Safety Policy and Procedure

Policy Number 015 Authorized By: The Cianbro Companies Alan Burton

Title: and Cutting Assessment Program Effective Date: 09/16/95

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1 Status

1.1 Update of existing policy, effective 06/03/11.

2 Purpose

2.1 To provide guidelines and requirements to protect team members from the associated with welding, cutting, and burning operations.

3 Applicability

3.1 This policy applies to all subsidiary companies and departments of the Cianbro Companies.

3.2 All organizations are required to comply with the provisions of this policy and procedure. Any deviation, unless spelled out specifically in the policy, requires the permission of the Safety Director or designee.

4 Definitions

4.1 Adequate Ventilation: Used in this policy means any of the following: Local exhaust ventilation is used to capture fumes or in open area with adequate air movement or adequate dilution ventilation with directional air flow away from team member.

4.2 Air Arc (Carbon Arc): A cutting process by which metals are melted by the heat of an arc using a carbon electrode. Molten metal is forced away from the cut by a blast of forced air.

4.3 Bug-O BUG-O Systems Inc.: A manufacturer of a system of drives, carriages, rails and attachments designed to automate welding guns, cutting torches and other hand held tools.

4.4 Cad Welding: An exothermic (gives off heat) welding process that fuses conductors together to form a molecular bond with a current-carrying capacity equal to that of the conductor. Typically used in grounding systems.

4.5 Downdraft Table: A downdraft table is a work station for welding (or grinding and cutting) that provides a ventilated table to work on top of. The air and contaminant is drawn down through the table and away from the worker.

4.6 Flux: A substance which facilitates welding (and and ) by chemically cleaning the metals to be joined. The primary purpose of flux in welding is to prevent oxidation of the base and filler materials. Note: Flux typically contains fluorides.

4.7 Flux Core Arc Welding (FCAW): An arc welding process which melts and joins metals by heating them with an arc between a continuous, consumable electrode wire and the work. Shielding is obtained from a flux contained within the electrode core. Added shielding may or may not be provided from externally supplied gas or gas mixture.

4.8 Gas Metal Arc Welding (GMAW) MIG: (also referred to as solid wire welding) Arc welding process which joins metals by heating them with an arc. The arc is between a continuously fed filler metal (consumable) electrode and the workpiece. Externally supplied gas or gas mixtures provide shielding.

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4.9 Inadequate Ventilation: As used in this policy means local exhaust ventilation is not being used or work is inside enclosed spaces with inadequate air movement or any other location with inadequate air movement or the air movement draws the contaminants through breathing zone of the team member.

4.10 Lance Rod: Thermal lance rod is a cutting tool that utilizes ignited iron (or aluminum or magnesium) fed with a stream of pressurized oxygen. A steel tube packed with steel rods (and aluminum or magnesium) is connected to a valved handle assembly fed by an oxygen line and tank. An intensely hot (6k - 10 k degrees Fahrenheit) oxy/steel fueled jet is created at the tip.

4.11 The National Institute for Occupational Safety and Health (NIOSH): Federal agency responsible for conducting research and making recommendations for the prevention of work-related injury and illness. NIOSH is part of the Centers for Disease Control and Prevention (CDC) in the Department of Health and Human Services. It is essentially the research arm of OSHA and is responsible for approving respirators.

4.12 Oxy-Fuel Cutting: A mixture of oxygen and the fuel gas is used to preheat the metal to its 'ignition' temperature which, for steel, is 700°C - 900°C (bright red heat) but well below its melting point. A jet of pure oxygen is then directed into the preheated area instigating a vigorous exothermic chemical reaction between the oxygen and the metal to form iron oxide or slag. The oxygen jet blows away the slag enabling the jet to pierce through the material and continue to cut through the material. Typical fuel gases used are acetylene, propane, MAPP (methylacetylene-propadiene), and propylene.

4.13 Plasma Cutting: Arc cutting process which severs metal by using a constricted arc to melt a small area of the work. This process can cut all metals that conduct electricity.

4.14 Shielded Metal Arc Welding (SMAW) or (Stick Welding): Arc welding process which melts and joins metals by heating them with an arc, between a covered metal electrode and the work. Shielding gas is obtained from the electrode outer coating, often called flux. Filler metal is primarily obtained from the electrode core.

