ESH Handbook 2002

ESH
ENVIRONMENTAL
SAFETY & HEALTH
HANDBOOK
2002 EDITION
The information contained in this booklet is purely advisory
and for the purpose of assisting contractors/employers in the
areas of environment, safety and health. The content in this
booklet does not purport to refer to or guarantee compliance
with regulations that may be applicable to such practices and
conditions. This booklet should not be considered a definitive
listing of all regulations nor an absolute solution to all
environmental, safety and health issues. Nike assumes no
responsibility for the implementation, management, or
procedures contained herein.
Nike, Inc.
One Bowerman Drive
Beaverton, Oregon 97005-6453
Copyright © 2002 Nike, Inc.

All rights reserved.
Table of Contents
1. ESH Management ............................................... 1-1

A. Management System ..................................... 1-1
B. ESH Committee .......................................... 1-12
C. Injury/Illness System Management .............. 1-15
• Incident/Accident Investigation System ... 1-16
• Reporting Hazards ................................... 1-17
• Evaluating Hazards .................................. 1-17
• Correcting Hazards .................................. 1-18
2. Environmental Protection ................................... 2-1
A. Air Emissions ................................................ 2-1
B. Hazardous Waste ........................................... 2-9
C. Polychlorinated Biphenyls (PCBs) ............... 2-14
D. Wastewater .................................................. 2-16
E. Solid Waste ................................................. 2-20
F. UST ............................................................ 2-22
G. AST ............................................................ 2-26
H. Spill Response ............................................. 2-29
3. Chemical Management ....................................... 3-1
A. Chemical Hazard Communication ................ 3-1
B. Hazardous Material Labeling ......................... 3-1
C. Restricted Manufacturing Substances (RMS) 3-9
D. Storage, Handling, Distribution, Dispensing 3-11
4. Facilities and Maintenance .................................. 4-1
A. General Work Environment .......................... 4-1
• Housekeeping ............................................ 4-1
• Floors and Walls ........................................ 4-2
• Stairs and Stairways ................................... 4-3
• Exits .......................................................... 4-7
• Illumination .............................................. 4-9
B. Ventilation .................................................. 4-14
• Exhaust Ventilation .................................. 4-14
• Fume Hoods ............................................ 4-18
C. Accident Prevention Signs and Tags ............. 4-21
ii ESH Handbook
D. Machine Shop Safety ................................... 4-23
• General Rules .......................................... 4-23
• Bench and Pedestal Grinders .................... 4-24
• Air Hoses, Tools and Compressors ........... 4-26
• Fan Guards .............................................. 4-28
• Portable and Powered Hand Tools ........... 4-28
• Tool and Equipment Maintenance ........... 4-32
• Ladder Safety ........................................... 4-45
• Compressed Gas Cylinders ...................... 4-48
E. Contractor and Subcontractor Safety ........... 4-52
F. Confined Spaces Protection ......................... 4-53
G. Welding, Cutting and Brazing (Hot-Work) . 4-55
5. Industrial Health ................................................. 5-1
A. Heat Stress Prevention ................................... 5-1
B. Cold Stress Prevention ................................... 5-4
C. Occupational Noise Exposure ........................ 5-7
D. Ergonomics ................................................. 5-15
E. Non-Ionizing Radiation (Ultraviolet (UV)
and Radio Frequency (RF) Radiation) ......... 5-23
F. Bloodborne Pathogens ................................. 5-32
G. Asbestos ...................................................... 5-35
H. Occupational Exposure Limits ..................... 5-39
6. Emergency Preparedness and Response ............... 6-1
A. Emergency Action ......................................... 6-1
B. Fire Protection ............................................... 6-4
• Fire Protection Plan ................................... 6-4
• Fire Protection Measures ............................ 6-7
• Fire Brigades .............................................. 6-7
• Fire Extinguishers .................................... 6-10
C. Medical Services and First Aid ..................... 6-18
• General .................................................... 6-18
• First Aid Kits ........................................... 6-20
• Eyewash and Shower/Drenching
Equipment ............................................... 6-22
Table of Contents iii
7. Personal Protective Equipment ............................ 7-1
• Job Attire ................................................... 7-1
• Head Protection ......................................... 7-2
• Eye and Face Protection ............................. 7-3
• Hand Protection ........................................ 7-6
• Foot Protection ........................................ 7-11
• Respiratory Protection ............................. 7-11
• Hearing Protection .................................. 7-17
• Fall Protection ......................................... 7-19
8. Machine and Equipment Safety ........................... 8-1
A. Motor Vehicle Operation and Forklifts .......... 8-1
B. Energy Control (Lockout/Tagout) ............... 8-10
C. Machine Guarding ...................................... 8-16
D. Mills and Calenders .................................... 8-27
E. Electrical Safety ........................................... 8-31
F. Cranes, Hoists, Chains and Slings ............... 8-43
9. General Health .................................................... 9-1
A. Dormitories ................................................... 9-1
B. Clinics ........................................................... 9-6
C. Canteens ..................................................... 9-11
D. Sanitation .................................................... 9-15
E. Drinking Water ........................................... 9-18
F. Childcare Facility Management ................... 9-21
10. Sampling Equipment/Device Guidelines ........... 10-1
A. 3M Organic Vapor Monitors (OVM) .......... 10-1
B. Sound Level Metering Guidelines ................ 10-5
11. General Information, Weights and Measures ..... 11-1
1. ESH Management
1
A. Management System
1. ESH Policy
Contractors/employers are required to establish and
maintain an ESH policy statement that is
documented, implemented and communicated to all
employees and addresses the following:
a. Appropriateness to the nature, scale and impacts
of its activities, products or services.
b. Commitment to continual improvement and
pollution prevention.
c. Commitment to comply with relevant ESH
legislation and regulations, and with other
requirements to which the organization subscribes.
d. A framework for setting and reviewing ESH
objectives and targets.
e. Availability to the public.
2. ESH Aspects
a. The purpose of this section is to define the process
by which contractors/employers identify
significant ESH aspects of its activities, products
or services.
b. This process must take into account the cost and
time of undertaking the analysis and the
availability of reliable data.
c. Information already developed for regulatory or
other purposes may be used in this process.
d. This section must address the degree of control
the organization may have over the ESH aspects
being considered.
1–2 ESH Handbook
e. In documenting the ESH aspects/impacts
1 identification process, this section must address
the following:
1) The criteria used to determine significance.
2) Applicable processes and operations of the
contractor/employer to be assessed (i.e., process
flow charts).
3) Responsibilities for aspects/impacts identifica-
tion.
4) Consideration of aspects/impacts under both
normal and abnormal operating conditions.
5) How new or planned activities and processes
are assessed.
3. Legal and Other Requirements
for identification and access to legal and other
requirements to which the contractor/employer
subscribes.
b. This section must also describe the process of
monitoring these requirements.
c. Things to look for:
1) This section must specifically identify the
regulatory and other relevant ESH require-
ments that apply to the contractor/employer
(e.g., a listing and the name of the individual
who maintains the list).
2) This section must identify who is responsible
for reviewing and analyzing draft and final
regulations/legislation and how their applica-
bility is documented (e.g., procedural refer-
ences).
ESH Management 1–3
3) This section must also address how these
requirements or changes to requirements are 1
communicated to employees and management.
4. Objectives and Targets
the contractor/employer uses to establish and
document ESH objectives and targets.
b. This section must clearly provide the links
between the contractor’s/employer’s ESH aspects/
impacts, ESH policy, and other commitments the
contractor/employer has made with regard to the
environment.
1) This section must specifically address how
objectives and targets are set and approved by
the contractor/employer, and specifically how
they are to be documented, measured, reviewed
and revised.
2) When establishing and reviewing its objectives,
the contractor/employer must consider its legal
and other requirements, its significant ESH
aspects, its technological options, the financial,
operational and business requirements, its
commitment to pollution prevention, and the
views of interested parties.
5. ESH Management Program
a. The purpose of this section of is to describe the
management program the contractor/employer
will utilize to achieve its established ESH
b. Things to look for:
1–4 ESH Handbook
1) This section must designate responsibility for
1 achieving objectives and targets at each relevant
function and level.
2) This section must include the means and
timeframe by which the objectives and targets
are to be achieved.
6. Structure and Responsibility
a. The purpose of this section is to define specific
roles, responsibilities and authorities the
contractor/employer has established to facilitate an
effective ESH management system.
b. This section must clearly designate the
responsibilities for implementation of the
contractor/employer management system.
c. It must identify the senior management
representative(s) who have specific responsibility
and authority to:
1) Ensure the management system requirements
are established, implemented and maintained.
2) Report on the performance of the management
system to top management. This section must
include some discussion of how the contractor/
employer is providing resources (human,
financial, and technological) to support the
management system.
7. Training, Awareness and Competence
a. The purpose of this section is to define how the
contractor/employer identifies training needs and
implements training programs.
b. These training programs ensure all employees
whose work may cause a significant impact on the
environment and/or the safety and health of
employees are aware of their roles and
responsibilities and are competent to carry out 1
their work activities as defined in the management
system.
1) This section must clearly describe the proce-
dures (related to training) the contractor/
employer has put in place to ensure its
employees understand:
a) The importance of conformance with the
ESH policy.
b) The significant impact (actual or potential)
of their work activities.
c) The consequences of deviating from
specified operating procedures
8. Communication
a. The purpose of this section is to provide an
overview of the contractor’s/employer’s internal
and external communication systems that support
the ongoing implementation of the management
system.
b. The contractor/employer is required to establish
and maintain procedures for internal
communication between various levels and
functions of the organization and for
documenting and responding to communications
from interested external parties.
c. This section of the manual must describe or
provide reference to the contractor’s/employer’s
major internal and external communication
systems or procedures for:
1–6 ESH Handbook
1) Communication of the contractor’s/employer’s
1 ESH policies, objectives, targets, and programs.
2) Communication of the contractor’s/employer’s
significant ESH aspects and procedures for
evaluating changes.
3) Communication of legal and other require-
ments (i.e., Nike requirements).
4) Communication of operating procedures and
criteria for operations associated with signifi-
cant ESH aspects.
5) Communication of emergency preparedness
and response procedures.
6) Communication of procedures to monitor and
measure key characteristics of its operations
and activities.
7) Communication of employee concerns and
questions.
8) Receiving, documenting, and responding to
relevant communication from external
interested parties (e.g., customers, the public).
9) Making the contractor’s/employer’s ESH policy
available to the public.
10) Communication of ESH requirements to
vendors, suppliers, and contractors/employers.
9. Documentation
a. The purpose of this section is to describe how the
contractor/employer establishes and maintains
information, in paper or electronic form, that
describes the core elements of the management
system, their interaction, and direction to related
documentation.
b. All 17 elements of this standard must be described
or cross-referenced in this section. 1
10. Document Control
a. The purpose of this section is to describe the
contractor’s/employer’s document-control system
for controlling all documents required by the
standard.
b. This section must address how management
system documents:
1) Can be located (i.e., are periodically reviewed,
revised and approved by authorized personnel).
2) Are available at all locations where operations
essential to the effective functioning of the
management system are performed.
3) Are properly removed from all points of use or
marked as obsolete as appropriate.
4) Are retained as necessary for legal or knowledge
preservation purposes when obsolete.
11. Operational Control
contractor/employer has identified those
operations and activities that are associated with
the identified significant ESH aspects.
b. This section must describe how the contractor/
employer plans these activities, including
maintenance, in order to ensure they are carried
out in line with its ESH policies, objectives and
targets.
1) This section must clearly describe how the
1–8 ESH Handbook
documented procedures to cover situations that
1 could lead to deviations from the ESH policy,
2) This section must describe how operating
criteria is established, as well as the individual
responsible for the procedural activities.
3) This section must cover procedures related to
identifiable significant ESH aspects of goods
and services used by the contractor/employer
and the process of communicating those
procedures and requirements to suppliers and
contractors/employers.
12. Emergency Preparedness and Response
system (procedures) the contractor/employer
maintains to enable it to identify and respond to
potential accidents and emergency situations, and
for preventing and/or mitigating the ESH impacts
that may result.
b. This section can be generally used to reference
emergency preparedness and response programs
the operation already has in place.
1) How the emergency preparedness and response
procedures are reviewed and revised.
2) How the procedures are periodically tested
(including drills).
3) Who is responsible for generating and main-
taining procedures.
13. Monitoring and Measurement
a. The purpose of this section is to identify how the
documented procedures to monitor and measure
the key characteristics of its operations and 1
activities that can have a significant impact on the
environment and/or safety and health of the
employees.
b. This section must discuss how information is
recorded and performance tracked with regard to
ESH objectives and targets, and how the process is
used to ensure that all equipment used in
monitoring and measurement is properly
calibrated and maintained.
1) This section must include specific procedures
in place for monitoring and measurement,
including the process for periodic evaluation of
compliance with relevant ESH legislation and
regulations.
2) This section must discuss the required features
of the monitoring and measurement proce-
dures including individuals responsible for
these programs.
14. Nonconformance and Corrective and Preventive
Action
a. The purpose of this section is to define how the
contractor/employer identifies, investigates and
resolves nonconformance in the ESH
management system.
b. This section must address how the contractor/
employer has assigned responsibility and authority
for these activities and how it records any changes
to documented procedures resulting from
corrective and preventive action.
1–10 ESH Handbook
1 1) This section must include various means of
measuring, monitoring, auditing, self-assessing
and other review systems that feed information
into the corrective action system.
2) This section must reveal how management
ensures that corrective and preventive actions
have been implemented and that there is a
systematic follow-up to ensure effectiveness.
15. Records
process the contractor/employer uses to identify,
maintain, and dispose of its ESH records.
b. This section describes the minimum requirements
for ESH records generation, maintenance and
retention procedures.
c. This section must also identify the records that
will be used as objective evidence of the
contractor’s/employer’s conformance to the
requirements of the management system.
d. Things to look for:
1) This section must include:
a) Who is responsible for determining what
records are required.
b) Who is responsible for filing and mainte-
nance.
c) Guidelines for records management.
d) Location of comprehensive ESH records
lists.
16. Management System Audit
a. The purpose of this section is to describe the 1
process the contractor/employer uses to evaluate
the effectiveness of the ESH Management System.
b. This section must describe the procedure used in
the management system evaluation and include
how the results are presented to senior
management.
c. This section must clearly describe the manage-
ment system audit program responsibilities
including:
1) Audit scheduling.
2) Audit scope.
3) Deficiency reporting.
4) Auditor requirements.
17. Management Review
contractor’s/employer’s top management reviews
the ESH management system to ensure its
continuing suitability, adequacy and effectiveness.
b. This section is intended to describe how senior
management will address changes to policy,
objectives and targets, and other elements of the
management system in light of management
system audit results or changing circumstances
which could effect the continual improvement
process.
c. This section must clearly describe:
1) The frequency of the management review.
2) The individual responsible for initiating the
review.
1–12 ESH Handbook
3) The scope of the review (e.g., audit results
1 (internal and external), complaints and
information requests, corrective action
summaries, objectives and targets).
4) How and where review results will be docu-
mented.
5) Individuals on the review team.
B. ESH Committee
1. Formation and Membership
a. A committee composed of both employee and
management representatives will be established at
the facility.
b. All working shifts must be represented.
c. Representatives must serve a minimum one-year
term.
d. The committee will select the chairperson.
2. Duties and Functions
a. The ESH committee’s function is to assist
management in developing and maintaining the
essential elements of the environment, safety and
health program. The committee will promote
awareness of and provide a means of
communicating environment, safety and health
issues and concerns between management and
employees. The ESH committee has the complete
support of senior management.
b. The committee will establish a written agenda to
prescribe the order in which the committee’s
business will be addressed during the meeting.
c. The committee will evaluate the facility’s
environment, safety and health policies and
procedures, and make written recommendations
for change or adoption of new policies and 1
procedures. A reasonable time limit must be
established for management to respond to the
recommendations presented by the ESH
committee.
3. Employee Involvement
a. ESH committee meetings will be held at least
monthly. The meetings will be documented in the
form of minutes. The minutes will be:
1) Posted where employees can read them.
2) Maintained for 3 years.
b. The ESH committee representatives may also elect
to review the minutes with their departments.
4. Incident/Accident Analysis
a. The committee will review any incidents/accidents
that have occurred during the past month. The
committee will also determine if any accident
trends are developing.
b. It may be necessary to invite the supervisor who
investigated an accident to attend the meeting to
clarify questions concerning the investigation
process.
5. Hazard Assessment and Control
a. The ESH committee will conduct environment,
safety, and health inspections of the facilities,
including the offices and grounds, at least
quarterly.
b. The inspections will be documented using an
environment, safety and health inspection
checklist.
1–14 ESH Handbook
6. Training
1 The ESH committee members must be properly
trained in the following:
a. ESH committee duties and functions.
b. Hazard identification in the workplace.
c. The applicable Nike Code Leadership Standards
(CLS) and any applicable local ESH requirements.
d. Techniques regarding incident/accident analysis
and implementation of corrective actions.
7. Minutes Guidelines
a. The minutes must be:
1) Typed.
2) Brief, concise, and well-organized.
3) Distributed within 3 working days. (The
committee must develop a distribution list.)
b. Contents must include:
1) Title.
2) Date meeting was held.
3) Time meeting was opened or called to order.
4) Names and departments of members present.
5) Names and departments of members absent.
6) Names, titles, and organizations of guests.
7) Statements indicating that minutes of previous
meetings were read or acknowledged.
8) Unfinished business including report(s) and/or
recommendation(s) not acted on.
9) Recommendations completed since last
meeting. 1
10) New business.
11) New recommendations.
12) Remarks/comments.
13) Time adjourned.
14) Date and time next meeting to be held.
15) Signature of chairperson.
c. Style and format should best fit needs, or use the
form provided.
C. Injury/Illness System Management

1. General Principles
a. Contractors/employers must prepare and maintain
records of occupational injuries and illnesses.
b. Each contrator/employer must investigate every
injury or illness that employees suffer in
connection with their employment, to determine
the means that must be taken to prevent
recurrence.
c. Contractors/employers must follow the reporting
procedures listed on pages 1-20 through 1-22.
2. Injury/Illness Tracking and Records
a. Contractors/employers must maintain in each
factory a log and summary of all injuries and
illnesses (resulting in a fatality, hospitalization, lost
workdays, medical treatment, job transfer or
termination, or loss of consciousness) for that
factory, and enter each event no later than 7
working days after receiving the information.
1–16 ESH Handbook
b. Contractors/employers must establish a written
1 supplementary record of factors (incident/accident
report form) that caused the injury or illness.
c. Contractors/employers must post an annual
summary of occupational injuries and illnesses.
This posting will include the year’s totals, calendar
year covered, company/factory name,
management signature, title and date. The
summary must be posted by February 1 of each
year and must remain in place until April 30 of
the same year. If country law requires different
dates than those mentioned, then those dates must
be met.
d. The log and summary, written supplementary
record, and the annual summary must be retained
in each factory for 5 years following the end of the
year to which they related.
e. Contractors/employers must apply these
requirements to all incidents involving factory
employees, on-site vendors, and visitors, which
results in personal injury or illness.
f. Contractors/employers must train all employees in
the incident/accident reporting procedures.
g. Contractors/employers must conduct an annual
review of this program to confirm that employees
are familiar with the incident/accident reporting
requirements and that the program is managed
properly.
3. Incident/Accident Investigation System
a. Supervisors must investigate an incident/accident
as soon as possible after the incident to preserve
physical evidence and obtain witness statements
while memories are fresh. The supervisor must
determine and record all facts surrounding the
incident. Causes and effects must be analyzed to
discover the basic reason for the incident. 1
Necessary action must be taken as soon as possible
to prevent recurrence of the incident.
b. The supervisor must complete the Supervisor’s
Incident/Accident Investigation Report, with help
from the employee. Each section of the report
must be thoroughly completed. It is important
that the employee describe the incident in his or
her own words and that the employee sign his or
her name on the appropriate line.
c. The Incident/Accident Investigation Report must
be completed for all incidents, even those that
don’t result in an injury or illness claim.
d. A copy of the completed form must be sent to
Nike. The original must be maintained by the
human resources department or clinic. If the
incident results in a work related injury or illness
claim, the insurance company needs to receive a
copy of the report form.
4. Reporting hazards
a. Employees are expected and encouraged to report
any hazard that they believe exists in the
workplace. No reprisals will be taken against
employees for reporting any condition they feel
constitutes an unsafe condition.
b. Employees must report hazards to their supervisor,
department ESH committee representative, or a
member of senior management. Employees must
report hazards on forms provided.
5. Evaluating hazards
Facilities must use the following methods and
procedures to identify and evaluate workplace hazards:
1–18 ESH Handbook
a. Quarterly environment, safety and health
1 inspections conducted by the ESH committee.
b. Employee reports of unsafe or unhealthy work
conditions and subsequent investigations and
actions.
c. Investigation after an employee sustains an on-
the-job occupational incident/accident.
d. Periodic environment, safety and health surveys
conducted by environment, safety and health
consultants employed by the location’s insurance
carrier.
6. Correcting hazards
a. Serious hazards (those with the potential to cause
death or serious physical harm to an employee)
will be corrected immediately. All employees
exposed to this hazard will be removed from the
area. Employees assigned to correct the hazard will
be provided with all necessary safeguards,
including personal protective equipment and
devices.
b. All other hazards will be corrected in a timely
fashion with times for correction being agreed
upon by senior management and the department
supervisor. Protection may include temporary
work procedures or personal protective
equipment.
c. In regard to a. and b. above, if warranted,
administrative action will be taken to protect the
environment, safety and health of affected
employees prior to the correction. (For example,
equipment violation, multiple-shift isolation, etc.)
d. Once a hazard is identified, the best course of
action is to immediately eliminate the hazardous,
unsafe condition. Since this is not always possible,
the senior manager sometimes must rank 1
identified hazards by the potential for destructive
consequences. Hazards that rank high in the
potential for both frequency (number of
accidents) and severity must be addressed first.
• Critical—Any condition that requires immedi-
ate action to correct.
• Potential—Any condition that, if left unat-
tended, may cause harm.
7. Contractor/Employer Incident/Accident Reporting
Procedures
a. Prior to initiating Nike procedures, factory must
identify and comply with country law.
b. All incidents and accidents resulting in death,
injury, or causing illness to employees and events
(near-miss accidents) must be reported in order to:
1) Establish a written record of factors that cause
injuries and illnesses and events (near-misses)
that might have resulted in death, injury or
illness.
2) Maintain a capability to promptly investigate
incidents and events in order to initiate and
support corrective and/or preventative action.
3) Provide statistical information for use in
analyzing all phases of incidents and events.
c. This Incident/Accident Reporting System applies
to all incidences involving contract factory
employees, on-site vendors, contracted third-party
employees, and visitors that results in (or might
have resulted in) personal death, injury or illness.
1–20 ESH Handbook
1
1
1–22 ESH Handbook
1
2. Environmental Protection
A. Air Emissions
2
a. Emissions of toxic substances to the outside
atmosphere from production and non-production
sources (e.g., welding, painting, waste burning,
etc.) are required to be controlled, minimized and/
or eliminated whenever possible at owned and
contracted facilities.
b. Contractors/employers must be aware how these
substances can be emitted to the outside
atmosphere and how these emissions can and
must be controlled, minimized or eliminated in-
accordance with Nike standards and applicable
local requirements. The primary areas where
potential air emission will be found are:
1) Solvent cleaning processes (Volatile Organic
Compound (VOC) emissions).
2) Dryers and curing ovens (VOC).
3) Painting and touch-up (VOC and Ozone
Depleting Chemicals (ODC) emissions).
4) Boiler operations (Carbon Dioxide (CO2)
emissions).
5) Air conditioning equipment (Chlorofluorocar-
bon (CFC) emissions).
6) Welding (CO2 and particulate emissions).
7) Grinding (particulate emissions).
8) Chemical storage and dispensing (VOC and
ODC emissions).
2–2 ESH Handbook
9) General operations where respiratory protec-
tion is required (all emissions).
10) Waste burning.
c. All emission sources must be addressed by
2 documentation and physical controls or a
combination of both.
1) Documentation Controls: Generally refer to
required operating procedures, inspections and
documentation (see Section 2).
2) Physical Controls: Generally refer to physical
equipment (see Section 3).
2. Air Emission Documentation Controls
To achieve Nike’s air emission objective, each facility
must be able to demonstrate they have the following
documentation controls in place:
a. Emission source inventory. The facility must have
available for inspection an inventory of all
emission sources. The inventory must include:
Figure 2-1: Stackhead Designs

Environmental Protection 2–3
1) Location of emission sources.
2) Types and quantities of pollutant emitted.
3) Air pollution control devices and removal
efficiencies.
2
4) Permit numbers for emission sources and
control devices.
b. Asbestos Inventory. Contractor/employer must
maintain an asbestos inventory that includes the
location and type (friable versus nonfriable).
c. Chlorofluorocarbon (CFC)
Inventory. Contractor/employer
must maintain a CFC inventory
that includes:
1) Location and type of equipment.
2) Quantity and type of CFCs.
d. Ozone Depleting Chemical (ODC) Inventory.
(Sample chemicals below.) Contractor/employer
must maintain an ODC inventory that includes:
1) Location, type and quantity of ODCs.
2) Chart depicting ODC quantity versus month/
year.
Table 2-1: Abbreviated ODC Table

2–4 ESH Handbook
e. Routine inspections and maintenance.
Contractor/employer must maintain a record of
inspections and maintenance for all pollution
control devices to ensure their effectiveness.
2 3. Air Emissions Physical Controls
Processes that utilize volatile organic chemicals
(VOCs) or emit other toxic substances must have air
quality physical control devices installed, such as:
Figure 2-2: Fume Hood Cutaway

a. Fume hoods and spray booths. Must be equipped
with pollution control devices.
b. Buffing and grinding equipment. Must be
equipped with exhaust fans and bag-houses to
collect dust particles. 2
c. Pollution control equipment
1) Used filters must be replaced on a regular basis.
2) Used filters must be tested to ensure they are
not a hazardous waste prior to disposal.
Figure 2-3: Dust and Centrifugal Collector

2–6 ESH Handbook
2
2
2–8 ESH Handbook
2
B. Hazardous Waste
a. Hazardous wastes from production and non-
production sources are required to be controlled,
minimized and/or eliminated whenever possible.
2
Many countries have specific laws and regulations
that regulate these substances and each facility
must know these requirements.
b. A hazardous waste is generally defined by the
following characteristics:
1) It is a solid, liquid or gas substance that can no
longer be used and must be discarded.
2) It is flammable (flash point below 100 degrees
Fahrenheit (37.8 degrees Celsius).
3) It is corrosive (acids or oxidizers).
4) It is toxic (generally referred to as poisons).
5) It is explosive (easily ignitable with violent
reaction).
6) It is radioactive.
c. The contractor/employer must be aware that
hazardous wastes come from a variety of sources
and that these wastes left uncontrolled can
adversely impact human health and the
environment. Hazardous wastes are required to be
controlled, minimized and/or eliminated in-
accordance with Nike standards and local
requirements. The primary areas where hazardous
wastes will be found are:
1) Solvent cleaning or materials preparation areas.
2) Spot cleaning areas (used rags).
2–10 ESH Handbook
3) Painting operations (paint gun cleaners and
paint removers).
4) Maintenance areas (cleaners, light ballasts, used
batteries, used hydrologic fluids, etc.).
2 5) Wastewater treatment sludges.
6) Empty solvent cleaning and wastewater
treatment chemical containers (e.g., drums and
5 gallon (19 liter) cans).
7) Laboratory wastes.
8) Cooling tower chemicals.
9) Landscaping (pesticides and herbicides).
10) Used filters.
d. All hazardous waste sources must be addressed by
Documentation and Physical Controls and
combinations of both.
2. Hazardous waste Documentation Controls. To achieve
Nike’s hazardous waste management objective each
facility must be able to demonstrate they have the
following administrative controls in place:
a. Hazardous waste inventory. The facility should
have available for inspection an inventory of all
hazardous waste sources.
1) Waste streams are characterized as hazardous by
laboratory testing or process knowledge.
b. Hazardous waste reporting. The facility must
maintain a hazardous waste reporting form.
c. Hazardous waste handling procedures and
training. The facility must have written procedures
for hazardous handling, storage and disposal and
documented employee training (including
emergency response and spill training).
2
d. Hazardous waste disposal facilities. The facility
must maintain a list of disposal facilities used for
all off site disposal including:
1) Date of disposal.
2) Location and name of disposal facility.
3) Name and quantity of waste disposed.
4) Tracking or shipping numbers as applicable.
e. Routine inspections and maintenance.
inspections for hazardous waste storage areas.
3. Hazardous Waste Physical Controls. Hazardous wastes
must have the following engineering controls in place:
a. Hazardous waste containers. The facility must use
containers for hazardous waste (including
containers in satellite accumulation areas) that
meet the following requirements:
1) Are appropriate for the waste being stored in
them (e.g., acids are not stored in metal
drums).
2) Are clearly labeled “Hazardous Waste.” (See
Figure 2-4 next page.)
3) Are closed (except when adding hazardous
waste).
4) Ignitable wastes are bonded and grounded.
(See Chapter 3, pages 17–22.)
2–12 ESH Handbook
b. Designated storage areas that include the
following:
1) Impermeable floor surface (concrete or other).
2) Emergency response equipment (spill kits).
2
3) Covered or otherwise protected from rain or
other elements.
Figure 2-4: Hazardous Waste Labels

4) Secondary containment equal to 110 percent
of volume of materials stored.
5) Separate areas for incompatible wastes (e.g.,
acids and oxidizers).
6) Signage indicating storage of hazardous wastes. 2
7) Locking gate or door.
c. Designated satellite/workplace hazardous waste
accumulation areas that include the following:
1) Clearly marked and designated as satellite/
workplace hazardous waste accumulation area.
2) Must be at or near the point of generation.
Figure 2-5: Secondary Containment Unit

