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1

PURPOSE

These procedures provide the Operations Manager with the ability to insure that all employees operating a company vehicle on public and private roadways are protected from traffic hazards. These guidelines are intended to be minimum standards that may be modified or augmented to comply with specific customers driving standards and requirements. These procedures meet or exceed the requirements of Federal Highway Administration Department of Transportation Regulation “Transportation”, 49 CFR Part 40, and Part 301 through Part 399.

2

SCOPE

This program covers all Versabar, Inc. employees, customer employees, contractor employees, vendor employees and visitors that enter into a company owned or leased vehicle or any privately owned vehicle, which is used for company business, for transportation on public and / or private roadways.

3

DEFINITIONS

1. Authorized Driver

An Authorized Driver shall be a Versabar employee that has been determined by a Versabar Operations Manager to be authorized to drive / operate a company vehicle.

2. Commercial Motor Vehicle

Means any self-propelled or towed vehicle used on the public highways in commerce to transport passengers or property when:

The vehicle has a gross vehicle weight rating or gross combination weight rating of 10,001 or more pounds; or

The vehicle is designed to transport more than 15 passengers, including the drivers; or The vehicle is used to transport hazardous materials in quantities requiring placarding under regulations issued by the Secretary of Transportation. (49 CFR 350.3 and 390.5)

3. Commercial Driver’s License (CDL)

Means a license issued by a State or other jurisdiction, in accordance with the standards contained in 49 CFR 383. The CDL is required of any individual that intends to drive / operate a Commercial Motor Vehicle(s):

With a gross combination weight rating of 11,794 kilograms or more (26,001 pounds or more) inclusive of a towed unit with a gross weight rating of more than ,536 kilograms (10,000 pounds); or

With a gross vehicle weight rating of 11,794 or more kilograms (26,001 pounds or more); or Is designed to transport 16 or more passengers, including the driver; or

Is any size and is used in the transportation of Hazardous Materials.

4. Company Vehicle

A motor vehicle (automobile and / or truck) designed for travel on public and private roadways, owned and / or leased by Versabar and any personally owned vehicle used in Versabar business. This would also included rented or leased vehicles being used for business purposes.

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4

AUTHORIZED DRIVERS

4.1

Driver Qualification

Requirements to operate a company vehicle are:

1. Driver must be an authorized driver as described in “Definitions”; and

2. Driver must have a current valid motor vehicle operator’s license issued by an appropriate federal or state government.

3. Upon assignment of driving duties / privileges, a verification of the individual’s driving record must be obtained from the license issuing authority (i.e., State Department of Motor Vehicles). This is done by the Human Resources Department at the request of the Operations Manager. This Motor Vehicle Record (MVR) report is to become part of the employee’s driver/operator file. Subsequent MVR checks must be obtained annually and processed in the same manner.

4. Each employee is allowed a maximum of fifteen (15) hours of duty time including a maximum of ten (10) hours of driving time before he / she must have a minimum of eight (8) hours rest (off duty). The driver shall not operate a company vehicle until after completing the minimum eight (8) hour rest period. This driving time will begin from the time the employee leaves his/her home or hotel.

5. Management of Change that has been approved by the Operations Manager is required to modify this policy.

4.2

Driver Performance Review

All Authorized Drivers shall immediately report to their Manager, any traffic accidents, violations or citations that they may receive (while on duty or on off time). A record of these accidents, citations or violations shall be maintained in the employee’s Driver / Operator Record File (DOT drivers) or the individual’s Personnel file (Non-DOT drivers) in the HSE Department.

Every year prior to annual auto policy renewal date the HR Department shall conduct MVR reports on all Authorized Drivers. The Operations Manager shall meet with the authorized driver/s to review the individual’s driving record MVR reports annually and whenever a traffic accident, citation or violation is reported. The Operations Manager shall determine at this meeting if the driver / operator is qualified to operate a company vehicle. The following schedule shall be followed in reviewing the qualifications of an Authorized Driver:

1. Does the driver meet the requirements of item 1 through 3 for Paragraph A. “Driver Qualification” above?

2. Minor Infraction(s) - parking tickets, minor vehicle accident (less than $200.00 vehicle damage) without citation requires a verbal warning and documentation in the individual’s Driver / Operator Record File (DOT drivers) or the individual’s Personnel File (Non-DOT drivers).

3. Serious Infraction(s)- speeding citations, significant damage to a company vehicle (greater than $200.00), other moving violations / citations require:

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First Occurrence - a written warning placed in the individual’s Driver / Operator Record File (DOT drivers) or the individual’s Personnel File (Non-DOT drivers).

Second Occurrence (In a 12 Month Period)driverwill NOTbe eligible to drive a company vehicle until one of the violations are removed from their MVR (in most States 3 years).

Third Occurrence (In a 3-Year Period) - driver will NOTbe eligible to drive a company vehicle until two of the violations are removed from their MVR (in most States 3 years).

4. Major Infraction(i.e., DWI, vehicle accident while speeding, felony traffic citation(s), etc.) - Temporary layoff or permanent employment termination depending on specific

circumstances.

5. Employees shall be disqualified / ineligible to operate a company vehicle under the following circumstances:

When an employee has experienced two or more at fault accidents and/or moving violation citations in any consecutive twelve-month period.

When an employee has experienced three or more at fault accidents and/or moving violation citations in any consecutive three-year period.

When the employee’s legal driving privilege is limited because of revocation, suspension, withdrawal, or denial of an operator’s license or permit.

When the employee is convicted of a disqualifying offense. Disqualifying offenses include:

1. DWI conviction(company vehicle or other vehicle).

2. Felony convictioninvolving the use of any motor vehicle.

3. Hit and Run conviction (unauthorized leaving of the scene of accident).

4. Allowing an unauthorized person to operate a company vehicle.

4.3

DOT Regulated Vehicles

No vehicles at Versabar are considered DOT Regulated Vehicles.

4.4

Reassignment of Employees

Employees who are unable to perform all essential and / or primary functions of their job as a result of motor vehicle accident, citation, violations or limitations, may, at the discretion of management, be reassigned to an existing open position where his/her work qualifications are compatible. The employee’s compensation base rate may be adjusted in conjunction with required job grades,

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employee is to be placed on temporary layoff status for a period not to exceed thirty (30) calendar days. Employees not recalled within the period of temporary layoff shall be permanently terminated.

5

VEHICLE OPERATING PROCEDURES

5.1

VEHICLE ACCIDENTS KITS

Each Company Vehicle shall contain the following “Vehicle Accident Kit”: 1. One or more copies of the “Vehicle Incident Report”; 2. One or more pencils or pens;

3. One disposable 35 MM camera with flash; 4. One Triangle Flare Kit;

5. One 2 1/2 pound ABC Dry Chemical Fire Extinguisher; and 6. One six (6) person First Aid Kit.

7. One flash light with spare batteries.

5.2

Vehicle Inspection

Before starting the engine each morning, the driver shall conduct a basic visual vehicle inspection. Once each week the driver shall complete the “Vehicle Inspection Check List” form number. The completed inspection form shall be maintained in the vehicle file in the Facility Office.