4.15 Sub-Arc Submerged Arc Welding: A process by which metals are joined by an arc or arcs between a bare metal electrode or electrodes and the work. Shielding is supplied by a granular, fusible material usually brought to the work from a flux hopper.

4.16 Threshold Limit Values TLV® (TLVs): Guidelines, not standards prepared by the American Conference of Governmental Industrial Hygienists, Inc (ACGIH) to assist industrial hygienists in making decisions regarding safe levels of exposure to various hazards found in the workplace. A TLV® reflects the level of airborne exposure that the typical worker can experience without an unreasonable risk of disease or injury. Cianbro uses the TLV in situations where it is more protective than the OSHA PEL. Some definitions obtained from the Miller Electric Manufacturing Co. website

4.17 Tungsten Inert-Gas Welding (TIG) or (GTAW) (HELIARC): Joins metals by heating them with a tungsten electrode which should not become part of the completed weld. Filler metal is sometimes used and argon inert gas or inert gas mixtures are used for shielding.

5 Policy

5.1 Adequate ventilation is required during welding and cutting operations. If adequate ventilation is not provided then respiratory protection is required.

6 Responsibilities

6.1 The top Cianbro manager of the job site is responsible for the implementation of this policy on the job site.

6.2 Corporate Safety is responsible for maintaining this document.

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7 Welding and Cutting Hazard Assessment Program Index

7.1 Health Effects ...... 3 7.2 Pre-Job Welding and Cutting Hazard Evaluation...... 3 7.3 Engineering and ...... 6 7.4 Respiratory Protection ...... 7 7.5 Exposure Monitoring...... 7 7.6 Medical Surveillance...... 8 7.7 Training...... 8 7.8 Physical Hazards...... 8 7.9 Safety At Home...... 9 9.1 Appendix A Minimum Respiratory Protection for Cutting and Welding Processes ...... 10 9.2 Appendix B Exposure Guidelines for Welding Fumes and Gases ...... 11 9.3 Appendix C Associated Guidelines for Gases Associated with Welding and Cutting...... 12

7.1 Health Effects

Welding, burning, and cutting produce metal fumes and gases that can be hazardous to your health. Breathing in these fumes and gases can and does make people sick. Luckily, a healthy body clears most toxic substances including welding fumes. Still, you can be exposed to too much of any fume or have a medical problem that makes you more likely to get sick from exposure to welding and cutting fumes. The length of time that you are exposed to these gases and fumes, the type of hot work you do, the work environment, and the protection you use determine the risks to your health and how you will be affected.

Like most other toxic substances, welding and cutting fumes have “acute” effects that may occur as soon as or shortly after you are exposed. Acute effects can include , cough, , eye irritation, or metal fume . Welding and cutting fumes also have “chronic” effects that may not be noticed for years. These effects may include lung, kidney, bone or joint disease and even cancer. Most acute effects are caused by brief overexposures. These effects almost always go away within a day or two and don’t cause any permanent damage. Chronic effects from lower exposures over longer periods of time, like lung disease or cancer, are more serious and can sneak up on you before you know it. Any time you think you are having any unexplained symptoms or effects, let your safety specialist know as soon as possible.

Pay attention to what you weld or cut, where you are welding or cutting, and which process you are using. Be sure to provide for appropriate ventilation and use all required PPE. Remember, the best “treatment” for any toxic exposure is prevention!

7.2 Pre-Job Welding and Cutting Hazard Evaluation

Before starting any task that involves welding, cutting and burning a pre-task is required. This should be done as part of the activity planning process and will include both health hazards and physical hazards (see section 7.6). Once the hazards are identified, appropriate engineering and administrative controls and personal protective equipment (PPE) can be selected to keep team member exposure to as low as reasonably practicable. When doing a hazard evaluation, make sure to include surrounding workers that could also have exposure and make provisions to protect them as well. Special precautions and planning are required when welding, cutting or heating on hollow metal. Containers and structures to ensure flammable or combustibles are not present. The following four factors need to be considered:

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What base metals are being worked on?

