the Hoistway. . . . . . . . . . . . . . . . . . . . . . . . . . 79
Hoistways and Machine Rooms. . . . . . . . . . . . . . . . . . . . 56
Hook Slings (Illustration). . . . . . . . . . . . . . . . . . . . . . . . . 101

I
Inclined Elevators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Inspecting for Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspecting Manila Rope (Illustration). . . . . . . . . . . . . . . . 128
Inspection, Safety Checklist . . . . . . . . . . . . . . . . . . . . . . . 17
Inspections, Need for Routine Safety. . . . . . . . . . . . . . . . 17

J
Job Hazard Assessment, Service
and Repair (Chart) . . . . . . . . . . . . . . . . . . . . . . 162, 163
Job Hazard Assessment,
Service and Repair Job . . . . . . . . . . . . . . . . . . . . . . . 157
Jumpers, Door Bypass Procedure . . . . . . . . . . . . . . . . . . 48
Jumpers, Maintenance and Troubleshooting . . . . . . . . . . 46
Jumpers, Modernization and New Construction. . . . . . . . 47
Jumpers, Proper Use of . . . . . . . . . . . . . . . . . . . . . . . . . . 45

K
Knots Are Weak. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Knots: (Illustrations)
Bowline on the Bight. . . . . . . . . . . . . . . . . . . . . . . . . 132
Bowline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Carrick Bend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Catspaw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

2015 Safety Handbook 189

 Clove Hitch (Builders Hitch) . . . . . . . . . . . . . . . . . . . 132
Figure Eight Follow Through . . . . . . . . . . . . . . . . . . . 133
Figure Eight Knot. . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure Eight on a Bight. . . . . . . . . . . . . . . . . . . . . . . . 133
Reef Knot or Square Knot . . . . . . . . . . . . . . . . . . . . . 131
Rolling Hitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Round Turn and Two Half Hitches. . . . . . . . . . . . . . . 133
Running Bowline. . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Sheepshank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Timber Hitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

L
Ladder, Proper Placement of (Illustration). . . . . . . . . . . . 77
Ladders, Portable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Lens Shade Numbers, Filter (Chart). . . . . . . . . . . . . . . . . 24
Lifeline, Typical Top Anchorage of (Illustration). . . . . . . . . 29
Lifting Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Lifting, Positions for (Illustration). . . . . . . . . . . . . . . . . . . . 86
Lights, Portable Electric. . . . . . . . . . . . . . . . . . . . . . . . . . 71
Liquids and Solvents, Flammable. . . . . . . . . . . . . . . . . . 146
Loads, Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Lockout/Tagout (Illustration) . . . . . . . . . . . . . . . . . . . . . . . 50
Lockout/Tagout Procedures for
Escalators and Moving Walks . . . . . . . . . . . . . . . . . . . 54
Lockout/Tagout Procedures. . . . . . . . . . . . . . . . . . . . . . . . 49
Lockout/Tagout, Supervisory/Emergency Removal. . . . . 53

M
Machine Rooms, Hoistways and. . . . . . . . . . . . . . . . . . . . 56
Maintenance, Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

190 2015 Safety Handbook

Manila Rope Knots, Approximate Efficiency
(Illustration). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Manila Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Manila Rope, Inspecting (Illustration). . . . . . . . . . . . . . . 125
Material Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Materials Handling Ramping and Blocking of . . . . . . . . 89
Mechanic/Mechanic-In-Charge Responsibilities of. . . . . . 13
Moving Walks, Escalators and . . . . . . . . . . . . . . . . . . . . 152

O
Occupational Foot Protection . . . . . . . . . . . . . . . . . . . . . . 25
Occupational Head Protection . . . . . . . . . . . . . . . . . . . . . 25
Oils and Grease (HAZCOM). . . . . . . . . . . . . . . . . . . . . . 141
Overhead Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Oxygen Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Painting (HAZCOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Personal Fall Arrest Equipment . . . . . . . . . . . . . . . . . . . . 26
Personal Fall Arrest System. . . . . . . . . . . . . . . . . . . . . . 159
Personal Protective Equipment. . . . . . . . . . . . . . . . . . . . . 22
Pit Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Planks, Allowable Loads for Wood (Chart). . . . . . . . . . . 183
Platforms, Running (Moving). . . . . . . . . . . . . . . . . . . . . . . 78
Platforms, Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Portable Electric Tools and Lights. . . . . . . . . . . . . . . . . . . 71
Portable Ladders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Pounds to Kilograms (Chart) . . . . . . . . . . . . . . . . . . . . . 173
PPE Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Pre-startup Safety Survey. . . . . . . . . . . . . . . . . . . . . . . . . 19