2–14 ESH Handbook
C. Polychlorinated Biphenyls (PCBs)

a. The presence of PCBs can pose a significant threat
to the environment and well being of employees.
2 PCBs are typically found in capacitors,
transformers and other electrical equipment and if
released, can contaminate air, soil and water.
b. PCBs have been used in many industrial
applications. Because of their insulating
properties, chemical instability and relative
inflammability, they have been typically found in
the following:
1) Capacitors
2) Transformers
3) Electrical equipment
4) Plasticizers
5) Surface coatings
6) Inks
7) Adhesives
8) Flame retardants
9) Paints
c. All PCBs must be managed using Documentation
and Physical Controls or a combination of both.
2. PCB Documentation Controls
To achieve Nike’s management objectives, each facility
must be able to demonstrate they have the following
a. PCB survey. The facility must have available for 2
inspection an inventory of all suspected PCB-
containing equipment. Inventory will include but
not be limited to:
1) Lighting equipment (ballasts)
2) On-site transformers
b. Laboratory analyses of suspected PCB containing
equipment.
c. If necessary, facility must develop PCB removal
plan or develop procedures to manage PCB-
containing equipment left in service, including
routine maintenance and equipment inspections.
d. Facility must establish procedures to ensure all
PCB-containing equipment that is removed for
disposal is removed to an approved disposal
facility; applicable employees must be trained on
these procedures.
e. Records of removal and disposal of PCB
containing equipment must be maintained.
3. PCB Physical Controls
The following physical control must be in place:
“Waste” light ballasts identified as PCB containing
must be accumulated separately from other solid
wastes.
2–16 ESH Handbook
D. Wastewater
a. Discharges of process and sanitary (people related)
wastewater to the outside environment are
2 required to be controlled, minimized and/or
treated at all owned and contracted facilities.
Uncontrolled (untreated) discharges can have an
adverse effect to both human health and the
environment and are specifically regulated by both
Nike standards and local/country requirements.
b. The contractor/employer must be aware of how
contaminated water discharges are emitted to the
outside environment and how these discharges can
be controlled, minimized and/or eliminated. The
typical areas where wastewater discharges will be
found are:
1) Solvent cleaning processes.
2) Outsole and midsole degreasers.
3) Compressor and boiler blow-down.
4) Cooling tower blow-down.
5) Sanitary systems (toilets, kitchens and canteens
in factories and dormitories).
6) Wastewater treatment plant.
7) Laminating.
8) Mold shops.
9) Dyeing.
10) Outside cleaning.
11) Outside chemical storage areas.
12) Waste storage areas.
13) Chemical dispensing areas.
14) Vehicle parking areas.
c. Documentation and Physical Controls or
combinations of both must address all discharge
sources. 2
2. Wastewater Documentation Controls
To achieve wastewater objectives, each facility must be
able to demonstrate it has the following administrative
controls in place:
a. Discharge source inventory. The facility must have
available for inspection an inventory of all
discharge sources. The inventory must include:
1) Location of discharge points and discharge
sources.
2) Types and quantities of pollutant discharged.
3) Water pollution control devices (wastewater
treatment plants, oil/water separators, etc.) and
removal efficiencies.
4) Permit numbers for discharge sources and
control devices as appropriate.
b. Discharge Sampling Plan. The facility must
maintain a wastewater (including rain water)
sampling plan that includes:
1) The locations and types of samples (including
sludge from wastewater treatment plants).
2–18 ESH Handbook
2) Name of certified laboratory performing the
analyses.
3) Frequency of sampling.
c. Employee Training. Facility must ensure
2 employees operating wastewater treatment
equipment are properly trained and include the
following;
1) Training records and certifications.
2) Personal protective equipment.
3) Emergency operational control (shutdown)
procedures.
d. Routine inspections and maintenance. Facility
must maintain a record of inspections and
maintenance for all wastewater pollution control
devices to ensure their effectiveness
3. Wastewater Physical Controls
Processes where water and toxic substances directly
interact and are discharged from the facility must have
one of the following wastewater engineering control in
place:
a. Wastewater Treatment Plant
Must be designed to meet discharge standards.
b. Oil/Water Separator
For operations where oil and gasoline are washed
down to drains.
c. Outside Drains and curbing. Rain water that may
interact with materials and equipment stored
outside the facility must be managed by:
1) Diverting from running off the facility by
curbs, berms, or culverts.
Figure 2-6: Wastewater Treatment Process
2
2–20 ESH Handbook
2) Collected in a drainage system that is separate
from the process and sanitary wastewater
system.
3) Tested prior to discharge.
2
E. Solid Waste
a. Solid wastes from production and non-production
sources are required to be controlled, minimized
and/or eliminated whenever possible.
b. The contractor/employer must be aware that solid
wastes come from a variety of sources and that
these wastes take resources to manage (money and
time) and can adversely impact the environment.
Solid wastes are required to be controlled,
minimized or eliminated in-accordance with Nike
standards and local requirements. Examples of
solid waste are:
1) Packaging scrap (boxes, straps, pallets, wraps,
etc.).
2) Cutting and trimming wastes.
3) Office waste (paper, boxes, etc.).
4) Cafeteria wastes.
5) Dorm wastes.
7) Maintenance wastes (waste oils, scrap metal,
wood, empty containers, landscaping debris).
8) Production wastes (defective product, gloves,
dust masks, empty containers, rags, etc.).
c. All solid waste sources must be addressed by
Documentation and Physical Controls or a
equipment (see Section 3). 2
2. Solid Waste Documentation Controls
To achieve the solid-waste management objective,
each facility must be able to demonstrate they have
the following documentation controls in place:
a. Solid waste inventory. The facility must have
available for inspection an inventory of all solid
waste sources.
b. Solid waste reporting. Contractor/employer must
maintain a solid waste reporting form on a
monthly basis that includes:
1) Total waste.
2) Disposed waste.
3) Recycled waste.
c. Routine inspections and maintenance.
inspections for solid waste storage areas.
d. Disposal method must be documented.
e. Solid waste disposal. The facility must maintain a
list for solid-waste disposal that includes the
following:
1) Name of vendors collecting solid waste and
removing offsite.
2) Vendor permits that may be necessary for solid
waste disposal and/or recycling.
3) Date of disposal.
2–22 ESH Handbook
4) Location and name of disposal facility.
3. Solid Waste Physical Controls
Solid wastes must have the following physical controls
in place:
2
a. Separate garages or bins for each waste (including
liquid wastes and recyclables).
1) Garages or bins must be covered.
2) Garages or bins must have adequate flooring
(concrete or other impermeable surface).
3) Garages or bins must be secured with fire
suppression equipment.
b. Solid wastes must be separated from liquid waste
storage.
c. Labeled and marked
1) Labels must indicate waste designation (e.g.,
trash, recycle, etc.).
2) Signs must indicate that smoking is prohibited.
3) All labels and signs must appear in both
English and the language of the employee.
F. Underground Storage Tank

a. The presence and use of underground storage
tanks (USTs) can pose a significant threat to the
environment. USTs are typically used for storage
of fuels and other industrial chemicals that if
released can contaminate both the soil and ground
water. Appropriate control and management of
USTs is required by Nike Code Leadership
standards and local requirements.
b. The contractor/employer must be aware that there
are various types of storage units that are
considered to be “underground” storage tanks,
these can include:
1) Bulk fuel storage tanks with more than 10 2
percent of the tank located below ground level.
2) Vaults.
3) Material conveyance piping (70 percent or
more located below ground).
4) Sumps.
5) Trenches.
c. All USTs must be managed using Documentation
2. UST Documentation Controls
To achieve the UST management objectives, each
following documentation controls in place:
a. Records that indicate UST type, location, size,
age, and contents.
b. Fill and overfill prevention procedures. The
facility must have UST fill procedures available for
inspection.
c. Certification of employee training. The facility
must have available for inspection employee
training records on proper tank management and
spill response.
2–24 ESH Handbook
d. Spill response procedures. The facility must have
appropriate spill response procedures available for
inspection.
e. Periodic tank inspections. The facility must
2 inspect all USTs daily and document equipment
inspected and any necessary repairs or corrective
actions.
f. The UST must be tested annually to ensure tank
is not leaking.
3. UST Physical Controls
USTs must have the following physical control devices
installed:
a. Secondary containment/protective barriers. All
USTs must have secondary containment.
1) Must be capable of holding 110 percent of the
storage tank capacity.
Figure 2-7: Underground Storage Tank With

Secondary Containment Barrier
2) Exposed UST components such as vent pipes
and fill valves must have appropriate physical
barriers to protect them from contact with
vehicles and machinery.
b. Corrosion protection is added to unprotected steel 2
USTs.
c. Leak detection systems.
1) All USTs must have an operating leak-
detection system. (See Figure 2-7 previous
page.)
2) Leak detection systems must be periodically
calibrated.
d. Marking and labeling.
1) All USTs must have appropriate markings and
labels indicating tank contents and applicable
hazards. (See Chapter 3, Section B, Hazardous
Materials Labeling).
2) Vent pipes and other ancillary tank compo-
nents must be labeled.
e. Spill response equipment. All USTs must have
appropriate spill response equipment located
within 50 feet (15 meters) of all USTs, or as
specified by regulatory requirements. Equipment
includes but is not limited to the following:
1) Alarms or other communication devices.
2) Booms and dykes.
3) Gloves, splash guards and other personal
protective equipment.
2–26 ESH Handbook
G. Aboveground Storage Tanks

a. The presence and use of aboveground storage
tanks (ASTs) can pose a significant threat to the
2 environment. ASTs are typically used for storage
of fuels and other industrial chemicals that, if
released, can contaminate soil, surface water and
ground water. Appropriate control and
management of ASTs is required by Nike Code
Leadership standards and local requirements.
b. The contractor/employer must be aware that there
are various types of storage units that are
considered to be “aboveground” storage tanks.
These can include but are not be limited to the
following:
1) Bulk fuel storage tanks.
2) Boiler fuel reservoirs.
3) Solvent baths.
c. All ASTs must be managed using Documentation
2. AST Documentation Controls
To achieve the AST management objectives, each
a. Records that indicate AST type, location, size, age,
and contents.
b. Fill and overfill prevention procedures. The
facility must have AST fill procedures available for
inspection.
c. Certification of employee/subcontractor training.
The facility must have available for inspection 2
employee training records on proper tank
management and spill response.
d. Spill response procedures. The facility must have
available for inspection appropriate spill response
procedures.
e. Periodic Tank inspections. The facility must
inspect all ASTs weekly and document equipment
inspected and any necessary repairs or corrective
actions.
3. AST Physical Controls
ASTs must have the following physical control devices
installed:
a. Secondary containment/protective barriers. All
ASTs must have secondary containment. (See
Figure 2-8 next page.)
1) Must be capable of holding 110 percent of the
storage tank capacity.
2) Exposed AST and AST components, such as
piping and fill valves, must have appropriate
physical barriers to protect them from contact
with vehicles and machinery.
b. Tank fill and dispensing pipe must be locked at all
times (except when in use).
c. Marking and labeling.
1) All ASTs must have appropriate markings and
labels indicating tank contents and applicable
2–28 ESH Handbook
Figure 2-8: Aboveground Storage Tanks With
Secondary Containment Barriers
2
hazards. (See Chapter 3, Section B, Hazardous
Materials labeling.)
2) Piping and other ancillary tank components
must be labeled.
d. Spill response equipment. All ASTs must have 2
appropriate spill response equipment located
within 50 feet (15 meters) of all ASTs or as
specified by regulatory requirements. Equipment
must include but not be limited to the following:
1) Alarms or other communication devices.
2) Booms and dykes.
3) Gloves, splash guards and other personal
protective equipment.
H. Spill Response
a. Chemicals, oils and other potentially hazardous
materials (Hazmat) are a part of many of the
manufacturing and maintenance processes at
owned and contracted facilities.
b. Contractors/employers must be aware that there is
a potential for these chemicals, oils and potentially
hazardous materials to be spilled. The facility must
always be prepared to respond to such spills so as
not to adversely affect human health and/or the
environment and to ensure that they are managed
in-accordance with Nike standards and local
requirements. The primary areas where spills can
occur are:
1) Hazmat receiving areas.
2) Hazmat dispensing and storage areas.
3) Chemical cleaning processes.
2–30 ESH Handbook
4) Maintenance areas.
5) Oil storage areas.
6) Waste water treatment facilities.
2 7) Anywhere Hazmat may be used.
c. All potential spills must be addressed by
Documentation and Physical Controls or a
Figure 2-9: HazMat Storage Area

2. Spill Response Documentation Controls
To achieve the spill response objective each facility
must be able to demonstrate they have the following 2
a. Spill response plan and procedures. The facility
must have available for inspection a spill response
plan which designates the following:
1) Individuals responsible for coordinating spill
response activities.
2) Alarms and warnings.
3) Evacuation procedures.
4) Area specific spill response procedures.
b. Spill response training. The facility must have
available for inspection spill response training
records for all employees identified as spill
responders.
c. Spill corrective action form. The facility must
maintain a record of spill causes and corrective
actions.
d. Periodic spill response drills. The facility must
have available for inspection records of periodic
spill response drills.
3. Spill Response Physical Controls
a. Spill Control Stations.
Facilities must have a spill
control station in place.
Spill control stations
must be located within
50 feet (15 meters) of all
2–32 ESH Handbook
potential spill sites and include but not be limited

to the following:
1) Personal protective equipment (see Material
Safety Data Sheet) for recommended equip-
2 ment).
2) Chemical absorbent.
3) Drain covers.
4) Waste receptacles (buckets, drums, etc.).
5) Decontamination procedures.
Figure 2-10: Spill Kit

Figure 2-11: Spill Response Cart

2
3. Chemical Management
A. Chemical Hazard Communication
Programs must consist of the following items:
1. A survey of potentially hazardous materials found at
facilities.
2. A written procedure outlining methods for dealing 3
with potentially hazardous materials found onsite.
This procedure must be available for employee
examination.
3. Material Safety Data Sheets (MSDS) are information
data sheets on each potentially hazardous material that
provide basic data on the characteristics and potential
hazards associated with the material. These sheets
must be readily accessible.
4. Labeling of containers of potentially hazardous
materials to inform users of the contents and their
potential hazards.
5. Employee training to acquaint employees with the
potential hazards associated with materials in the
workplace and the safe methods for working with
them.
B. Hazardous Material Labeling

There are three main systems of hazard warning labels
that employees are likely to encounter: U.S. Department
of Transportation (DOT), Hazardous Material
Identification System (HMIS®), and the National Fire
Protection Association (NFPA). Employees must be
aware of each of these systems.
3–2 ESH Handbook
1. The following is a partial listing of the more
commonly encountered DOT labels. DOT labels
must be used on vehicles transporting hazardous
materials and on containers used for transportation.
a. Explosives. Substances that will
ignite with a violent reaction
and can cause massive
destruction.
3
Figure 3-1: Hazard Communications

Chemical Management 3–3
b. Non-Flammable Gas. A
compressed gas that will not
readily burn and is not
poisonous. It is hazardous
because it is under pressure
and/or it can suffocate a person
within a confined space.
c. Flammable Gas. A gas that, at
ambient temperature
3
and pressure, forms a
flammable mixture with air at a
concentration of 13 percent by
volume or less.
d. Poison Gas. Gases such as
chlorine and anhydrous
ammonia that are poisonous to
humans or animals when
inhaled.
e. Flammable Liquid. Any liquid
having a flash point below 100o
F (37.8o C). Excluded are
mixtures of liquids having
components with flash points
of 100 o F (37.8 o C) or higher,
if the total of these components
makes up 99 percent or more
of the total volume of the mixture.
f. Flammable Solid. A solid,
other than a blasting agent or
explosive, that is liable to cause
fire through friction,
absorption of moisture,
spontaneous chemical change,
or retained heat from
manufacturing, or that can be
3–4 ESH Handbook
ignited readily and when
ignited burns so vigorously and
persistently as to create a
serious hazard.
g. Oxidizer and Oxidizing Agent.
A substance that yields oxygen
readily to stimulate the
combustion (oxidation) of
3 organic matter.
h. Poison. A substance that is
harmful to human health. Also
called toxic.
i. Radioactive. Material that
emits radioactive particles or
rays, such as many of the
materials used in well logging
or for industrial radiography.
j. Corrosive. Causes visible
destruction or irreversible
alterations in living tissue by
chemical action at the site of
contact. Causes a severe
corrosion rate in steel.
2. The Hazardous Material Identification System
(HMIS®) is a registered trademark of the National
Paint & Coating Association. The code numbers are
on a scale of 0 for no hazard to 4 for high hazard.
Labels are coded for degree of health hazard,
flammability, and reactivity. Recommended personal
protective equipment (PPE) is written on the label at
the time the label is placed into service. The codes are
presented in Figure 3-2 facing page. The numbers on
the label (Figure 3-3 on page 3-6) were selected solely
for illustration purposes.
Figure 3-2 HMIS® Chart
3
3–6 ESH Handbook
Figure 3-3: HMIS® Label
3
3. The National Fire Protection Association (NFPA)
system is used in industrial plant and storage locations
to provide information for fire fighting and emergency
response personnel. The code numbers are on a scale
of 0 for no hazard to 4 for high hazard. The labels are
coded for degree of health hazard, fire hazard,
reactivity, and special hazard. The numbers in Figure
3-4 below were created solely for illustration purposes.
(See also Table 3-1: Hazardous Materials Guide next 3
page.)
Figure 3-4: NFPA Hazardous Materials

Classification Chart
3–8 ESH Handbook
Table 3-1: NFPA Hazardous Materials Guide
3
C. Restricted Manufacturing Substances (RMS)

1. General Principals
a. A number of chemicals are considered to be
harmful to human health and the environement
and are banned from being used at any phase of
the manufacturing process at owned and
contracted facilities.
3
b. Contractors/employers must be aware that these
chemicals are not to be used at any time and each
facility is responsible for ensuring that only
approved chemicals are used in accordance with
Nike Code Leadership standards and local
requirements. The primary areas where potentially
non-approved chemicals will be found are:
1) Solvent-cleaning processes
2) Mixing rooms
3) Dye-preparation areas
4) Chemical storage areas
5) Maintenance areas
6) Rubber rooms
7) Molding areas
8) Painting/silk screening areas
9) Waste water pretreatment
c. Prevention of banned chemicals entering into
production and other processes can be effectively
addressed by Documentation Controls.
3–10 ESH Handbook
2. Banned Chemicals Documentation Controls
To achieve the banned chemical use objective, each
facility should be able to demonstrate they have the
a. Chemical Inventory. The facility should have
available for inspection a current inventory of all
chemicals used on site. The inventory must
3 include:
1) Name and process where chemicals are used
2) Quantities used and stored on site
3) MSDS
4) Certification the chemicals are not on the
applicable RMS
b. Purchase Approval Procedure. The facility must
maintain a procedure to review all requests for
new chemical purchases. The procedure must
include:
1) Review of MSDS
2) Cross-check of proposed purchase against the
RMS
3) Chemicals approved for purchase list
4) Chemical requisition form
c. Routine Inspections. The facility must maintain a
record of inspections for all chemical storage areas
to ensure all chemicals on site are not on the
RMS.
D. Chemical Storage, Handling, Distribution,

Dispensing
1. Solvents and Cleaning Agents
a. Do not use gasoline or any other similar
flammable materials for cleaning purposes.
b. Review cleaning agent container labels to
determine if contents are acceptable for the 3
intended use.
c. Incompatible materials must be stored separately.
d. Cleaning agents must not be heated, or used on
hot surfaces or near flames.
e. Place rags that have been used with cleaning
agents in designated covered metal containers
until they can be properly cleaned or disposed of.
f. Avoid skin contact with solvent liquids or inhaling
vapors. Use nitrile, neoprene, or other suitable
gloves to protect hands when using solvents and
cleaning agents. If a cleaning agent or solvent
comes in contact with the skin, clean the affected
area with soap and water and apply a lotion to
replace the natural body oils.
g. Remove clothing that becomes contaminated with
a cleaning agent as soon as possible. Clean skin
with soap and water to prevent a chemical burn.
h. Areas where cleaning solvents are used must be
well ventilated.
i. Fusible links on parts washers must not be
modified or bypassed.
[See Some Incompatible Chemicals next pages.]
3–12 ESH Handbook
3
3
3–14 ESH Handbook
3
2. Electrical Bonding and Grounding

a. Before transfer or collection of flammable liquids,
dispensing containers or process equipment must
be properly grounded and bonded to a receiving
container.
b. Static electricity is generated by the contact and
separation of dissimilar material. For example,
static electricity is generated when a fluid flows
through a pipe, or from an orifice, into a tank.
The principal hazards created by static electricity
are those of fire and exposure, which are caused by
spark dischargers containing sufficient energy to
ignite any flammable or explosive vapors, gases, or
dust which are present. Also, the shocking of
personnel may cause an involuntary reaction, such
as falling, which may lead to an injury.
c. A point of great danger from a static spark is the
place where a flammable vapor may be present in
3–16 ESH Handbook
the air, such as an outlet of a flammable liquid fill
pipe, a delivery hose nozzle, near an open
flammable liquid container and around a tank
truck fill opening or barrel bunghole. A spark
between two bodies occurs when there is not a
good electrical conductive path between them.
Hence, grounding and bonding of flammable
liquid containers is necessary to prevent static
3 electricity from causing a spark.
d. The terms “bonding” and “grounding” often have
been used interchangeably because of poor
understanding of the terms. Bonding is done to
eliminate the difference in potential between
objects. The purpose of grounding is to eliminate
the difference in potential between an object and
the ground. Bonding and grounding are effective
only when the bonded objects are conductive.
Although bonding will eliminate a difference in
potential between the objects that are bonded, it
will not eliminate a difference in potential
between these objects and the earth unless one of
the objects possesses an adequate conductive path
to earth. Therefore, bonding will not eliminate the
static charge, but will equalize potential between
the objects bonded so that the spark will not occur
between them.
e. When two objects are bonded, the charges flow
freely between the bodies and there is no
difference in charge.
f. An adequate ground will always discharge a
charged conductive body and is recommended as a
safety measure whenever any doubt exists
concerning a situation, or a governing authority
requires it.
g. To avoid a spark from discharge of static electricity
during filling operations, a wire bond should be
provided between the storage container and the
container being filled, unless the metallic path
between the container is otherwise present. For
additional safety, it is advisable to have the
bonding wire or one of the containers grounded.
h. Bonding and grounding systems should be
checked regularly for performance, especially
3
electrically. Preferably before each fill, the exposed
part of the bonding and grounding system should
be inspected for parts which have deteriorated
because of corrosion or have otherwise been
damaged. Many companies specify that bonds and
grounds be constructed of bare, braided, flexible
wire because it facilitates inspection and prevents
broken wires from being concealed.
i. Figure 3-5 (next page) shows one method of
bonding and grounding a metal receiving
container.
3. Flammable Liquids
a. Proper storage and use of flammable liquids can
significantly reduce the possibility of accidental
fires and injury to employees. The following are
guidelines for handling flammable/combustible
liquids.
b. Definitions
1) Flammable Liquid—A liquid with a flashpoint
below 100° F (38° C).
a) Class IA—Flashpoint below 73° F (23° C)
and boiling point below 100° F (38° C).
b) Class IB—Flashpoint below 73° F (23° C)
and boiling point above 100° F (38° C).
3–18 ESH Handbook
c) Class IC—Flash at or above 73° F (23° C)
and below 100° F (38° C).
2) Combustible Liquids—A liquid having a flash
point at or above 100° F (38° C).
3) Class II Combustibles—Flashpoint above 100°
F (38° C) and below 140° F (60° C).
4) Class III Combustibles—Flashpoint at or
3 above 140° F (60° C).
Figure 3-5: Bonding and Grounding

Metal Receiving Container
a) Subclass IIIA—Flashpoint at or above 140°
F (60° C) and below 200° F (93° C).
b) Subclass IIIB—Flashpoint at or above 200°
F (93° C).
c. Responsibilities
1) Facility Management
a) Provide proper storage for flammable 3
liquids.
b) Ensure proper training is provided to
employees who work with flammable
liquids.
c) Ensure containers are properly labeled.
2) Supervisors
a) Provide adequate training in the use and
storage of flammable liquids.
b) Monitor for proper use and storage.
c) Keep only the minimum amount required
on hand.
d) Ensure MSDS are current for all flammable
liquids.
3) Employees
a) Follow all storage and use requirements.
b) Report deficiencies in storage and use to
supervisors.
c) Immediately report spills to supervisors.
d. Hazard Control
1) Engineering Controls
a) Properly designed flammable storage areas.
3–20 ESH Handbook
b) Ventilated storage areas.
c) Grounding straps on drums and dispensing
points.
2) Administrative Controls
a) Designated storage areas.
b) Limited amount of flammable liquids in use
3 and storage.
c) Employee training.
d) Limited and controlled access to bulk
storage areas.
e) Posted danger, warning and hazard signs.
e. Substitution
Flammable liquids sometimes may be substituted
by relatively safe materials in order to reduce the
risk of fires. Any substituted material should be
stable and nontoxic and should either be
nonflammable or have a high flashpoint.
f. Storage and Usage of Flammable Liquids
Flammable and combustible liquids require
careful handling at all times. The proper storage of
flammable liquids within a work area is very
important in order to protect personnel from fire
and other safety and health hazards.
1) Storage of Flammable liquids should be in
NFPA approved flammable storage lockers. Do
not store other combustible materials near
flammable storage areas or lockers.
2) Bulk drums of flammable liquids must be
grounded and bonded to containers during
dispensing. (See Figures 3-6 and 3-7 following
pages.)
3) Portable containers of gasoline or diesel are not
to exceed 5 gallons (19 liters).
4) Safety cans used for dispensing flammable or
combustible liquids should be kept at points of
use.
5) Appropriate fire extinguishers are to be
mounted within 75 feet (22.86 meters) of
outside areas containing flammable liquids, 3
and within 10 feet (3 meters) of any inside
storage area for such materials.
6) Storage rooms for flammable and combustible
liquids must have explosion-proof light
fixtures.
7) Bulk storage of gasoline, diesel, or oil are kept
in above ground tanks. Tank areas are diked to
contain accidental spills. All tank areas must be
designated no smoking, no hot work, no open
flame areas.
Figure 3-6: Examples of Bonded and Grounded

Metal Receiving Containers
3–22 ESH Handbook
Figure 3-7: Examples of Bonded and Grounded
Metal Receiving Containers
3
8) No flames, hotwork, or smoking is permitted
in flammable or combustible liquid storage
areas.
9) The maximum amount of flammable liquids
that may be stored in a building are:
a) 20 gallons (76 liters) of Class IA liquids in
containers
b) 100 gallons (378 liters) of Class IB, IC, II,
3
or III liquids in containers
c) 500 gallons (1,893 liters) of Class IB, IC,
II, or III liquids in a single portable tank
10) Flammable liquid transfer areas are to be
separated from other operations by distance or
by construction having proper fire resistance.
11) When not in use, flammable liquids must be
kept in covered containers.
12) Class I liquids must be used only where there
are no open flames or other sources of ignition
within the possible path of vapor travel.
13) Flammable or combustible liquids must be
drawn from or transferred into vessels,
containers, or portable tanks within a building
only through a closed piping system, from
safety cans, by means of a device drawing
through the top, or from a container or
portable tanks by gravity through an approved
self-closing valve that is bonded and grounded.
Transferring by means of air pressure on the
container or portable tanks must be prohibited.
14) Maintenance and operating practices must be
in accordance with established procedures
which will tend to control leakage and prevent
the accidental escape of flammable or combus-
3–24 ESH Handbook
tible liquids. Spills must be cleaned up
promptly.
15) Combustible waste material and residues in a
building or unit operating area must be kept to
a minimum, stored in covered metal recep-
tacles, and disposed of daily.
16) Rooms in which flammable or combustible
3 liquids are stored or handled by pumps must
have exit facilities arranged to prevent occu-
pants from being trapped in the event of fire.
17) Inside areas in which Class I liquids are stored
or handled must be heated only by means not
constituting a source of ignition, such as steam
or hot water.
g. Cabinets
Not more than 120 gallons (454 liters) of Class I,
Class II, and Class IIIA liquids may be stored in a
storage cabinet. Of this total, not more than 60
gallons (227 liters) may be Class I and II liquids.
Not more than three such cabinets (120 gallons
(454 liters) each) may be located in a single fire
area except in an industrial area. (See Figure 3-8
next page.)
h. Containers
The capacity of flammable and combustible liquid
containers will be in accordance with Table 3-2 on
page 3-26.
i. Storage Inside Buildings
Where approved storage cabinets or rooms are not
provided, inside storage will comply with the
following basic conditions:
1) The storage of any flammable or combustible
liquid must not physically obstruct a means of
egress from the building or area.
2) Containers of flammable or combustible
liquids must remain tightly sealed except when
transferred, poured or applied. Remove only
that portion of liquid in the storage container
required to accomplish a particular job.
3
3) If a flammable and combustible liquid storage
building is used, it will be a one-story building
Figure 3-8: Storage Cabinet

3–26 ESH Handbook
devoted principally to the handling and storing
of flammable or combustible liquids. The
building will have 2-hour fire-rated exterior
walls having no opening within 10 feet (3
meters) of such storage.
4) Flammable paints, oils, and varnishes in 1 or 5
gallon (3.8 or 19 liter) containers, used for
building-maintenance purposes, may be stored
3 temporarily in closed containers outside
approved storage cabinets or room if kept at
the job site for less than 10 calendar days.
Table 3-2: Recommended Storage Containers

j. Ventilation
Every inside storage room will be provided with a
continuous mechanical exhaust ventilation system.
To prevent the accumulation of vapors, the
location of both the makeup and exhaust air
openings will be arranged to provide, as far as
practical, air movement directly to the exterior of
the building and, if ducts are used, they will not 3
be used for any other purpose. (See figure 3-9
below.)
Figure 3-9: Storage Locker Ventilation Fans

4. Facilities and Maintenance
A. General Work Environment
1. Housekeeping
a. Each employee is responsible for good
housekeeping practices.
b. Work areas must be maintained in an orderly
manner.
c. Tools and equipment must be stored when not in
use. 4
d. Work areas, walkways, and stairways must be kept
free of slipping/tripping hazards.
e. All spills must be promptly cleaned up.
f. Exits must be kept free of obstructions.
g. Access to emergency equipment (air packs, fire
extinguishers, etc.) must be kept free and open at
all times.
h. All places of employment must be kept clean to
the extent that the nature of the work allows.
Figure 4-1: Cluttered Shop Floor

4–2 ESH Handbook
i. The floor of every workroom must be maintained,
so far as practicable, in a dry condition. Where
wet processes are used, drainage must be
maintained and false floors, platforms, mats, or
other dry-standing places must be provided, where
practicable, or appropriate waterproof footgear
must be provided.
j. To facilitate cleaning, every floor, working place,
and passageway must be kept free from protruding
nails, splinters, loose boards, and unnecessary
holes and openings.
4
k. All aisles, emergency exits, fire extinguishers,
eyewash/shower stations, etc., must be kept clear
(a minimum of 3 feet (0.9144 meters) of either
side) of product storage, material storage, fork
trucks and pallet jacks (temporary and
permanent) at all times.
l. Storage areas are kept orderly at all times.
m. Smoking is not permitted inside buildings and/or
within 50 feet (15.24 meters) of material storage.
This includes all offices, rest rooms, production
floor, storage areas, coolers, etc. Smoking is
permitted outside in designated areas. To prevent
fires and keep the grounds neat and orderly, all
cigarette/cigar ashes and butts are to be disposed
in the provided butt cans or ashtrays only.
2. Floors and Walls
a. A standard railing and toeboard must guard every
floor opening. The railing must be provided on all
exposed sides (except at entrance to stairway). For
infrequently used stairways where traffic across the
opening prevents the use of fixed standard railing
(as when located in aisle spaces, etc.), the guard
must consist of a hinged floor opening cover of
Facilities and Maintenance 4–3
standard strength and construction and removable
standard railings on all exposed sides (except at
entrance to stairway).
b. Every wall opening from which there is a drop of
more than 4 feet (1.22 meters) must be guarded.
c. Every open-sided floor or platform 4 feet (1.22
meters) or more above adjacent floor or ground
level must be guarded by a standard railing on all
open sides except where there is entrance to a
ramp, stairway, or fixed ladder. The railing must
be provided with a toeboard if a person can pass 4
beneath the open sides, if there is moving
machinery, or there is equipment with which
falling materials could create a hazard.
d. Every flight of stairs having 4 or more risers must
be equipped with standard stair railings or
standard handrails.
e. A standard railing must consist of top rail,
intermediate rail, and posts, and must have a
vertical height of 42 inches (106.68 centimeters)
nominal from upper surface of top rail to floor,
platform, runway, or ramp level. The top rail must
be smooth-surfaced throughout the length of the
railing. The intermediate rail must be
approximately halfway between the top rail and
the floor, platform, runway, or ramp. The ends of
the rails must not overhang the terminal posts
except where such overhang does not constitute a
projection hazard.
3. Stairways and Elevated Work Surfaces
a. Fixed stairs must be provided for access from one
structure level to another where operations
necessitate regular travel between levels, and for
access to operating platforms at any equipment
4–4 ESH Handbook
that requires attention routinely during
operations. Fixed stairs must also be provided
where access to elevations is daily or at each shift
for such purposes as gauging, inspection, regular
maintenance, etc., where such work may expose
employees to acids, caustics, gases, or other
harmful substances, or for which purposes the
carrying of tools or equipment by hand is
normally required. (It is not the intent of this
section to preclude the use of fixed ladders for
access to elevated tanks, towers, and similar
4 structures, overhead traveling cranes, etc., where
the use of fixed ladders is common practice.)
Spiral stairways shall not be permitted except for
special limited usage and secondary access
situations where it is not practical to provide a
conventional stairway. Winding stairways may be
installed on tanks and similar round structures
where the diameter of the structure is not less than
5 feet (1.52 meters).
b. Fixed stairways shall be designed and constructed
to carry a load of 5 times the normal live load
anticipated but never of less strength than to carry
safely a moving concentrated load of 1,000
pounds (373 kilograms).
c. Fixed stairways must have a minimum width of 22
inches (56 centimeters).
d. Fixed stairs must be installed at angles to the
horizontal of between 30 degrees and 50 degrees.
Any uniform combination of rise/tread
dimensions may be used that will result in a
stairway at an angle to the horizontal within the
permissible range.
e. All treads must be reasonably slip-resistant and the
nosings must be of nonslip finish. Welded bar
Figure 4-2: Runs and Risers for Stairs
Figure 4-3: Safe Angles for Ladders,