Base Metal Contaminant Generated Carbon (Mild) Steel Iron oxide, Iron oxide, hexavalent , , ozone gas, manganese Galvanized Iron oxide, oxide, manganese Aluminum Aluminum, ozone Exotic metals , titanium (examples)

Iron, Zinc, Aluminum – have relatively high exposure limits. If welding outdoors, natural ventilation and limiting actual welding time during the day should suffice for controlling exposures. For indoor welding or confined spaces, available mechanical or natural ventilation will need to be reviewed on a case-by-case basis along with daily duration of welding. If respirators are required, any “100” efficiency particulate respirator should be adequate (assuming sufficient oxygen is present).

Chromium, Nickel, - are suspect human carcinogens, have very low recommended exposure limits and therefore will require more careful planning in regards to ventilation. There is a new OSHA standard for Hexavalent chromium with a very low permissible exposure limit (5.0 ug/m3). Limiting the amount of welding time per day is not allowed as a control option for cadmium or chromium. If respirators are required, “100” efficiency respirators and possibly air supplied respirators should be used. See 29CFR1926.1127 for cadmium specific regulations and 29CFR1926.1126 the hexavalent chromium standard.

Note: Working with stainless steel is much more dangerous than working with galvanized steel because the hexavalent chromium and nickel in stainless have serious long term health effects while the zinc from galvanized causes metal fume fever but has no known long term health effects.

Manganese - Manganese is a highly reactive gray-white metal resembling iron, and adding manganese to steel increases its hardness, stiffness and strength. Manganese is a major component of welding fumes, particularly those from mild steel welds using shielded metal arc welding (SMAW). Mild steel is the most common steel used in industry, and SMAW is the most common type of commercial welding, but manganese exposures can result from other types of welding as well.

Exotic Metals - contact Safety Department for consultation.

7.2.1 What type of welding process is being used?

Welding Process Contaminant Generated Flame cutting Carbon monoxide, oxides of nitrogen Gas metal arc welding (MIG) UV radiation, ozone, CO if CO2 gas is used, low Gas tungsten arc welding (heli-arc or TIG) oxygen, manganese Plasma cutting UV radiation, ozone, oxides of nitrogen Carbon arc (air arc) cutting Ozone, oxides of nitrogen, noise, low oxygen Flux cored arc welding Noise, iron oxide, copper Shielded metal arc welding (stick) Barium, iron oxide, aluminum, magnesium Cad Welding UV radiation, fluorides, manganese Lance rod cutting Copper oxide, aluminum, fluorides, heat (exothermic reaction) Magnesium or Aluminum oxides, O2 enrichment

Ozone, Oxides of nitrogen are irritating to the eyes, nose and throat. Excessive exposure may cause pulmonary edema (fluid in the lungs) that can to heart failure. Ventilation is the only way to feasibly control both gases. Respirators (except air line) are not an option. Reducing the welding arc amperage to the lowest level that still allows an acceptable product will help reduce ozone levels and welding fume in general. Arc welding, especially on stainless steel, aluminum and when using argon gas tends to generate the most UV radiation and therefore the most ozone.

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Noise - Exposure to excessive noise may cause noise induced . All welding operations should be reviewed for noise exposure. Plasma arc, arc air gouging, and metal spraying will almost always require use of hearing protection devices.

Low oxygen - Oxygen deficiency (less than 19.5%) is possible whenever gas shields are use in confined spaces, or areas with poor ventilation. Note: Improper use of oxygen in a confined space can produce an oxygen-enriched atmosphere - a serious fire and explosion hazard.

Oxygen Enrichment – Oxygen present at levels higher than 21% makes flammable and combustible materials burn violently when ignited.

Aluminum, magnesium, and copper fume – may cause metal fume fever and irritation of the respiratory tract. Aluminum and magnesium have relatively high exposure limits while copper fume has a relatively low exposure limit of 0.2 mg/m3.

UV Radiation - See Section 7.6

7.2.2 What is in the welding rod or filler rod being used?

MSDS must be reviewed to determine what components (e.g. filler metals, fluxes) may be in the welding rod being used. Hazards and controls will vary with the specific rod used. Some rods will be copper coated (e.g. gas metal arc). Excessive exposure to copper may cause metal fume fever. Other rods contain manganese. Fluoride fluxes may cause irritation to the eyes, nose and throat.