5.3

Vehicle Loading

No company vehicle shall be driven or allowed to be driven unless the vehicle is properly loaded, distributed and secured. Included in this requirement are vehicles carrying people, equipment, materials, chemicals, etc. The driver shall not move the vehicle until all passengers are properly wearing the seat belt and shoulder strap provided for their position in the vehicle. A passenger shall not be allowed to travel in/on a vehicle that does not have a seat belt and shoulder strap provided for that position.

5.4

Driving of Vehicles

All company vehicles shall be operated in accordance with federal, state and local laws, ordinances and regulations.

No driver shall operate a company vehicle while the driver’s ability or alertness is so impaired, or so likely to become impaired, through fatigue, illness, or any other cause, as to make it unsafe for him/her to begin or continue to operate the vehicle.

No driver shall operate a company vehicle while the driver’s ability to hear emergency vehicle alarms is diminished by the loud volume sound produced by radios, tape players, C.D. players, walkmans, etc.

No driver shall operate a company vehicle or be on duty, while in the possession of or under the influence of the drugs and other materials proscribed by 49 CFR 392.4, “Drugs and Other Substances.” No driver shall operate a company vehicle or be on duty, while under the influence of alcohol as required by 49 CFR 392.5.

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No driver shall operate a company vehicle at speeds greater then those permitted by the jurisdictions in or through which the vehicle is being operated. The Manager shall insure that all drivers have sufficient time to travel the distance required without causing the vehicle to operate at speeds greater then those permitted by the jurisdictions in or through which the vehicle is being operated.

Each driver is allowed a maximum of fifteen (15) hours of duty time including a maximum of ten (10) hours of driving time before he / she must have a minimum of eight (8) hours rest (off duty).

All company vehicles shall have their headlights on while the vehicle is in motion or on a public / private road, day or night.

All drivers operating large trucks (requiring a CDL) shall comply with the hours of service, travel logs and other requirements of 49 CFR 395.

5.5

Accident Reporting

Allvehicle accidents shall IMMEADITAELY be reported verbally to the Operations Manager. The vehicle driver and the Manager shall follow the directions given in Section (C) “Incident Management & Reporting” of this manual for the investigation and further reporting of the accident.

6

MOTOR VEHICLE MAINTENANCE

Motor vehicles are one of the most basic and essential tools of our business. Because of the distances which our operations require us to travel, often in bad weather, it is essential that motor vehicles be kept in proper operating condition at all times. The best way to ensure that a vehicle is in good operating condition is to inspect it regularly. Daily inspections shall be made prior to leaving the shop. Quarterly inspections should be made by a qualified repair facility either as a specific process or as part of equipment repair or maintenance.

Each vehicle shall have a separate maintenance file (Fleet Vehicle Record). All invoices for service and parts should be kept in this file. Dates and types of repairs and maintenance should be kept in this file.

Daily inspections should be documented on the form Vehicle Inspection Form. This form shall be

completed daily and kept on file for one year. Each file shall be discarded at the end of a year and replaced with the new month’s file.

A copy of the Vehicle Checklist label shall be placed on the dashboard of all Versabar vehicles.

7

EMPLOYEE TRAINING

7.1 Responsibility for Training

The Operations Manager is responsible for ensuring that all personnel at his/her facility are trained in the requirements of the “Company Vehicle Driving & Operating Procedures” and for nstructing employees covered by the program with specific

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7.2

Employees to be Trained

Each Versabar employee shall be trained on the requirements of the “Vehicle Operating Procedures” before they start work and annually there after. All employees shall be provided training prior to driving / operating a company vehicle.

NO Employee shall drive / operate a company vehicle, unless they have been trained and qualified as per the requirements of the “Vehicle Operating Procedures”.

8

OPERATIONAL INSTUCTIONS

The vehicle is fit for the purpose and has been maintained in safe working order, with seatbelts installed and functional.

The number of passengers does not exceed manufacturer’s specification for the vehicle. Loads are secure and do not exceed manufacturer’s specifications and legal limits for the vehicle. Drivers must be appropriately assessed, licensed, trained and medically fit to operate the vehicle.

Drivers are appropriately rested and alert.

Drivers must not use a mobile phone or two-way radio while operating the vehicle.

The risks of the journey have been assessed and plans in place in specific risk areas and high-risk countries.

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SUMMARY OF RESPONSIBILITIES

9.1

HSE Manager

Develop, review, and periodically update the Vehicle Operating Procedures format designed to

effectively protect employees from the hazards of operating a vehicle on public and private roadways and to comply with the requirements of the 49 CFR Part 40, Part 301 through Part 399).

Ensure and document employee instruction required by the Vehicle Operating Procedures.

Provide technical and administrative assistance to company locations in their on-going efforts to maintain effective Vehicle Operating Procedures.

Conduct annual audits of each location’s Vehicle Operating Procedures to identify necessary corrections or modifications and to assist in developing and implementing such measures.

9.2

Operations Manager

Support the HSE Manager in the administration of the Vehicle Operating Procedures.

Actively participate in administrative activities such as material selection, process design, production operation’s and loss control planning to reduce or eliminate vehicle accidents.

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9.3

Supervisors

Shall be responsible for implementing the Vehicle Operating Procedures within their work group.

Shall maintain copies of current copy of the Vehicle Operating Procedures and make them readily available to all employees.

9.4

Employees

Are expected to cooperate actively in instruction sessions, follow personal protective equipment use requirements and other Safety & Environmental rules and regulations for driving / operating company vehicles.

Shall report all incidents / accidents immediately to their supervisor.

Shall not to attempt drive / operate a company vehicle until they are properly trained and have taken the precautions required in the Versabar Vehicle Operating Procedures.

(9)

VERSABAR SAFETY MANAGEMENT SYSTEM

Form (E-1)(F-1)

Weekly Vehicle Inspection Form

CHECK LIST

Vehicle Description:

Make _________________________ Model ___________________

Year _______________ License ___________________ Color ____________

CHECK ALL THAT APPLIES: YES/OK NO

WATER FUEL

SERVICE BRAKES PARKING BRAKES LIGHTS & REFLECTORS WINDSHIELD WIPERS

LEFT FRONT TIRE AIR PRESSURE LEFT REAR TIRE AIR PRESSURE RIGHT FRONT TIRE AIR PRESSURE RIGHT REAR TIRE AIR PRESSURE STEERING

HORN

REARVIEW MIRROR BATTERY

EMERGENCY EQUIPMENT

LICENSE PLATE EXPIRATION DATE INSPECTION STICKER EXPIRATION DATE SERVICE DUE DATE

(10)

1

PURPOSE

This program provides the Operations Manager with the procedures to ensure the safety and health of personnel conducting compressed gas handling. This program complies with 29 CFR 1910.101, 29 CFR 1910.166 - .169, 29 CFR 1910.253, Compressed Gases.