Stairs and Ramps
4–6 ESH Handbook
grating treads without nosings are acceptable,
providing the leading edge can be readily
identified by personnel descending the stairway
and provided the tread is serrated or is of definite
nonslip design. Rise height and tread width must
be uniform throughout any flight of stairs
including any foundation structure used as one or
more treads of the stairs.
f. Stairway platforms must be no less than the width
of a stairway and a minimum of 30 inches (76.2
centimeters) in length measured in the direction
4 of travel.
g. Standard railings must be provided on the open
sides of all exposed stairways and stair platforms.
Handrails must be provided on at least one side of
closed stairways, preferably on the right side
descending.
h. Vertical clearance above any stair tread to an
overhead obstruction must be at least 7 feet
(2.134 meters) measured from the leading edge of
the tread.
i. Employees must not climb onto vessels, tank
roofs, etc., without safeguards (planking, scaffolds,
etc.). Working from any surface over 4 feet (1.22
meters) above adjacent floor or ground requires
guardrails or that employees use safety belts.
j. Where guardrails are installed, toe boards must be
provided if a person can pass beneath the open
sides or where falling materials can create a
hazard.
k. When on stairways or elevated work surfaces,
employees must avoid carrying loads that extend
above eye level or otherwise obstruct vision.
4. Exits
a. Every building or structure must be provided with
exits of kinds, numbers, location, and capacity
appropriate to the individual building or structure,
with due regard to the character of the occupancy,
the number of persons exposed, the fire protection
available, and the height and type of construction
of the building or structure, to afford all
occupants convenient facilities for escape.
b. In every building or structure exits must be so
arranged and maintained as to provide free and 4
unobstructed egress from all parts of the building
or structure at all times when it is occupied. No
lock or fastening to prevent free escape from the
inside of any building must be installed.
c. Every exit must be clearly visible and the route to
reach it must be conspicuously indicated in such a
manner that every occupant of every building or
structure who is physically and mentally capable
will readily know the direction of escape from any
point, and each path of escape, in its entirety,
must be so arranged or marked that the way to a
place of safety outside is unmistakable.
d. Any doorway or passageway not constituting an
exit or way to reach an exit, but of such a
character as to be subject to being mistaken for an
exit, must be so arranged or marked as to
minimize its possible
confusion with an
exit and the resultant
danger of persons
endeavoring to
escape from fire
finding themselves
trapped in a dead-
4–8 ESH Handbook
end space, such as a cellar or storeroom, from
which there is no other way out.
e. Adequate and reliable illumination must be
provided for all exit facilities.
f. In every building or structure of
such size, arrangement, or
occupancy that a fire may not
itself provide adequate warning
to occupants, fire alarms must be
provided where necessary to
4 warn occupants of the existence
of fire so that they may escape,
or to facilitate the orderly
conduct of fire exit drills.
g. Every building or structure,
section, or area thereof of such
size, occupancy, and
arrangement that the reasonable
safety of numbers of occupants may be
endangered by the blocking of any single means of
egress due to fire or smoke, must have at least 2
means of egress remote from each other, so
arranged as to minimize any possibility that both
may be blocked by any one fire or other
emergency conditions.
h. Every required exit, way of approach, and way of
travel from the exit into the street or open space,
must be continuously maintained free of all
obstructions or impediments to full immediate use
in the case of fire or other emergency.
i. Every automatic sprinkler system, fire detection
and alarm system, exit lighting, fire door, and
other item of equipment, where provided, must be
continuously in proper operating condition.
5. Illumination
a. The purpose of industrial lighting is to provide
illumination in quality and quantity sufficient for
safety and to enhance visibility and productivity
within the work environment. It is essential to
investigate and to understand the task, the
environment, the lighting and their
interrelationships.
b. Luminance is frequently the one controllable
factor in task visibility. Luminance resulting from
the light on the task and its surroundings may be 4
controlled by varying the amount and distribution
of light. Luminance needed to see well is usually
many times what is necessary for mere
discernment. Higher luminance may compensate
for deficiencies in the other contributing factors.
c. Example of Illuminance Selection
1) Suppose a machine shop is to be relighted. The
supervisor, with consultation with the depart-
ment, determines the following:
a) Worker Age: Young (under 40).
b) Demands: Workers are under pressure to
maintain close tolerances on die production.
Speed and accuracy are considered impor-
tant, but not critical, to production.
2) The supervisor then follows this step-by-step
procedure:
a) STEP 1. Define the visual task. Here, the
supervisor uses the information obtained in
a) and b) above.
b) STEP 2. Find an illuminance category.
Here, the supervisor refers to Table 4-2
4
Table 4-1 A and B: Illuminance Values, Maintained, in Lux for a Combination of
Illuminance Categories and User, Room and Task Characteristics
4–10 ESH Handbook
(page 4-12) to find an illuminance category

of “E” under “Machine Shops,” in the
subhead “medium bench or machine work.”
c) STEP 3. Determine the illuminance on task
category by cross referencing “E” and the
appropriate weighting category in Table 4-
1B (above).
d) STEP 4. Refer to Table 4-1A (General
Lighting Throughout Room) (facing page).
4–12 ESH Handbook
Table 4-2: Recommended Illuminance

Categories for Industrial Interiors
Area/Activity ............................................. Illuminance Category

Clothing Manufacture (see Sewn Products)
Receiving, opening, storing, shipping .................................. D
Examining (perching) ........................................................... I
Sponging, decating, winding, measuring ............................. D
Piling up and marking ......................................................... E
Cutting ............................................................................... G
Pattern making, preparation of trimming, piping, canvas and
shoulder pads ...................................................................... E
4 Fitting, bundling, shading, stitching .................................... D
Shops .................................................................................. F
Inspection ........................................................................... G
Pressing ............................................................................... F
Sewing ................................................................................ G
Leather Manufacturing
Cleaning, tanning and stretching, vats ................................. D
Cutting, freshing and stuffing ............................................. D
Finishing and scarfing ......................................................... E
Leather Working
Pressing, winding, glazing ................................................... F
Grading, matching, cutting, scarfing, sewing ....................... G
Machine Shops
Rough bench or machine work ........................................... D
Medium bench or machine work, ordinary automatic
machines, rough grinding, medium buffing and polishing .. E
Fine bench or machine work, fine automatic machines,
medium grinding, fine buffing and polishing ...................... G
Extra-fine bench or machine work, grinding, fine work ...... H
Materials Handling
Wrapping, packing, labeling ................................................ D
Picking stock, classifying ..................................................... D
Loading, inside truck bodies and freight cars ....................... C
Sewn Products
Receiving, packing, shipping ............................................... E
Opening, raw goods storage ................................................ E
Designing, pattern-drafting, pattern grading and
markermaking ..................................................................... F
Computerized designing, pattern-making and grading,
digitizing, marker-making, and plotting .............................. B
Cloth inspection and perching ............................................. I
Spreading and cutting (includes computerized cutting) ....... F
Fitting, sorting and blunding, shading, stitch marking ........ G
Sewing ................................................................................ G
Pressing ............................................................................... F
In-process and final inspection ............................................ G
Finished goods storage and picking orders ........................... F
Trim preparation, piping, canvas and shoulder pads ............ F
Machine repair shops .......................................................... G
Knitting .............................................................................. F
Sponging, decating, rewinding, measuring .......................... E
Leather working (see Leather working)
Shoe manufacturing (see Shoe manufacturing)
4
Shoe Manufacturing—Leather
Cutting and stitching cutting tables ..................................... G
Marking, buttonholding, skiving, sorting, vamping,
counting .............................................................................. G
Stitching, dark materials ...................................................... G
Making and finishing, nailers, sole layers, well beaters
and scrafers, sluggers, randers, wheelers, treers, cleaning,
spraying, buffing, polishing, embossing ............................... F
Shoe Manufacturing—Rubber
Washing, coating, mill run compounding ........................... D
Varnishing, vulcanizing, calendering, upper and sole
cutting ................................................................................ D
Sole rolling, lining, making and finishing processes ............. E
Textile Mills
Finishing
Fabric preparation (desizing, scouring, bleaching,
singeing, and mercerization) ......................................... D
Fabric dyeing (printing) ................................................ D
Fabric finishing (calendering, sanforizing, sueding,
chemical treatment) ..................................................... Ea
Inspection .................................................................. Ga,b
a
Supplementary lighting should be provided in this space to
produce the higher levels required for specific seeing tasks
involved.
b
Color temperature of the light source is important for color
matching.
4–14 ESH Handbook
B. Ventilation
1. Exhaust Ventilation
a. Exhaust ventilation systems are classified in 2
generic groups: General Exhaust System and Local
Exhaust System.
b. The general exhaust system can be used for heat
control and/or removal of contaminants generated
in a space by flushing out a given space with large
quantities of air. When used for heat control, the
air may be tempered and recycled. When used for
4 contaminant control (the dilution system),
enough outside air must be mixed with the
contaminant to reduce the average concentration
to a safe level. The contaminated air is then
typically discharged to the atmosphere. A supply
system is usually used with a general exhaust
system to replace the exhausted air.
c. Dilution ventilation systems are normally used for
contaminant control only when local exhaust is
impractical, as the large quantities of tempered
Figure 4-4: Direction of Air Flow

replacement air required to offset the air exhausted
can lead to high operating costs.
d. Local exhaust ventilation systems operate on the
principle of capturing a contaminant at or near its
source. It is the preferred method of control
because it is more effective and the smaller exhaust
flow rate results in lower heating costs compared
to high flow rate general exhaust requirements.
The present emphasis on air pollution control
stresses the need for efficient air-cleaning devices
on industrial ventilation systems, and the smaller
flow rates of the local exhaust system result in 4
lower costs for air-cleaning devices.
e. Local exhaust systems are comprised of up to 4
basic elements: the hood(s), the duct
system(including the exhaust stack and/or
recirculation duct), the air-cleaning device and the
fan. The purpose of the hood is to collect
contaminants generated in the air stream directed
toward the hood. A duct system must then
Figure 4-5: Inlet and Exhaust Locations

4–16 ESH Handbook
transport the contaminated air to the air cleaning
device, if present, or to the fan. In the air cleaner,
the contaminant is removed from the air stream.
The fan must overcome all the losses due to
friction, hood entry, and fittings in the system
while producing the intended flow rate. Figure 4-
6 below shows examples of good and poor branch
entry designs.
Table 4-3: Range of Capture Velocities
Figure 4-6: Branch Entry

4
Figure 4-7: Exhaust Monitoring
4–18 ESH Handbook
2. Fume Hoods
a. Testing Fume Hoods
1) A performance test to determine the operating
condition of a fume hood must be conducted
periodically. The test procedure outlined here
presumes a bench-type laboratory hood. If
other types of hoods are used, some modifica-
tion of the test procedure may be required. The
Figure 4-8: Fume Hoods

4
performance test does not constitute an
engineering investigation of what the causes
may be for poor performance of the fume hood
or of ways to improve performance. However,
the performance test could be used as an aid to
such an investigation.
2) Generally, the toxicity level of the work done
within the hood will determine the hood face
velocities and the total amount of the exhaust
air. Materials of little or no toxicity need face
velocities only sufficient to maintain control
under normal operating conditions. As toxicity 4
levels rise, the face velocity should be increased
to assure control. The recommended velocities
for different toxic levels range from 80 FPM
(24.38 MPM) to 130 FPM (39.62 MPM).
Generally, 100 FPM (30.48 MPM) is satisfac-
tory for most applications [Note: a Class B
laboratory fume hood with a minimum average
face velocity of 100 feet per minute (FPM)
(30.48 meters per minute) would have about
1000 to 1300 cubic feet per minute (CFM) (305
to 396 cubic meters per minute (CMM)) of air
exhausted through the hood. The equation for this
calculation is Q = AV, where Q is air volume in
CFM; A is face in square feet; and V is face
velocity in FPM]. The facility must specify
what level of performance is required for each
hood. The tests must be in agreement with
the toxicity level of the work to be performed
in the fume hood and the safety standards
established by the facility.
3) General activity in the facility must be normal.
Air currents in front of the hood must be
reduced or eliminated if possible. Conduct the
test with the normal hood apparatus in place
4–20 ESH Handbook
and operating. The following list is typical of
the test devices needed to perform smoke tests:
a) Smoke candles, ½ minute
b) Smoke tubes
c) Titanium tetrachloride
d) Cotton swabs
b. Smoke Test Procedure
1) To determine that a positive air flow is entering
4 the hood over the entire face, take a complete
traverse of the hood face with either:
a) Titanium tetrachloride on a cotton swab.
b) A smoke candle.
c) A smoke tube.
2) Use a smoke tube, a smoke candle, or swab a
stripe of titanium tetrachloride on pieces of
tape to produce the necessary amount of smoke
at the following test locations: (1) along both
sides, the top and the work surface of the hood
about 6 inches (15 centimeters) behind and in
parallel to the hood face, (2) along the back
panel and the baffle of the hood, and (3)
around any equipment in the hood. Verify that
all smoke is carried to the back of the hood and
exhausted. The hood fails the test if visible
smoke flows out the front of the hood. Reverse
air flows or dead air spaces are not permitted.
3) With the sash open, ignite a smoke candle
within the hood enclosure to observe the
exhaust capacity of the hood. All smoke should
flow quickly and directly to the back of the
hood and be exhausted. Set the candle on the
work surface and close the sash. With the sash
closed, the hood must have enough air to dilute
and exhaust the smoke. The hood fails the test
if visible smoke flows out the front of the hood.
Reverse airflows or dead air spaces are not
permitted.
4) Place a pan of hot water in the center of the
work area and add enough chunks of dry ice to
the hot water to form a large volume of heavy
white smoke. All smoke should flow directly to
the back of the hood and be exhausted. The
hood fails the test if visible smoke flows out the 4
front of the hood. Reverse airflows or dead air
spaces are not permitted.
C. Accident Prevention Signs and Tags

1. Signal Word. The word or words that designate a
degree or level of hazard seriousness. The signal words
for product safety signs are DANGER, WARNING,
and CAUTION.
a. DANGER: Indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury. This signal word is to be limited
to the most extreme situations.
b. CAUTION: Indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. It may also be used to
alert against unsafe practices.
Note: DANGER or WARNING must not be
considered for property-damage accidents, unless
personal injury risk appropriate to these levels is
also involved. CAUTION is permitted for
property-damage-only accidents.
4–22 ESH Handbook
Figure 4-9: ANSI Tag Warnings
4
Table 4-4: Color Table
D. Machine Shop Safety

1. General Rules
a. Keep shop areas clean and orderly.
b. Place junk, scrap, and waste in containers or
specialized areas for proper disposal.
c. The shop area must be properly lighted.
d. Fire protection equipment effective for the
potential hazards must be readily accessible. Refer
to Chapter 6, Emergency Preparedness &
Response.
e. Appropriate first aid equipment must be provided,
stocked, and readily available. Employees must
know the locations of this equipment. Refer to
Chapter 6, Emergency Preparedness & Response.
f. Personal protective equipment (PPE) must be
provided as needed. Such equipment must be
4–24 ESH Handbook
properly maintained. Refer to Chapter 7, Personal
Protective Equipment.
2. Bench and Pedestal Grinders
a. Use appropriate eye protection when using
grinders.
b. Grinders must be equipped with tool/work rests
adjusted to clear the abrasive wheel by not more
than 1/8 inch (3.17 millimeters).
c. Adjust the tongue guard so that clearance is no
4 more than ¼ inch (6.35 millimeters).
d. In addition, protective shield guards must be
provided on grinders and the grinding wheel must
be rated for at least the RPM of the motor.
e. Powered Abrasive Wheel Tools
1) Powered abrasive grinding, cutting, polishing,
and wire buffing wheels create special safety
problems because they may throw off flying
fragments.
Figure 4-10: Bench/Pedestal Grinder

2) Before an abrasive wheel is mounted, it must
be inspected closely and sound- or ring-tested
to be sure that it is free from cracks or defects.
To test, wheels should be tapped gently with a
light non-metallic instrument. If they sound
cracked or dead, they could fly apart in
operation and so must not be used. A sound
and undamaged wheel will give a clear metallic
tone or “ring.” (See Figure 4-12: Ring Test next
page.)
3) To prevent the wheel from cracking, the user
must be sure it fits freely on the spindle. The 4
spindle nut must be tightened enough to hold
the wheel in place, without distorting the
flange. Follow the manufacturer’s recommen-
dations. Care must be taken to assure that the
spindle wheel will not exceed the abrasive
wheel specifications.
4) Due to the possibility of a wheel disintegrating
(exploding) during start-up, the employee must
never stand directly in front of the wheel as it
accelerates to full operating speed.
Figure 4-11: Grinder Hood Adjustment
The hood or gap adjustment must be kept ¼ inch (6.35

millimeters) from the wheel and must be adjusted for wear.
4–26 ESH Handbook
5) Portable grinding tools need to be equipped
with safety guards to protect workers not only
from the moving wheel surface, but also from
flying fragments in case of breakage.
6) Powered Grinder Safety Precautions
a) Always use eye protection.
b) Turn off the power when not in use.
c) Never clamp a hand-held grinder in a vise.
3. Air Hoses, Tools, and Compressors
4
a. Air hoses must be raised over aisles and work areas
to prevent tripping hazards.
b. Eye protection must be worn when using an air
tool for cleaning.
c. Do not use more than 30 psi (pounds per square
inch) (11.2 ksi (kilograms per square inch)) when
using an air tool for cleaning. A sign must be
posted stating that 30 psi (11.2 ksi) is the
maximum pressure allowed.
d. Do not dust off clothing with compressed air.
Figure 4-12: Ring Test

e. Hoses must be kept clean and stored in a manner
that protects them and maintains their good
condition when not in use.
f. Air compressor and air receiver tanks must be
equipped with spring-loaded pressure relief valves.
These valves must be tested. Block valves must not
Figure 4-13: Air Nozzle with Dead-end Safety Tip
Figure 4-14: Acceptable Methods

for Use of Compressed Air
4–28 ESH Handbook
be placed between the air receiver tank and the
pressure relief valve.
g. Drain liquid accumulation from air tanks
periodically.
h. Automatic starting compressors must have a
warning sign stating that the unit starts
automatically.
NOTE:
Pressure relieving valves and gauges must be rated
4 and set at air receiver manufacturer’s specifications.
4. Fan Guards (Exposure of Blades)
When the periphery of the blades of a fan is less than
7 feet (2.13 meters) above the floor or working level,
the blades must be guarded. The guard should have
openings no larger than ½ inch (1.27 centimeters).
(See Figure 4-15 below.)
5. Portable Hand Tools and Powered Hand Tools
a. Hand tools are non-powered. They include
anything from sledges to wrenches. Appropriate
Figure 4-15: Some Types of Fan Guards

personal protective equipment (e.g., safety
goggles, gloves, etc.) must be worn, due to hazards
that may be encountered while in use.
1) Tools must be examined, kept clean and
functional, and repaired (if necessary) prior to
use. Unrepairable tools must be removed from
service and destroyed.
2) Tools must be used only for the purpose for
which they are designed.
3) An employee must assume a safe and stable
position before applying pressure to a tool 4
handle, to avoid losing balance or falling if the
tool should slip.
4) Holders must be used when striking chisels,
punches, rods, stakes, etc., to prevent hand
injuries. Eye protection must be worn when
striking tools are used. (See Figure 4-16 below.)
5) “Mushroomed” or expanded heads of impact
tools such as chisels and sledgehammers must
be dressed (filed off ) as needed. (See Figure 4-
17 next page.)
6) A hammer must not be struck against another
hammer.
Figure 4-16: A Striking Holder

4–30 ESH Handbook
7) Adjustable crescent wrenches must not be used
if a box or open-end wrench of the correct size
is available.
8) Jaws on adjustable crescent wrenches must be
tightened around fitting/nut and the force
applied on the side with the stationary jaw.
9) Wrenches must be pulled instead of pushed
when possible.
10) Handles of sledges, hammers, mauls, and the
4 like must be securely wedged into the heads.
Wooden handles must not be painted because
paint causes handles to be slick and hides
cracks and other defects. Cracked or split
handles must be replaced; they must not be
taped.
b. Power Tool Precautions
1) Power tools can be hazardous when improperly
used. There are several types of power tools,
based on the power source they use: electric,
pneumatic, liquid fuel, hydraulic, and powder-
actuated.
Figure 4-17: Figure 4-18:

Mushroomed Crescent Wrench
Striking Tool Direction of Force
2) The following general precautions must be
observed by power tool users:
a) Never carry a tool by the cord or hose.
b) Never yank the cord or the hose to discon-
nect it from the receptacle.
c) Keep cords and hoses away from heat, oil,
and sharp edges.
d) Disconnect tools when not in use, before
servicing, and when changing accessories
such as blades, bits and cutters. 4
e) All observers must be kept at a safe distance
away from the work area.
f ) Secure work with clamps or a vise, freeing
both hands to operate the tool.
g) Avoid accidental starting. The worker must
not hold a finger on the switch button while
carrying a plugged-in tool.
h) Tools must be maintained with care. They
must be kept sharp and clean for the best
performance. Follow instructions in the
user’s manual for lubricating and changing
accessories.
i) Be sure to keep good footing and maintain
good balance.
j) The proper apparel must be worn. Loose
clothing, ties, or jewelry can become caught
in moving parts.
k) All portable electric tools that are damaged
must be removed from use and tagged “Do
Not Use.”
4–32 ESH Handbook
6. Tool and Equipment Maintenance
a. Guards
1) Hazardous moving parts of a power tool need
to be safeguarded. For example, belts, gears,
shafts, pulleys, sprockets, drums, chains, or
other reciprocating, rotating, or moving parts
of equipment must be guarded.
2) Guards, as necessary, must be provided to
protect the operator and others from the
following:
4
a) Point of operation
b) In-running nip points
c) Rotating parts
d) Flying chips and sparks
3) Safety guards must never be removed when a
tool is being used. For example, portable
circular saws must be equipped with guards.
An upper guard must cover the entire blade of
the saw. A retractable lower guard must cover
the teeth of the saw, except when it makes
contact with the work material. The lower
guard must automatically return to the
covering position when the tool is withdrawn
from the work.
Figure 4-19: Retractable Safety Guard

b. Pulleys
1) Exposed parts of pulleys 7 feet (2.13 meters) or
less above the ground, floor or working
platform must be guarded. (See Figure 4-20
below.)
c. Shafting
1) All horizontal, vertical or inclined shafting 7
feet (2.13 meters) or less above the ground,
floor or working platform must be guarded.
Figure 4-20: Combination Belt 4

and Pulley Guard
Figure 4-21: Shaft Guards

4–34 ESH Handbook
2) Shafting under benches or tables must be
completely enclosed.
3) Projecting shaft ends within 7 feet (2.13
meters) of the working surface must have
smooth, rounded edges and must not project
more than half the diameter of the shaft
beyond the end of the bearing, unless the shaft
end is guarded by a non-rotating casing.
4) Unused exposed keyways less than 7 feet (2.13
meters) above the working surface must be
4 filled, covered or guarded.
d. Couplings, Collars, and Clutches
1) Clutches, collars, cut-off couplings and clutch
pulleys with projecting parts need guards if any
part is 7 feet (2.13 meters) or less above the
working surface. (See Figure 4-22 below.)
e. Gears, Sprockets, Friction Drives
1) As a general rule, gears and sprockets should be
completely enclosed. (See Figure 4-23 next
page.) Exceptions are gears and sprockets in
inaccessible places. They need not be guarded
if they have extension lubrication fittings or
Figure 4-22: Coupling, Collar, Clutch Guards

systems that can be serviced from the mesh
point of gears and sprockets.
2) Sprockets, open-web gears and friction drives
need guarding to prevent accidental contact.
f. Band Saws
1) Band saw wheels must be completely enclosed
or guarded, except the part between the guide
roll and the table.
2) The down travel guard from the upper wheel
to the guide must be made of heavy metal and 4
adjusted so the blade will travel within the
angle or channel.
Figure 4-23: Gear, Sprocket, Friction Drive Guards

4–36 ESH Handbook
3) The guard must come to within ½ inch (1.27
centimeters) of the stock being cut.
4) Band saws must have tension-control devices.
g. Crosscut and Ripsaw.
1) The contractor/employer must provide each
circular crosscut saw and ripsaw with a hood
that covers the saw at all times at least to the
depth of the teeth, and that adjusts itself
automatically to the thickness of the material
being cut. It is important that the hood remain
4 in contact with the material at the point where
the stock meets the saw. (See Figure 4-25
Figure 4-24: Band Saw Guarding

below.) In addition, the exposed parts of the
sawblade under the table must be guarded.
2) A spreader slightly thicker than the saw disk
and slightly thinner than the saw set or kerf
should be used on circular ripsaws, except
when grooving, dadoing, or rabbetting.
3) Anti-kickback devices are recommended for
circular ripsaws. A pusher stick must be
provided and used.
4) The contractor/employer must provide a
positive means of shutting off power to all 4
Figure 4-25: Table Saw Guarding

4–38 ESH Handbook
woodcutting machinery while repairs and
adjustments are made. Power and operating
controls must be within easy reach of the
operator.
Figure 4-26: Overhead Circular Saw Guarding
Figure 4-27: Grinder Guarding

h. Safety Switches
1) The following hand-held powered tools are to
be equipped with a momentary contact “on-
off ” control switch: drills, tappers, fastener
drivers, horizontal, vertical and angle grinders
with wheels larger than 2 inches (5 centime-
ters) in diameter, disc and belt sanders,
reciprocating saws, saber saws, and other
similar tools. These tools also may be equipped
with a lock-on control provided that turnoff
can be accomplished by a single motion of the
same finger or fingers that turn it on. 4
2) The following hand-held powered tools may be
equipped with only a positive “on-off ” control
switch: platen sanders, disc sanders with discs 2
inches (5 centimeters) or less in diameter;
grinders with wheels 2 inches (5 centimeters)
or less in diameter; routers, planers, laminate
trimmers, nibblers, shears, scroll saws and
jigsaws with blade shanks ¼-inch (6.35
millimeters) wide or less.
3) Other hand-held powered tools such as circular
saws having a blade diameter greater than 2
inches (5 centimeters), chain saws, and
percussion tools without positive accessory
holding means must be equipped with a
constant pressure switch that will shut off the
power when the pressure is released.
i. Electrical Safety
1) To protect the user from shock, tools must
either have a three-wire cord with ground and
be grounded, be double insulated, or be
powered by a low-voltage isolation transformer.
Three-wire cords contain two current-carrying
conductors and a grounding conductor. One
4–40 ESH Handbook
end of the grounding conductor connects to
the tool’s metal housing. The other end is
grounded through a prong on the plug.
Anytime an adapter is used to accommodate a
two-hole receptacle, the adapter wire must be
attached to a known ground. The third prong
must never be removed from the plug.
2) Double insulation is more convenient. The
user and the tools are protected in two ways: by
normal insulation on the wires inside, and by a
housing that cannot conduct electricity to the
4 operator in the event of a malfunction.
3) Electric Power Tool General Safety Practices:
a) Electric tools must be operated within their
design limitations.
b) Gloves and safety footwear are recom-
mended during use of electric tools.
c) When not in use, tools must be stored in a
dry place.
d) Electric tools must not be used in damp or
wet locations.
e) Work areas must be well lighted.
Figure 4-28: Typical 120 Volt Branch Circuit

with Correct Wiring
4) Unqualified and Qualified Persons
a) Unqualified persons. Employees whose job
assignments require them to be close to
exposed parts of electrical circuits at 50 volts
or more must be trained in and familiar
with any electrically related safety practices
not specifically addressed in this standard
but which are necessary for their safety.
b) Qualified persons. Employees permitted to
work on or near exposed energized parts
who perform electrical work must be 4
trained to recognize the hazards associated
with their work environment and use
appropriate procedures and protective
equipment to minimize the risk of an
accident or injury. Work supervisors must
verify the qualifications and training of all
electrical workers before they are permitted
to perform electrical work. Qualified
employees must, at a minimum, be trained
in and familiar with the following:
• The skills and techniques necessary to
distinguish exposed live parts from other
parts of electric equipment.
• The skills and techniques necessary to
determine the nominal voltage of exposed
live parts.
• The clearance distances specified and the
corresponding voltages. (See Table 4-5
next page.)
• The safety-related work practices required
by Nike’s Electrical Safety CLS.
• Techniques necessary to de-energize
electrical systems, identify live parts of
4–42 ESH Handbook
equipment, and determine the nominal
voltage of exposed live parts and clearance
distances.
• Procedures for locking out and tagging
energized electrical circuits and equipment
safely. See Nike’s Control of Hazardous
Energy CLS.
• National Electrical Code (NFPA 70).
• National Electrical Safety Code (ANSI/
IEEE C2).
4
• Use of personal protective grounds.
• Use of testing and measuring equipment.
Table 4-5: Minimum Depth of Clear Working

Space at Electric Equipment
• Safety plans and work-authorization
documents.
• Use and care of personal protective
equipment.
• Hazard categories and personnel require-
ments.
j. Pneumatic Tools
1) Pneumatic tools are powered by compressed air
and include chippers, drills, hammers, and
sanders. There are several dangers encountered 4
in the use of pneumatic tools. The main one is
the danger of getting hit by one of the tool’s
attachments or by some kind of fastener the
worker is using with the tool. Eye protection is
required and face protection is recommended
for employees working with pneumatic tools.
Working with noisy tools such as jackhammers
requires proper, effective use of hearing
protection.
2) When using pneumatic tools, employees are to
check to see that they are fastened securely to
the hose to prevent them from becoming
disconnected. A short wire or positive locking
device attaching the air hose to the tool will
serve as an added safeguard.
3) A safety clip or retainer must be installed to
prevent attachments, such as chisels on a
chipping hammer, from being unintentionally
shot from the barrel.
4) Screens must be set up to protect nearby
workers from being struck by flying fragments
around chippers, riveting guns, staplers, or air
drills.
4–44 ESH Handbook
5) Compressed air guns must never be pointed
toward anyone. Users must never “dead-end” it
against themselves or anyone else.
k. Hydraulic Power Tools
1) The fluid used in hydraulic power tools must
be an approved fire-resistant fluid and must
retain its operating characteristics at the most
extreme temperatures to which it will be
exposed. The manufacturer’s recommended
safe operating pressure for hoses, valves, pipes,
4 filters, and other fittings must not be exceeded.
l. Jacks
1) All jacks—lever and rachet jacks, screw jacks,
and hydraulic jacks—must have a device that
stops them from jacking up too high. Also, the
manufacturer’s load limit must be permanently
marked in a prominent place on the jack and
must not be exceeded.
2) A jack must never be used to support a lifted
load. Once the load has been lifted, it must
immediately be blocked up.
3) Use wooden blocking under the base if
necessary to make the jack level and secure. If
the lift surface is metal, place a 1-inch (2.54
centimeter) thick hardwood block or equiva-
lent between it and the metal jack head to
reduce the danger of slippage.
4) To set up a jack, make certain of the following:
a) The base rests on a firm level surface.
b) The jack is correctly centered.
c) The jack head bears against a level surface.
d) The lift force is applied evenly.
5) Proper maintenance of jacks is essential for
safety. All jacks must be inspected before each
use and lubricated regularly. If a jack is
subjected to an abnormal load or shock, it
must be thoroughly examined to make sure it
has not been damaged.
6) Hydraulic jacks exposed to freezing tempera-
tures must be filled with an adequate antifreeze
liquid.
7. Ladder Safety
a. General 4
1) Ladders must be examined for defects before
each use. Defective ladders must be removed
from service and reported to the appropriate
supervisor.
2) Wooden ladders must not be painted. Paint
hides cracks and other damage.
3) When climbing or descending a ladder,
employees must face the ladder and have free
use of both hands. Employees must grasp side
rails and not rungs with their hands.
4) Employees must not carry objects or tools in
their hands while ascending or descending
ladders. Tools must be carried in a sack
strapped over the shoulder or otherwise secured
to the person or hoisted by an appropriate
method.
b. Portable Ladders
1) Employees must only use ladders that have
labels showing that the ladders conform to
appropriate ANSI or equivalent Standards.
2) Metal ladders must not be used for electrical
4–46 ESH Handbook
work or where they may contact electrical
conductors. Special nonconductive ladders
(approved wooden, fiberglass, etc.) are available
for electrical
maintenance
work.
3) Employees
must not lean
from a ladder
to reach work;
the ladder must
4 be reposi-
tioned.
4) Straight and
extension
ladders must
extend 3 feet
(0.9 meters)
beyond the top
resting point
when used for
climbing onto
Figure 4-29: Proper Position of Straight and

Extension Ladders
a platform. The upper portion of an extension
ladder must be secured (“lashed”) or the ladder
held by another person. The base of the ladder
must be placed away from the wall ¼ the
working-height distance of the ladder. (See
Figures 4-29 previous page and 4-30 below.)
5) A folding stepladder must not be used in a
straight closed position.
c. Fixed Ladders
1) Employees must not climb a permanently fixed
ladder longer than 20 feet (6.1 meters) unless 4
the ladder is equipped with a cage or the
employee uses a fall protection device. Employ-
ees must report ladders that do not meet these
conditions to the appropriate supervisor.
Figure 4-30: Proper Position of Straight and