7.2.3 Are there any coatings or cleaning solvents residue on the object to be welded?

Coating or Solvent Contaminant Paint primers or coatings Lead, Cadmium, Zinc, Hexavalent Chromium (lead chromates, zinc chromates) Plating or corrosion protection Cadmium Polyurethanes, isocyanate based paints Variety of organic pollutants (e.g. Marine coatings, anti-fouling diisocyanates) Chlorinated solvents Mercury, tin Anti-spatter (may contain chlorinated solvents) Decomposition products (e.g. phosgene Residue from previous contents gas) Refer to MSDS

Varies, refer to MSDS

Note: Preferred control method is to remove coating or solvent prior to welding.

Lead, Cadmium and Chromium - For lead see Cianbro’s Workplace Lead and Other Safety Policy and Procedure and 29CFR1926.62 for lead specific regulations. For hexavalent chromium see 29CFR1926.1126 and for cadmium see 29CFR1926.1127. Cadmium plating on bolts and nuts is common in high corrosion areas.

Chlorinated solvents (e.g. trichloroethylene, perchloroethylene) - Chlorinated decomposition products (e.g. phosgene) especially common with high UV producing welding.

Isocyanates, polyurethane coatings - Numerous materials can be generated depending on the situation. Even at low concentrations, many of them are extremely irritating. These materials can also be sensitizers. Always refer to MSDS.

Mercury - Low Permissible Exposure Limit. Excessive exposure may cause tremors, headache, and weakness. Respirators with mercury specific filter or mechanical ventilation will probably be required. May be absorbed through intact skin.

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Anti-spatter compounds - May contain chlorinated solvents.

Residue from previous contents - Know what material was present in the tank or line before beginning hot work. Refer to the MSDS.

If caustic was present, it may leave traces of mercury in the metal due to the process used to manufacture the caustic.

Paper mill stock lines may contain hydrogen due to anaerobic bacteria called Clostridia: There have been several reported cases of explosions in the literature attributed to hydrogen. The anaerobic condition required is most likely to be present during shutdown conditions. Ventilation of stock lines and tanks can control this hazard. Hydrogen may show up as a reading of carbon monoxide and LEL on a multigas monitor. It can be tested for using colorimetric (detector) tubes.

7.3 Engineering and Administrative Controls

7.3.1 Once the hazards are identified, determine what controls will reduce or eliminate the risks. The most effective way to protect you from the hazards associated with hot work is to substitute less hazardous materials or methods, make physical changes in the work environment, and use administrative controls (safe work practices). Below are some engineering and administrative controls that should be considered for each task. • Spec areas to be welded on new material to be left bare of coatings. • Spec bolt-up connections rather than welds. • Use mechanically guided welding processes (e.g. Bug-O) so welder can stay back away from the plume. • Use welding guns that capture the fume. These units are highly recommended for all work using wire feeders. They control the contaminants at the point of generation. • Use general ventilation (air movers to blow or exhaust the fumes away from you) making sure the fumes are not drawn through your breathing zone or exposing other workers. As a rule of thumb, visible welding fume should clear within 30 seconds of the welding stopping or it is probably not adequate. • Use local exhaust ventilation positioned 4”-6” from the work to remove fumes and gases at their source. This is the most effective form of ventilation and should be used whenever possible, especially in fab areas and fixed locations. • Stay out of the plume! Make sure you position yourself so the plume does not pass through your breathing zone. Also, pay attention to other welders as they may not even realize that they are in the plume. • Move the work into open areas if possible. Do not work in confined or enclosed spaces if it is not necessary. • Use mechanical means rather than hot work (sawcut grating rather than burning to size or rivet bust rather than burn rivets off, etc.). There is a circular saw available that cuts grating, angle, pipe, etc. up to 2 inches thick as easily as cutting plywood. • Limit the length of time you weld during a shift. Sampling results should be used to determine safe lengths of time to weld. • Use long-handled torches. • Remove all coatings and residues from the pieces to be welded. For paint and other preservative coatings remove at least 4 inches back from the point of heat generation. Far enough back that the operation does not raise the temperature of the coating appreciably. • Use less hazardous flux materials if process allows. • Use the safest welding method for the job (e.g. Stick welding makes less fume than flux core welding but may take longer). • Use low fume rods if process allows. • Use downdraft tables to weld small pieces on. • Know what materials and hazards you are dealing with. Refer to MSDS for the electrodes, base metals, and coatings.