2

SCOPE

This program covers all Versabar, Inc. employees, customer employees, contractor employees, vendor employees and visitors that enter on to Versabar property and / or work site.

3

PROCEDURES

3.1

General

Use only the type of gas for which the compressed gas equipment is designed.

Ensure that the cylinder valve is shut off, except when cutting or welding is in progress.

Do Not allow sparks, flames or other sources of ignition to come into contact with cylinders, regulators or hoses of a compressed or liquefied gas system.

Keep the nozzle guard of airless spray machinery in place at all times when the machinery is being operated.

When moving pressurized cylinders, always make sure they are in their proper containers, and that the valves are turned off and that the valve caps are fastened securely.

Do not leave the valves on empty cylinders open. Close the valve before installing the valve cap.

All cylinders, empty or full, shall be stored away from open flame furnaces, radiators, flammable and volatile liquids, or other hot places.

Cylinders shall be stored, transported, and used in an upright position. In storing, secure them with a chain or bar to prevent toppling. See that protective caps are in place when cylinders are not in use.

Cylinders shall not be handled roughly; do not drop them or permit them to fall or strike other cylinders or materials.

Cylinders shall be transported only in an approved safe manner and in the recommended container.

Inspect gas hoses and supply gas valves frequently.

Clean new hoses to insure that they are free of dust and talcum before using.

Keep torches, regulators, hoses, valves, etc., free of oil, dirt and dust.

Avoid using long lengths of hose wherever possible.

Use proper connections. Never use connections that do not fit properly.

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Never use white lead, grease or pipe fitting compound in making joints on gas systems. Oxygen under pressure contacting such materials can be very dangerous.

Always use the proper regulator to reduce gas pressure from a compressed gas cylinder.

Open or crack valves slowly.

Always close the cylinder and line valves at end of each shift, and purge hose and torch of gases.

Never use a gas cylinder as a prop when cutting material.

Never let hot slag fall on cylinders, hoses or on flammable material.

Always refer to gases by their proper names.

NEVER use oxygen as a substitute for compressed air in pneumatic tools or other devices.

Treat equipment with respect. Do not misuse or abuse it.

No compressed gas cylinders are allowed in confined spaces during hot work.

3.2

Marking and Labeling

3.2.1 Cylinders

Compressed gas cylinders shall be legibly marked with either the chemical or the trade name of the gas. Such labeling shall not be readily removable. When ever possible the marking shall be on the shoulder of the cylinder. Marking shall conform to the requirements of the “American National Standard Method for Marketing Portable Compressed Gas Containers to

Identify the Material Contained,” ANSI Z48.1-1965.

3.2.2 Piping and Hose Lines

Each pipe carrying compressed gas shall be marked with the name of the gas, the pressure of the gas and the direction of flow.

Each hose carrying compressed gas shall be identified by the color of the line.

Each hose and / or pipe shall be color coded as per the following:

1. Combustible and Flammable Gas - RED

2. Oxygen - GREEN

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1

PURPOSE

These procedures provide the Operations Manager with the ability to ensure the safety and health of personnel operating and maintaining electrical equipment.

2

SCOPE

This program covers all Versabar, Inc. employees, customer employees, contractor employees, vendor employees and visitors that enter on to Versabar property and / or work site.

3

PROCEDURES

3.1

General

Electrical shock can cause more damage to the body than is visible. A person may suffer internal hemorrhages and destruction of tissues, nerves and muscles.

The voltage is not of the most concern with electrical shock. Voltage in a wire can be equated to the pressure in a pipe. The pressure (voltage) pushes the electricity volume (amperage) through the wire. It is the amperage that usually causes the damage during an electrical shock.

The “Effects of Electric Current (Amperage) on the Human Body” table demonstrates the damage even very low amperages can cause to the body.

EFFECTS OF ELECTRIC CURRENT (AMPERAGE) IN THE HUMAN BODY 1 Milliampere or Milliamp Perception level. Just a faint tingle. (1/1000 Amps)

5 Milliamperes Slight shock felt; not painful but disturbing. (5/1000 Amps) Average individual can let go. However, strong

involuntary reactions to shocks in this range can lead to other injuries.

6 to 25 Milliamperes (women) Painful shock, muscular control is lost. or This is called the freezing current or “let-go” 9 to 30 Milliamperes (men) range.

50 to 150 Milliamperes Extreme pain, respiratory arrest, severe muscular contractions. Individual cannot let go. Death is possible.

1,000 to 4,300 Milliamperes Ventricular fibrillation. (The rhythmic pumping (1 to 4.3 Amps) action of the heart ceases.) Muscular

contraction and nerve damage occur. Death is most likely.

10,000 + Milliamperes Cardiac arrest, severe burns and probable (10

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The following are minimumrequirements and are not all-inclusive:

1. All electrical equipment, cords and outlets for defects shall be inspected before being used. Use only equipment that is in good condition. Report unsafe conditions, such as defective cord insulation, poor connections to terminals, broken switches or plugs, sparking or

overheating equipment or outlets without a Ground Fault Circuit Interrupters (GFCI) in damp areas.

2. Start and end from the “OFF” position. Make sure the power switch is off before plugging in equipment. When you are finished, turn the equipment off before unplugging it to protect yourself and the next user.

3. Don’t kink, cut, or crush any electrical cord. Never carry equipment by its cord.

4. If equipment has a three-prong plug, use a three-slot outlet or extension cord. Never modify three prongs to fit two slots by removing the third prong. Use an adapter instead, making sure that the metal grounding piece on the adapter is connected to a grounded object, such as the screw on the receptacle cover plate.

5. Keep water and electricity far apart. Don’t use electrical equipment when your hands are wet or any part of you is touching water. If you must work in damp areas, use a GFCI.

6. Don’t overload equipment.

3.2

MAINTENANCE

Before inspecting, servicing or repairing any electrical equipment, ALWAYS LOCK OUT / TAG OUT the device.

Disconnect power for inspections, servicing, or changing accessories.

Ensure that equipment is serviced regularly and repaired or replaced as needed.

Only qualified and authorized persons shall inspect, service or repair electrical equipment.

3.3

PORTABLE ELECTRICAL EQUIPMENT

When you use portable electrical equipment, you are exposed to voltages with the potential to injure and even kill. Faulty wiring, improper grounding and misuse of electrical outlets and plugs are just some of the hazards that may cause serious shocks and burns.

3.4

GUARDING

The live parts of electrical equipment operating at fifty (50) volts or more must be guarded against accidental contact with the human body.

Entrances to rooms and other guarded locations containing exposed live electrical parts must be marked with conspicuous warning signs forbidding unqualified persons to enter.

(14)

Indoor electric wiring with more than 600 volts and that is open to unqualified persons must be guarded with metal-enclosed equipment or enclosed in a vault or area controlled by a lock. In addition, the equipment must be marked with appropriate caution signs.