Extension Ladders
4–48 ESH Handbook
8. Compressed Gas Cylinders
a. Handling
1) When necessary to move compressed gas
cylinders, a cart or other mechanical device
especially designed for that purpose must be
used. Cylinders may also be rolled on the
bottom edge, but never dragged.
2) Cylinders handled by hoisting equipment must
be carried in a cradle or similar device and care
taken to prevent their being dropped. Slings,
4 ropes, or an electromagnet must never be used
to move cylinders.
3) Cylinders must never be dropped or allowed to
strike each other violently.
4) Cylinders must never be used for any purpose
other than to contain the gas for which the
cylinder was designed.
5) Empty cylinders must be marked or labeled
“EMPTY.” Valves must be tightly closed and
the valve protection caps replaced.
6) Cylinders to be transported must be loaded
and secured in an upright position, unless
specifically designed for horizontal service.
7) Valve protection caps must never be used for
lifting the cylinder.
8) Cylinder valves must be kept closed with the
valve protection cap in place during handling.
b. Use
1) Acetylene cylinders must be used in a secured
and upright position.
2) Valve protector caps must be kept on cylinders
except when the regulator is attached or the
cylinder is connected to a manifold system.
3) Threads on a regulator or union must corre-
spond to those on the cylinder valve outlet.
Connections must not be forced.
4) A cylinder of compressed gas must never be
used without a pressure-reducing regulator
attached to the cylinder valve.
5) Regulators and pressure gauges must only be
used with the gases for which they are designed
and intended. 4
6) The cylinder valve must always be closed
before attempting to stop leaks.
7) Sparks, molten metal, electrical currents,
excessive heat, or flames must not be permitted
to come in contact with the cylinder or
attachments. This includes propane or
acetylene torches and space heaters.
8) Oil or grease must never be used as a lubricant
on valves or attachments to oxygen cylinders,
since oil and oxygen under pressure can be a
fire hazard. Also, oxygen regulators must not
be handled with oily or greasy hands or gloves.
9) Cylinder contents must never be used for
purposes other than those for which they were
intended.
c. Examination
1) Compressed gas cylinders must bear all
markings and be hydrostatically tested as
required.
2) Cylinders must be examined for signs of
corrosion or other damage.
4–50 ESH Handbook
4
3) Leaky or damaged cylinders must be reported
and taken out of service immediately. They
must be removed to a safe location and
observed until safely depressurized. They must
be marked or labeled “DAMAGED.”
d. Storage
1) Oxygen cylinders must not be stored within 20
feet (6.1 meters) of fuel gas cylinders or
combustible/flammable materials (especially oil
or grease), unless protected by a noncombus-
tible barrier at least 5 feet (1.52 meters) high 4
having a fire resistance rating of at least ½
hour.
2) Cylinders, both empty and full, must be stored
and secured in an upright position, unless
designed for horizontal use. Cylinders must be
secured with a chain or by some other accept-
able means and kept in a safe, dry, well-
Figure 4-32: Compromised and Normal

Compressed Gas Cylinders
4–52 ESH Handbook
ventilated place that is not exposed to heat or
the direct rays of the sun.
3) Cylinders must be mounted and used in a
fashion that will prevent the bottoms from
becoming corroded or otherwise damaged.
4) Acetylene cylinders must not be placed in a
horizontal position.
5) Cylinder valves must be kept closed during
storage with the protective valve caps in place.
4 6) Compressed gas cylinders must not be accepted
from the supplier unless they are properly
labeled and have protective valve caps in place.
E. Contractor and Subcontractor Safety

1. Contractors/subcontractors are expected to:
a) Inform their employees of the site emergency
action plan and of the known potential fire,
explosion, or toxic release hazards related to their
work and the process.
b) Conduct operations in such a manner that
constitutes no potential hazard to employees,
property, or the environment.
c) Provide the designated contractor/subcontractor
with reports of hazards presented by the
contractor’s work or identified during the
contractor’s work.
d) Report to the contractor/subcontractor all
accidents, injuries, and significant near-misses
occurring at the worksite.
e) Conduct investigations of incidents involving
contractor/subcontractor employees, equipment,
or processes.
f ) Comply with all safety policies and procedures as
well as those of their own organization.
g) Satisfy all federal, state, local, and country
regulations and have written safety programs and
procedures, as required.
h) Provide and maintain all required personal
protective equipment (PPE), safety equipment,
and instrumentation necessary to perform their
work effectively, efficiently, and safely.
i) Train their employees in the proper use of
equipment and safe performance of their jobs. 4
j) Conduct appropriate industrial hygiene
monitoring and, if requested, provide copies of the
results.
F. Confined Spaces Protection

1. Definition
a. Confined spaces are spaces that:
1) Are large enough and configured such that an
employee can bodily enter and perform work.
2) Have limited or restricted means for entry and
exit.
3) Are not intended for continuous human
occupancy.
b. A permit-required confined space is a confined
space that has one or more of the following
characteristics:
1) Contains or could contain a hazardous
atmosphere.
2) Contains a material that could engulf an
entrant.
4–54 ESH Handbook
3) Has an internal configuration that could trap
an entrant or cause asphyxiation.
4) Contains a recognized health/safety hazard.
2. Employees assigned to
permit-required confined
space operations must be
trained in safe entry and
emergency procedures and
be periodically retrained as
an entrant, entry
4 supervisor, attendant, or
rescue team member. They
must have a thorough
knowledge and
understanding of their
equipment and the
potential hazards that exist.
3. The atmosphere in the
confined space must be
tested for oxygen
deficiency, flammability,
and toxicity before entry.
The atmosphere must also
be continuously monitored
as feasible throughout the
confined space operation.
4. No one must enter a
permit-required confined
space unless a Confined
Space Entry Permit has been
completed and posted.
5. Appropriate personal
protective equipment (PPE)
must be used.
Figure 4-33: Confined Spaces
G. Welding, Cutting, and Brazing

1. General Guidelines
a. Welding must be performed by welders who are
qualified in the type of welding they are to
perform.
b. Welders are responsible for the maintenance of
their equipment and for the protection and safety
of people in the immediate work area.
4–56 ESH Handbook
c. The welder and the welder’s helper must use the
proper protective clothing and eye protection as
required by applicable regulations for the job
being performed.
d. Fire extinguishers must be available for fire control
at all welding operations.
e. All persons must stand to one side of any
compressed gas cylinder regulator gauge when
pressure is being applied to the regulator.
f. When a welder is cutting or welding on a pipe, no
4 person must be in front of or near the open pipe
end.
g. Welding or cutting operations must not be
performed in a confined space until the area has
been tested for oxygen level, toxics, and
flammables and the appropriate permits have been
posted. Consult the facility’s local work permits
requirements for further information.
h. Ventilation or respiratory protection may be
required while welding or burning under certain
conditions, including, but not limited to:
1) On stainless steel, galvanized, or coated
materials, such as, but not limited to, paints
that contain lead or mercury.
2) With fluxes or other materials containing
fluorides.
3) Inside a confined space.
4) Where ventilation is inadequate.
5) In an oxygen-deficient atmosphere.
i. Steel drums, barrels, or other closed tanks or
vessels that have contained volatile liquids or gases
must be thoroughly steam cleaned, filled with
water, or made safe by other approved methods
before the cutting or welding torch is applied.
(Mechanical drum cutters must be used whenever
feasible.)
j. A physical examination of the immediate work
area must be completed prior to initiating hot
work, to determine that no hazardous conditions
exist.
k. When welding in a hazardous area, the
atmosphere must be continuously monitored to
warn of any dangerous changes in the atmosphere. 4
Figure 4-34: Oxyfuel Gas Welding Unit
4–58 ESH Handbook
2. Oxyfuel Gas Welding
a. Oxygen and fuel gas hoses must be protected from
flying sparks and hot slag. They must be examined
frequently for leaks, wear, and loose connections.
Immediate action must be taken to replace
damaged or worn hoses and to correct unsafe
conditions.
b. The hose on oxyfuel welding units must be racked
when not in use. Master valves on oxygen and fuel
gas cylinders must be closed and the pressure bled
4 from regulators and hoses after use.
c. Torches must be examined frequently for leaky
valves and damaged nozzles and tips.
d. The cylinder valve must be closed immediately if a
hose catches fire.
e. Spark igniters must be used to light welding
torches. Matches and cigarette lighters must not
be used for this purpose.
f. Flashback arrestors (check valves) must be
provided to prevent the flame from passing down
the hose into the fuel gas system.
3. Arc Welding
a. Welders using arc welding equipment must
provide a protective screen around the arc when
practicable and advise persons in the surrounding
area not to look at the arc without appropriate eye
protection. Refer to Chapter 7, General (Eye &
Face, Head, Foot and Hand Protection).
b. Suitable precautions must be taken to avoid shock
from arc welding equipment:
1) Do not stand in water while arc welding.
2) Use proper protective equipment, such as
rubber boots and rubber pads, if performing
arc welding in wet or high humidity condi-
tions.
3) Do not dip energized (“hot”) electrode holders
in water.
c. Do not use cables with damaged insulation or
exposed conductors. If it is necessary to repair
damaged cable, the repaired section must have an
insulating quality equal to that of the original
cable. Never make splices within 10 feet (3
meters) of the electrode holder. 4
d. Protect cables from vehicular traffic or other
hazards that may subject them to being cut or
pinched.
e. Turn off arc welding equipment when not in use.
Figure 4-35: Hot Work Warning Tag

5. Industrial Health
A. Heat Stress Prevention
1. Probably the most elementary factor of environmental
control is contol of the thermal environment in which
people work.
2. In all cases, the objective is the prevention of heat
stroke, which is life threatening and the most serious
of the heat-related disorders.
3. The following charts are designed to assist in assessing
and counteracting the affects of heat stress.
5
5–2 ESH Handbook
5
Industrial Health 5–3
5
5–4 ESH Handbook
B. Cold Stress Prevention

1. Fatal exposures to cold in the workplace have almost
always resulted from accidental exposures involving
failure to escape from low air temperatures or from
immersion in low-temperature water.
2. The most important aspect of life-threatening
hypothermia is a fall in the deep-core body
temperature. The intent is to prevent the deep body
temperature from falling below 36° C (96.8° F) and
to prevent cold injury to body extremities.
5
5
5–6 ESH Handbook
5
C. Occupational Noise Exposure

This section helps facilities identify noise hazards in
the workplace and protect employees by means of
engineering controls and hearing protection devices.
2. Terms
a. Noise is measured in units of energy called
“decibels” (dB). OSHA requires noise to be
measured according to a weighted scale, “A.”
Therefore, the noise levels discussed in this section
will be expressed in “dBA.”
b. Representative noise samples are expressed as an
eight hour time-weighted average (“8 hr. TWA”). 5
The general thresholds the facility must follow are
the “Action Level” (AL) of 85 dBA over an 8 hr.
TWA and the “Permissible Exposure Limit” (PEL)
of 90 dBA over an 8 hr. TWA.
Note: Because these thresholds are based upon an
eight-hour exposure, the allowable dBA will
decrease if the facility work shifts exceed eight
hours (e.g., 10 hr. = PEL 88.39 and AL 83.39, 12
hr. = PEL 87.08 and AL 82.08).
c. A loss of hearing of 25 dBA at certain frequencies
(2000, 3000, and 4000 Hz) is termed a “standard
threshold shift” (STS).
3. Scope
This section applies if any of the facility employees are
exposed to occupational noise levels equal to or greater
than 85 dBA over an 8 hr. TWA.
4. Identification of Hazardous Noise
a. The facility will arrange for representative noise
monitoring to be performed of all workers
5–8 ESH Handbook
suspected of being exposed above 85 dBA over an
8 hr. TWA. Regardless of who performs the
monitoring, affected workers are allowed to
observe the monitoring, if interested.
b. Additional monitoring will be performed
whenever there is a change in production
processes, layout, or equipment which may
significantly increase employees’ exposure to noise.
c. A sound level meter will be used to identify noisy
areas in the facility. To determine worker TWA
exposures, however, an audiodosimeter will be
used. The results of that monitoring will
determine who is included in the Hearing
Conservation Program, what the attenuation
5 factor of their hearing protectors must be, and
whether the facility must investigate engineering
controls.
d. The sampling strategy must consider worker
mobility, noise variations over time, and office
personnel who enter the production areas
routinely.
e. The calibration of all noise monitoring
instruments (sound level meters, audiodosimeters,
etc.) should be verified for accuracy immediately
before and after all readings.
f. The facility will inform each worker who, as a
result of the monitoring, is believed to be exposed
at or above 85 dBA over an 8 hr. TWA.
g. As mentioned previously, if employees work
longer than eight hours (i.e., overtime,
compressed work week, etc.), then the permissible
exposure limit and the action level are lowered
hours (e.g., 10 hr. = PEL 88.39 and AL 83.39, 12
hr. = PEL 87.08 and AL 82.08). The facility
should refer to Table 5-1 below to estimate the
permissible exposure limits to noise under such
circumstances.
h. In no event is a worker ever allowed to be exposed
to a noise level equal to or greater than 115 dBA.
Table 5-1: Permissible Exposure Limits
Figure 5-1: Permissible Noise Exposure

5–10 ESH Handbook
5. Provision of Hearing Protection
a. The facility will provide hearing protectors for all
workers exposed above the action level and require
hearing protection use by all workers exposed
above the permissible limit (see Chapter 7, Section
7).
b. The facility will provide a variety of hearing-
protection devices so that workers may select those
that are most comfortable and easy to use.
However, employees must not use protective
devices that do not afford sufficient attenuation
(see Chapter 7, Section 7).
6. Audiometric Testing
5 a. Because hearing loss is permanent, it is critical to
detect it as soon as possible so corrective action
can prevent further damage. To identify hearing
loss in its early stages, the facility should require
all workers who are exposed above the action level
(85 dBA over 8 hr. TWA) to participate in
audiometric testing. This test will be available at
no cost to workers.
b. The baseline audiometric exam must be given to
workers as close as practicable to the time of hire,
and in no event more than six months later. All
workers will be given audiometric exams
according to a regular annual schedule.
c. For the test to be valid, it is important that
workers avoid noise for at least 14 hours prior to
the exam. Where that is not practicable, workers
will be given redundant hearing protectors (i.e.,
plugs and muffs) to minimize the likelihood of a
temporary hearing loss confounding the
audiogram.
d. The facility will arrange for each worker’s annual
audiogram to be compared to the corresponding
baseline audiogram. In this manner, hearing loss
can be detected before it becomes severe.
e. As mentioned previously, a loss of hearing of 25
dBA at certain frequencies (2000, 3000, and 4000
Hz) is termed a “standard threshold shift” (STS).
If an STS is identified, the facility will notify the
affected employee, in writing, within 21 days and
may require that the worker be retested within 30
days (from the date the medical professional
evaluated the audiogram) to verify the accuracy of
the test.
f. All workers who experience a persistent STS will
be referred to a specialist to determine the cause of 5
the hearing loss. If occupational exposure is
identified as a contributing factor to the hearing
loss, then the facility will evaluate the effectiveness
of the current hearing protectors, and retrain the
affected employee in the proper fit and use of the
protectors. The facility will ask the examiner to
determine if the most recent audiogram results
should be used as a baseline for future hearing
tests.
g. If the STS is not persistent, then the facility will
inform the affected employee of this fact.
h. The facility must verify that any potential provider
of audiometric testing follows all applicable
standards.
7. Hearing Protector Effectiveness
a. Two factors determine whether a hearing-
protection device protects an individual’s hearing:
1) The device is appropriate for the level of
exposure.
5–12 ESH Handbook
2) The device is used properly.
b. The facility will only provide hearing-protection
devices which have a Noise Reduction Rating
(NRR) readily available. This NRR will be used to
estimate the effectiveness of the device.
c. Maximum Noise Levels. The maximum amount
of noise a person can be exposed to safely is
measured by the duration of the exposure and the
intensity of the noise. The Permissible Noise
Exposure graph (Figure 5-1, page 5-9) shows
permissible exposures (dBA) to continuous noise
(workers should never to exposed to continuous
noise at levels greater than 115 dBA).
5 d. The adequacy of hearing protection should be

determined using the formula:
e. Typically, figure a 50% safety factor in calculating

the field attentuation of hearing protection
because many workers do not wear the protection
properly:
f. When choosing hearing protection for workers,

keep the above evaluation in mind and remember
that hearing protection must be fitted and worn
properly and conscientiously to be of value.
g. For workers exposed above the PEL (Permissible
Exposure Limit), hearing protection must
attenuate noise to below 90 dBA. If an STS
(Standard Threshold Shift) has been experienced,
attenuation provided must be below 87 dBA.
Double protection should be considered for any
jobs where attenuation is not below 90 dBA,
especially if audiograms indicate a hearing loss.
Double protection offers an additional 5 decibel
attenuation. As an example, if a worker uses plugs
with an NRR of 29 and a muff with an NRR of
23, calculate using the highest NRR and applying
the 50% factor, then add 5 dB for the protector
with the lower NRR:
h. Because the effectiveness of the hearing-protection

device is a function of the noise exposure level, it
will be re-evaluated whenever the noise level 5
increases substantially (i.e., increases 3 dBA or
more).
8. Training
a. The facility will conduct training at orientation,
annually, and whenever the facility has reason to
believe there have been deviations from the
procedure.
b. This general training will cover at least the
following subjects:
1) This program and its requirements.
2) The effects of noise on hearing.
3) The purpose of hearing protectors.
4) The benefits and limitations of various models
of hearing protectors.
5) How to select, fit, use, and care for hearing
protectors.
6) The purpose of audiometric testing.
5–14 ESH Handbook
c. All training should be documented.
9. Record Keeping
a. If audiometric testing reveals a loss of hearing of
25 dBA or greater by comparing the baseline
audiogram with the most recent test, the case will
be listed on the ESH log of occupational injuries
and illnesses as an “illness.” Notice that this
threshold differs from the criterion for a standard
threshold shift.
b. Cases of hearing loss need to be recorded only
once for every time an additional 25 dBA loss is
confirmed. That is, if a worker suffers a 25 dBA
loss one year, then another loss the next year
5 which is less than 25 dBA, the case needs to be
recorded only in the first year. However, if at a
later time, another 25 dBA loss is detected, a
second entry should be made on the log.
c. All audiometric tests for all workers will be
maintained by the facility for at least the duration
of the worker’s employment plus 30 years.
d. All noise exposure measurements (i.e., sound-level
surveys, audiodosimetry, etc.) will be retained for
at least 30 years from the date they were
conducted.
10. Program Availability
This hearing conservation program and its training
materials are available to the following parties:
a. Employees of the facility.
b. Contract employees on facility property and their
employees.
D. Ergonomics
1. Definition
Ergonomics is an applied science that concentrates on
the human factors involved in the design of a process
or product.
a. The goal of ergonomics is to:
1) Reduce occupational injury and illness.
2) Improve productivity and work quality.
3) Reduce absenteeism.
b. The objective of ergonomics is to design work
tasks so they are within limitations. 5
3. Back Injury—Low Back Pain
a. Most back injuries occur because the worker:
1) Uses his or her back muscles for something the
muscles cannot tolerate.
2) Is not flexible enough to meet the required
range of motion.
3) Had to compensate for a large mid-section.
4) Experiences inflammation caused by excessive
use of the back muscles.
b. To avoid back injury the employee should focus
on:
1) Exercises to strengthen the muscles of the back.
2) Obtaining training on lifting techniques and
proper use of back muscles.
3) Using stretching exercises for the upper legs
and lower back prior to beginning work.
5–16 ESH Handbook
4) Maintaining appropriate body weight.
5) Using back resting techniques and endurance
training.
4. Lifting Procedures
a. Planning
1) Plan the lift and identify the path to be taken
to be sure it is clear of obstructions.
2) Examine the object for sharp corners, slippery
spots, or other potential hazards.
3) Employees are not to lift an object they are not
sure is within their physical ability. When
unsure, use a lifting device (cart, hand truck,
5 etc.) or get help.
4) If possible, do not set an item on the ground if
it must be picked up again.
5) Avoid unnecessary bending or reaching. Do
not reach over or around items blocking the
object to be lifted.
b. Lifting
1) Lift comfortably. Always
use a material handling
device whenever necessary.
2) Stand close to the load
with your feet spread
apart about shoulder
width, with one foot
slightly in front of the
other for balance.
3) Squat down bending at
the knees (not your
waist). Tuck your chin
while keeping your back
as vertical as possible.
4) Place the lead hand (the
hand on the side of the
lead foot) to the front of
the item. Placing the
trailing hand to the rear,
tilt the item forward and
slide the trailing hand
underneath.
5) Get a firm grasp of the object
before beginning the lift.
6) Keep the load to the front,
and bring it close to the 5
body’s center of gravity (near
the waist).
7) Begin slowly lifting with your
legs by straightening them.
Never twist your body during
this step—pivot with your
feet.
8) Once the lift is complete,
keep the object as close to the
body as possible. As the load’s
center of gravity moves away
from the body, there is
dramatic increase in stress to
the lumbar region of the back.
9) Be sure the view is not
blocked by the item, then
carry the load to the desired
location carefully.
10) When placing an item on a desk top, counter,
or shelf, place the lead or forward edge (the
5–18 ESH Handbook
edge away from the body) on the surface and
push the item into position. Be sure there is
room for the item, with nothing to interfere
with its placement.
11) When placing an item on the ground, bend at
the knees. Place the forward edge down first.
Slide both hands to the rear and clear of the
bottom, then set the rear end down.
c. Team lifting
1) When team lifting, establish a leader and
follow his or her instructions and signals.
2) Make sure everyone understands the plan
(where and how the object will be moved) and
5 any signals to be used. Be sure all persons lift,
lower, and carry the item at the same time.
3) Lower the object slowly. Place one end down
first, then the other. Be sure all hands are out
from underneath the item.
4) Back belts, if worn, are to be loosened when
not engaged in lifting.
5. Computer Workstations
a. Repetitive movements, such as keyboarding and
using a mouse, combined with restrictive posture,
can cause injuries commonly known as repetitive
stress injuries.
b. To help prevent repetitive stress injuries, clear
enough room to work efficiently and place
materials or supplies where they don’t interfere
with your movements. Be sure to arrange your
work area so that you can face the display and
keyboard directly, without having to twist your
body. (See VDT Selection and Set-up Checklist
on pages 5-21 and 5-22.)
c. If overhead lighting is uneven or insufficient, use
task lighting to shed light on hard copy or high-
use areas of your desk to minimize eyestrain.
d. If you use the telephone often, don’t cradle it
between your neck and shoulder. See if a headset
can be adapted to your phone, or try a receiver
shoulder rest.
e. Making the right ergonomic adjustments to your
chair, keyboard, and display are important too. If
you find it uncomfortable or painful in any way,
alter your position slightly.
f. Breaks and Stretches
1) Remember to get up and move around
periodically. If you type continuously, a good 5
rule of thumb is to do other tasks for 10
minutes every 2 hours.
2) The following exercises can help you release
muscle tension and reduce the risk of aches and
pains. Do stretches gently. Don’t do any stretch
that causes pain. Hold each stretch 15 to 20
seconds.
a) Shoulder rolls—Gently roll shoulder
forward, up and drop back. Do slowly and
rhythmically 5 to 10 times.
b) Finger Stretch—Gently open and close
hand, stretching fingers while hand is in the
open position.
c) Trap Stretch—Sit on hands to help stabilize.
Tip head down as if looking in your shirt
pocket. Hold.
d) Pyramid Stretch—Start with hands in
pyramid position. Keeping shoulders
relaxed, raise palms together overhead.
5–20 ESH Handbook
Slowly bring arms down, staying together,
until you feel a good stretch on the under-
side of your forearms.
e) Side Bending—Lower ear toward shoulder.
Repeat other side.
f ) Shoulder Blade Pinch—Rotate arms to
back, pinching shoulder blades together.
Palms will naturally rotate back—let them.
g) Hug Stretch—Grasp arm at elbow. Pull arm
forward and across body as if you are
hugging somebody.
h) Chin Tuck—Keeping head level, slide chin
back making a double chin. Hold 2 seconds
5 and release.
i) Hand Stretch—Make gentle fist. Open
hand at first joint keeping fingers bent.
Open hand, straightening fingers all the
way.
5
5–22 ESH Handbook
5
E. Non-Ionizing Radiation (Ultraviolet (UV) and

Radio Frequency (RF) Radiation)
1. UV Radiation
a. UV has the highest photon energy range.
Penetration is limited—target organs are the skin
and cornea. UVA or Near UV are those UV
frequencies “near” the visible frequencies and may
also effect the lens. UVB or Actinic UV, the mid-
frequencies, are the most damaging. UVC, or “Far
UV,” or “Vacuum UV” (i.e., UV wavelengths <
200 nm, which are “far” from the visible
wavelengths), have photon energies in excess of 12
eV, but are quickly absorbed in air. (See Figure 5-2
below.)
5
b. Protective measures (e.g., welding goggles) are
needed. The ACGIH/TLV curve is most stringent
at 270 nm, and limits near UV to 1 mW/cm2;
based on protection against sunburn (erythema),
actinic skin, and conjunctivitis and photokeratitis
(welder’s flash). Also, concern for skin cancer;
most cases caused by sun. UV also causes
increased skin pigmentation (tanning). Intense
acute exposures, and possibly less intense
cumulative exposures can cause cataracts.
c. UV is more hazardous because the symptoms are
delayed (no immediate sensation of being over
exposed). Effects are exaggerated for skin, which
has been photosensitized by agent such as coal tar
Figure 5-2: Electromagnetic Spectrum

5–24 ESH Handbook
products, by photoallergens, or by certain diseases
(e.g., erythropoietic porphyria).
d. Common UV sources are the sun, mercury vapor
and quartz lamps (black lights), welding arcs, and
UV lasers.
e. Measurement. Radiometer or light meter (photo-
cell with a sensitive volt meter) with UV filters to
select desired wavelengths provide irradiance
readings in mW/cm2.
f. UV Safety Precautions
1) Identify all UV light sources at the facility.
These may include lights used in mercury-
vapor lamps, etc.
5
2) Ensure that all UV lights are fully covered or
enclosed.
3) Have warning signs posted in UV hazard areas.
4) Turn off UV lights whenever workers remove
PPE or during maintenance activities.
5) Ensure workers are protected (i.e., eyes, skin)
from indirect stray UV light. Equipment seals
should be intact.
6) Ensure glasses and/or goggles are specifically
designed to protect workers from UV light.
7) Ensure UV lamps are approved for the purpose
and manufacturer’s guidelines are being
followed.
2. RF Radiation (Heat Sealers)
a. Radio Frequency (RF) radiation sealers generate,
by means of electronic circuitry, oscillating fields
of electric and magnetic energy. RF sealers
generally operate within the band of frequencies
from 10–70 MHz (a megahertz is one million
cycles per second), although most of the sealers
operate at normal frequencies from 10–40 MHz.
A few used for plastics operate at frequencies as
high as 300–400 MHz. RF electromagnetic
energy emitted from an RF sealer is considered
non-ionizing radiation by virtue of its frequency
and energy. (See Figure 5-3 below.)
b. Control of the emission of RF energy from RF
sealers should rely on the application of properly
designed and installed shielding material. The
shielding should be placed on or around the
equipment so as to minimize exposure due to
emissions of stray RF energy. All shielding should
be properly grounded. Shielding conductors 5
Figure 5-3: RF Heat Sealer
5–26 ESH Handbook
should be used for conveying RF current, and
path impedence should be minimized by using
good conductor materials.
c. To minimize the risk of adverse health effects,
radiofrequency (RF) fields as well as induced and
contact currents must be in compliance with
applicable guidelines (e.g., CNIRP, ANSI,
ACGIH). Reduction in RF exposures can be
accomplished through the implementation of
appropriate administrative, work practice and
engineering controls. The following outlines the
principal elements of an RF Protection Program
and examples of the RF measurements necessary
to implement the program elements.
5 1) Element 1. Utilization of RF source equipment
which meets applicable RF and other safety
standards when new and during the time of
use, including after any modifications.
a) Manufacturers of RF source equipment are
responsible for making equipment that
complies with applicable standards, and for
providing information on the hazards of
operating and servicing equipment. The
information must be sufficient to alert the
end user of potential hazards and necessary
controls applicable to using the equipment.
Manufacturers are therefore required to
make detailed RF emission measurements of
their products. Appropriate RF survey
results should be provided to the end user
for comparison purposes.
b) The users should conduct RF “screening”
measurements of equipment emissions after
installation, major maintenance, and any
modifications that could affect RF emis-
sions. Significant deviations from previous
measurements should be resolved.
2) Element 2. RF hazard identification and
periodic surveillance by a competent person
who can effectively assess RF exposures.
a) Screening measurements are normally
sufficient to identify potentially hazardous
RF areas that will require some control
strategy, such as to determine where a fence
should be located. More complex measure-
ments are necessary if the employer intends
to allow exposures to employees approach-
ing RF standards. For example, detailed
measurements are necessary if whole-body
and/or time-weighted averaging of expo- 5
sures are necessary to bring exposures into
compliance.
b) RF fields can induce currents in nearby
conducting objects, such as a metal barrier
or fence used to restrict access to RF hazard
areas. These must be evaluated to ensure
they do not constitute RF shock.
3) Element 3. Identification and control of RF
hazard areas.
a) Controlling exposure time and the distance
between the RF source and the operator are
important in maintaining workers' expo-
sures below recommended levels. When
necessary due to excessive leakage, “RF
hazard areas” must be identified to alert
workers of areas that are not to be occupied
during RF application. The location of the
hazard areas must be based on exposure
measurements made during maximum field
generation and duty factor (i.e., ratio of RF
5–28 ESH Handbook
“on” time during any 6-minute period,
assuming intermittent exposure).
b) Access to RF hazard areas should be
controlled with standard Lockout/ Tagout
procedures (see Chapter 8, Section B) to
ensure workers are not occupying these
areas during the application of RF energy.
c) The RF hazard areas must be clearly marked
with appropriate signs, barricades, floor
markings, etc., such that any worker who
has access to the facility will be alerted not
to occupy the hazardous locations. Signs
must be of standard design and shape (ref.
ANSI C95.1), and of sufficient size to be
5 recognizable and readable from a safe
distance.
d) Screening measurements can be used to
determine where to locate signs to alert
workers approaching an RF hazard area,
including the appropriate warning message
on the sign (e.g., Notice, Caution, Danger).
e) Compliance with the evacuation of hazard
areas prior to RF application must be
strictly enforced. For example, workers may
be reluctant to follow a procedure which
requires an RF sealer operator to first load
the sealer, step back 6.5 yards (2 meters) to
get outside the RF hazard area prior to
activating the RF energy, and then walk
back to unload the sealer.
4) Element 4. Implementation of controls to
reduce RF exposures to levels in compliance
with applicable guidelines (e.g., ANSI,
ICNIRP), including the establishment of safe
work practice procedures.
a) Reliance on averaging is normally not
recommended when establishing basic
control strategies because it obligates the
facility to conduct “measurement” of
employee activity to ensure the averaging is
applicable, such as timing an employee's
access inside an area which cannot be
occupied for 6 minutes without exceeding
Figure 5-4: Radio-Frequency Radiation Hazard