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7.3.2 Is the Ventilation Adequate or Poor?

Adequate Ventilation: The following situations would be considered adequate ventilation. • Local exhaust ventilation is used to capture fumes (must be positioned within one to two duct diameters of the work) or • Work is in an open area with adequate air movement or • There is adequate dilution ventilation with directional airflow away from team member (the fume cannot be drawn through the team member’s breathing zone) or • Fume capture guns are used.

Poor Ventilation: The following situations would be considered poor ventilation. • Local exhaust ventilation is not used and • The work is inside enclosed spaces with poor air movement or • The air movement draws the contaminant(s) through the breathing zone of the team member.

If you are not sure if you have an adequate or a poor ventilation situation, then consider it poor ventilation. If adequate ventilation can not be provided, respirators are required.

7.4 Respiratory Protection

If adequate ventilation cannot be provided, all jobs will require a respirator until air sampling proves otherwise! If a respirator is required you must follow the requirements of 29CFR1910.134 and Cianbro’s Respiratory Protection Program Safety Policy and Procedure. Respirators are a last resort and should be used only when feasible engineering and administrative controls are not enough. Refer to Appendix A of this Safety Policy and Procedure for minimum respiratory protection requirements for the most common hot work activities. Respiratory protection is almost always required when welding in a confined space.

7.5 Exposure Monitoring

OSHA has limits for exposure to the metals, gases, and fumes during welding. However some of these limits are out of date and may not protect you enough. Other more protective published limits may be used like the ACGIH Threshold Limit Values. These more protective suggested limits should be used in most cases to better protect the health of our team members. NIOSH has reported that the levels of sickness and death are higher than expected in welders, even when the exposures are below the current OSHA PEL’s for the many individual components of welding emissions. NIOSH also says welding fumes may cause cancer. Therefore it is very important to keep exposure to welding fumes as low as possible.

When deciding what to sample or monitor for the safety specialist needs to be involved and will use the information obtained in the pre-job hazard evaluation required in Section 7.2 of this Safety Policy and Procedure. Sampling is the only way to know whether or not our team members are being protected from the airborne hazards associated with the welding process.

7.5.1 Metals

The metals will be sampled using the same procedure as for lead and multiple metal contaminants can be tested from a single sample. Typical sampling would include manganese for mild steel and hexavalent chromium for stainless steel. Hexavalent chromium requires a different type of filter than the other metals. Sample should be positioned on the welder’s collar so that it is underneath the welding hood as close to the welders breathing zone as possible. Contact the Manager of Health and Environmental Hazards, the Scott Lawson Group, Travelers Laboratory, or other approved laboratory when sampling for a metal contaminant you have not sampled for previously. Reference Appendix B for exposure limits.

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7.5.2 Gases

Gases can usually be monitored using direct reading instruments such as multi-gas monitors and detector tubes. These should be used to determine if ventilation and other controls are adequate and to determine if further monitoring should be done. To determine actual team member exposure however, personal air sampling needs to be done using either passive monitors or a sample pump and appropriate collection media such as cassettes or charcoal tubes. Contact the Manager of Health and Environmental Hazards, the Scott Lawson Group, Travelers Laboratory, or other approved laboratory to obtain the correct sampling media and method. Reference Appendix C for exposure limits.

7.6 Medical Surveillance

Any team member who performs welding or cutting for Cianbro is required to fill out the welding and cutting section of the periodic medical questionnaire. Cianbro’s Medical Director will use this information along with other information (like the PFT results every third year) to determine the need for a welding physical and/or other medical testing. Reference the welding/cutting portion of the periodic medical questionnaire in Appendix B. If there are any symptoms possibly caused by exposure to welding processes report it to your supervisor and safety specialist. Symptoms can be very similar to many other types of illnesses so it is important to report them. The job site will contact Occupational Medical Consulting as soon as possible to help determine the proper care and to recommend specialty evaluation. Cianbro’s Medical Director will make recommendations for medical removal from the welding environmental, PPE, and other actions to reduce ill effects from exposure as necessary.