3.5

GROUNDING

Grounding is another method of protecting employees from electrical shock; however, it is normally a secondary measure. If faulty circuits or equipment allow current leakage, electricity will flow to the ground along the path of least resistance. Grounding substantially reduces the possibility of electrical shock, but it does not guarantee that no one will receive a shock, be injured, or be killed. Be sure to observe good safety habits whenever working with electricity.

3.6

CIRCUIT PROTECTION DEVICES

A Ground Fault Circuit Interrupter (GFCI) is designed to shut off electric power within as little as 1/40 of a second. Make sure all electrical equipment is properly grounded, and plugged into grounded outlets installed with a GFCI. GFCI’s are primarily used in damp or wet areas.

Fuses are designed to melt when too much current flows through them. Fuses will be used on electrical supply lines as per the local life safety and fire codes.

Circuit Breakers are designed to open the electrical circuit when too much current is measured flowing through the device. Circuit Breakers like fuses shall be used on electrical supply lines as per the local life safety and fire codes.

3.7

TRAINING

All employees shall be trained in these procedures Section. The Operations Manager shall insure that each employee is properly trained before starting work when:

1. The employee is first hired,

2. The employee is appointed to a new job assignment, and

3. The employee is exposed to new substances, processes, procedures, equipment, etc. that represent a new hazard to the employee.

All training shall be conducted as per the requirements of Section (B-4) “Employee Training” of this manual.

The “Training Record”, Section (B-4), shall be completed for each training session.

3.8

RECORDS

Documentation of each training, required above must be kept on file for each employee. This documentation shall be maintained for three (3) years after the employee terminates employment with Versabar. This documentation shall be maintained in the HSE Department.

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1

PURPOSE

This program provides the Manager with the procedures to ensure the safety and health of personnel working with and maintaining hand tools. This program complies with 29 CFR 1910.242, “Hand and Portable Powered Tools and Equipment.”

2

SCOPE

This program covers all Versabar, Inc. employees, customer employees, contractor employees, vendor employees and visitors that enter on to Versabar property and / or work sites.

3

PROCEDURES

3.1

General

Use hand tools only for the purpose for which they are designed.

Inspect tools daily for defects.

Tools with mushroomed heads must not be used.

Tools with split or splintered handles or loose handles, must not be used. All defective tools must be returned to the tool room.

Return all tools to their proper place when not in use.

Never play with tools or point tools at anyone.

Keep all tools in proper working condition.

3.2

Power Hand Tool Procedures

3.2.1 Personal Protective Equipment

As protection from chips and dust, a face shield and safety glasses with side shields or goggles shall always be worn when using power tools. A sign shall be posted at each powered tool station requiring the wearing of a face shield and safety glasses with side shields or goggles.

Wear work gloves when buffing, grinding or chipping. All buffers, grinders and chippers shall have guards.

Most hand buffers, grinders and chippers produce noise above 100 Decibels at the operator’s ears. Hearing protection, both ear plugs and ear muffs, shall be worn at all times when buffing. This is to protect your hearing.

Buttoned long sleeve shirts shall be worn when buffing, grinding or performing other types of work where sparks or hot metals are present. Wire particles can cause injury striking bare arms.

Loose, torn or ragged clothing creates a special hazard when operating reamers and other machines with revolving spindles or cutting tools. Loose, torn or ragged clothing shall not be worn while working.

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3.2.2 General

Check each tool to make certain it is in safe condition.

Make no repairs to electric tools. Return the tool to the Tool Room Supervisor or the work sit supervisor for repair.

Never yank on an electric cord to unplug it.

Never use an electric tool with wet hands or when standing on a wet surface.

Protect electric cords and air hoses to prevent damage and stumbling hazards.

All electric tools shall be grounded.

Never point a compressed air hose or tool at anyone. Never use compressed air to dust clothing, or for cleaning floors.

Never stand over an air hose. If an air hose breaks, do not go near it or attempt to grab it until the air pressure is shut off.

Clamp or otherwise secure small or light material before attempting to ream, drill, grind, etc.

Take care that small power tools are not left where their cases may be broken by something falling or striking them.

3.2.3 Buffing Procedures

All employees operating chipping guns and working near a person using a chipping gun shall wear both ear plugs and ear muffs to protect against the high noise.

The buffer operator shall insure that the RPM rating of the wire wheels are equal to/or greater then the RPM rating of the buffer.

Before attaching electrical cord to outlet, make sure switch is in “off” position.

Do not use buffers with defective wheels. Be sure wire is securely fastened to the spindle.

Do not drop or throw buffers on floor.

When buffing in close or tight areas, make sure you have a firm grip on the buffer so that it cannot bounce out of your hands.

Do not allow sparks and particles to fly towards other employees.

Secure electrical extension cords--don’t leave cords lying on the floor. 3.2.4 Grinding Procedures

All employees operating grinders and working near a person using a grinder shall wear both ear plugs and ear muffs to protect against the high noise.

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The grinder operator shall insure that the RPM rating of the wire wheels, dics and stones are equal to/or greater then the RPM rating of the grinder.

New discs and rocks are to be installed and a “Ring” test performed by authorized personnel only.

Make smooth grinding contact with the work. Avoid “bumping” or impact action. Don’t jam portable grinder into corners, etc.--the rock and disc may shatter.

When grinders are not in use, they should be stored in a safe place. Never leave grinders lying around the shop floor where they are likely to be damaged. All grinders shall have guards installed as per the manufacturer’s recommendations.

Keep in mind that the most common causes of rock and disc breakage are:

1. Improper mounting of the rock and disc. 2. Improper speed.

3. Abusive operation.

4. Careless handling and storage.

See that the wheel is properly dressed at all times. Do not use a wheel or disc with broken edges.

The governor on each grinder should be checked once each month with a tachometer by an authorized employee.

When using a grinder or power wire brush in the painting area, do not leave the tool where paint and dirt will get on or in it.

When grinding tools and small parts on a stationary grinder do not wear gloves.

Do not stand directly in front of a stationary grinder when first start up.

The maximum clearance between the wheel and the tool rest is 1/8”. Do not attempt to make any adjustments to the tool rest while the grinding wheel is in motion.

If you think a grinder is running too fast or slower than normal, or appears to be defective in any way, report it immediately.

If a wheel seems out of balance (indicated by excessive vibration in the grinder) replace the grinding wheel.

Handle rocks and discs carefully to prevent dropping, bumping or any other action that is likely to cause damage. If a grinder is dropped or damaged take it to the tool room supervisor or work site supervisor immediately.

Rocks and discs should be stored in a room not subject to extreme temperature changes. Keep in mind that dampness and extreme temperature changes may affect the bonding of the stone.

Rocks and discs must be stored so as to protect them from shipping and breakage.

Do not drop or throw a grinder on the floor as this may crack the rock or disc.

Inspect rocks and discs daily for cracks and defects. Do not use rocks or discs with broken edges.