Warning Symbol
5
5–30 ESH Handbook
the allowable time-weighted exposure.
Where possible, controls should be estab-
lished under the assumption that standards
are not time-weighted, i.e., assume the
standards are ceiling limits which are not to
be exceeded.
b) Measurements are necessary during the
development of work practices to ensure the
practices are effective in preventing excessive
exposures. Detailed measurements are
required if exposures are approaching
guideline limits as discussed above.
c) Appropriate work practices must be
followed during the repair and maintenance
5 of RF equipment. Occasionally, cabinet
panels must be removed by service person-
nel to allow access for maintenance. Failure
to replace a panel properly may result in
excessive RF leakage. RF screening measure-
ments can be used to determine which
panels can be removed during operation
(assuming other hazards, such as electrical
shock, are controlled), and to ensure the
shielding is reinstalled properly.
d) Detailed measurements must be made by
the manufacturers of RF personal protective
equipment (PPE) to show its effectiveness
and limitations. Limited measurements are
necessary by the user to ensure the PPE is
applicable and effective for the specific
worksite conditions.
5) Element 5. RF safety and health training to
ensure that all workers understand the RF
hazards to which they may be exposed the
means by which the hazards are controlled.
a) Measurement of worker exposures is
necessary so that this information can be
provided as part of employee hazard
training.
b) The scope of training, including reviews of
potential biological effects, will be depen-
dent on measure exposure levels.
6) Element 6. Worker involvement in the
structure and operation of the program and in
decisions that affect their safety and health, to
make full use of their insight and to encourage
their understanding and commitment to the
safe work practices established.
RF screening measurements should be made in 5
the presence of workers to facilitate under-
standing and confidence in the program.
7) Element 7. Implementation of an appropriate
medical surveillance program.
a) RF measurements are necessary to deter-
mine the need and scope of medical
surveillance. For example, medical surveil-
lance may consist of reporting the occur-
rence of RF burns or the sensation of non-
routine heating as a means of identifying
potential problem areas.
b) A medical exam may be appropriate for
“accidental” exposures defined as an
exposure above some measured trigger level.
8) Element 8. Periodic (e.g., annual) reviews of
the effectiveness of the program so that
deficiencies can be identified and resolved.
Periodic RF screening measurements are
necessary to ensure conditions have not
5–32 ESH Handbook
changed and that the RF Protection Program
continues to be effective in preventing excessive
RF exposures.
9) Element 9. Assignment of responsibilities,
including the necessary authority and resources
to implement and enforce all aspects of the RF
Protection Program.
a) Although this element does not directly
require RF measurements, it is included for
completeness of the list of RF Program
elements.
b) Without the commitment to the Program,
as demonstrated by the assignment of
5 necessary responsibility, authority and
resources, the previous elements will not be
effective.
d. As described above, a variety of RF measurements
are necessary for an effective RF Protection
Program. Usually RF screening measurements are
adequate unless control strategies allow exposures
approaching RF limits. Detailed RF
measurements are required of manufacturers of
RF products to document their effectiveness and
limitations. The effectiveness of the RF Protection
Program depends primarily on a facility’s
understanding and commitment to the listed
program elements, rather than on sophisticated
RF survey equipment or measurement procedures.
F. Bloodborne Pathogens
1. “Universal precautions,” as defined by the U.S.
Centers for Disease Control, are a set of precautions
designed to prevent transmission of human
immunodeficiency virus (HIV), hepatitis B virus
(HBV), and other bloodborne pathogens when
providing first aid or health care. Under universal
precautions, blood and certain body fluids of all
persons are considered potentially infectious for HIV,
HBV and other bloodborne pathogens.
2. Each contractor/employer having employees who may
have skin, eye, mucous membrane, or parenteral
contact with blood or other potentially infectious
materials as a result of performing their professional
duties must establish a written exposure control plan
designed to eliminate or minimize exposure.
3. Methods of Compliance
a. Universal precautions must be observed to prevent
contact with blood or other potentially infectious 5
materials. All body fluids must be considered
potentially infectious.
b. Engineering and work practice controls.
c. Personal Protective Equipment (PPE).
4. Housekeeping
a. Contractors/employers must ensure that the
worksite is maintained in a clean and sanitary
condition. The contractor/employer must
determine and implement an appropriate written
schedule for cleaning and method of
decontamination based upon the location within
the facility, type of surface to be cleaned, type of
soil present, and tasks or procedures being
performed in the area.
b. All equipment, environmental and working
surfaces must be cleaned and decontaminated
after contact with blood or other potentially
infectious materials.
5–34 ESH Handbook
5. Persons trained in first aid/CPR must also be trained
in avoiding exposure to bloodborne pathogens. Use
universal precautions when there is a possibility of
being exposed to other people’s body fluids.
6. First aid kits/body fluid barrier packs must be
available for those providing first aid. These packs
include, but are not limited to, CPR mouth barriers,
disposable latex gloves, and eye protection.
7. Contractor/employer must
provide proper means of disposal
for materials that are considered
regulated medical wastes
(biohazards). Bags or containers
marked with the biohazard
5 symbol must be handled by
designated employees only.
8. Sharps Disposal Containers
a. Use the criteria below for
evaluating the
performance of
containers for disposing
of sharp objects (i.e.,
sewing needles, razor
blades):
1) Functionality—Containers should remain
functional during their entire usage (i.e., they
should be durable, closable, leak resistant on
their sides and bottom, and puncture resistant
until final disposal).
2) Accessibility—Containers should be accessible
to workers who use, maintain, or dispose of
sharp devices. They should be conveniently
located and portable within the workplace, if
necessary.
3) Visibility—The following should be plainly
visible to the workers who use the containers:
the container, the degree to which it is full, the
proper warning labels, and the color coding of
the container.
b. Disposal of non-contaminated sewing needles, as
an accepted practice in the United States, is to
close the lid of the sharps container, wrap it in
duct tape, and throw it into the trash.
c. Syringes/hypodermic or other contaminated
needles should be disposed of in the same type of
container, but the method of disposal is different.
A biowaste vendor may be used or, in some cases,
hospitals accept needles and incinerate them
onsite. Contact your local waste hauler for more 5
details.
G. Asbestos
Each facility should identify and manage asbestos
materials in place. The facility should control the release
of hazardous asbestos fibers through education, training,
and communication to all personnel. The removal of
asbestos containing material (ACM) should be done
whenever feasible.
1. Definitions: The following definitions will be used
throughout this section:
a. Asbestos Containing Material (ACM): Any
material containing more than 1% asbestos.
b. Friable Asbestos Material: Any material
containing more than 1% asbestos by weight that
hand pressure can crumble, pulverize, or reduce to
powder when dry.
c. Presumed Asbestos Containing Material
(PACM): Thermal system insulation and surfacing
5–36 ESH Handbook
material found in buildings constructed no later
than 1980.
2. Information and Training
An awareness training course should be required for
all facility employees and/or contractor supervisors
who perform work within or adjacent to facilities
where ACM/PACM are present. The contractor’s/
employer’s supervisor is responsible for passing the
information on to his/her employees. The training
will include the following:
a. The health affects of asbestos.
b. Locations, signs of damage and deterioration of
ACM/PACM.
5
c. Proper response to fiber release episodes.
Figure 5-5: Exposed Asbestos Pipe Wrap

d. Housekeeping requirements.
3. Hazards Communication
The facility should communicate the hazards of
asbestos to personnel who work in or adjacent to areas
containing asbestos:
a. Identify the presence of ACM/PACM at the
worksite.
b. Notification should be in writing and personal
communication, between facility employees/
contractors concerning the presence of PACM and
ACM.
c. All friable asbestos materials should be labeled.
d. Any ACM/PACM that is disturbed should be 5
reported immediately to the supervisor.
Figure 5-6: Asbestos Warning Sign

5–38 ESH Handbook
4. Removal of Asbestos
There are two scenarios for the removal of ACM/
PACM:
a. Planned removal—This ACM/PACM removal is
required because of facility maintenance in the
area or new construction requiring the removal of
the material. The project engineer in charge of the
asbestos removal contractor/employer must be
contacted and the material must be moved.
b. Minor emergency clean-up/removal—This ACM/
PACM is removed because a small amount of
material has come loose or needs to be moved for
immediate work.
5 1) If the minor emergency occurs during normal
working hours, contact the engineer in charge
of the asbestos removal contractor/employer.
2) If the minor emergency occurs after normal
working hours, the facility supervisor should be
contacted immediately. The facility supervisor
will barricade the area to restrict access. The
facility supervisor/foreman will contact the
maintenance personnel on call, and the facility
engineer in charge of the ACM/PACM
removal contractor/employer. The ACM/
PACM removal contractor/employer will
remove the ACM/PACM.
5. Disposal
All ACM/PACM must be disposed of in an approved
landfill.
6. Recordkeeping
a. The information kept in the asbestos files is as
follows:
1) Asbestos abatement supervisor’s log sheet.
2) Verbal notification memo.
3) Government required reports.
4) Bulks sample reports.
5) Monthly contractor/employer reports on
asbestos abatements performed.
6) Contractor/employer location monitoring
results and list of personnel in area.
7) Tracking documents (for hauling ACMs to a
landfill).
b. These documents must be kept by the facility
engineer in the engineering files until completion 5
of the project.
H. Occupational Exposure Limits

1. Requirements: Exposure Limits
a. Contractors/employers must abide by the more
restrictive of the country legal requirements, the
American Conference of Governmental Industrial
Hygienists (ACGIH) Threshold Limit Values
(TLVs), or US Occupational Safety and Health
Administration (OSHA) Permissible Exposure
Limits (PEL).
b. The occupational exposure limits, listed in Table
5-2 next page, are defined as guidelines for best
management practices. These limits represent
conditions to which employees can be exposed to
on a regular basis without adverse health effects.
c. Occupational exposure limits are the maximum
average air concentration that most employees can
be exposed to for an 8-hour work day, 40-hour
5–40 ESH Handbook
work week for a working lifetime (40 years)
without experiencing significant adverse health
effects. A very small percentage of individuals
experience some discomfort or adverse health
effects at or below the exposure limit because of
wide variation in individual sensitivities or pre-
existing conditions. When employees work a shift
longer than 8 hours per day, the exposure limit
Table 5-2: Occupational Exposure Limits
5
must be adjusted (lowered) to prevent the
employee from overexposure.
d. Occupational Exposure Limits for hazardous air
contaminants must be listed on the material safety
data sheets (MSDS) for each product in use.
e. In the absence of either quantitative legal or Nike
requirements, quantitative guidelines will be set by
Nike CRC, giving consideration to consensus
guidelines and other relevant information.
f. Exposure limits will be periodically evaluated. See
the Indoor Air Quality Management Plan below
for more information regarding when, where, and
how to sample.
2. Indoor Air Quality Management Plan 5
a. Contractors must develop and implement a
written Indoor Air Quality Management Plan.
This plan must include the following elements:
1) A description of the plan and a functional
overview of the day-to-day operation. This
section must contain a detailed description of
the site, the location of buildings and what
structures and organizations are covered by the
plan.
2) A communications strategy that describes how
the various departments within the factory will
communicate, and the roles and responsibilities
of each group.
3) A methodology for responding to factory/
building air quality complaints.
4) A building-by-building specific plan to manage
air quality. Each building plan will contain the
following components:
5–42 ESH Handbook
a) A general description of the building and its
function, including work activity, number
of occupants, hours of operation, weekend
use, tenant requirements, and known air
contaminants released into the work
environment.
b) A single line schematic or as-built construc-
tion (blueprints) documents, which locate
major building systems equipment and the
areas they serve.
c) A written plan for maintenance of building
systems that is preventive in scope and is
based on the equipment manufacturers’
recommendations. It will describe the
5 equipment to be maintained, who will
maintain it and the schedule for mainte-
nance.
d) Methodology for the use of site-specific,
area or spot air purification technology to
manage air quality for sensitive individuals
or problematic areas.
5) A building-specific baseline testing and
evaluation plan. The evaluation plan or
assessment must include:
a) Identification of potentially hazardous
materials encountered or in use.
b) Establishment of how the substance could
enter the body (i.e., inhalation, ingestion,
etc.).
c) Identification of the potential health effects.
d) Examination of the work environment:
• Review of available process flow charts.
• Controls in place (ventilation, enclosures,
personal protective equipment).
• Observations and odors.
• Assessment of worker complaints and
clinic admissions data.
• Past air sampling results.
e) Identification of workers exposed and the
degree of exposure.
6) Based upon the results of the evaluation/
assessment survey, air quality monitoring
should be conducted to determine the level of
exposure and potential health risk to employ-
ees. 5
7) Contractors must train employees on the
following:
a) Familiarize employees with the plan and the
operational components therein.
b) Notify employees of the potential airborne
hazards and their sources in their workplace
(see Chemical Hazard Communication
CLS).
c) The nature and extent of risks to health
(both acute and chronic).
d) Reasons for the control measures and their
proper use.
e) The correct use, maintenance and limita-
tions of safety equipment and facilities.
f ) The need for personal air sampling,
biological monitoring and medical surveil-
lance.
5–44 ESH Handbook
g) The importance of good housekeeping and
personal hygiene.
h) The results of monitoring.
i) Procedures for employee concerns and
complaints.
j) Procedures for emergency releases of toxic
chemicals.
8) Recordkeeping
a) Contractors must keep a suitable record of
any monitoring carried out for the purpose
of this standard.
b) Employee exposure records will be kept
5 until the employee leaves the job and for 30
years thereafter.
c) Area monitoring records must be kept for at
least 5 years.
6. Emergency Preparedness
& Response
A. Emergency Action
Contractors/employers must establish an action plan
and procedures for the orderly and coordinated
evacuation of, or sheltering within, all factory buildings
in the response to all emergencies (i.e., fire, tornado,
typhoon, tsunami, bomb threat, flood, earthquake,
hurricane, gas leaks, power outages, water failures).
1. Contractors/employers must develop and implement a
written emergency action plan, to include:
a. Emergency escape procedures.
b. Emergency escape route assignments.
c. Procedures to be followed by employees who
remain to operate critical plant operations before 6
they evacuate.
d. Procedures to account for all employees after
emergency evacuation has been completed.
e. Rescue and medical duties for those employees
who are to perform them.
f. The preferred means of reporting fires and other
emergencies.
g. Names or regular job titles of persons or
departments who can be contacted for further
information or explanation of duties under the
plan.
2. The contractor/employer must establish an employee
alarm system, to include:
a. The employee alarm system must provide warning
for necessary emergency action as called for in the
6–2 ESH Handbook
emergency action plan, or for reaction time for
safe escape of employees from the workplace or
the immediate work area, or both.
b. The employee alarm must be capable of being
perceived above ambient noise or light levels by all
employees in the affected portions of the
workplace. Tactile devices may be used to alert
those employees who would not otherwise be able
to recognize the audibile or visual alarm.
c. The employee alarm must be distinctive and
recognizable as a signal to evacuate the work area
or to perform actions designated under the
emergency action plan.
d. The employer must explain to each employee the
preferred means of reporting emergencies, such as
manual pull box alarms, public address systems,
radio or telephones.
6
e. The contractor/employer must post emergency
telephone numbers near telephones, employee
notice boards, and other conspicuous locations
when telephones serve as a means of reporting
emergencies. Where a communication system also
serves as the employee alarm system, all
emergency messages must have priority over all
non-emergency messages.
f. The contractor/employer shall establish
procedures for sounding emergency alarms in the
workplace.
g. Maintenance and testing
1) The contractor/employer must ensure that all
employee alarm systems are maintained in
operating condition except when undergoing
repairs or maintenance.
Emergency Preparedness and Response 6–3
2) The contractor/employer must ensure that a
test of the reliability and adequacy of non-
supervised employee alarm systems is made
every 2 months. A different actuation device
must be used in each test of a multi-actuation
device system so that no individual device is
used for two consecutive tests.
3) The contractor/employer must maintain or
replace power supplies as often as is necessary
to assure a fully operational condition. Back-up
means of alarm, such as employee runners or
telephones, shall be provided when systems are
out of service.
4) The contractor/employer must ensure that the
servicing, maintenance and testing of employee
alarms are done by persons trained in the
designed operation and functions necessary for
reliable and safe operation of the system. 6
h. Manual operation
1) The contractor/employer must ensure that
manually operated actuation devices for use in
conjunction with employee alarms are unob-
structed, conspicuous, and readily accessible.
3. If the employee alarm system is used for alerting fire
brigade members, or for other purposes, a distinctive
signal for each purpose must be used.
4. The contractor/employer must establish in the
emergency action plan the types of evacuation to be
used in emergency circumstances (i.e., fire, explosion,
and major hazardous material incident, bomb threats,
etc.). A take-shelter procedure is required for severe
weather.
6–4 ESH Handbook
5. Training
a. Before implementing the emergency action plan,
the contractor/employer must designate and train
a sufficient number of persons to assist in the safe
and orderly emergency evacuation of employees.
b. The contractor/employer must review the plan
with each employee covered by the plan at the
following times:
1) Initially when the plan is developed.
2) Whenever the employee’s responsibilities or
designated actions under the plan change.
3) Whenever the plan is changed.
c. The contractor/employer must review with each
employee upon initial assignment those parts of
the plan which the employee must know to
6 protect the employee in the event of an
emergency.
d. The written plan must be kept at the workplace
and made available for employee review.
B. Fire Protection
1. Fire Protection Plan
Should include the following:
a. A list of the major workplace fire hazards and their
proper handling and storage procedures.
b. A list of potential ignition sources (such as
welding, smoking and others) and their control
procedures.
c. The type of fire protection equipment or systems
which can control a fire involving the potential
ignition sources.
d. Names or regular job titles of those personnel
responsible for maintenance of equipment and
systems installed to prevent or control ignitions or
fires.
e. Names or regular job titles of those personnel
responsible for control of fuel source hazards.
f. Procedures to control accumulations of flammable
and combustible waste materials and residues so
that they do not contribute to a fire emergency.
g. Training requirements
1) Communication to employees of the fire
hazards of the materials and processes to which
they are exposed.
2) Review with each employee upon initial
assignment those parts of the fire prevention
plan which the employee must know to protect
the employee in the event of an emergency. 6
The written plan must be kept in the work-
place and made available for employee review.
h. Maintenance requirements
Regularly and properly maintain, according to
established procedures, equipment and systems
installed on heat-producing equipment to prevent
accidental ignition of combustible materials.
i. General requirements
1) Contractors/employers must become familiar
with the emergency response and evacuation
plan.
2) Store materials to allow adequate access
throughout the area and minimize the spread
of fire.
6–6 ESH Handbook
3) Do not store anything within 18 inches (46
centimeters) of ceiling fire sprinkler heads.
4) Collect and dispose of waste or scrap regularly
to prevent their accumulation. Follow proper
housekeeping procedures at all times.
5) Tobacco smoking rules are to be established
and followed.
6) Storage and use of flammable materials:
a) You must use approved (for example, UL)
safety containers to transport gasoline or
other flammable material. Such materials
shall not be stored in vehicle passenger
compartments or automobile trunks. Only
in an emergency may such materials be
transported in automobile trunks. (See
Figure 6-1 below.)
6 b) Store flammable and combustible liquids
only in designated cabinets and areas.
c) Flammable liquids (for example, gasoline)
shall not be used as cleaning agents.
Figure 6-1: Approved Safety Containers

2. Fire Protection Measures
a. A smoke detector’s battery shall not be removed
unless it is replaced immediately with a fresh/
charged one.
b. Fire doors
1) Each factory building must have at least two
means of escape remote from each other.
2) Must not be left open unless equipped with
self-closing mechanisms.
3) Must not be locked or chained closed.
4) Must be kept free of obstructions that would
prevent the door from closing.
5) Exit routes from buildings must be clear and
free of obstructions and properly marked with
signs designating exits from the building.
6
c. Fire alarm system(s) shall be periodically tested (at
least monthly).
3. Fire Brigades
The following requirements apply if the contractor/
employer has established a fire brigade:
a. Contractors/employers must prepare and maintain
a statement or written policy which establishes:
1) The existence of a fire brigade.
2) The basic organizational structure.
3) The type, amount, and frequency of training to
be provided to fire brigade members.
4) The expected number of members in the fire
brigade.
5) The functions that the fire brigade is to
perform at the workplace.
6–8 ESH Handbook
b. The organizational statement must be available for
inspection.
c. Contractors/employers must ensure that
employees who are expected to do interior
structural fire fighting are physically capable of
performing duties that may be assigned to them
during emergencies. Contractors/employers must
not permit employees with known heart disease,
epilepsy, or emphysema to participate in fire
brigade emergency activities unless a physician’s
certificate of the employees’ fitness to participate
in such activities is provided.
d. Training and education
1) Contractors/employers must provide training
and education for all fire brigade members
commensurate with those duties and functions
that fire brigade members are expected to
6 perform. Such training and education must be
provided to fire brigade members before they
perform fire brigade emergency activities. Fire
brigade leaders and training instructors must
be provided with training and education that is
more comprehensive than that provided to the
general membership of the fire brigade.
2) Contractors/employers must ensure that
training and education is conducted frequently
enough to ensure that each member of the fire
brigade is able to perform the member’s
assigned duties and functions satisfactorily and
in a safe manner so as not to endanger fire
brigade members or other employees. All fire
brigade members must be provided with
training at least annually. In addition, fire
brigade members who are expected to perform
interior structural fire fighting must be
provided with an education session or training
at least quarterly.
3) Contractors/employers must inform fire
brigade members about special hazards—such
as storage and use of flammable liquids and
gases, toxic chemicals, radioactive sources, and
water reactive substances—to which they may
be exposed during fire and other emergencies.
The fire brigade members must also be advised
of any changes that occur in relation to the
special hazards. The contractor/employer must
develop and make available for inspection by
fire brigade members written procedures that
describe the actions to be taken in situations
involving the special hazards and must include
these in the training and education program.
e. Fire fighting equipment
1) Contractors/employers must maintain and 6
inspect, at least annually, fire-fighting equip-
ment to ensure the safe operational condition
of the equipment. Portable fire extinguishers
and respirators must be inspected at least
monthly.
2) Fire fighting equipment that is damaged or in
unserviceable condition must be removed from
service and replaced.
f. Protective clothing
The following requirements apply to those
employees who perform interior structural fire
fighting. The requirements do not apply to
employees who use fire extinguishers or standpipe
systems to control or extinguish fires only in the
incipient stage.
6–10 ESH Handbook
1) Contractors/employers must provide protective
clothing at no cost to the employee. As the new
equipment is provided, the employer must
assure that all fire brigade members wear the
equipment when performing interior structural
fire fighting.
protective clothing protects the head, body, and
extremities, and consists of at least the follow-
ing components: foot and leg protection, hand
protection, body protection, eye, face, and
head protection.
4. Fire Extinguishers
a. Portable Fire Extinguishers
1) Each factory building must have a full comple-
ment of the proper type of fire extinguisher for
6 the fire hazards present, except when the
contractor/employer has employees evacuate
instead of fighting small fires.
2) Employees expected or anticipated to use fire
extinguishers must be instructed on the hazards
of fighting fire, how to properly operate the fire
extinguishers available, and what procedures to
follow in alerting others to the fire emergency.
a) Contractors/employers must provide
training upon initial hire and at least
annually thereafter.
b) Contractors/employers must provide
employees who have been designated to use
fire-fighting equipment as part of an
emergency action plan with training in the
use of the appropriate equipment.
3) Where the contractor/employer wishes to
evacuate employees instead of having them
fight small fires there must be written emer-
gency action plans and employee training for
proper evacuation.
4) The contractor/employer must mount, locate,
and identify extinguishers so they are readily
Figure 6-2: Wheeled Extinguisher
Figure 6-3: Hand-Held Portable Extinguisher

(Dry Chemical Cartridge Type)
6–12 ESH Handbook
accessible to employees without subjecting the
employees to possible injury.
5) Extinguishers must be conspicuously located
and readily accessible for immediate use.
6) Extinguishers must be clearly visible. In
locations where visual obstruction cannot be
completely avoided, directional arrows must be
provided to indicate the location of extinguish-
ers and the arrows marked with the extin-
guisher classification.
7) Extinguishers must be marked/labeled to
ensure that the proper class extinguisher
selection is made at the time of a fire. Labels
will be placed on the front of the shell.
8) Operating instructions must always face
outward and the extinguisher must be placed
6 so that it can be removed easily.
9) Markings/labels must be of a size and form to
be legible from a distance of 3 feet (0.9
meters).
10) Extinguishers having a gross weight not
exceeding 40 pounds (15 kilograms) must be
installed so that the top of the extinguisher is
not more than 5 feet (1.5 meters) above the
floor.
11) Extinguishers with a gross weight greater than
40 pounds (15 kilograms), except wheeled
types, must be installed so that the top of the
extinguisher is not more than 3½ feet (1.3
meters) above the floor.
12) In no case can the clearance between the
bottom of the extinguisher and the floor be less
than 4 inches (10 centimeters).
13) Extinguishers must be maintained in a fully
charged and operable condition and kept in
their designated places at all time except during
use.
14) Portable fire extinguishers or hose must be
visually inspected monthly.
15) Only approved fire extinguishers are permitted
to be used in factories.
a) Contractors/employers must provide
portable fire extinguishers based on the
classes of anticipated workplace fires and on
the size and degree of hazard that would
affect their use.
b) Contractors/employers must distribute
portable fire extinguishers for use by
employees on Class A fires so that the travel
distance for employees to any extinguisher is 6
75 feet (22.9 meters) or less.
c) Contractors/employers may use uniformly
spaced standpipe systems or hose stations
connected to a sprinkler system installed for
emergency use by employees instead of
Class A portable fire extinguishers, provided
that such systems have total coverage of the
area to be protected, and that employees are
trained at least annually in their use.
d) Contractors/employers must distribute
portable fire extinguishers for use by
employees on Class B fires so that the travel
distance from the Class B hazard area to any
extinguisher is 50 feet (15.2 meters) or less.
e) Contractors/employers must distribute
portable fire extinguishers used for Class C
6–14 ESH Handbook
hazards on the basis of the appropriate
pattern for the existing Class A or Class B
hazards.
f ) Contractors/employers must distribute
portable fire extinguishers or other contain-
ers of Class D extinguishing agent for use
by employees so that the travel distance
from the combustible metal working area to
any extinguishing agent is 75 feet (22.9
meters) or less. Portable fire extinguishers
for Class D hazards are required in those
combustible metalworking areas where
combustible metal powders, flakes, shav-
ings, or similarly sized products are gener-
ated at least once every two weeks.
g) Contractors/employers will not provide or
make available in the factory portable fire
6 extinguishers using carbon tetrachloride or
chlorobromomethane extinguishing agents.
16) Portable fire extinguishers must be given
maintenance service at least once a year and a
written record kept showing the maintenance
or recharging date.
17) Contractor/employer must ensure that trained
persons with suitable testing equipment and
facilities perform hydrostatic testing.
portable fire extinguishers are hydrostatically
tested at the intervals listed in Table 6-1 next
page.
19) Extinguishers with the following conditions are
not eligible for testing and recharging and
should be removed from service:
a) When the unit has been repaired by
soldering, welding, brazing, or use of
patching compounds.
b) When the cylinder or shell threads are
damaged.
c) When there is corrosion that has caused
pitting, including corrosion under remov-
able name plate assemblies.
d) When the extinguisher has been burned in a
fire.
e) When a calcium chloride extinguishing
agent has been used in a stainless steel shell.
Table 6-1: Extinguisher Testing

6
6–16 ESH Handbook
20) Contractors/employers must maintain and
provide upon request evidence that the
required hydrostatic testing of fire extinguishers
has been performed at the time intervals shown
in Table 6-1 previous page. Such evidence must
be in the form of a certification record that
includes the date of the test, the signature of
the person who performed the test and the
serial number, or other identifier, of the fire
extinguisher that was tested. Such records shall
be kept until the extinguisher is hydrostatically
retested at the time interval specified in Table
6-1 or until the extinguisher is taken out of
service, whichever comes first.
21) Portable fire extinguishers are to be used for
extinguishing beginning-stage fires only.
Beginning-stage fires are fires in early stages of
development that, in the judgment of the
6 employee, can be extinguished with portable
equipment.
22) Extinguishers are to be located no more than
30 feet (9 meters) from fire hazards such as
flammable storage areas, cleaning tanks, etc.
23) Fire extinguishers are to be selected to ensure
that they are suited to the hazards in the area
and the type of fire that is likely to occur:
a) Class A—Fires
involving ordinary
combustibles such as
paper, wood, rubber,
and many plastics
where the cooling
effects of water
solutions are most
efficient.
b) Class B—Fires
involving flammable or
combustible liquids,
gases, and greases
where air exclusion by
blanketing is most
effective.
c) Class C—Fires
involving energized
electrical equipment
where the extinguishing
media must be non-
conductive (unless the
equipment is de-
energized; then Class A
or Class B extinguishers
must be used).
d) Class D—Fires 6
involving combustible
metals such as magne-
sium, titanium,
zirconium, sodium, and
potassium.
e) Some fire extinguishers
carry multiple classes.
b. Inspection and Maintenance of Portable
Equipment
The ESH Committee must inspect fire
extinguishers in their regular inspections.
c. Fixed Fire Extinguishers
Consult with your local Nike compliance manager
for fixed suppression equipment requirements.
d. Inspection and Maintenance of Fixed Systems
6–18 ESH Handbook
Water spray, sprinkler, halon, CO2, dry chemical,
and foam systems shall be inspected and tested as
required by the manufacturer.
C. Medical Services and First Aid

1. General Requirements
a. Contractors/employers must develop and
implement a medical and first aid program
specific to each factory. The program must include
the following elements:
1) An evaluation/assessment of the workplace for
medical and first aid requirements. Among the
factors that must be considered are:
a) Location and availability of medical facilities
and emergency services.
b) Availability of medical personnel for
6 consultation on occupational health issues.
c) Types of accidents that could reasonably
occur at the workplace.
d) Response time for external emergency
services.
e) Number of employees at the plant and the
locations of employees within the plant.
f ) Use of corrosive materials at any place in the
workplace.
g) Applicable industry specific requirements or
country requirements.
h) What first aid supplies should be available.
i) What level(s) of training employees should
receive, and which employees should be
trained.
2) The availability of medical personnel for
consultation regarding occupational health
issues. Provide the names and telephone
numbers for professionals with whom the
contractor/employer has agreements.
3) At least one person, and preferably two or
more, trained in first aid must be available at
the worksite if either of these conditions exist:
a) If life-threatening injuries can reasonably be
expected, trained personnel must be
available within 4 minutes. This generally
means that community emergency medical
services cannot be relied on since their
response time is usually greater than 4
minutes.
b) If serious injuries other than life threatening
injuries can be expected, the response time
for trained personnel is extended to 15 6
minutes.
c) Multiple individuals must be trained in
order to provide coverage when the primary
responder is unavailable.
4) The trained first aid responder(s) must be
designated and the other employees must know
who they are and how to contact them so they
can respond within the required time.
The trained responder must have a current first
aid certificate.
5) A first aid kit must be available at the worksite.
The program must note the location of the first
aid kit(s). The contractor/employer is respon-
sible for determining the need for additional
first-aid kits, quantities and the types of
supplies at the factory.
6–20 ESH Handbook
6) Emergency telephone numbers must be
conspicuously located by each telephone.
7) Sufficient ambulance service must be available
to handle any emergency. This requires
advance contact with ambulance services to
ensure they become familiar with plant
location, access routes, and hospital locations.
8) If corrosive materials are used, eyewash and
body flush facilities must be provided.
9) Records of first aid and medical treatments
must be maintained.
b. Contractors/employers must ensure the ready
availability of medical personnel for advice and
consultation on matters of occupational health.
c. Contractors/employers must train an employee or
employees to render first aid when a medical
6 facility/clinic/infirmary/hospital for treatment of
injured employees is not available in proximity to
the workplace.
2. First Aid and Kits
First aid and CPR training is an
integral part of a safety program.
Employees must be trained in
these skills.
a. The basic procedures to
follow in a serious or life threatening first aid
incident are:
1) Protect yourself first. Do not put yourself at
risk.
2) Notify. Get help. Summon emergency medical
services to the scene.
3) Stabilize. While waiting for medical help, an
employee shall provide first aid and reassur-
ance. Do not move the victim unless absolutely
necessary.
4) Transport. The person in charge of the facility
must ensure appropriate measures are taken to
transport the sick or injured person to a
suitable medical facility.
b. Contractors/employers must
ensure that adequate first aid
supplies are readily available.
Additional items must be
added to the minimum
requirements listed below,
based upon specific
workplace hazards. The selection of additional
supplies must be made by consulting with a health
care professional or a person competent in first aid 6
who is knowledgeable of the hazards found in that
specific factory.
Figure 6-4: Proper and Improper Methods for