2015 Safety Handbook 191

 R
Ramping and Blocking of Material . . . . . . . . . . . . . . . . . . 89
Resistors, Fixed Color Code for Values in OHMS
(Chart) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Respiratory Protection. . . . . . . . . . . . . . . . . . . . . . . . 27, 159
Rigging Hardware (Illustration). . . . . . . . 114, 115, 116, 118
Rigging Plan, The Basic. . . . . . . . . . . . . . . . . . . . . . . . . 103
Rigging Practices, Right and Wrong (Illustration). . 100, 101
Rigging, Hoisting and . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Rope Knots, Approximately Efficiency . . . . . . . . . . . . . . 130
Rope, Inspecting Manila (Illustration). . . . . . . . . . . . . . . 128
Rope, Manila. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Running Platforms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

S
Safety Belts (Vehicle Safety). . . . . . . . . . . . . . . . . . . . . . 164
Safety Inspection Checklist. . . . . . . . . . . . . . . . . . . . . . . . 17
Safety Inspections, Need for Routine. . . . . . . . . . . . . . . . 17
Safety Responsibilities of the Mechanic/
Mechanic-In-Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety, Driving and Vehicle. . . . . . . . . . . . . . . . . . . . . . . 164
Safety, Electrical General Precautions. . . . . . . . . . . . . . 40
Scaffolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Screening, Hoistway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Service and Repair Job
Hazard Assessment (Chart) . . . . . . . . . . . . . . . 162, 163
Service and Repair Job Hazard Assessment. . . . . . . . . 157
Seven-Part Falls (Illustration) . . . . . . . . . . . . . . . . . 126, 127
Signals, Hand Hoisting (Illustration) . . . . . . . . . . . . . . 98, 99
Six-Part Falls (Illustration). . . . . . . . . . . . . . . . . . . . 126, 127
Sling Angles (Illustration). . . . . . . . . . . . . . . . . . . . . . . . . 113

192 2015 Safety Handbook

Sling Capacities, Chain Lbs (Illustration) . . . . . . . . 109, 110
Sling Capacities, Web (Illustration). . . . . . . . . . . . . . . . . 111
Sling Capacities, Wire Rope Lbs. (Illustration) . . . . . . . 106
Sling Capacities, Wire Rope Tons (Illustration). . . . . . . . 107
Sling Loading, Center of Gravity (Illustration). . . . . . . . . 112
Sling Operating Practices. . . . . . . . . . . . . . . . . . . . . . . . 117
Slings and Connections to Fittings, Wire Rope. . . . . . . 108
Slings and Hitches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Slings, Endless Assembly (Illustration). . . . . . . . . . . . . . . 97
Slings, Inspection of Chain. . . . . . . . . . . . . . . . . . . . . . . 105
Slings, Inspection of Synthetic . . . . . . . . . . . . . . . . . . . . 105
Slings, Inspection of Wire Rope . . . . . . . . . . . . . . . . . . . 104
Slings, Synthetic Webbing. . . . . . . . . . . . . . . . . . . . . . . . 119
Soldering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Solvents, Flammable Liquids and. . . . . . . . . . . . . . . . . . 146
Structural Steel, Hoisting (Illustration). . . . . . . . . . . . . . . 101
Substance Abuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Sulfuric Acid Type Batteries (HAZCOM) . . . . . . . . . . . . 147
Suspending Needle Beams or Scaffolds (Illustration). . . 100
Synthetic Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Synthetic Slings, Inspection of . . . . . . . . . . . . . . . . . . . . 105
Synthetic Webbing Slings. . . . . . . . . . . . . . . . . . . . . . . . 119

T
Tagout Procedure, Lockout/ . . . . . . . . . . . . . . . . . . . . . . . 49
Temporary Cars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Timber Used for Headbeams (Chart). . . . . . . . . . . . . . . 181
Tools, Hand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Tools, Portable Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2015 Safety Handbook 193

 V
Vehicle Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Vehicle Safety, Driving and. . . . . . . . . . . . . . . . . . . . . . 164
Vertical Pull Only Beam Clamps (Illustration) . . . . . . . 92

W
Web Sling Capacities (Illustration) . . . . . . . . . . . . . . . . 111
Welding (HAZCOM). . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Welding, Cutting and Soldering . . . . . . . . . . . . . . . . . . 135
Wire Rope Deterioration. . . . . . . . . . . . . . . . . . . . . . . . . 94
Wire Rope Sling Capacities Lbs. (Illustration). . . . . . . 106
Wire Rope Sling Capacities Tons (Illustration). . . . . . . 107
Wire Rope Slings and Connections to Fittings. . . . . . . 108
Wire Rope Slings, Inspection of . . . . . . . . . . . . . . . . . . 104
Wire Ropes, Allowable Number of Broken Strands
for Use in Hoisting Equipment. . . . . . . . . . . . . . . . . . 94
Wire Rope Failure, Causes of. . . . . . . . . . . . . . . . . . . . . 94
Wire Rope Fastenings. . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Working Platforms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Workplace Hazards, Assessing . . . . . . . . . . . . . . . . . . 160

194 2015 Safety Handbook

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2015 Safety Handbook 195

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196 2015 Safety Handbook