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Never put a grinder down with the disc or rock still turning.

Never operate a grinder or wire brush when holding onto the air hose or electrical cord only.

NEVER BY PASS OR PUT OUT OF SERVICE ANY SAFETY DEVICE PROVIDED BY THE MANUFACTURER ON ANY POWER TOOL.

3.2.5 Chipping Gun Procedures

All employees operating chipping guns and working near a person using a chipping gun shall wear both ear plugs and ear muffs to protect against the high noise.

Inspect the chisels and the chipping gun daily before use. Turn in any defective equipment to the tool room supervisor or the work site supervisor for repair.

Inspect the air hose for any loose connections. Keep hose out of the aisles and walkways and arrange them in orderly fashion to eliminate tripping hazards.

Never point a chipping hammer at anyone. Never throw the tool down or use it as a hammer to remove chipped metal.

Open air valves gradually on air hose or tools so as to avoid sudden kickbacks.

Maintain safe footing and be sure that the material you are chipping is clamped or otherwise secured to prevent movement.

When chipping tack welds apart, hold the chisel so that fingers will not be caught when the weld breaks.

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1

PURPOSE

This program provides the Operations Manager with the procedures to ensure the safety and health of personnel working with and maintaining hand tools. This program complies with 29 CFR 1910.212, Subpart “O”.

2

SCOPE

This program covers all Versabar, Inc. employees, customer employees, contractor employees, vendor employees and visitors that enter on to Versabar property and / or work sites.

3

PROCEDURES

3.1

General

Use tools and machines only for the purpose for which they are designed.

Inspect tools and machines daily for defects.

Tools and machines that are damaged must not be used. Lock Out and Tag this equipment “Out of Service.”

Never play with tools or machinery.

Keep all tools and machinery in proper working condition.

Make no repairs to electric tools. Return the tool to the Supervisor for repair.

Never yank on an electric cord to unplug it.

Never use electric powered tools or machinery with wet hands or when standing on a wet surface.

Protect electric cords, welding hoses, hydraulic hoses and air hoses to prevent damage and stumbling hazards.

All electric tools and machinery must be grounded.

Never point a compressed air hose or tool at anyone. Never use compressed air to dust clothing, or for cleaning floors.

Never stand over an air hose. If an air hose breaks, do not go near it or attempt to grab it until the air pressure is shut off.

Clamp or otherwise secure material before attempting to ream, drill, mill, grind, etc.

3.2

Personal Protective Equipment

As protection from chips and dust, a face shield and safety glasses with side shields or goggles shall always be worn when using power tools or machines. A sign shall be posted at each powered tool station requiring the wearing of a face shield and safety glasses with side shields or goggles.

(20)

Wear work gloves when buffing, grinding or chipping. All buffers, grinders and chippers shall have guards.

Most buffers, grinders and chippers produce noise above 100 Decibels at the operator’s ears. Hearing protection, both ear plugs and ear muffs, shall be worn at all times when buffing. This is to protect your hearing.

Buttoned long sleeve shirts shall be worn when buffing, grinding or performing other types of work where sparks or hot metals are present. Wire particles can cause injury striking bare arms.

Loose, torn or ragged clothing creates a special hazard when operating reamers and other machines with revolving spindles or cutting tools. Loose, torn or ragged clothing shall not be worn while working.

3.3

Drill Press Operating Procedures

Review the written Work Order for the job, conduct a JSA meeting and wear the appropriate PPE.

Review the pinch points involved in the job.

Review the tool / machine emergency shut down system operation.

Review any special conditions specific to this job.

Assign each employee his/her specific work duties for this job.

Clear the work area of all trash, debris and items not needed for the job.

Lift the piece of stock onto the drill press table. If necessary, use Jib crane and / or get help.

Position the stock so as not to drill into the drill press table.

Clamp the stock in place on the drill press table. Use two or more clamps as needed. Place the clamp bolts as near to the stock as possible.

Remove all non-essential equipment and tools from the work area. Only the tools needed for the job should be in the immediate work area.

Select the proper drill bit and install the bit in the drill press.

Select the proper drill rotation speed and the proper drill feed speed for the job.

Line up the drill bit with the location of the hole to be drilled.

Start the coolant pump.

Start the drill press. “Remember it only takes one hand to start the drill press. So Keep the other hand away from the rotating Tool”.

Engage the spindle and slowly lower the tool to the stock.

(21)

Stand Back and observe operation.

At job termination disengage the drill feed and manually back the bit out of the stock.

Turn off the drill press motor.

Turn of the drill press coolant pump.

Clean off the stock of any shavings.

Remove the clamps from the stock and the table.

Remove the stock from the drill press table.

Clean the back side of the stock.

Verify the drilled hole measurements and dimensions.

Remove the completed stock to the holding area.

Clean the work area.

Start the next project.

3.4

Lathe Operating Procedures

Review the written Work Order for the job, conduct a JSA meeting and wear the appropriate PPE.

Review the pinch points involved in the job.

Review the tool / machine emergency shut down system operation.

Review any special conditions specific to this job.

Assign each employee his/her specific work duties for this job.

Clear the work area of all trash, debris and items not needed for the job.

Measure the stock.

Align the chuck. Make sure that the chuck is of the proper design for the job.

Set the tail stock at the desired length as needed.

Use mechanical lifting device (i.e. – cherry picker, jib crane, etc.) to lift the stock into the lathe.

Align the stock in the machine to needed specifications.

Select the proper tool for the job and install it in the lathe.

Set the lathe at the correct spindle rotation speed and feed speed for the tool.

(22)

Start the lathe. “Remember it only takes one hand to start the lathe. So Keep the other hand away from the rotating Stock”.

Start the coolant pump (if necessary).

Engage the lathe spindle.

Engage the lathe tool feed.

Stand back observe the operation.

Make adjustments as needed.

Continue machining the stock until the desired results are achieved.

At job termination disengage and turn off the spindle feed.

Turn off the off the spindle.

Turn off the lathe.

Turn off the coolant pump.

Check all the measurements of the stock.

Use a mechanical lifting device (i.e. – cherry picker, jib crane, etc.) and secure it to the stock in the lathe.

Loosen the chuck holding the stock.

Use the mechanical lifting device (i.e. – cherry picker, jib crane, etc.) to remove the stock from the lathe.

Clean the stock and verify the stock measurements and dimensions.

Remove the completed stock to the holding area.

Clean the work area.

Start the next project.

3.5

Horizontal Boring Mill Operating Procedures

Review the written Work Order for the job, conduct a JSA meeting and wear the appropriate PPE.

Review the pinch points involved in the job.

Review the tool / machine emergency shut down system operation.

Review any special conditions specific to this job.

Assign each employee his/her specific work duties for this job.

(23)

Determine the mounting method for the stock to be milled. Be sure to consider the limitations of the mounting brackets and the machine operation. If the stock is mounted improperly you will not be able to machine all the positions required without repositioning the stock. “PLAN AHEAD”.