Moving an Injured Person
6–22 ESH Handbook
c. Basic Supplies:
1) Absorbent Compress, 32 square inches (206.5
square centimeters) (No side smaller than 4
inch (10 centimeters), Qty (1)
2) Adhesive bandages, 1 × 3 inch (2.54 × 7.62
centimeter), Qty (16)
3) Adhesive tape, 5 yards (4.57 meters), Qty (1)
4) Antiseptic, 0.5 gram application, Qty (10)
5) Burn Treatment, 0.5 gram application, Qty (6)
6) Medical exam gloves, Qty (2 pair)
7) Sterile pad, 3 × 3 inch (7.62 × 7.62 centime-
ter), Qty (4)
8) Triangular bandage, 40 × 40 × 56 inch (101.5
× 101.5 × 142.24 centimeter), Qty (1)
6 d. Each complete first aid kit must have a label on
the back or outside of the kit listing its contents.
e. First aid kits must be inspected on a weekly basis
to ensure that they are full, in good condition and
have not expired. The contents list for the first aid
kits must be periodically reviewed to ensure that it
meets the needs of the workplace hazards at all
times.
f. Over-the-counter medicine may be put in first aid
kits if packaged in single dose, tamper-evident
packaging and labeled. Over-the-counter drug
products must not contain ingredients that are
known to cause drowsiness.
3. Eyewash and Shower/Drenching Equipment
a. Where the eyes or body of any person may be
exposed to injurious corrosive materials, suitable
facilities for quick drenching or flushing of the
eyes and body must be
provided within the work
area for immediate
emergency use.
b. General requirements for
standard eyewash and body
flushing stations:
1) The water in the eyewash station must be
potable (drinkable).
2) A controlled flow of water must be provided to
both eyes simultaneously at a velocity low
enough to not injure the user.
3) There must be no sharp projections anywhere
in the operating area of the unit.
4) Nozzles must be protected from airborne
contaminants. The removal of such protection
must not require a separate motion by the 6
operator when activating the unit.
5) Eyewash equipment must be capable of
delivering to the eyes a minimum of 0.4
gallons (1.5 liters) per minute for 15 minutes.
Note: Medical and industrial experiences have
shown that the initial first aid treatment for
chemical splash must be to flush the eyes for
15 minutes prior to medical treatment. Most
Material Safety Data Sheets recommend this,
or state that eyes must be flushed with copious
amounts of water. Data sheets must be
consulted for additional recommendations.
6) There must be sufficient space around the
eyewash equipment to allow eyelids to be held
open with the hands while the eyes are being
flushed.
6–24 ESH Handbook
7) The control valve must be:
a) Capable of being quickly located and
operated,
b) Capable of being fully activated in one
second or less, and
c) Designed to remain on until intentionally
shut off.
8) The eyewash unit must be in an accessible
location as close to the hazard as possible, but
with a travel/distance no greater than 100 feet
(30.5 meters) and must require no more than
10 seconds to reach.
9) The eyewash unit must
be identified with a
highly visible sign. The
area around or behind,
6 or both, must be painted a bright color, and
must be well lit.
10) Water nozzles must be positioned between 33
inches (83.8 centimeters) and 45 inches (114.3
centimeters) from the floor.
11) Plumbed eyewash units must be activated
weekly to flush the line and verify proper
operation. Self-contained units must be
inspected according to manufacturers'
specification.
12) All employees who may be exposed to eye
injury must be instructed in the proper use of
emergency eyewash units.
13) Self-contained units containing a reservoir of
flushing fluid must be constructed of materials
that will not corrode. The flushing fluid must
be protected from airborne contaminants.
14) Outdoor units must be freeze protected.
15) Water temperature in units must be main-
tained at between 60 and 90 degrees Fahren-
heit (15 and 35 degrees Celsius).
c. Selection and Installation
1) Showers (Plumbed and Self-Contained)
a) Plumbed Shower: An emergency shower
permanently connected to a source of
potable water.
b) Self-Contained Shower: A shower that
contains its own flushing fluid, and must be
refilled or replaced after use.
2) Specifications (for plumbed showers)
a) Heads
• Positioned 82 inches to 96 inches (208 6
centimeters to 244 centimeters) from
floor.
• Spray pattern must have a minimum
diameter of 20 inches (51 centimeters) at
60 inches (152 centimeters) above the
floor.
• Flow Rate=20 gallons (76 liters) per
minute (GPM) at 30 pounds (11 kilo-
grams) per square inch (PSI).
• The center of the spray pattern must be
located at least 16 inches (41 centimeters)
from any obstruction.
b) Valves
• Activate in 1 second or less.
• Stay-open valve (no use of hands).
6–26 ESH Handbook
• Valve remains on until the user shuts it
off.
3) Installation
a) Shower must be located in an area that
requires no more than 10 seconds to reach.
Figure 6-5: Emergency Drenching and

Eyewash Shower
6
Note: Consult a medical professional to
determine the appropriate distance for harsh
acids and caustics (high hazard=closer
distance).
b) Shower location must be in a well-lit area
and identified with a sign.
c) Shower must be located on the same level as
the hazard.
4) Maintenance and Training
a) Plumbed showers will be activated weekly to
verify correct operation.
b) All employees who might be exposed to a
chemical splash must be trained in the use
of the equipment.
c) All showers must be inspected annually.
5) Eyewashes (Plumbed and Gravity-Feed) 6
a) Plumbed Eye Wash: An eye wash unit
permanently connected to a source of
potable water.
b) Gravity-Feed Eye Wash: An eye wash device
that contains its own flushing fluid and
must be refilled or replaced after use.
6) Specifications
a) Heads
• Positioned 33 inches (83.8 centimeters) to
45 inches (114.3 centimeters) from floor.
• Positioned 6 inches (15.24 centimeters)
from wall or nearest obstruction.
• Plumbed units must provide 0.4 gallons
(1.5 liters) per minute (GPM) for 15
minutes flushing fluid at 30 PSI.
6–28 ESH Handbook
• Gravity-feed units must provide 0.4
gallons (1.5 liters) per minute (GPM) for
15 minutes.
b) Valves
• Activate in 1 second or less.
• Stay-open valve (leaving hands free).
7) Installation
a) Eyewash equipment must be located in an
area that requires no more than 10 seconds
to reach.
Note: Consult a medical professional to
determine the appropriate distance for harsh
acids and caustics (high hazard=closer
distance).
b) The location of the eye wash unit must be
6 in a well-lit area and identified with a sign.
Figure 6-6: Pressurized and Nonpressurized

Self-Contained Eyewash Units
c) Eyewash equipment must be on the same
level as the hazard.
a) Plumbed eye wash units must be activated
weekly to verify proper operation.
b) Gravity-feed units must be maintained
according to the manufacturer’s
instructions.
c) All employees who might be exposed to a
of the equipment.
d) All eyewash equipment must be inspected
annually.
9) Eye/Face Wash
A device used to irrigate and flush both the
face and the eyes. 6
10) Specifications
a) Heads
• Positioned 33 inches (83.8 centimeters) to
45 inches (114.3 centimeters) from floor.
• Positioned 6 inches (15.24 centimeters)
from wall or nearest obstruction.
• Large heads to cover both eyes and face or
regular size eye wash heads plus a face
spray ring.
• 3 gallons (11.4 liters) per minute (GPM)
for 15 minutes.
b) Valve
Same as eye wash.
6–30 ESH Handbook
11) Installation
Same as eye wash.
Same as eye wash
13) Drench Hoses (Hand Held)
A flexible hose connected to a water supply and
used to irrigate and flush eyes, face and body
areas.
14) Specifications
a) Heads
3 gallons (11.4 liters) per minute (GPM).
b) Valve
Activate in 1 second or less.
6 15) Installation
a) Assemble per the manufacturer’s
instructions.
b) The location of the drench hose must be in
a well-lit area and identified with a sign.
Figure 6-7: Hand-Held Drench Hose

a) Activate weekly to verify proper operation.
b) All employees who might be exposed to a
of the equipment.
c) All drench hose equipment must be
inspected annually.
Note: Hand-held drench hoses support
shower and eyewash units but must not
replace them.
17) Personal Eyewash
A supplementary eyewash that supports
plumbed units, gravity-feed units, or both by
delivering immediate flushing fluid.
Note: Personal eyewash units can
provide immediate flushing when 6
they are located near the worksta-
tions. Personal eyewash equipment
does not meet the requirements of
plumbed or gravity-feed eyewash
equipment. Personal eyewash
units can support plumbed or
gravity-feed eyewash units, but
cannot be a substitute.
7. Personal Protective Equipment
Appropriate clothing and personal protective equipment
(PPE) must be worn by all employees and visitors where
designated or posted.
PPE must meet standards established by recognized
governmental and/or industry groups.
Employees are responsible for the maintenance and care
of their PPE.
1. Job Attire
a. General Guidelines
1) Employees must be properly clothed at all
times.
2) Loose clothing, neckties, and loose jewelry
must not be worn when working around
moving machinery.
3) Clothing that has been contaminated by a
potentially hazardous (flammable or toxic)
material must be removed as soon as possible 7
and not worn until the clothing has been
cleaned.
Figure 7-1: Some Personal Protective Equipment

7–2 ESH Handbook
4) Hair long enough to be potentially hazardous
while working around moving machinery or
rotating tools and equipment must be secured.
5) Facial hair that may present a potential hazard
while working around moving or rotating
machinery is not permitted.
2. Head Protection
a. Hard hats must be worn by employees, visitors,
and contract employees in all designated areas.
b. Figure 7-2 below presents examples of hard hats.
c. Electricians and other employees who could be
exposed to electrical hazards should wear hard hats
with dielectric properties. Nonmetallic accessories,
such as liners and chinstraps, are also available for
dielectric hard hats.
d. Hard hats must not be altered.
Figure 7-2: Hard Hats

Personal Protective Equipment 7–3
3. Eye and Face Protection
a. General Guidelines
1) Eye protection must be worn by employees
whose duties indicate the need for protection.
Safety glasses must meet ANSI Z87.1 (or
equal) standards.
2) When required, safety glasses (nonprescription)
with side shields must be furnished by the
contractor/employer.
3) Contact lenses do not provide eye protection.
On the contrary, they increase the need for eye
protection since small foreign particles may
become trapped under the lenses and damage
the cornea. Contact lens wearers must inform
their supervisor and co-workers of their use.
b. Requirements
1) Goggles
a) Impact-type goggles must be worn during
activities involving flying or falling objects 7
or particles, such as, but not limited to,
chipping, scraping, buffing, grinding, and
hammering.
b) Splash-proof chemical goggles and face
shields must be worn when handling
potentially hazardous chemical liquids and
solids or in any other operation where the
eyes may be exposed to potentially hazard-
ous chemicals in either liquid or solid form.
c) Goggles are also required in areas that
include, but are not limited to, the follow-
ing hazards:
7–4 ESH Handbook
d) Potential dust hazards.
e) The use of compressed air to clean or blow
out debris.
f ) Cutting and tying of cable or wire rope.
g) Operations where there may be danger from
spraying of hot oils or chemicals.
2) Shaded Lenses
a) Arc welding requires the use of a welding
helmet fitted with the proper shaded lenses.
b) Use Table 7-1 below to select the proper
shaded lens for welding.
Table 7-1: Recommended Lens Shading
7
Figure 7-3: Eye Protection
7
7–6 ESH Handbook
4. Hand Protection
a. Employees must wear hand protection appropriate
for the activity and conditions. Examples of
appropriate hand protection include but are not
limited to:
1) Chemical resistant gloves when handling acids
or caustic chemicals.
2) Insulated or heat-resistant gloves when
performing duties requiring burn protection.
3) Hydrocarbon-resistant gloves when using
hydrocarbon-based solvents, cleaning agents,
or chemicals.
4) Mesh steel gloves when using fabric cutters.
[See Glove Chart next pages.]
Figure 7-4: Protective Steel Mesh Glove

Table 7-2: Glove Chart—Compare Chemical Compatibility
7
7–8 ESH Handbook
7
7
7–10 ESH Handbook
7
5. Foot Protection
a. Employees must
wear foot
protection
appropriate for
the activity and
conditions.
b. Safety-toe
footwear must
meet ANSI
Z41.1
requirements (or
equivalent) and
must be
furnished by
contractor/
employer.
6. Respiratory Protection
a. Employees must wear respiratory protection
appropriate for potential workplace atmospheric
hazards. 7
Figure 7-5: Examples of Respiratory Protection

7–12 ESH Handbook
b. Prior to being approved for the use of respiratory
protection equipment, employees must:
1) Have medical clearance.
2) Receive required training in the selection, use,
care, and limitations of the specific respirator
model.
3) Be seal or fit-tested, as appropriate for the
equipment.
Figure 7-6: Dust Filters No Substitute

for Respirators
7
c. If an employee has previous successful experience
wearing contact lenses, the employee may wear
soft or gas permeable lenses.
d. Specially designed eyeglass adapters must be
obtained and used if an employee requires
prescription glasses when using a full-facepiece
respirator.
e. Nothing must pass between the wearer’s face and
the facepiece, including but not limited to the
following:
1) Glasses with temple pieces.
2) Facial hair such as stubble, mustaches, side-
burns, and beards.
3) Bangs.
f. Respirators must be examined prior to each use.
g. Employees must clean, disinfect, and properly
store respirators after each day’s use, unless this
responsibility is assigned to others.
7
7–14 ESH Handbook
7
7
7–16 ESH Handbook
7
7. Hearing Protection
a. Hearing protection must be worn in high-noise
areas. This may require wearing a combination of
hearing protection devices (for example, earplugs
and earmuffs).
b. Employees included in a hearing conservation
program must comply with its requirements.
Figure 7-7: Examples of Hearing Protection
7
7–18 ESH Handbook
7
8. Fall Protection
a. Fall protection should be used when fall hazards
equal or exceed 6 feet (1.83 meters).
b. Fall protection devices include, but are not limited
to, safety belts/harnesses, lanyards, lifelines, ladder
climbing devices, and safety nets.
1) Personal Fall Arrest Systems:
a) The system must withstand a minimum
force of 5,000 pounds (1,866 kilograms).
b) Free-fall distance generally ranges between
4–6 feet (1.22–1.83 meters).
2) Anchor Systems:
a) Must withstand a minimum force (breaking
strength) of 5,000 pounds (1,866 kilo-
grams).
b) Many manufacturers require 5,400 pounds
(2,015 kilograms) minimum anchorage
strength for their equipment.
7
c) No knots shall be tied in anchorage
connectors.
3) Snap-hooks and Carabiners:
Figure 7-6: Examples of Anchor Systems

7–20 ESH Handbook
a) Minimum strength 5,000 pounds
(1,866 kilograms); must be self-
locking type.
b) Must withstand a side loading
force of 350 pounds (130
kilograms); the gate must
withstand a force of 220 pounds
(82 kilograms).
4) Lanyards:
a) Strength of 5,000 pounds (1,866
kilograms).
b) Length varies
from 2–6 feet
(0.6–1.83
meters).
Table 7-3: Visual Indications of

Equipment Damage
7
c) Synthetic rope lanyard minimum diameter
is 0.5 inch (1.25 centimeters).
b. Fall protection devices must be examined before
each use for excessive wear or damage. Worn or
damaged equipment must be immediately
removed from service and destroyed.
NOTE:
It is important that the belt/
harness is properly worn, and
that the wearer allows no
more slack in the secured
safety line than is necessary.
Tie-off points should be
above waist height.
Consider the potential for a
“swing fall” whenever you
use a self-retracting lifeline.
You increase the risk of a
“swing fall” by moving away
from the anchorage point and
increasing the lifeline length. 7
You will swing back under the
anchorage during a fall. A
“swing fall” increases your risk
of striking an object or lower
level during the pendulum
motion.
c. Calculating Total Fall Distances
To calculate total fall distance for worker exposed
to a fall, determine the location where the tie-off
point is, including lanyard length, deceleration
distance, which is not more than 42 inches (107
centimeters), height of the worker, and clearance
distance from foot of the worker to the ground
below. If the tie-off point location is below the D-
7–22 ESH Handbook
ring of the harness, this will increase the total fall
distance.
d. Elevated Working Surfaces
1) Fall protection must be used in certain
situations. These include but are not limited
to:
a) Open-sided floors, floor openings, catwalks,
or platforms elevated 4 feet (1.22 meters) or
higher where handrails or barricades are not
provided;
b) Working above potential hazards.
e. Fixed Ladders
1) Employees must use fall protection devices
where they are installed.
Figure 7-8: Calculating Total Fall Distance
7
2) Where cage protection is not provided on
ladders over 20 feet (6.1 meters) in unbroken
length, employees must use appropriate fall
protection devices.
7
8. Machine and Equipment Safety
A. Motor Vehicle Operation and Forklifts
1. Safe driving policy
a. Employees operating vehicles must:
1) Have in their possession a valid driver’s license
appropriate for the vehicle and its use.
2) Operate vehicles in a proper manner and
observe traffic regulations.
3) Use vehicles only for authorized purposes.
4) Wear seat belts in all vehicles. The vehicle
operator is responsible to see that passengers
fasten their seat belts.
b. Operating a vehicle while under the influence of
intoxicating beverages or drugs is prohibited.
2. General guidelines
a. Vehicle operators must practice defensive driving
at all times. Defensive driving means being alert
for potential accident-producing situations and
being prepared to take evasive action.
b. Vehicles must be maintained in proper operating 8
condition. A vehicle operator who detects a
mechanical defect or a potential safety hazard in a
vehicle must make arrangements for prompt
repairs or report the mechanical defect or
potential safety hazard to his/her supervisor or the
designated person responsible for vehicle
maintenance.
c. Speed must be consistent with road and weather
conditions and posted limits.
8–2 ESH Handbook
d. Vehicles must be parked so as not to roll out of
control.
e. When practical, vehicles must be parked so they
can be driven forward when next moved.
f. The vehicle operator must check for potential
hazards behind the vehicle before backing. This
may require the operator to walk around the
vehicle.
g. When operators are out of their vehicles, the
engine must be shut off and the parking brake set.
h. Gasoline or other flammable material must be
transported only in approved (for example, UL)
safety containers. Such materials must not be
stored in vehicle passenger compartments or
automobile trunks.
i. Portable safety containers must be removed from
vehicles while being filled with flammable liquids.
j. Employees must not ride in the rear area (truck
bed) of trucks or pickups.
k. Cargo or heavy tools must not be transported in
the passenger compartment of vehicles at the same
time as passengers.
8
l. Loose objects must not be stored in the rear
window tray or the front dashboard of vehicles.
m. Operators of the contractor-/employer-owned or
rented/leased vehicles, and operators of personal
vehicles on an allowance basis in contractor/
employer service must report accidents in which
they are involved to their supervisor as soon as
possible. The supervisor must coordinate a review
to determine the facts and complete the required
reports.
Machine and Equipment Safety 8–3
3. Forklift Safety
a. These procedures are set
forth to insure operator
safety and the safety and
health of all
employees, and to
reduce equipment
“down time.”
b. Required training
1) Before operating powered equipment, you
must complete the forklift safety training
program.
2) Never attempt to operate a piece of equipment
unless you are trained and authorized to
operate it.
c. Inspection and repairs
1) Inspect equipment daily before use.
2) Report any “unsafe condition” immediately.
3) Do not make repairs to equipment without
prior authorization. Your supervisor must
approve any repairs, alterations, or modifica-
tions to equipment. 8
4) Never drive a lift with a DO NOT OPERATE
tag on it.
5) Battery chargers must be used only by autho-
rized personnel.
d. Operating powered equipment
1) All operators are expected to conduct their
daily functions in an orderly and business-like
manner. All operators are responsible for
maintaining a safe and clean work area.
8–4 ESH Handbook
2) All machines must be operated from the
designated operating position. Never have
arms, legs, fingers, etc., protruding from the
operator compartment.
3) All operators must pay particular attention to
sprinkler heads when operating with the lift
mechanism raised.
4) Any damage to equipment and/or building
must be reported immediately to your supervi-
sor. Abuse of equipment will not be tolerated.
5) Always yield right of way to pedestrians. Use
EXTREME CAUTION when traveling
through highly traveled pedestrian areas,
especially during breaks and lunch hour.
6) Do not allow anyone to stand or pass under lift
equipment.
7) Start, stop, change direction, travel, and brake
smoothly. Slow down for turns or when on
uneven or slippery surfaces that could cause
truck to slide or tip.
8) Before any powered equipment is driven in or
out of a trailer, the lift operator must make sure
8 the trailer wheels are chocked.
9) You must use mirrors and slow down at all
intersections, particularly when entering a
main aisle from a secondary aisle.
10) Use the horn when:
a) Starting the machine from a stopped
position.
b) At all intersections.
c) Changing directions, i.e., turning or
changing from forward to reverse.
d) Approaching a pedestrian from behind.
11) During a fire drill or evacuation, stop your
machine immediately and exit building via
nearest fire exit.
12) Do not eat or drink while on equipment.
13) No horseplay on equipment.
Figure 8-1: The Stability Triangle
8
8–6 ESH Handbook
e. Battery charging
DANGER! RISK OF BATTERY EXPLOSION FROM
HYDROGEN GAS. MAY RESULT IN BLINDNESS,
SERIOUS INJURY, PERMANENT DISFIGUREMENT
AND SCARRING.
1) Safety
a) Batteries generate explosive hydrogen gas,
even during normal operation. People have
been injured by battery parts flying in an
explosion. They can explode under normal
operating conditions, such as starting your
car. They can explode under abnormal
conditions, such as jump starting, or if
short-circuited by a tool. They can explode
in a parked car or sitting on a table.
b) To help reduce the risk of these dangers and
injury, it is of the utmost importance that
each time before using your charger, you
Figure 8-2: Wear Safety Goggles!
8
read and understand this manual and any
warnings and instructions by the battery
manufacturer. Follow these instructions
exactly.
c) Wear personal protective equipment.
Always wear complete eye protection (that
protects eyes from all angles).
d) Avoid flames or sparks near battery and
fuel.
• Always keep flames, matches, lighters,
cigarettes, or other ignition sources away
from battery.
• Do not put flammable material on or
under charger. Do not use near gasoline
vapors.
• Make sure charger clips make good
contact by twisting or rocking them back
and forth several times. The second clip
connection must always be made away
from the battery. Always plug the charger
into an electrical outlet after all connec-
tions have been made. See operating
instructions. 8
• If necessary to remove battery from vehicle
to charge, always turn off all accessories in
the vehicle. Then always remove grounded
terminal (connected to vehicle frame)
from battery first.
• A tool touching both battery posts or
battery post and vehicle metal parts is a
short circuit and will spark. Be careful
when using metal tools on or near battery.
Do not drop a tool on battery.
8–8 ESH Handbook
e) Reduce explosive gas (hydrogen)
• Before connecting charger, always add
water to each cell until battery acid covers
plates to help purge extra gas from cells.
Do not overfill. Battery acid expands
during charge. After charging, fill to level
specified by battery manufacturer. For a
battery without removable caps (i.e.,
maintenance-free battery), carefully follow
manufacturer’s instructions on charging.
• Some sealed maintenance-free batteries
have a battery-condition indicator. A light
or bright colored dot indicates low water.
Such a battery needs to be replaced, not
charged or jump started.
• Charge battery with caps in place. Most
US batteries are made with flame-arresting
caps. Do not pry caps off sealed batteries.
Place wet cloth on batteries with non-
flame arresting caps.
• Be sure area around battery is well
ventilated before and during charging
process. Never charge in a closed or
8 restricted area.
f ) Stay away from battery when possible.
• Never put face near battery.
• Always locate charger as far from battery
as DC cables permit.
• Always have plenty of fresh water and soap
nearby in case battery acid contacts eyes,
skin, or clothing. If battery acid contacts
skin or clothing, wash immediately with
soap and water. If acid enters eye, immedi-
ately flood eye with cold running water for
at least 15 minutes and get medical help
immediately.
f. Battery charger instructions
Connecting the charger to the battery
1) If charger has switch with off position, it must
be set to off.
2) AC power cord must be unplugged.
3) Charging battery in vehicle:
a) If vehicle has negative ground (most vehicles
do; if you are not sure, have it checked),
connect positive (red) charger clip to
positive post of battery. Some newer vehicles
have a remote positive terminal located
away from the battery. Use this remote
terminal for charging connections. See your
vehicle owner’s manual.
b) Connect negative (black) charger clip to car
frame or engine block away from battery.
CAUTION: DO NOT CONNECT CLIP TO
CARBURETOR, FUEL LINES, OR SHEET METAL
BODY PARTS. CONNECT TO HEAVY GAUGE 8
Figure 8-3: Charging Typical Negative-Ground
Battery Inside Vehicle
8–10 ESH Handbook
METAL PART OF THE FRAME OR ENGINE BLOCK.
DO NOT FACE BATTERY WHEN MAKING FINAL
CONNECTION.
c) If vehicle has positive ground (most vehicles
do not; be sure to check), connect the
negative (black) charger clip to the negative
ungrounded post of battery.
d) Connect positive (red) charger clip to
vehicle frame or engine block away from
battery.
B. Energy Control (Lockout/Tagout)

1. General
a. Energy control is required while employees are
servicing and/or maintaining machines and
equipment if an unexpected
start-up or release of energy
or substances could cause
injury.
b. Only an authorized
employee (one who has been
trained and is authorized to
both lock out the equipment
8 and to work on it) shall
implement lockout/tagout.
c. The supervisor or authorized
employee must notify
affected employees in the
work area of the type and
duration of the work to be
performed, and of the
application and/or removal
of lockout and/or tagout
devices. Notification must be
given before the controls are applied and after they
are removed from the machine or equipment.
d. A tag, identifying who placed the lock, the date,
and the area/lease, must be attached to each lock.
e. Locks and tags must remain in place until the
work is completed. Employees must follow the
procedures outlined in the facility’s lockout/tagout
to remove locks and tags other than their own.
f. Employees must use only lockout/tagout devices
specified by the facility and issued by the facility.
g. Locks used for lockout must not be used for other
purposes.
h. Employees must position themselves outside the
path of potential energy releases when equipment
is being opened or returned to service. These
releases can include pressurized gases and liquids,
falling objects, electrical energy.
Figure 8-4: Lockout/Tagout Tags
8
8–12 ESH Handbook
i. All isolation and lockout/tagout operations must
be performed according to the requirements of the
facility’s Lockout/Tagout programs/policy.
2. Procedures
a. Energy-control procedures must clearly identify
the sources of energy and describe how workers
will:
1) Secure energy-isolating devices
2) Use and remove locks and tags
3) Test the effectiveness of energy-isolating devices
b. Energy-control procedures will vary depending on
equipment design and types of energy involved.
However, the procedures do need to meet certain
minimum requirements and the procedures must
be done in the proper sequence. Here is a checklist
that covers the minimum requirements.
1) Prepare to shut down the equipment
a) Each authorized employee who shuts down
equipment must know the type and
magnitude of the energy, its hazards, and
how to control the energy.
8 b) All affected employees must know that the
equipment is being serviced or maintained
and that it will be shut down and locked
out for the duration of the service or
maintenance work.
2) Shut down the equipment
a) If the equipment is operating, shut it down
by the normal stopping procedures.
b) Shutdown may be as simple as pressing the
stop switch.
3) Isolate the equipment from the energy source
a) Locate every energy-isolating device that
controls energy to the equipment.
b) Position the energy-isolating device(s) so
that the equipment is isolated from the
energy source(s).
c) Keep in mind that when two or more
authorized employees are working together,
each must apply his or her own lock.
4) Lock out or tag out the energy-isolating device
a) Locks: Lock out the energy-isolating devices
with designated locks. The person who does
the service or maintenance work must place
the locks and a personal identification tag.
Secured locks must hold the energy-isolating
devices in a “safe” or “off ” position.
b) Tags: The authorized employee who will be
doing the service or maintenance work must
place tags on the energy-isolating devices.
Tags must clearly state that changing the
energy-isolating devices from the “safe” or
“off” position is prohibited. Because tags
don’t eliminate the hazard, you must use 8
additional methods such as blocking a
control switch or opening an extra discon-
nect. If you can’t place a tag on the energy-
isolating device, you must place it as close as
possible to the device.
5) Eliminate potentially hazardous stored energy
a) Capacitors, coiled springs, elevated machine
members, rotating flywheels, air, gas, steam,
chemical, and water systems are sources of
stored energy.
8–14 ESH Handbook
b) If stored energy can return to a hazardous
level, you must make sure that the energy
remains isolated from the equipment until
all service or maintenance work is com-
pleted.
6) Remove the lockout or tagout device
a) The person who applied the device also
must remove it.
b) If the person who applied the device is not
available to remove it, the employer may
authorize another employee to remove the
device. However:
• The employer must be trained and follow
the appropriate procedures.
• The employer must verify that the person
who applied the device is not available to
remove it.
• The employer must attempt to contact
and inform the person that the lockout/
tagout device has been removed.
• The employer must make sure the person
knows about the removal before he or she
8 returns to work.
c) Be sure to have a documented procedure for
removing another person’s lock.
7) Documentation
a) You need to document procedures for each
particular machine or piece of equipment.
b) You can use a single procedure for more
than one piece of equipment if the energy
sources and control methods are identical.
3. Blinding Piping and Equipment
a. Purpose
1) A blind is a metal plate inserted on the end of a
pipe or between gasketed pipe flanges to
prevent the flow of gas or liquid in either
direction.
2) A blind must be of sufficient strength to
withstand the pressure it could reasonably be
expected to encounter.
b. Blinding Procedure
1) The decision to install and/or remove a blind
must be made by or at the direction of facility
supervision or a designated representative.
2) Blinds must be installed on or in all piping
connected to tanks or vessels or equipment
scheduled for maintenance, entry, or hot work.
Blinds must be near the tank or vessel,
preferably on the first flange from the tank or
vessel shell.
3) In some instances a valve, spool piece, or other
device must be removed from the line and a
blind flange installed on the line and the tank
or vessel. 8
4) A blind must be installed with three major
considerations in mind:
Figure 8-5: Blinds and Spacers

8–16 ESH Handbook
a) Will the blind effectively accomplish its
purpose in the location selected?
b) Can the blind be safely removed?
c) Is there access to the selected location?
5) A list must be maintained of the blinds used in
a specific job. This list includes the size,
location, and date of installation and removal
of any blind.
C. Machine Guarding
1. Guarding
a. Power transmission points must be guarded. This
includes, but is not limited to, counterweights on
pumping units, flywheels, rotating shafts, in-
running pinch points, V-belt drives, gears, moving
parts, etc. The guarding can take many forms but
must be effective in preventing employee contact
with the hazard. Forms of guarding include, but
are not limited to, enclosures, barriers, fences, and
interlock systems.
b. Machinery guards must be in place before starting
and during operation of the equipment.
8 c. Damaged machine guards must be repaired before
returning the equipment to service.
d. Follow lockout/tagout procedures when removing
machine guards. Guards removed during repair
operations must be replaced upon completion of
the repairs.
2. Machinery in Motion
Whenever feasible, equipment must be shut down
when servicing. When operations must be performed
around engines or equipment while they are running,
proper precautions must be taken.
3. Rotating Machinery
a. General
Rotating machinery is dangerous because of the
high speeds and pressures used in its operation.
Repairs must not be initiated until the fuel supply
is shut off and the starting circuits disconnected,
locked out, and tagged.
Figure 8-6: Examples of Guard Construction
8
8–18 ESH Handbook
b. Pumps
1) Prior to initiating repairs or maintenance, the
pump must be shut down, isolated, and the
internal pressure bled down.
2) Main electrical disconnects and valves must be
locked out and tagged prior to initiating work.
4. General Rules
To prevent accidents, the following guidelines must be
followed:
a. Read and comply with the instruction supplied
with the machine.
b. Check whether safety devices are working
properly.
c. Immediately report any trouble to the appropriate
person and warn any person likely to work with
the machine of the trouble.
d. Refuse to work with the machine when any safety
device is not working properly.
e. Make sure the work area around the machine and
the machine itself is kept clean and neat.
8
Figure 8-7: Guard Location Guide
f. Do not clean the machine while it is running.
5. Machine Guarding and Safety Devices
Wear and tear of the machine’s parts may have an
impact on the proper function of safety devices and
guards. For this reason, a qualified and specifically
designated person must regularly check the safety
devices and guards with regard to the machine
manufacturer documentation.
6. Safety Guards
On every safety guard, the following must be checked:
a. The guards must be complete and in good
condition.
b. The guards and their electrical contacts must be
kept clean.
c. All machine components must STOP as soon as a
single interlock is open.
7. Push-button for Emergency Stops
Check the following items on every mushroom-
shaped emergency stop push-button:
a. Press each emergency stop push-button and make
sure that all machine components stop 8
immediately.
b. Make sure that each emergency stop push-button
remains in its pushed in and locked position by
itself and that in this position, the machine cannot
be restarted.
c. Button must be red color.
(See Figures 8-8 through 8-10 next pages for
examples of machine guards.)
8–20 ESH Handbook
Figure 8-8: Types of Machine Guards
8
8
8–22 ESH Handbook
8
Figure 8-11: Methods of Guarding Actions and
Motions: Enclosure Guards
8
8–24 ESH Handbook
Motions: Interlocking Guards
8
Motions: Automatic Guards
8
8–26 ESH Handbook
Motions: Remote, Placement, Feeding, Ejecting
8
D. Mills and Calenders