5” Milling Machine: Additional supports are needed for any stock piece that weighs more then 20,000 lbs.

10” x 52” Milling Machine: Additional supports are needed for any stock piece that weighs more then 200 lbs.

Get help and Use the mechanical lifting device (i.e. – cherry picker, jib crane, etc.) to move the stock into position to mount on the mill.

Secure the stock into the mounting position. Use as many clamps and back supports as needed to secure the stock.

Remove all non-essential equipment from the work area.

Select the proper tool for the job (i.e. - mill, bore, slab boring bar, etc.).

Install the tool in the on the mill.

Select and set the proper tool rotation speed and the proper tool feed speed.

Adjust the tool alignment for the job.

Start the coolant pump.

Start the mill. “Remember it only takes one hand to start the mill. So Keep the other hand away from the rotating tool”.

Engage the spindle.

Engage the tool feed.

Stand back observe the operation.

Make adjustments as needed.

At the job termination disengage the tool feed and manually back the tool away from the stock.

Turn off the mill motor.

Turn off the coolant pump.

Get help and Use the mechanical lifting device (i.e. – cherry picker, jib crane, etc.) to secure the stock in the mount on the mill.

Clean the shavings from the stock.

Check all the measurements of the stock.

(24)

Use the mechanical lifting device (i.e. – cherry picker, jib crane, etc.) to remove the stock from the mill.

Remove the completed stock to the holding area.

Clean the work area.

Start the next project.

3.6

200 Ton Press Operating Procedures

Review the written Work Order for the job, conduct a JSA meeting and wear the appropriate PPE.

Review the pinch points involved in the job.

Review the tool / machine emergency shut down system operation.

Review any special conditions specific to this job.

Assign each employee his/her specific work duties for this job.

Clear the work area of all trash, debris and items not needed for the job.

Inspect all hydraulic hoses and fittings for possible damage and / or leaks. Repair all damage and / or leaks before applying pressure to the hydraulic system.

Measure the stock.

Determine the placement of the stock on the press and the working height of the machine.

Get help and Use the mechanical lifting device (i.e. – cherry picker, jib crane, etc.) to place the stock on the press.

Install the any tool/s needed in the press.

Turn on the press.

Lower the press to the stock and apply a small amount of pressure to stabilize the tool/s on the stock.

Check the tool placement for the proper alignment.

Check for any potential hazards (i.e. – stock being ejected, stock being moved by the press, etc.).

Continue to move the press down on the tool/s forcing them into the stock piece, while maintaining a safe pressure on the tool/s.

Observe the stock piece and tool/s for stability.

At the job termination and the desired results are achieved, release the pressure on the press and raise the press to a safe height above the stock piece.

Lock the press in the raised position.

(25)

Remove the tools.

Get help and Use the mechanical lifting device (i.e. – cherry picker, jib crane, etc.) to remove the stock from the press.

Remove the completed stock to the holding area.

Clean the work area.

Start the next project.

3.7

18” and 20” Band Saw Operating Procedures

Review the written Work Order for the job, conduct a JSA meeting and wear the appropriate PPE.

Review the pinch points involved in the job.

Review the tool / machine emergency shut down system operation.

Review any special conditions specific to this job.

Assign each employee his/her specific work duties for this job.

Clear the work area of all trash, debris and items not needed for the job.

Install the proper blade for the job.

Select and set the proper blade speed and stock feed speed for the job.

Get help and Use the mechanical lifting device (i.e. – cherry picker, jib crane, etc.) to mount the stock on the table.

Align the stock piece on the table.

Secure the stock piece with vise and / or other means if necessary.

Start the coolant pump. ***The coolant pump on the 20” saw will start automatically when the band saw is started.

Start band saw. “Remember it only takes one hand to start the band saw. So Keep the other hand away from the moving blade”.

Manually bring the blade up to the stock piece.

Engage the stock feed.

Observe the stock piece and the blade.

At the job termination and the desired results are achieved, turn off the power to the saw blade motor. The coolant pump will stop automatically.

(26)

Get help and Use the mechanical lifting device (i.e. – cherry picker, jib crane, etc.) to remove the stock saw table.

Inspect the stock piece for proper measurement and proper cut.

Remove the completed stock to the holding area.

Clean the work area.

Start the next project.

3.8

Bench Grinder Operating Procedures

The intended use of the bench grinder is to sharpen and reshape tools. This device is to be used to grind steel tools ONLY. No brass or aluminum devices will be worked on this grinder.

Review the written Work Order for the job, conduct a JSA meeting and wear the appropriate PPE.

Review the pinch points involved in the job.

Review the tool / machine emergency shut down system operation.

Review any special conditions specific to this job.

Assign each employee his/her specific work duties for this job.

Clear the work area of all trash, debris and items not needed for the job.

Inspect the grinder before each job. Insure that the proper wheel is installed for the work to be done. The maximum RPM of the grinder must be equal to or less then the maximum RPM of the wheel installed. Any damaged wheels shall be removed from the grinder IMMEDIATELY.

Start the grinder. “Remember it only takes one hand to start the grinder. So Keep the other hand away from the rotating wheels”.

Hold the tool horizontal and 90 degrees to the rotation of the wheel. The tool must be held securely on the tool guide.

When the tool is properly shaped or sharpened, turn off the grinder.

Clean the work area.

Start the next project.

3.9

48” Belt Sander Operating Procedures

Review the written Work Order for the job, conduct a JSA meeting and wear the appropriate PPE.

Review the pinch points involved in the job.

(27)

Review any special conditions specific to this job.

Assign each employee his/her specific work duties for this job.

Clear the work area of all trash, debris and items not needed for the job.

Inspect the sander before each job. Insure that the sandpaper installed is designed for the work to be done. The maximum RPM of the sander must be equal to or less then the maximum RPM of the sand paper belt installed. Any damaged belts shall be removed from the sander IMMEDIATELY.

Start the sander. “Remember it only takes one hand to start the sander. So Keep the other hand away from the rotating belts”.

Remember, any items with sharp edges may cut the sand paper and create a flying object hazard.

When the device is properly shaped turn off the sander.

Clean the work area.

Start the next project.

3.10

48” Belt Sander with 12” Disc Device Operating Procedures

Review the written Work Order for the job, conduct a JSA meeting and wear the appropriate PPE.

Review the pinch points involved in the job.

Review the tool / machine emergency shut down system operation.

Review any special conditions specific to this job.

Assign each employee his/her specific work duties for this job.

Clear the work area of all trash, debris and items not needed for the job.

Inspect the sander before each job. Insure that the sandpaper and the disc installed is designed for the work to be done. The maximum RPM of the sander must be equal to or less then the maximum RPM of the sand paper belt and the disc installed. Any damaged belts or discs shall be removed from the sander

IMMEDIATELY.

Start the sander. “Remember it only takes one hand to start the sander. So Keep the other hand away from the rotating belts”.