1. Mill Roll Heights
a. All new mill installations must be installed so that
the top of the operating rolls is not less than 50
inches (127 centimeters) above the level on which
the operator stands, irrespective of the size of the
mill.
b. This distance must apply to the actual working
level, whether it be at the general floor level, in a
pit, or on a platform.
2. Mill Safety Controls
A safety trip control must be provided in front and in
back of each mill. It must be accessible and must
operate readily on contact. The safety trip control
must be one of the following types or a combination
thereof:
a. Pressure-sensitive body bars. Installed at front
and back of each mill having a 46-inch (117-
centimeter) roll height or over. These bars must
operate readily by pressure of the mill operator’s
body.
b. Safety triprod. Installed in the front and in the
8
back of each mill and located within 2 inches (5
centimeters) of a vertical plane tangent to the
front and rear rolls. The top rods must be not
more than 72 inches (183 centimeters) above the
level on which the operator stands. The triprods
must be accessible and must operate readily,
whether the rods are pushed or pulled.
c. Safety tripwire cable or wire center cord. Installed
in the front and in the back of each mill and
located within 2 inches (5 centimers) of a vertical
plane tangent to the front and rear rolls. The
8–28 ESH Handbook
cables must not be more than 72 inches (183
centimeters) above the level on which the operator
stands. The tripwire cable or wire center cord
must operate readily, whether cable or cord is
pushed or pulled.
d. Auxiliary equipment. All auxiliary equipment
such as mill divider, support bars, spray pipes, feed
conveyors, strip knives, etc., must be located in
such a manner as to avoid interference with access
to and operation of safety devices.
3. Calender Safety Controls
a. Safety trip, face. A safety triprod, cable, or wire
cord must be provided across each pair of in-
running rolls extending the length of the face of
the rolls. It must be readily accessible and operate
Figure 8-15: Pressure-Sensitive Body Bar
8
whether pushed or pulled. The safety tripping
devices must be located within reach of the
operator and the bite.
b. Safety trip, side. On both sides of the calender
and near each end of the face of the roll, there
must be a cable or wire center cord connected to
the safety trip. They must operate readily when
pushed or pulled.
4. Trip and Emergency Switches
All trip and emergency switches must not be of the
automatically resetting type, but must require manual
resetting.
5. Stopping Limits
a. Determination of distance of travel. All
measurements on mills and calenders must be
taken with the rolls running empty at maximum
operating speed. Stopping distances must be
expressed in inches of surface travel of the roll
from the instant the emergency stopping device is
actuated.
b. Stopping limits for mills. All mills, irrespective of
size of the rolls or their arrangement (individually
or group-driven) must be stopped within a 8
distance, as measured in inches of surface travel,
not greater than 1.5 percent of the peripheral no-
load surface speeds of the respective rolls as
determined in feet per minute.
c. Example: Using 100 feet (30.5 meters) per
minute, we would calculate stopping distances as
follows:
100 FPM × 1.5% = 1.5 = 18 inches stopping distance
d. The stopping distance is obtained by multiplying
the running speed in feet by the 1.5% constant
8–30 ESH Handbook
permitted for stopping. This results in a figure
showing feet which must be multiplied by 12 to
obtain inches for permissible stopping distance.
6. Stopping Limits for Calenders
a. All calenders, irrespective of size of the rolls or
their configuration, must be stopped within a
distance as measured in inches of surface travel,
not greater than 1.75 percent of the peripheral no-
load surface speeds of the respective calender rolls
as determined in feet per minute.
Table 8-1: Mill and Calender Safety Stopping

Equipment Inspection Form
8
b. Where speeds above 250 feet (76 meters) per
minute as measured on the surface of the drive roll
are used, stopping distances of more than 1.75
percent are permissible. Such stopping distances
must be subject to engineering determination.
E. Electrical Safety
1. General
a. Only authorized personnel, licensed for electrical
work, are permitted to repair, adjust, test, or
service electrical equipment. Follow federal, state,
and local codes and regulations at all times.
b. Live electrical equipment or electrical component
parts must be grounded, isolated or provided with
some other means of protection to prevent
potential exposure to employees.
c. Wiring must be fully closed in metal conduits.
2. Using Electrical Equipment
a. All electrical equipment must be in safe condition
before using. If you have questions regarding the
safety and health impacts of equipment, notify a
supervisor immediately. Remove defective
equipment from service until it is repaired or 8
replaced.
Figure 8-16: 120 Volt Branch Circuit Wiring

8–32 ESH Handbook
Figure 8-17: Correctly Wired 110-Volt Circuit
Figure 8-18: Duplex Receptacle Correctly Wired

to Designated Terminals
8
b. Personal portable electrical equipment, such as
heaters, etc., must be approved prior to use.
c. All electrical office equipment and appliances
must be certified by Underwriters Laboratory
(UL). Avoid using electrical equipment/appliances
in wet or moist locations.
d. Do not overload electrical equipment or electrical
outlets. Only use approved extension cords and
outlets.
e. Only use extension cords that are intended for the
equipment and conditions associated with the
operation. Cords must be grounded and inspected
prior to use to assure proper grounding.
f. Power strips must be used, whenever possible,
instead of extension cords.
3. Inspecting Equipment
Inspect electrical equipment prior to its use, including:
a. Check for evidence of loose or visibly damaged
parts, switches, shielding devices, nuts, bolts, etc.
b. Examine the electrical cord outer insulation for
cuts and abrasions.
c. Examine the plug for loose or missing prongs. 8
d. Inspect the outlet receptacle for burn marks,
cracks, broken insulation, missing cover plates, or
other noticeable defects.
e. If the receptacle is discovered to be loose when
you insert the plug, immediately disconnect the
plug.
f. Immediately report the above defects. Do not use
any electrical equipment or outlets with identified
defects.
8–34 ESH Handbook
4. Ground-Fault Circuit Interrupters
a. General
1) Insulation and grounding are used to prevent
injury from electrical-wiring systems or
equipment.
However, there are
instances when
these recognized
methods do not
provide the degree
of protection
required.
2) A few instances
where ground-fault
circuit interrupters
would provide
additional protec-
tion:
a) Many portable hand tools, such as electric
drills, are now manufactured with non-
metallic cases, sometimes referred to as
“double-insulated.” Although this design
method assists in reducing the risk from
8 grounding deficiencies, a shock hazard can
still exist. In many cases, employees must
use such electrical equipment where there is
considerable moisture or wetness. Although
the employee is insulated from the electrical
wiring and components, there is still the
possibility that water can enter the tool
housing. Ordinary water is a conductor of
electricity. Therefore, if the water contacts
energized parts, a path will be provided
from inside the housing to the outside,
bypassing the double insulation. When an
employee holding a hand tool under these
conditions touches another conductive
surface in their work environment, an
electric shock will result.
b) Double-insulated equipment or equipment
with non-metallic housings that does not
require grounding under the National
Electrical Code (NEC) is frequently used
around sinks or in situations where the
equipment could be dropped into water.
Frequently, the initial human response is to
grab for the equipment. If an employee’s
hand is placed in the water and another
portion of his or her body is in contact with
a conductive surface, a serious or deadly
electric shock can occur.
c) In construction work and regular factory-
maintenance work, if is frequently necessary
to use extension-cord sets with portable
equipment. These cords are regularly
exposed to physical damage. Although safe
work procedures require adequate protec-
tion, it is not possible to prevent all damage.
Frequently, the damage is only to the
insulation, exposing energized conductors. 8
It is not unusual for an employee to handle
the cord often with the possibility of
contacting the exposed wires while holding
a metal case tool or while in contact with
other conductive surfaces.
3) Since neither double insulation nor grounding
can provide protection under these conditions,
it is necessary to use other protective measures.
One acceptable method is a ground-fault
circuit interrupter, commonly referred to as a
GFCI.
8–36 ESH Handbook
b. How a Ground-Fault Circuit Interrupter Works
1) A ground-fault circuit interrupter is not an
overcurrent device like a fuse or circuit breaker.
GFCIs are designed to sense an imbalance in
current flow over the normal path.
2) The GFCI contains a special sensor that
monitors the strength of the magnetic field
around each wire in the circuit when current is
flowing. The magnetic field around a wire is
directly proportional to the amount of current
flow. Thus, the circuitry can accurately
translate the magnetic information into current
flow.
3) If the current flowing in the black (un-
grounded) wire is within 5 (plus or minus 1)
milliamperes (mA) of the current flowing in
the white (grounded) wire at any given instant,
the circuitry considers that situation normal.
All the current is flowing in the normal path.
Figure 8-19: How the GFCI Protects

8
4) If, however, the current flow in the two wires
differs by more than 5mA, the GFCI will
quickly open the circuit. (See Figure 8-19
previous page.)
5) Note that the GFCI will open the circuit if
5mA or more of current returns to the service
entrance by any path other than the intended
white (grounded) conductor. If the equipment
grounding conductor is properly installed and
maintained, this will happen as soon as the
faulty tool is plugged in. If by chance this
grounding conductor is not intact and of low-
impedance, the GFCI may not trip out until an
employee provides a path. In this case, the
employee will receive a shock, but the GFCI
should trip out so quickly that the shock will
not be harmful.
c. Types of Ground-Fault Circuit Interrupters
There are several types of GFCIs available, with
some variations within each type. Although all
types will provide ground-fault protection, the
specific application may dictate one type over
another.
1) Circuit-Breaker Type—The circuit-breaker 8
type includes the functions of a standard circuit
breaker with the additional functions of a
GFCI. It is installed in a panelboard and can
protect an entire branch circuit with multiple
outlets. It is a direct replacement for a standard
circuit breaker of the same rating.
2) Receptacle Type—The receptacle style GFCI
incorporates within one device one or more
receptacle outlets, protected by the GFCI. Such
devices are becoming very popular because of
their low cost. Most are of the duplex-recep-
8–38 ESH Handbook
tacle configuration and can provide GFCI
protection for additional non-GFCI type
receptacles connected “downstream” from the
GFCI unit.
3) Permanently Mounted Type—The perma-
nently mounted types are mounted in an
enclosure and designed to be permanently
wired to the supply. Frequently, they are used
around large commercial swimming pools or
similar wet locations.
4) Portable Type—Several styles of portable
GFCIs are available that are designed to be
easily transported from one location to
another. They usually contain one or more
integral receptacle outlets protected by the
GFCI module. Some models are designed to
plug into existing non-GFCI protected outlets
or, in some cases, are connected with a cord
and plug arrangement. The portable type also
incorporates a no-voltage release device which
will disconnect power to the outlets if any
supply conductor is open. Units approved for
use outdoors will be in enclosures suitable for
the environment. If exposed to rain, they must
8 be listed as rainproof.
5) Cord Connected Type—The power supply
cord type GFCI consists of an attachment plug
that incorporates the GFCI module. It provides
protection for the cord and any equipment
attached to the cord. The attachment plug has
a non-standard appearance and is equipped
with test and reset buttons. Like the portable
type, it incorporates a no-voltage release device
which will disconnect power to the load if any
supply conductor is open.
d. Classes of Ground-Fault Circuit Interrupters
Ground-Fault Circuit Interrupters are divided into
two classes:
1) Class A devices are designed to trip when
current flow, in other than the normal path, is
6 milliamperes or greater. The specification is
5mA plus or minus 1mA.
2) Class B devices will trip when current flow, in
other than the normal path, is 20mA or
greater. Class B devices are approved for use on
underwater swimming pool lighting installed
prior to the adoption of the 1965 National
Electrical Code.
e. Testing Ground-Fault Circuit Interrupters
1) Due to the complexity of a GFCI, it is
necessary to test the device on a regular basis.
2) For permanently wired devices, a monthly test
is recommended.
3) Portable type GFCIs must be tested each time
before use.
4) GFCIs have a built-in test circuit which
imposes an artificial ground fault on the load 8
circuit to assure that the ground fault protec-
tion is still functioning.
5) Test and reset buttons are provided for testing.
5. Circuit Breakers and Electrical Panels
a. Electrical panels, switch boxes, and other electrical
control devices must;
1) Have an access clearance of three feet in front.
8–40 ESH Handbook
2) Be provided with a lock or other means to
restrict access at the housing box when
necessary.
3) Be labeled to indicate the circuits or equipment
they affect.
b. All openings in switch boxes, circuit breaker
panels, etc., are to be covered.
c. Damaged or missing electrical fixtures must be
replaced.
d. Adapters which increase the number of outlets are
not allowed.
6. Cabinets, Boxes and Fittings
1) Conductors Entering Boxes, Cabinets, or Fittings
a) Conductors can be damaged if they rub against
the sharp edges of cabinets, boxes, or fittings;
they must be protected from damage where
they enter. To protect the conductors, some
type of clamp or rubber grommet must be
used. The device used must close the hole
through which the conductor passes as well as
provide protection from abrasion. If the
conductor is in a conduit and the conduit fits
8 tightly in the opening, additional sealing is not
required.
b) The knockouts in cabinets, boxes, and fittings
should be removed only if conductors are to be
run through them. However, if a knockout is
missing or if there is another hole in the box,
the hole or opening must be closed.
2) Covers and Canopies
a) All pull boxes, junction boxes, and fittings
must be provided with covers approved for the
purpose. If metal covers are used, they must be
grounded.
b) In completed installations, each outlet box
must have a cover, faceplate, or fixture canopy.
c) Covers of outlet boxes having holes through
which flexible cord pendants pass must be
provided with bushings designed for the
purpose or must have smooth, well-rounded
surfaces on which the cords may bear.
7. Flexible Cords and Cables
a) There is a definite need and place for cords, but
there is also a temptation to misuse them because
they seem to offer a quick and easy way to carry
electricity to where it is needed. The basic
problem is that flexible cords in general are more
vulnerable than the fixed wiring of the building.
Therefore, cords must not be used if one of the
recognized wiring methods can be used instead.
b) Use of Flexible Cords and Cables
1) Flexible cords and cables must be approved and
suitable for conditions of use and location. The
standard lists specific situations in which
flexible cords may be used. Flexible cords and 8
cables must be used only for:
a) Pendants (a lampholder or cord-connector
body suspended by a length of cord
properly secured and terminated directly
above the suspended device).
b) Wiring of fixtures.
c) Connection of portable lamps or appli-
ances.
d) Elevator cables.
8–42 ESH Handbook
e) Wiring of cranes and hoists (where flexibil-
ity is necessary).
f ) Connection of stationary equipment to
facilitate their frequent interchange
(equipment which is not normally moved
from place to place, but might be on
occasion).
g) Prevention of the transmission of noise or
vibration. (In some cases vibration might
fatigue fixed wiring and result in a situation
more hazardous than flexible cord.)
h) Appliances where the fastening means and
mechanical connections are designed to
permit removal for maintenance and repair
(e.g. water coolers, exhaust fans).
i) Data processing cables approved as a part of
a data processing system.
2) Note that all of the above situations involve
conditions where flexibility is necessary. Unless
specifically permitted by one of these situa-
tions, flexible cords and cables may not be
used:
8 a) As a substitute for the fixed wiring of the
structure.
b) Where run through holes in walls, ceilings,
or floors.
c) Where run through doorways, windows, or
similar openings.
d) Where attached to building surfaces.
e) Where concealed behind building walls,
ceilings, or floors.
3) There is usually not much question about use
of the short length of cord which is furnished
as part of an approved appliance or tool; there
is usually no question about an extension cord
used temporarily to permit use of the appliance
or tool in its intended manner at some distance
from a fixed outlet; but there are questions
when the usage is not obviously temporary, and
when the cord is extended to some distant
outlet in order to avoid providing a fixed outlet
where needed.
8. Identification, Splices and Terminations
a. Flexible cords must be used only in continuous
lengths without splice or tap. Hard service flexible
cords, No. 12 or larger, may be repaired if spliced
so that the splice retains the insulation, outer
sheath properties, and usage characteristics of the
cord being spliced.
b. Flexible cords must be connected to devices and
fittings so that strain relief is provided which will
prevent pull from being directly transmitted to
joints or terminal screws.
F. Cranes, Hoists, Chains & Slings

8
1. General Safety Rules
a. All crane and hoist hooks must have safety latches.
b. Hooks must not be painted (or re-painted) if the
paint previously applied by the manufacturer is
worn.
c. Crane pendants must have an electrical disconnect
switch or button to open the main-line control
circuit.
8–44 ESH Handbook
d. Cranes and hoists must have a main electrical
disconnect switch. This switch must be in a
separate box that is labeled with lockout
capability.
e. Crane bridges and hoist monorails must be
labeled on both sides with the maximum capacity.
f. Each hoist-hook block must be labeled with the
maximum hook capacity.
g. All newly installed cranes and hoists, or those that
have been extensively repaired or rebuilt
structurally, must be load tested at 125% capacity
prior to being placed into service.
h. If an overload device is installed, a load test to the
adjusted setting is required.
i. Do not engage in any practice that will divert your
attention while operating the crane.
Figure 8-20: Gantry Crane
8
j. Respond to signals only from the person who is
directing the lift, or any appointed signal person.
Obey a stop signal at all times, no matter who
gives it.
k. Do not move a load over people. People must not
be placed in jeopardy by being under a suspended
load. Also, do not work under a suspended load
unless the load is supported by blocks, jacks, or a
solid footing that will safely support the entire
weight. Have a crane or hoist operator remain at
the controls or lock open and tag the main
electrical disconnect switch.
l. Ensure that the rated load capacity of a crane’s
bridge, individual hoist, or any sling or fitting is
not exceeded. Know the weight of the object being
lifted or use a dynamometer or load cell to
determine the weight.
m. Check that all controls are in the OFF position
before closing the main-line disconnect switch.
n. If spring-loaded reels are provided to lift pendants
clear off the work area, ease the pendant up into
the stop to prevent damaging the wire.
Figure 8-21: Overhead Traveling Crane 8

8–46 ESH Handbook
o. Avoid side pulls. These can cause the hoist rope to
slip out of the drum groove, damaging the rope or
destabilizing the crane or hoist.
p. To prevent shock loading, avoid sudden stops or
starts. Shock loading can occur when a suspended
load is accelerated or decelerated, and can
overload the crane or hoist. When completing an
upward or downward motion, ease the load slowly
to a stop.
2. Rigging
a. General Rigging Safety Requirements
1) Use only rigging equipment that is in good
condition. All rigging equipment must be
inspected annually; defective equipment is to
be removed from service and destroyed to
prevent inadvertent re-use. The load capacity
limits must be stamped or affixed to all rigging
components.
2) Facility policy requires a minimum safety factor
of 5 to be maintained for wire rope slings. The
following types of slings must be rejected or
destroyed:
8 a) Nylon slings with:
• Abnormal wear.
• Torn stitching.
• Broken or cut fibers.
• Discoloration or deterioration.
b) Wire-rope slings with:
• Kinking, crushing, bird-caging, or other
distortions.
• Evidence of heat damage.
• Cracks, deformation, or worn end
attachments.
• Six randomly broken wires in a single rope
lay.
• Three broken wires in one strand of rope.
• Hooks opened more than 15% at the
throat.
• Hooks twisted sideways more than 10
degrees from the plane of the unbent
hook.
c) Alloy steel chain slings with:
• Cracked, bent, or elongated links or
components.
• Cracked hooks.
d) Shackles, eye bolts, turnbuckles, or other
components that are damaged or deformed.
b. Rigging a Load
Do the following when rigging a load:
1) Determine the weight of the load. Do not
guess.
8
2) Determine the proper size for slings and
components.
3) Do not use manila rope for rigging.
4) Make sure that shackle pins and shouldered eye
bolts are installed in accordance with the
manufacturer's recommendations.
5) Make sure that ordinary (shoulderless) eye
bolts are threaded in at least 1.5 times the bolt
diameter.
8–48 ESH Handbook
6) Use safety hoist rings (swivel eyes) as a
preferred substitute for eye bolts wherever
possible.
7) Pad sharp edges to protect slings. Remember
that machinery foundations or angle-iron edges
may not feel sharp to the touch but could cut
into rigging when under several tons of load.
Wood, tire rubber, or other pliable materials
may be suitable for padding.
8) Do not use slings, eye bolts, shackles, or hooks
that have been cut, welded, or brazed.
9) Install wire-rope clips with the base only on the
live end and the U-bolt only on the dead end.
Follow the manufacturer's recommendations
for the spacing for each specific wire size.
10) Determine the center of gravity and balance
the load before moving it.
11) Initially lift the load only a few inches to test
the rigging and balance.
3. Hand Signals
Signals to the operator must be in accordance with the
standard hand signals unless voice communications
8 equipment (telephone, radio, or equivalent) is used.
Signals must be discernible or audible at all times.
Some special operations may require addition to or
modification of the basic signals. For all such cases,
these special signals must be agreed upon and
thoroughly understood by both the person giving the
signals and the operator, and must not be in conflict
with the standard signals. (See Figure 8-22 next
pages.)
Figure 8-22: Hand Signals
8
8–50 ESH Handbook
8
4. Inspection, Maintenance, and Testing
All tests and inspections must be conducted in
accordance with the manufacturers recommendations.
a. Monthly Tests and Inspections
1) All in-service cranes and hoists must be
inspected monthly and the results documented.
2) Defective cranes and hoists must be locked and
tagged “out of service” until all defects are
corrected. The inspector must initiate correc-
tive action by notifying the manager.
b. Annual Inspections
A qualified contractor (Crane Maintenance
Contractor and/or Manufacturer) must schedule
and supervise annual preventive maintenance
(PM) and annual inspections of all cranes and
hoists. The annual PM and inspection must cover:
1) Hoisting and lowering mechanisms.
2) Trolley travel or monorail travel.
3) Bridge travel.
4) Limit switches and locking and safety devices.
5) Structural members. 8
6) Bolts or rivets.
7) Sheaves and drums.
8) Parts such as pins, bearings, shafts, gears,
rollers, locking devices, and clamping devices.
9) Brake system parts, linings, pawls, and ratchets.
10) Load, wind, and other indicators over their full
range.
11) Gasoline, diesel, electric, or other power plants.
8–52 ESH Handbook
12) Chain-drive sprockets.
13) Crane and hoist hooks.
14) Electrical apparatus such as controller contrac-
tors, limit switches, and push button stations.
15) Wire rope.
16) Hoist chains.
c. Load Testing
1) Newly installed cranes and hoists must be load
tested at 125% of the rated capacity by
designated personnel.
2) Slings must have appropriate test data when
purchased. It is the responsibility of the
purchaser to ensure that the appropriate test
data are obtained and maintained.
3) Re-rated cranes and hoists must be load tested
to 125% of the new capacity if the new rating
is greater than the previous rated capacity.
4) Fixed cranes or hoists that have had major
modifications or repair must be load tested to
125% of the rated capacity.
8 5) Cranes and hoists that have been overloaded
must be inspected prior to being returned to
service.
6) Personnel platforms, baskets, and rigging
suspended from a crane or hoist hook must be
load tested initially, then re-tested annually
thereafter or at each new job site.
7) All cranes and hoists with a capacity greater
than 3 tons (2722 kilograms) must be load
tested every four years to 125% of the rated
capacity. Cranes and hoists with a lesser
capacity must be load tested every eight years
to 125% of the rated capacity.
8) All mobile hoists must be load tested at
intervals to be determined by the manufac-
turer.
d. Records
The Facility must maintain records for all cranes,
hoist and rigging equipment.
5. Alloy Chain Slings
Alloy chain slings are made by bending, electric
welding, and heat treating alloy steel rods into chain
links. Alloy chain slings are more rugged and flexible,
but less shock resistant than wire rope, manila rope, or
braided slings. The size is measured by the diameter of
the link stock.
6. Safe Practices
a. Alloy chain
slings must be
protected
against
chemicals, rust
and corrosion.
Extremely low temperatures (below zero) may 8
cause brittle fractures, and it is advisable to reduce
safe load rating
under those
conditions by
about 50%.
b. Knots weaken
alloy chain
slings and may
cause chain
links to bend or
8–54 ESH Handbook
otherwise fail. Knots
must not be used.
c. Alloy chain slings may
be shortened by
hooking back into the
chain, into the master
link, or with grab
hooks. A chain must
never be shortened by
twisting, knotting, or by
use of bolts.
d. Alloy chain slings must be
protected from sharp
corners which might bend
the links. Lagging, corner
irons, etc., should be used
for this purpose.
e. When making choker
hitches with alloy chain
slings, always face the
hook opening out and
away from the pull of the
sling so the hooks will not
slip out when slack is
8 taken out of the sling.
f. Alloy chain slings must be
checked for:
1) Nicks, cracks, gouges,
and wear.
2) Bent links, lifted weld
fins, opened hooks,
and stretch.
3) Rust and corrosion.
4) Uneven lengths when sling legs are handing

free.
g. If all the legs of
an alloy steel
chain sling are
hooked back into
the master link,
the safe load
capacity of the
whole sling may
be increased 50
percent.
h. Finished surfaces
may be protected
from alloy chain
slings by bagging,
lagging, etc.
i. Sling hooks must
not be point loaded
unless designated
and rated for that
use.
j. The larger end of pear-shaped links must be used
on the crane hook so as to prevent the master
8
links from binding. The smaller end is used for
the alloy sling chain.
k. Interlink wear, not accompanied by stretch in
excess of 5 percent, must be noted and the chain
removed from service when maximum allowable
wear at any point of link, as indicated in table
below, has been reached.
l. Chain slings must be removed from service when,
due to stretch, the increase in length of a
measured section exceeds 5 percent; when a link is
8–56 ESH Handbook
bent, twisted or otherwise damaged, or when
raised scarfs or defective welds appear.
m. All sling chains, including end fastenings, must be
given a visual inspection before being used on the
job. A thorough inspection of all chains in use
must be made every three months. Each chain
must bear an indication of the month in which it
is thoroughly inspected. The thorough inspection
must include inspection for wear, defective welds,
deformation and increase in length or stretch.
n. All repairs to chains must be made under qualified
supervision. Links or portions of the chain found
to be defective as described in subparagraph l of
this section must be replaced by links having
proper dimensions and made of material similar to
that of the chain. Before repaired chains are
returned for service, they must be proof tested to
the proof-test load recommended by the
manufacturer.
Figure 8-23: Maximum Allowable Wear

at Any Point of Link
8
7. Applying Wire Rope Clips
a. A correct method of attaching U-bolt wire rope
clips to rope ends is shown in Figure 8-24 below.
The base of the clip bears against the live end of
the rope, while the “U” of the bolt presses against
the dead end.
b. The clips are usually spaced about six rope
diameters apart, to give adequate holding power.
c. Before ropes are placed under tension, the nuts on
the clips must be tightened. It is advisable to
tighten them again after the load is on the rope to
take care of any reduction in the rope’s diameter
caused by the weight or tension of the load.
d. A wire-rope thimble must be used in the loop eye
to prevent kinking when wire-rope clips are used.
e. The correct number of clips for safe application,
and spacing distances, are shown in Table 8-2 next
page.
Figure 8-24: Wire Rope Clips
8
The right way to clip wire rope The wrong way to clip wire rope
8–58 ESH Handbook
Table 8-2: Number of Clips and Spacing
for Safe Application
8
9. General Health
A. Dormitories
1. Housing
a. Housing must be structurally sound, in good
repair, in a sanitary condition, and must provide
protection to the occupants against the elements.
b. Housing must have flooring constructed of rigid
materials, smooth finished, and readily cleaned.
c. In dormitory accommodations using double bunk
beds only, not less than 40 square feet (12.2
square meters) per occupant must be provided.
d. Separate sleeping accommodations must be
provided for each gender.
e. Adequate and separate arrangements for hanging
clothing and storing personal effects for each
person must be provided.
f. Each habitable room (not including partitioned
areas) must have at least one window or skylight
opening directly to the out-of-doors.
g. All outside openings must be protected with
screening of not less than 16 mesh.
h. All screen doors must be tight fitting, in good
repair, and equipped with self-closing devices.
9
i. Sleeping facilities must be provided for each
person, and must consist of comfortable beds,
cots, or bunks.
j. Any bedding that is provided by the housing
operator must be clean and sanitary.
k. Triple-deck bunks are prohibited.
9–2 ESH Handbook
l. Beds used for double occupancy may be provided
only in family accommodations.
2. Toilets
a. Toilets must be constructed, located, and
maintained so as to prevent any nuisance or public
health hazard.
b. Toilets or privy seats for each gender must be in
the ratio of not less than one such unit for each 15
occupants, with a minimum of one unit for each
gender in common-use facilities.
c. Urinals, constructed of nonabsorbent materials,
may be substituted for men’s toilet on the basis of
one urinal or 24 inches (61 centimeters) of
trough-type urinal for one toilet.
d. Except in individual family units, separate toilet
accommodations for men and women must be
provided.
e. If toilet facilities for men and women are in the
same building, they must be separated by a solid
wall from floor to ceiling.
f. Toilets must be distinctly marked “men” and
“women” in the native language of the persons
expected to occupy the housing.
g. Common-use toilets must be well lighted and
ventilated and must be clean and sanitary.
9
h. Toilet facilities must be located within 200 feet
(61 meters) of each living unit.
i. All toilet facilities must be cleaned at least daily
with anti-bacterial soap and water.
3. Bathing
a. Bathing and hand-washing facilities, supplied with
hot and cold water under pressure, must be
General Health 9–3
provided for the use of all occupants. These
facilities must be clean and sanitary and located
within 200 feet (61 meters) of each living unit.
b. There must be a minimum of 1 showerhead per
15 persons.
c. Showerheads must be spaced at least 3 feet (0.914
meters) apart.
d. Shower floors must be constructed of
nonabsorbent, nonskid materials and sloped to
properly constructed floor drains.
e. Separate shower facilities must be provided for
each gender, and must be plainly designated
“men” or “women” in the native language of the
persons expected to occupy the housing.
f. When common-use shower facilities for both
genders are in the same building, a solid,
nonabsorbent wall extending from the floor to
ceiling must separate them.
g. Adequate, dry dressing space must be provided in
common-use facilities.
4. Safety
a. Any stoves or other sources of heat utilizing
combustible fuel must be installed and vented in
such a manner as to prevent fire hazards and a
dangerous concentration of gases.
9
b. Any wall or ceiling within 18 inches (46
centimeters) of a solid- or liquid-fuel stove or a
stovepipe must be of fireproof material. A vented
metal collar must be installed around a stovepipe,
or vent passing through a wall, ceiling, floor or
roof.
9–4 ESH Handbook
c. All buildings, in which people sleep or eat, must
be constructed and maintained in accordance with
applicable state or local fire and safety laws.
d. In family housing and housing units for less than
10 persons, of one story construction, two means
of escape must be provided.
e. All sleeping quarters intended for use by 10 or
more persons, central dining facilities, and
common assembly rooms must have at least two
doors remotely separated so as to provide alternate
means of escape to the outside or to an interior
hall.
f. Sleeping quarters and common areas on the
second story and above must have a stairway, and
a permanent, affixed exterior ladder or a second
stairway.
g. Fire-extinguishing equipment must be provided in
a readily accessible place located not more than
100 feet (30 meters) from each housing unit.
h. There must be at least 2 clearly marked exits on
each floor, and emergency lighting installed in
halls, stairwells, and above each exit.
i. Halls and exits must be kept clear of obstructions
to allow for a safe and rapid evacuation in case of
fire or other emergencies.
9 j. Directions for evacuation in case of fire or other
emergencies must be posted in all sleeping
quarters.
k. Fire drills must be conducted at least quarterly.
l. No flammable or volatile liquids or materials must
be stored in or adjacent to rooms used for living
purposes, except for those needed for current
household use.
m. Agricultural pesticides and toxic chemicals must
not be stored in the housing area.
n. First-aid kits must be provided and readily
accessible for use at all times, in a ratio of 1 per
every 50 persons.
5. Electrical
a. All dormitories must be provided with electric
service.
b. Each habitable room, all common-use rooms, and
areas such as halls and stairways must contain
adequate ceiling or wall-type light fixtures.
c. At least one wall-type electrical outlet must be
provided in each individual living room.
d. All wiring and lighting fixtures must be installed
and maintained in a safe condition.
e. Adequate lighting must be provided for the yard
area, and pathways to common-use facilities.
6. Sanitation
a. Housing and facilities must be free of insects,
rodents, and other vermin.
b. Durable, fly-tight, clean containers in good
condition must be provided adjacent to each
housing unit for the storage of garbage and other
refuse.
9
c. Provisions must be made for collection of refuse at
least twice a week, or more often if necessary.
d. The disposal of refuse must be in accordance with
state and local law.
9–6 ESH Handbook
B. Clinics and Occupational Health Programs