Remember, any items with sharp edges may cut the sand paper and create a flying object hazard. The “Disc” is designed to work objects with sharp edges and corners.

When the device is properly shaped turn off the sander.

Clean the work area.

(28)

1

PURPOSE

This program provides the Operations Manager with the procedures to ensure the safety and health of personnel working with and maintaining the pull testing equipment.

2

SCOPE

This program covers all Versabar, Inc. employees, customer employees, contractor employees, vendor employees and visitors that enter on to Versabar property and / or work sites.

3

PROCEDURES

3.1

General

The Versabar pull testing processes are unique to the company and provide a very important service to our customers. The pull testing equipment is grouped into three (3) categories.

The VJ Test Machine (Singapore) is designed to test any lifting or pulling device that has the following dimensions: length 108 feet or less; width or less; with a center of pull between 4 foot to 5 foot above the ground.

The VT Test Machine (Big Chief) is designed to test any lifting or pulling device that has the following dimensions: length 168 feet or less (can be expanded to 200 feet with special adaptation); width 8 foot 6 inches or less; with a center of pull between 4 foot 6 inches and 5 foot 4 inches above the ground.

The VS Test Machine is designed to test any lifting or pulling device that has the following dimensions: length 60 feet or less; width 3 foot 6 inches or less; with a center of pull between 1 inch and 3 inches above the floor.

The VM Lift Test System is designed to test any lifting or pulling device that fits the weight restrictions of the VERSABAR cranes.

These systems will normally be used to test the following types of equipment, but are not limited to those items listed:

1. Slings (wire rope and round nylon), 2. Spreader Bars, 3. Shackles, 4. Link Plates, 5. Hooks, 6. Turn Buckles, 7. Etc.

3.2

Hydraulics Maintenance for Test Systems

Check the hydraulic fluid in the reservoir weekly for the proper level,

Prior to operation of the system inspect for and report any leaks in hoses and/or fittings.

(29)

3.3

Personal Protective Equipment

As protection from chips and dust safety glasses with side shields or goggles shall always be worn when not in the test machine control room.

Cranes normally are very noisy and will require the wearing of Hearing protection while operating the crane.

Safety Toe Boots are required in all Pull Test Areas.

Hard Hats are required in all Pull Test Areas.

Dress for the weather you will be working in with good serviceable clothing. Loose, torn or ragged clothing creates a special hazard when operating the crane and rigging the test machines. Loose, torn or ragged clothing shall not be worn while working.

3.4

Procedures for Operating the VT and VJ Test Systems

The test systems shall always be locked out of service when the operator is not actually at the control panel and operating the machine. This is accomplished by placing the lock out cover over the ESD button on the control panel in the control room and locking the cover in place. Only the Test Machine Operators and the Test Supervisor shall have a key to the lock.

Review the written Work Order for the job and conduct a JSA meeting.

Verify that the crane operator and all of the riggers are currently qualified.

Verify that communications (radios, hand signals, visual, etc.) are established and clear to all personnel.

Inspect the slings to be used and verify that they are in good condition and have a current inspection date.

Review the confined space restrictions of the test bed.

Review the pinch points involved in the job.

Review any special conditions specific to this job.

Assign each employee his/her specific work duties for this job.

Unlock and reset the ESD button in the run position on the control panel. The Test Machine Operator must maintain station at the control panel at all times while the ESD button is in the run position and / or unlocked.

Position the “Dead End” at the proper stop for the length of the pull.

Install the end piece pull linkages starting with the primary linkage first followed by each reducer one at a time from the largest to the smallest.

Rig the equipment to be tested with the proper sized slings.

(30)

Attach the equipment rigging to the crane and lift the equipment into the test bed. No personnel will be inside the test bed until the equipment is lowered onto the ground or in position to be connected to the “live” and “dead” ends of the pulling mechanism.

Connect the equipment to the pulling ends of the test bed. This is a confined space work area and there is danger of pinch point injury.

All personnel must exit the inside of the test bed and move to the designated safe area. The “Safe Area” shall be determined by the Test Supervisor.

Conduct the Standard Pull Test

Start the hydraulic pump and manually bring the pressure up to the desired test load pressure.

Hold the test load pressure for one (1) minute or as per the client’s requirements. If you are testing slings – lower the pressure to the rated maximum safe working load.

Shut down the hydraulic pump:

1. Depress the Pump Stop button and

2. Depress the “ESD” button to the shut in position and lock in place.

The appropriate number of employees will enter the test bed to:

1. Measure and Record the sling length,

2. Check for broken wires and other sling damage,

3. Paint the proper “Color Code” on the sling swedge.

4. Re-stamp identification number if needed and apply spiral identification tag.

Remove all personnel from the test bed.

Unlock and reset the “ESD” button. The Test Machine Operator must maintain station at the control panel at all times while the ESD button is in the run position and / or unlocked.

Retract the rams.

Shut down the hydraulic pump:

1. Depress the Pump Stop button and

2. Depress the “ESD” button to the shut in position and lock in place. Record test data.

Remove the equipment being tested from the Test Bed.

Verify that the hydraulic pump is shut in and locked.

(31)

Move the live end of the test machine to the release position. This is accomplished by rigging the crane to pull the live end.

Have employees enter the test bed and remove the pins or the bushings and the pins.

All personnel are removed from the inside of the test bed and to the designated “Safe Area”.

Use the Crane to lift the tested equipment out of the test bed.

Lower the tested equipment to a safe location and rig down from the crane.

Remove the slings from the tested equipment.

Secure the area and the test machine or start another test procedure.

Special client requests will require the issuance of a work order by the designated Versabar engineer.

3.5

Procedures for Operating the VS Test System

The test systems shall always be locked out of service when the operator is not actually at the control panel and operating the machine. This is accomplished by placing the lock out cover over the ESD button on the control panel in the control room and locking the cover in place. Only the Test Machine Operators and the Test Supervisor shall have a key to the lock.

Review the written Work Order for the job and conduct a JSA meeting.

Verify that the crane / cherry picker operator and all of the riggers are currently qualified.

Verify that communications (radios, hand signals, visual, etc.) are established and clear to all personnel.

Inspect the slings to be used and verify that they are in good condition and have a current inspection date.

Review the confined space restrictions of the test bed.

Review the pinch points involved in the job.

Review any special conditions specific to this job.

Assign each employee his/her specific work duties for this job.

Unlock and reset the ESD button in the run position on the control panel. The Test Machine Operator must maintain station at the control panel at all times while the ESD button is in the run position and / or unlocked.

Position the “Dead End” at the proper stop for the length of the pull.

Install the end piece pull linkages starting with the primary linkage first followed by each reducer one at a time from the largest to the smallest.

Rig the equipment to be tested with the proper sized slings.

Move the crane / cherry picker / chain hoist / lifting personnel into position to lift the equipment into the test bed.

(32)

Attach the equipment rigging to the crane and lift the equipment into the test bed. No personnel will be inside the test bed until the equipment is lowered onto the ground or in position to be connected to the “live” and “dead” ends of the pulling mechanism.