1. Clinics
a. All health care staff must be trained in the practice
of Occupational and Emergency Medicine.
b. All health care staff should be licensed and
registered for the level of care that they are
providing.
c. Guidelines should be established for triage of
patients to allow for better access to the health-
care system.
d. Guidelines should be established for the
admission, treatment, transport and discharge of
patients.
e. Infection control procedures should be
implemented, and appropriate equipment on-
hand (e.g., sterile gloves, CPR barrier mask,
autoclave, disposable needles, and suture kits).
Figure 9-1: Clinic
9
f. Protocols for the use, testing, maintenance and
calibration of medical and surveillance
instruments should be developed and
implemented.
g. All health-care facilities should have equipment
available to provide an advanced level of trauma
life support (e.g., Ambu-bag, EKG, AED, oxygen
tanks, airways, IV capability).
h. Protocols should be established for the return to
work of employees who have been absent from
work as a result of infectious or contagious
diseases.
i. The contractor should establish procedures to
ensure that all employees have access to health
surveillance that is appropriate to the health and
safety risks they incur at work.
j. The contractor/employer should provide a
minimum of 1 private bed for every 1,000
employees.
k. The contractor/employer should equip the clinic
facility with a mechanical ventilation system that
is capable of maintaining the temperature between
70 and 80 degrees Fahrenheit (21– 27 degrees
Celsius) at all times.
l. The contractor/employer should establish clinical
guidelines for the treatment of all infectious
9
diseases and have them available in the health care
facility at all times.
m. Strict adherence to sanitation standards should be
in place at all times.
2. Health Risk Assessment
a. The contractor/employer should measure existing
exposure levels to include: noise, temperature, UV
9–8 ESH Handbook
rays, VOC vapor, dust, exhaust ventilation, and
repetitive trauma.
b. The contractor/employer should review all on-
hand Material Safety Data Sheets for the purpose
of establishing or verifying PPE requirements.
c. The contractor/employer should establish a
procedure to insure compliance with PPE
requirements.
d. The contractor/employer should periodically
review the PPE program for effectiveness.
e. The contractor/employer should implement
standards to control the exposure to identified
risks (e.g., Hearing Conservation Program, Heat
Stress Reduction, VOC reduction, Eye Protection,
Foot Protection, Bloodborne Pathogens program,
Hazard Communication, Infectious Diseases,
etc.).
3. Health Surveillance
a. The contractor/employer should establish a
structured health-surveillance program based on
the results of the Risk Assessment.
b. A system should be established to analyze the
results of the surveillance programs, and provide
guidance for corrective action and medical
treatment.
9 c. A procedure should be developed to insure that
confidentiality of medical information is
maintained.
d. A procedure should be established to evaluate the
general health of employees at all stages of the
employment continuum (pre-employment,
baseline testing, pre-assignment, post sickness).
4. First Aid and Emergency Medical Response
a. The contractor/employer should develop, post,
implement and test a Medical Emergency
Response Plan.
b. The contractor/employer should develop the
capability of handling a medical emergency
through training of the workforce in basic first
aid, CPR, and First Response.
c. The number of employees trained should be
sufficient to insure that there is adequate coverage
available at all times. Names of these employees
should be posted in each work area.
Figure 9-2: First Aid Station
9
9–10 ESH Handbook
d. The contractor/employer should insure that all
employees who provide first aid or other
emergency care are trained in and adhere to the
Bloodborne Pathogens standard.
e. Protocols should be established for the transport
of injured workers via ambulance to off-site
medical treatment centers.
f. All transport vehicles should be equipped with
Advanced Life Support apparatus (oxygen tanks,
emergency air ways, back boards, cervical collars,
EKG, AED, etc.).
g. The contractor/employer should hold mock
emergency drills on a regular basis to insure that
the process is effective.
5. Recordkeeping
a. The contractor/employer should establish a
procedure to insure that the confidentiality of all
medical records is maintained at all times.
b. Occupational health records should be maintained
for a period of 30 years.
c. Health Assessment and Surveillance data should
be included as part of the medical record, and
maintained as such.
d. The contractor/employer should establish a
computerized system for the tracking of
9 occupational health records and data.
e. Summary surveillance data should be forwarded
to supervisors for corrective action, in a
confidential manner.
f. Occupational health data should be analyzed
regularly for the purposes of trend identification,
corrective action, and health promotion activity
planning.
6. Health Promotion
a. The contractor/employer should utilize health risk
assessment data to target high-risk occupational,
environmental and lifestyle diseases for the
development of health promotion activities.
b. Heath-promotion activities should be multi-media
and culturally relevant whenever possible.
c. Preventative measures should be instituted as a
means of reducing the overall health risk of the
workforce (e.g., smoking cessation, AIDS training,
family planning, tetanus vaccinations, Hepatitis B
vaccinations, etc.).
d. The contractor/employer should establish a
process to monitor and measure the effectiveness
of health promotion activities.
e. All health promotion activities should be
documented.
C. Canteens
a. When central food service facilities are provided,
the kitchen and dining hall must be in proper
proportion to the capacity of the housing, and be
separate from the sleeping quarters.
b. All food service facilities must be maintained 9
clean, clear of refuse and garbage, and free of
rodent and insect infestations.
c. All floors, walls, ceilings, studs, joints, rafters, and
pipes must be constructed to provide easy access
for cleaning.
d. Adequate light must be provided to all surfaces
and equipment in food service spaces.
9–12 ESH Handbook
e. All rooms must be adequately ventilated and air-
intake ducts and interiors of ventilation ducting
cleaned at least quarterly to prevent accumulation
of dirt and grease.
f. Ventilation hoods and grease filters must be
cleaned weekly to prevent fires.
g. Garbage and refuse must be kept in leak-proof,
nonabsorbent containers.
h. Sufficient numbers of garbage and refuse
containers are required to prevent overfilling.
They must be provided with tight-fitting covers
and emptied as necessary during operation hours
and at a minimum of each working day.
i. Garbage and refuse on the premises must be
stored in a location inaccessible to insects and
rodents. When garbage or refuse rooms are used,
they should not be located within 100 feet of the
food-service facility.
j. Garbage containers must be cleaned inside and
out after they are emptied at the end of the day.
k. Effective measures to eliminate or control the
presence of rodents, flies, cockroaches, and other
pests must be maintained.
l. The food-service facility and its adjacent grounds
must be kept free of litter and debris.
9 m. Floors must be of nonabsorbent, easily cleaned
materials.
n. Floors must be cleaned and disinfected daily.
o. All floor drains must be cleaned and disinfected
daily.
p. Wall surface adjacent to all food preparation and
cooking areas must be of nonabsorbent, easily
cleaned material. In addition, the wall surface
adjacent to cooking areas must be of fire-resistant
material.
q. Tables and chairs or equivalent seating must be
provided, and must be adequate in number to
accommodate the workers that will be served.
2. Food Preparation/Handling
a. All food-service workers must undergo medical
examinations at a minimum of twice annually,
and certified as being free from communicable
diseases.
b. Certification must be posted in the service area.
c. Food-service workers must wear hairnets, gloves,
and aprons while preparing and serving food.
d. Food-service workers must thoroughly wash and
disinfect hands after using toilet facilities or
engaging in any other activities that could
contaminate the hands. Signs must be posted in
the toilet areas clearly stating this requirement.
e. Food-service workers must thoroughly wash and
disinfect hands when switching between working
with raw food and food that is ready to eat.
f. Food-service workers who contract a disease that
is transmissible through food must be removed
from all food-handling activities until they are
9
certified as being disease free by a medical doctor.
g. Mechanical refrigeration that is capable of
maintaining a temperature of not more than 41°
Fahrenheit (5° Celcius) must be provided for the
storage of potentially hazardous food.
h. Sinks with hot and cold water under pressure
must be provided.
9–14 ESH Handbook
i. All cooking, serving, and eating utensils must be
constructed of stainless steel, and must be
thoroughly washed and disinfected after every use.
j. All tabletops and counters must be thoroughly
washed and disinfected after each use.
k. Countertops that are used for food preparation
must be constructed of stainless steel.
l. All food must be cooked and served or discarded
within 4 hours after being removed from
refrigeration.
Figure 9-3: Proper Hand Washing
9
m. All potentially hazardous food must be cooked to
a temperature of 140° Fahrenheit (60° Celcius), or
above.
n. Food must be stored off of the floor, and covered.
o. All food-service facilities should be maintained
clean, clear of refuse and garbage, and free of
rodent and insect infestations.
p. All food-service facilities must be provided with
adequate food-storage shelves.
D. Sanitation
1. General
a. The floor of every workroom must be maintained
in a dry condition to the extent that is possible
considering the work being performed.
b. Where wet processes are used, drainage must be
maintained and platforms, mats or other dry
standing places must be provided. If that is not
possible, appropriate waterproof footwear must be
provided at no cost to the employee.
c. To facilitate cleaning, every floor, working place
and passageway must be kept free of protruding
nails, splinters, loose boards, and unnecessary
holes or floor openings.
2. Waste Disposal (Non-Hazardous) 9
a. Any receptacle used for solid or liquid waste or
refuse with the potential to decay must be
constructed so that it does not leak and may be
thoroughly cleaned and maintained in a sanitary
condition. These receptacles should also be
equipped with a solid, tight fitting cover.
9–16 ESH Handbook
b. All solid or liquid wastes, garbage or refuse must
be removed as often as necessary to maintain the
sanitary condition of the work place.
3. Vermin/Pest Control
a. Every enclosed workplace must be constructed,
equipped and maintained in such a way as to
prevent the entrance or harborage of rodents,
insects or other vermin to the extent possible.
b. Where the presence of pests is detected, a
continuous and effective extermination program
must be instituted.
4. Toilet Facilities
a. Toilet rooms must be provided that are separated
by gender, and clearly marked as such. Where
physical space does not allow for separate toilet
rooms, gender signs must be posted outside of
each individual toilet facility/compartment.
b. The number of toilet facilities that are necessary
must be determined by the number of employees
Figure 9-4: Lavatory
9
of each gender that will utilize the facilities, based
on the following chart:
Number of Employees .................................... Min. No. Toilets1

1–15 ....................................................................................... 1
16–35 ...................................................................................... 2
36–55 ...................................................................................... 3
56–80 ...................................................................................... 4
81–110 ..................................................................................... 5
111–150 .................................................................................... 6
Over 150 ..................................................................................... 2
1
Where toilet facilities will not be used by women, urinals
may be provided instead of toilets, except that the number
of toilets in such cases must not be reduced to less than two-
thirds of the minimum specified.
2
Additional fixture for each additional 40 employees.
c. Each toilet must occupy a separate compartment
with a door and walls, or partitions between
fixtures that are sufficiently high to assure privacy.
d. Covered trash receptacles must be provided in
each compartment.
e. Trash receptacles must be emptied and disinfected
at least daily.
f. All toilet facilities must be maintained in a
sanitary condition, with floors and fixtures
cleaned using soap and disinfectant at least daily.
9
g. All toilet facilities must be adequately ventilated
and have enclosed pipes and drains.
h. Deodorant tablets must be used in all urinals.
i. No chemicals other than cleaning products may
be stored in a toilet room.
9–18 ESH Handbook
5. Washing Facilities
a. Lavatories (washing basins or sinks) must be made
available in all work places.
b. Each lavatory must be provided with hot and cold
running water, to the extent possible. Where hot
water is not available, cold or tepid running water
must be available.
c. Hand soap or similar cleansing agent must be
provided.
d. Individual paper hand towels, warm air blowers,
clean individual sections, or continuous cloth
toweling must be provided convenient to the
lavatories.
e. All washing facilities must be maintained in a
sanitary condition, with floors and fixtures
cleaned using soap and disinfectant at least daily.
6. Eating and Drinking Areas
a. No employee must be allowed to consume food or
beverages in a toilet facility, or in any other area
that is exposed to toxic material.
b. Receptacles with a tight-fitting cover must be
provided for the disposal of waste food, and must
be emptied and disinfected at least daily.
c. No food or beverages must be stored in a toilet
9 room or in any other area that is exposed to toxic
material.
E. Drinking Water
a. Potable water must be provided in all work areas.
b. Drinking water dispensers must be designed,
constructed, and serviced in such a way that
sanitary conditions are maintained.
c. Drinking water dispensers must be capable of
being closed to the work environment.
Figure 9-5: Methods of Providing Drinking Water
9
9–20 ESH Handbook
d. Individual drinking cups or other containers must
be available for each employee’s use. Common
drinking cups or utensils are prohibited.
e. Outlets for non-potable water, such as that used
for firefighting or other industrial purposes must
be marked in a manner that clearly indicates that
the water is not fit for human consumption.
f. All non-potable water systems must be
constructed in such a way that back flow or
siphonage into a potable water system is
prevented.
g. Non-potable water must be boiled or otherwise
decontaminated prior to being used for food
preparation or cooking.
h. Non-potable water may be used to clean the
general work premises, provided that it does not
contain chemicals or other substances that could
be harmful to employees or the environment.
i. Contractors/employers must establish a water
sampling program. Sampling frequency for a
water system is based on user population.
Population Served .......................... Minimum Samples/Month

25–1,000 .............................................................................. 1
8,501–12,900 ......................................................................... 10
17,201–21,500 ........................................................................ 20
9 41,001–50,000 ........................................................................ 50
j. A water system is considered to be in compliance

if the following bacteria and disinfection levels are
met:
1) Fecal coliforms = 0; however, if the samples per
month are less than 40, then 1 failure per
month is acceptable.
2) 99.9 percent inactivation of Giardia lamblia
cysts, 99.99 percent inactivation of viruses;
however, 1 failure per month is acceptable.
3) Residual disinfectant concentration in the
water entering the system cannot be less than
0.2 milligrams/liter.
4) The residual disinfectant concentration in the
distribution system measured as total chlorine,
combined chlorine or chlorine dioxide must be
detectable in 95 percent of the samples each
month.
F. Childcare Facility Management

a. Each childcare center must have a program
director that is employed full time.
b. When mobile classroom units are used, they must
be securely anchored to the ground and must meet
all requirements for permanent structures.
c. All stairs that have more than two steps must be
provided with sturdy handrails. When balusters
are more than 4 inches (10 centimeters) apart,
provisions must be made to prevent a child’s head
or body from falling through.
d. Landings or gates must be provided beyond each
exterior door, and any door opening onto a full- 9
length stairway.
e. Each window and glass door must be screened or
guarded.
f. Floors must be smooth and not slippery, free from
cracks, clean and in good condition. A floor
covering is required over concrete.
9–22 ESH Handbook
g. Walls must be clean and free of cracks.
h. All surfaces must be free of toxic materials.
i. Electrical outlets within the reach of children must
be provided with receptacle covers when not in
use.
j. Extension cords must not be used.
k. Each room occupied by children must have
adequate lighting in all parts of the room.
l. The premises must be maintained in good
condition and must be clean at all times, free from
accumulated dirt and trash, and any evidence of
vermin or rodent infestation. Each outdoor trash
and garbage container must be covered, and the
contents must be removed at least weekly.
m. Each room occupied by the children must be
heated, ventilated and cooled. The temperature in
each room must be not be less than 65°
Fahrenheit (18° Celcius) nor more than 90°
Fahrenheit (32° Celcius).
n. Each electric fan, if used, must be mounted high
on the wall or must be guarded.
o. When a gas heater is used, it must be approved by
a fire inspector before use. Open-faced heaters are
prohibited.
9 p. All heating elements, including hot water pipes,
must be insulated or installed in such a way that
children cannot come in contact with them.
Asbestos insulation must not be used. Fireplaces
must not be used when children are present.
q. Medicines, poisons, and other dangerous
substances and instruments must be in locked
storage.
r. Storage of firearms in any area used for children’s
activities is prohibited. Firearms stored in any
other area of the premises must be in locked
storage, or must be equipped with trigger locks.
s. Carpeting must be clean and in good repair.
Newly installed carpeting must meet fire safety
requirements of the local fire authorities.
2. Fire Safety
a. The building must meet the legal requirements of
the community as to fire protection, water supply,
and sewage disposal.
b. The building must have two exits approved by a
fire inspector. One exit must lead directly to the
outside.
c. Second floors approved by a fire inspector may be
used for children 2½ years or over. Second-floor
windows must be guarded.
d. Fire evacuation drills must be conducted at least
once a month for all children and adults present
using at least 2 means of exit.
e. Drills must be conducted according to procedures
which are posted in each room utilized by
children.
f. A record of drills must be available for inspection
by the local authorities.
9
3. Play Area
a. A fenced outdoor play area must be provided for
children 6 weeks to kindergarten age.
b. The outdoor play area must be able to
accommodate at least 25 percent of the capacity at
one time.
9–24 ESH Handbook
c. The fence for the outdoor play area must be at
least 3 feet (1 meter) high, free from sharp,
hazardous edges, and of sufficient construction to
keep animals and intruders out.
d. There must be no farm animals or fowl in the play
area. Pets, if present, must be physically controlled
or restrained.
e. The grounds must be kept neat and clean and
safe, and must be properly sloped or drained to
prevent stagnant water collection.
f. Hazards, such as flammable materials, deep pools,
or farm equipment, must be inaccessible; potential
hazards, such as uncovered wells, broken glass,
boards containing nails, and other debris must be
eliminated.
4. Water Supply
a. The water supply must be from a source approved
by a local health authority.
b. Sanitary drinking facilities must be available to
children while indoors or outdoors. One of the
following methods must be used:
1) Individual disposable cups and a water
dispenser.
2) Individually-marked glasses or cups which
must be washed daily.
9
3) A fountain designed so that a child can get a
drink of water without assistance.
c. Drinking fountains must not be plumbed to sinks.
d. Cold water and hot water not exceeding 110°
Fahrenheit (43° Celcius) must be supplied to
lavatory fixtures accessible to children.
5. Sanitation
a. All plumbing fixtures and building sewers must be
connected to public sewers where available.
b. When a public sewer is not available, a private
sewage disposal system meeting requirements of
the local health and environmental authorities
must be installed and connected to all plumbing
fixtures.
6. Bathroom Facilities
a. Plumbing must be installed and maintained
according to local plumbing codes.
b. Bathroom facilities must be readily accessible to
the children, and must be placed low or be
provided with safety steps.
c. There must be 1 toilet and 1washbasin for each
15 children.
d. Bathroom facilities must be planned to assure
privacy for staff.
e. Soap, individual cloth towels or paper towels, and
toilet paper must be provided. The use of
common towels and wash cloths is prohibited.
f. When cloth towels and wash cloths are used, they
must be labeled with the child’s name and
laundered at least weekly.
9
7. Sleeping Accommodations
a. Individual cribs, cots, or mats (suitable to the
child’s age and level of development) and a cover
must be provided for each child.
b. For evening care, each child must be provided
with a cot with a firm, waterproof mattress.
9–26 ESH Handbook
c. At least 3 feet (0.914 meters) of space must
separate the cribs, cots, and mats.
d. Cots, cribs, and mats must be disinfected daily or
marked for individual use and disinfected weekly
or more often when needed.
e. Stacked cribs must not be used for infant sleeping/
napping.
f. Smoking is prohibited in the center or preschool.
g. Alcohol or non-prescribed controlled substances
(drugs) must not be consumed on the premises
during hours of operation, nor while children are
present.
h. Each child’s hands must be washed with soap and
water before and after eating and after toileting.
i. Children must be allowed to go to the bathroom
individually as needed.
8. Illness
a. When a child is absent due to a communicable
disease, staff must inform other parents of the
nature of the illness.
b. Communicable diseases (anthrax, influenza,
Hepatitis A, B, or C, etc.) must be reported to the
relevant local authorities.
c. Symptoms of illness must be reported immediately
9 to parents.
d. A quiet area must be provided for sick children,
who must be supervised by an adult.
e. Non-prescription medications must not be
administered to any child except on written order
of the parent or guardian.
f. Orders must be renewed yearly.
g. A designated staff member must administer
medication.
h. One designated staff member, per session, per unit
must administer prescription medication from a
pharmacy container labeled with the child’s name,
the name of the medication, dosage, dosage
intervals, the name of the physician, and the date
the prescription was filled. The label must be
considered the order from the physician.
i. A record must be kept in the child’s file as to who
gave the medication and of the date and time it
was given.
9
10. Sampling Equipment/Device
Guidelines
A. 3M Organic Vapor Monitors (OVM)
These diffusion monitors are a sampling device designed to
measure average concentrations over a measured time
interval. Sampling times will vary according to contaminant
concentrations and environmental conditions such as
humidity. For complete details on sampling times refer to
the last page of this document. This monitor can be used as
either a personal or area monitor. As a personal monitor, it is
worn near the breathing zone of individuals exposed to
potentially hazardous environments. When used as an area
monitor, hang it away from walls, corners, table tops, or
other regions where the air movement in the room may be
limited.
Diagram 1 Diagram 2 Diagram 3
10
Diagram 4 Diagram 5
10–2 ESH Handbook
1. Preparation of Blanks
Good industrial hygiene practice indicates that a
blank monitor be included with each set of samples to
check for any contamination of the samples. The
blank is a monitor which has been handled in the
same manner as the sample monitors, but has not
been exposed to the atmosphere in the area being
monitored. For every ten samples submit at least one
blank.
2. Sampling Instructions
a. Remove monitor from its container and record the
time on both the monitor back section and on the
corresponding data sheet. Keep the container.
b. Before monitoring, record the following
information in your data sheet: 1) monitor serial
number (each monitor has a four digit number
and letter), 2) sampling date, 3) employee or area
I.D., 4) temperature and relative humidity (if
known), and 5) compounds to be analyzed.
c. Record the date, employee or area I.D. and
sampling start time on the monitor label
(Diagram 1). DO NOT REMOVE WHITE
FILM AND PLASTIC RING.
d. Monitor can be used as an area or personal
monitor. For personal sampler attach the monitor
near employee breathing zone (Diagram 2). Place
the monitor on the worker by affixing the alligator
clip to the shirt collar with the white membrane
side exposed (on the outside). When used as an
10 area monitor, hang it away from walls, corners,
table tops, or other regions where the air
movement in the room may be limited.
e. When removing the monitor record the end time
on both the monitor and data sheet. Calculate the
Sampling Equipment/Device Guidelines 10–3
total time of sampling on the data sheet. If the
sampling period spans the lunch hour, subtract
the lunchtime from the total time between
monitor placement and removal.
f. After sampling period is ended, remove plastic
ring and white film from the monitor (Diagram
3). Snap the elution cap (with plugs) onto the top
of the primary body. Separate the primary body
and secondary body sections (Diagram 4). Snap
the bottom cup (no plugs) into the bottom of the
primary section (Diagram 5). Snap elution cap on
the secondary body. You may wish to secure them
with scotch tape before placing them back in cans.
Monitor is now ready for shipment. Note: The
primary and secondary sections should have the
same identification numbers.
g. Return monitor to can and close with plastic lid
provided. Pack monitors securely into a box and,
where possible, with a cool pack to further ensure
sample preservation.
h. Send samples “Next Day Air” to an accredited
laboratory for analysis.
Note: Certain compounds (e.g., acetone, MEK, vinyl
acetate, etc.) may show a decreased recovery when sampled
in high relative humidity. Refrigerate and/or expedite for
analysis to help ensure accurate results.
The placement of any sampling material or equipment on
workers should be voluntary. Workers should be instructed
to go about their normal duties and not alter their routines
in any way. Monitors can be kept on during lunch if the 10
sampling period requires it.
It is important to periodically check the monitors during the
sampling period to make sure they are still properly placed
and not damaged or covered with material or clothing.
10–4 ESH Handbook
For many situations passive sampling, Organic Vapor
Monitors (OVM), is preferred over comparable active
methods. This section is based upon guidelines for the 3M
organic vapor monitors.
Desorbing Solvents are listed for each compound in the
following table. The desorbing solvent allows an individual
to determine what other compounds if any may be sampled
on the same organic vapor monitor at the same time. Two or
more compounds with the same desorbing solvent can be
sampled concurrently on the same OVM. It is essential that
the minimum and maximum exposure times be adhered to
for the compounds being sampled. The following table
specifies this information.
*Shading denotes the most typical chemicals sampled in
footwear, apparel, and equipment factories.
Table 10-1: Desorbing Solvents
10
B. Sound Level Meter Guidelines

1. Monitoring Equipment
a. The Quest™ 2400 Type 2 sound-level meter will
primarily be used to quantify continuous or
intermittent noise exposure surveys. The operator
must record the measured sound level. The sound
level meter kit will include a calibrator, calibration
tool, wind guard, wrist strap and two 9-volt
alkaline batteries. Calibration must occur prior to
sampling and after sampling each day. Do not
substitute with another type of calibrator. The
Quest™ 2400 and calibrator must be sent back to
an authorized maintenance and calibration vendor
each year. It is recommended that the user read
the Quest instructions and this guide and becomes
familiar with the equipment prior to use.
b. The Quest™ 2400 sound level meter must not be
used in flammable atmospheres or near open
containers of flammable materials.
c. Calibrating the Quest™ 2400 sound level meter:
1) Slide the frequency weightings switch to “A.”
2) Slide the range switch to high (70–140 dBA).
3) Slide the response switch to “Slow.”
4) Slide the display mode to “Run.”
5) Tun on the power to the meter. The LCD
(liquid crystal display) should indicate the
status of the batteries and the current sound
level. 10
6) If low battery status is indicated, turn off the
power. Open the batteries door and discard the
old batteries. Slide two new 9-volt alkaline
batteries into the space as shown by the label in
10–6 ESH Handbook
the battery door. New batteries should provide
approximately 25 hours of continuous use.
Recording the date on each battery is recom-
mended.
7) Turn on the power. The display should indicate
sufficient battery power for the planned survey
and the current sound levels.
8) Slide the calibrator onto the silver microphone
until fully inserted. The current sound level
reading should be lower. (The calibration date
by the authorized vendor must be on the
calibrator and be current within one year.)
9) Turn on the calibrator. The sound level should
rise to the calibrator source level. Note on the
calibrator label the appropriate sound level.
10) If the sound level meter reads the same as the
calibrator source level label, the meter is
properly calibrated.
11) If the sound level meter is not calibrated, use
the calibrator tool to adjust the calibration
screw on the sound level meter until it matches
the calibrator source level label. If the sound
level meter will not calibrate, install a new
battery in the calibrator. Start at Step 8) to
complete the calibration. If the sound level
meter will not calibrate, return it to an
authorized maintenance and calibration
vendor.
12) Turn off the calibrator and remove it from the
10 microphone. The sound level meter is cali-
brated. Record in your notes that calibration
was conducted including, date, time and name.
13) After monitoring is complete for the day,
follow calibration Steps 7) through 12).
d. Using the Quest™ 2400 sound level meter:
1) Assure that proper calibration was conducted
before use.
2) Attach the wrist strap to the meter and your
wrist to prevent damage if dropped.
3) Do not talk or create noises while monitoring.
All sound levels measured should be from the
typical work environment.
4) Wind or high air velocities can create whistles
or distortions around the microphone that can
cause sampling data errors. Where high air-
velocities are present during sampling, the
wind guard should be installed over the
microphone. Note in the documentation if the
wind guard was used.
5) The meter should be held with your arm
extended away from your body approximately
at the employee’s ear level. Areas with seated
employees should be sampled at seated
employee ear level and standing employee ear
level. If no employee is present, hold the meter
approximately 5 feet (1.5 meters) above the
floor. Similar to the employee’s ear, the
microphone should point sideways approxi-
mately perpendicular to the direction the
employee is standing. Record the sampling
height and location.
6) Monitor and record the sound levels from
different task specific areas around a noise
source. (Example, for a product grinder, 10
monitor near the loading area, control panel
and discharge area.)
7) Each different employee task that involves a
noise source should be monitored and re-
10–8 ESH Handbook
corded. (For example, for a product grinder,
the product loader, operator and maintenance
person may have different noise exposures.)
8) Some sound level fluctuations are common.
After 10 seconds, record the estimated average
or center tendency sound level for each
position. If the fluctuation is greater than 3
dBA, record the minimum, maximum and
estimated average levels.
9) Maximum levels can also be determined by
sliding the display switch to “Max Hold”
mode. Reset to “Run” mode before continuing
the sample.
10) Record the time, date, exact location, equip-
ment in operation and rate. Record operation,
name of task or operation, sine of room or
area, number of employees present, duration of
the task or exposure to the noise source,
identity of sound level meter, sound levels
measured, name of person conducting the
survey and other applicable information.
11) Noise dosimeters may be worn by an employee
to document the various noise exposures
throughout a work period. The dosimeter
records and calculates the daily noise dose for
the workday. Dosimeters must be calibrated
and all settings set for A weighting, slow
response, threshold at 80 dBA, exchange rate
of 5 dBA and criterion at 90 dBA. The
microphone should be attached to the collar
10 approximately 6 inches (15.2 centimeters)
from the ear and pointing up toward the ear.
e. Exposure Monitoring
All facilities should be systematically assessed for
high noise sources and work areas. All areas
believed or known to be higher than 85 dBA
should be identified and monitored. Any work
area that requires the employees to shout to be
heard or understood from a distance of
approximately 1 meter should be evaluated. The
sound level meter can survey specific operations,
machines or work areas. Adjacent equipment can
be turned off to determine the noise caused by a
single machine. A simple plan should include the
following issues:
1) A person experienced with the facility should
conduct an initial walk through of all work and
maintenance areas identifying potential high
noise locations. Develop a detailed listing and
diagram of noise sources and areas of high
noise. Different shift operations and scheduled
maintenance activities should be listed.
2) Locate employee work areas near all of the
noise sources. Record how long they work with
specific equipment and the duration of work in
a high noise area.
3) Conduct sound level measurements for each
identified work area or noise source. Record
the sound levels and status (on or off, full or
half speed, production rate) of each adjacent
piece of equipment.
4) All equipment with employee exposure to
sound levels above a time weighted average of
90 dBA should be evaluated for engineering
controls, enclosures, adding sound absorbing
materials, replacement with quieter equipment, 10
etc.
5) If available, a dosimeter can be worn by an
employee to record the duration of exposure
and exposure levels. Compare the dosimeter
10–10 ESH Handbook
record with the measured sound levels and
estimated time of exposures. All significant
differences (>3 dBA) should be monitored
again.
6) Summarize all noise source areas greater than
85 dBA and all employee work areas. Writing
the sound levels on a floor plan, blue print,
photo or a simple sketch of the work area may
be helpful.
7) All employees with an 8-hour time weighted
average of 85 dBA will be included in the
hearing conservation program. See Calcula-
tions section.
f. Calculations
A maximum time weighted average of 90 dBA or
1.0 (100%) for noise exposures are based on the
8-hour workday. Employees exposed above this
level will be included in the hearing conservation
program. The dBA scale is logarithmic and can
not be simply added or subtracted. A worker who
works a full 8 hours in one location with
continuous noise exposure will average that
exposure. Maximum exposures are listed in the
Table 10-2 next page.
10
Table 10-2: Maximum Exposure Levels
Duration Per Day ......................................... Sound Level dBA

8 ........................................................................ 90
6 ........................................................................ 92
4 ........................................................................ 95
3 ........................................................................ 97
2 ...................................................................... 100
1.5 ................................................................... 102
1 ...................................................................... 105
0.5 ................................................................... 110
0.25 ................................................................. 115
Shorter duration or mixtures of exposures must be calcu-

lated.
C1 C2 Cn
D = ---- + ---- + ----
T1 T2 Tn
With:
D = the total noise dose
C = employee’s duration of exposure at a specific
noise level
T = total duration of exposure allowed at that noise
level
A dose of 1.0 (100%) is the same as an 8-hour time

weighted average of 90 dBA. 10
TWA = 16.61 times log10 (D) + 90 dBA

11. General Information, Weights
and Measures
11
11–2 ESH Handbook
11
General Information, Weights & Measures 11–3
11

ESH Handbook 2002

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ESH Handbook 2002

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Copyright © 2002 Nike, Inc.

1. ESH Management ............................................... 1-1

C. Injury/Illness System Management

Figure 2-1: Stackhead Designs

Table 2-1: Abbreviated ODC Table

Figure 2-2: Fume Hood Cutaway

Figure 2-3: Dust and Centrifugal Collector

Figure 2-4: Hazardous Waste Labels

Figure 2-5: Secondary Containment Unit

C. Polychlorinated Biphenyls (PCBs)

F. Underground Storage Tank

Figure 2-7: Underground Storage Tank With

G. Aboveground Storage Tanks

Figure 2-9: HazMat Storage Area

potential spill sites and include but not be limited

Figure 2-10: Spill Kit

Figure 2-11: Spill Response Cart

B. Hazardous Material Labeling

Figure 3-1: Hazard Communications

Figure 3-4: NFPA Hazardous Materials

C. Restricted Manufacturing Substances (RMS)

D. Chemical Storage, Handling, Distribution,

2. Electrical Bonding and Grounding

Figure 3-5: Bonding and Grounding

Figure 3-6: Examples of Bonded and Grounded

Figure 3-8: Storage Cabinet

Table 3-2: Recommended Storage Containers

Figure 3-9: Storage Locker Ventilation Fans

Figure 4-1: Cluttered Shop Floor

Figure 4-3: Safe Angles for Ladders,

(page 4-12) to find an illuminance category

Table 4-2: Recommended Illuminance

Area/Activity ............................................. Illuminance Category

Figure 4-4: Direction of Air Flow

Figure 4-5: Inlet and Exhaust Locations

Figure 4-6: Branch Entry

Figure 4-8: Fume Hoods

C. Accident Prevention Signs and Tags

D. Machine Shop Safety

Figure 4-10: Bench/Pedestal Grinder

Figure 4-11: Grinder Hood Adjustment

The hood or gap adjustment must be kept ¼ inch (6.35

Figure 4-12: Ring Test

Figure 4-13: Air Nozzle with Dead-end Safety Tip

Figure 4-14: Acceptable Methods

Figure 4-15: Some Types of Fan Guards

Figure 4-16: A Striking Holder

Figure 4-17: Figure 4-18:

Figure 4-19: Retractable Safety Guard

Figure 4-20: Combination Belt 4

Figure 4-21: Shaft Guards

Figure 4-22: Coupling, Collar, Clutch Guards

Figure 4-23: Gear, Sprocket, Friction Drive Guards

Figure 4-24: Band Saw Guarding

Figure 4-25: Table Saw Guarding

Figure 4-26: Overhead Circular Saw Guarding

Figure 4-27: Grinder Guarding

Figure 4-28: Typical 120 Volt Branch Circuit

Table 4-5: Minimum Depth of Clear Working

Figure 4-29: Proper Position of Straight and

Figure 4-30: Proper Position of Straight and

Figure 4-32: Compromised and Normal