Connect the equipment to the pulling ends of the test bed. This is a confined space work area and there is danger of pinch point injury.

All personnel must exit the inside of the test bed and move to the designated safe area. The “Safe Area” shall be determined by the Test Supervisor.

Conduct the Standard Pull Test

Start the hydraulic pump and manually bring the pressure up to the desired test load pressure.

Hold the test load pressure for one (1) minute or as per the client’s requirements. If you are testing slings – lower the pressure to the rated maximum safe working load.

Shut down the hydraulic pump:

1. Depress the Pump Stop button and

2. Depress the “ESD” button to the shut in position and lock in place.

The appropriate number of employees will enter the test bed to:

1. Measure and Record the sling length,

2. Check for broken wires and other sling damage,

3. Paint the proper “Color Code” on the sling swedge.

4. Re-stamp identification number if needed and apply spiral identification tag.

Remove all personnel from the test bed.

Unlock and reset the “ESD” button. The Test Machine Operator must maintain station at the control panel at all times while the ESD button is in the run position and / or unlocked.

Retract the rams.

Shut down the hydraulic pump:

1. Depress the Pump Stop button and

2. Depress the “ESD” button to the shut in position and lock in place. Record test data.

Remove the equipment being tested from the Test Bed:

Verify that the hydraulic pump is shut in and locked:

1. Depress the Pump Stop button and

(33)

Move the live end of the test machine to the release position. This is accomplished by rigging the crane to pull the live end.

Have employees enter the test bed and remove the pins or the bushings and the pins.

All personnel are removed from the inside of the test bed and moved to the designated “Safe Area”.

Use the Crane to lift the tested equipment out of the test bed.

Lower the tested equipment to a safe location and rig down from the crane.

Remove the slings from the tested equipment.

Secure the area and the test machine or start another test procedure.

Special client requests will require the issuance of a work order by the designated Versabar engineer.

3.6

Procedures for Operating the VM Test System

Review the written Work Order and conduct a JSA Meeting.

Move the crane to the proper radius position prior to installation of load into the test bed.

Attach the weight indicator to the lift line on the crane.

Rig up the equipment to be tested with the proper slings.

Install the anchor slings on the Test Machine to provide anchor for the pull test,

Or

Install the anchor slings to the special weights to provide anchors for the pull test.

Attach the equipment to be tested to the anchors.

All personnel except the crane operator are to be removed from the test area to the designated “Safe Area”. The Test Supervisor shall determine the designated “Safe Area”.

The crane operator will slowly lift the load to apply pulling pressure on the equipment to be tested, while constantly monitoring the “weight indicator”.

When the “Test” weight is reached the lift shall be maintained at that weight for one (1) minute or for the time period requested by the client.

When the test is completed, the crane operator shall lower the load so that it can be detached from the anchor.

When the tested equipment is released from the anchor, the crane operator shall move the tested equipment to a safe area and the equipment shall be detached from the crane.

(34)

Start the next test or secure the crane and rigging equipment.

3.7

RECORDS

The Test Data records, JSA meeting minutes, Work Order and another pertinent information shall be collected in a Job File and maintained for the client and future jobs.

(35)

1

PURPOSE

These procedures provide the Operations Manager with the ability to insure that all employees

involved in handling material are protected from the hazards of the material handling. These

procedures meet or exceed the requirements of OSHA Regulations “ Materials Handling”, 29

CFR 1910.176; “Forklift Operations”, 29 CFR 1910.178; “Overhead and Gantry Cranes,” 29

CFR 1910.179; “ Crawler & Truck Cranes,” 29 CFR 1910.180; “Slings,” 29 CFR 1910.184,

ASME B30.9c-2000 and ASME B30.20a-1999.

2

SCOPE

This section applies to all Versabar, Inc. facilities, vehicles, boats, barges and work sites.

3

PERSONAL MATERIAL HANDLING

3.1

General

Evaluate the load--weight, size, center of gravity, shape, sharp edges. Can you see over and/or

around the load? In a choice between injury to yourself or equipment, save yourself. But

remember, if you plan your work and follow the correct procedures, you won’t have to make the

choice.

The maximum lifting load limit for one employee shall not exceed 50 pounds.

Mentally select the best travel path, Don’t Rush.

Decide if you need help before you start to lift a load. If in doubt--get help. Use another person

or mechanical equipment, for example: forklift, crane, dolly, etc.

Use the proper body position, as determined by the size and shape of the load. (See One Person

Carries and Multiple Person Carries below)

Wear gloves when handling rough or jagged edged objects. Versabar would prefer that

employees wear gloves 100% of the time while handling material. There will be the rare

situation where the gloves could cause more problems.

3.2

One Person Carry

NEVER LIFT MORE THAN 50 POUNDS WITHOUT ASSISTANCE.

Squat--Don’t stoop or bend from the waist, keep back straight.

Place your right foot parallel to one edge of the box (opposite, if you’re left handed.)

Place your left hand on the corner of the box or as far as is comfortable. On circular or irregularly

shaped objects place your left hand at a point comfortable for you.

(36)

Place your right hand along or under the edge of the container (tip the container slightly to get

your grip.)

With your back straight, lift up using your leg muscles NOT your back muscles!

Walk slowly--to change directions, stop, then turn your feet in the direction you wish to go.

Don’t turn your body at the waist. Lean back slightly as you travel.

To place the object down without injury; Stop walking. Keep you back straight. Move your left

foot back slightly. Squat down, taking the strain on your leg muscles. Let the front left point of

the container or its front edge rest on the ground; slip your right hand up from under the right side

of the container and lower the container flat on the floor/ground.

Stand up smoothly KEEPING YOUR BACK STRAIGHT!!

3.3

Multiple Person Carry

Decide on a leader to give directions, set the pace, etc.

Follow the techniques for body positioning as just discussed in “ One Person Carry” above

.

4

FORKLIFT OPERATING PROCEDURES

4.1

General

Forklift Operators must be Versabar certified before being allowed to operate a forklift. Forklifts

must be inspected prior to operating. The pre-use inspection must be done at least daily or at the

beginning of each shift. Employees must use the form, “Versabar Forklift Daily Inspection

Checklist.”

Operator must know the rated load capacity of his/her forklift and never exceed it.

Operator must know the weight of the object and center of gravity before picking it up with the

forklift.

When picking up a load, drive the forks directly under the center of the load as far as they will go.

Adjust distance between forks to best suit the load to be lifted in order to prevent any deformation

of load and for greatest possible stability.

The design of the forklift is based on a stability triangle. The front axle, with its drive wheels,

acts as the base of the triangle and supports the weight of the load. The sides of the stability

triangle meet at the point where the forklift steers, either at a single wheel or in the middle of the

steering axle on four-wheel models.

Keeping the downward force of the load (center of gravity) within the stability triangle keeps the

forklift stable and keeps the load from crashing to the ground.

References

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