7.7 Training

Team members who perform welding or operate and maintain oxygen/fuel gas equipment for Cianbro must be trained initially and annually in the contents of this Safety Policy and Procedure and the content of applicable OSHA standards. Team members in charge of oxygen/fuel gas supply equipment must be trained and deemed competent to do so. In addition, the OSHA Hazard Communication standard 29CFR 1926.59 requires team members to be trained in the hazards of the materials that they may come into contact with. To meet this requirement, the results of the pre-job welding and cutting hazard assessment must be covered with the crew as part of the activity plan review.

7.8 Physical Hazards

7.8.1 Radiation – arc welding produces three types of radiation: • UV radiation burns exposed skin much like an sunburn and affects the cornea of the eye which causes “flashburn” that feels like sand in the eye. • Visible radiation produces an intense light from the arc that can damage the retina of the eye. • IR radiation generates intense heat that can cause burns when sparks and spatter fly off the welding process or hot metal and sparks blow out from the cutting process. Burns can also occur when touching hot work pieces or equipment.

For , use lens shade as recommended by OSHA 29CFR1926.102 Table E-2. Welding helmets are considered secondary eye protection and must be used with primary protection (e.g. safety glasses side shields and UV protection). Other workers in the area need to be protected as well using welding screens and UV protective safety glasses.

For skin protection use personal protective equipment, welding gloves, shirts with long sleeves, welding leathers, coveralls or aprons. Clothing should be of fire resistant material like wool, heavy tight weave cotton or Nomex®. No pockets or cuffs. Avoid synthetic materials, as many are extremely flammable. Fire resistant shoulder covers, head covers, ear covers are needed for overhead work. Sunscreen (SPF 15 or higher) should be used on all exposed skin.

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7.8.2 Electrical Shock

Inadequate grounding of equipment, worn or damaged , lack of proper gloves and working in wet conditions can lead to electrical shock. Electrical shock from welding and cutting equipment can kill, cause severe burns, or result in serious injury form falls caused by the shock. Equipment and sometimes the work piece should be grounded. Use a separate connection to ground the equipment or work piece to the earth. Clothes and work surfaces should be dry. If the work area is wet you must eliminate the hazard by moving out of the wet area, protecting from dripping, raising the work up out of the wet, etc.

7.8.3 Fire and explosion can result from welding or cutting close to combustible materials, from leakage of welding or cutting gases through poorly fitting or leaking hoses, from vapors given off by flammable liquids too close to the work (the vapors can travel until they encounter a source of ignition and then flash back), from welding on tanks or containers that have held flammable or combustible materials. To reduce the risk from fire and explosive wear flame retardant clothing (gauntlet gloves, wool or tight weave cotton or leather long sleeved shirt, coveralls without cuffs), inspect the work area and remove or protect all combustibles prior to starting, use a trained fire watch, have appropriate extinguishing media available. Report any equipment defects or other potential hazards to your supervisor. Remove any defective equipment from service immediately and either replace it or have it repaired by a qualified person. Use a hot work permit when appropriate to ensure the area is safe for hot work. Refer to Cianbro’s Watch for Fire, Smoke, and Sparks Safety Policy and Procedure for additional information and for a Hot Work Permit form.

Never carry a butane lighter when doing hot work; sparks or slag may cause it to explode.

7.8.4 Heat stress must be considered due to the protective clothing worn and the heat generated from the welding process especially when there are high ambient temperatures (indoors or out doors), work in confined spaces, or spaces with inadequate ventilation. Follow Cianbro’s Exposure to Heat and Cold Safety Policy and Procedure.

7.8.5 Noise is a hazard in the welding environment because of the process (air arc and plasma arc cutting are very noisy for example), the power source, other equipment in the area, and other operations going on like grinding. If engineering or administrative controls like shielding the noise source or separating operations by distance or time don’t reduce the hazard to an acceptable level, then appropriate hearing protection must be used. Refer to Cianbro’s Hearing Conservation Program Safety Policy and Procedure.

7.9 Safety At Home

Welding and other hot work provides the same hazards whether you are at home or at work other than possibly length of exposure. Please follow the guidelines contained in this policy to help recognize and control hazards associated with welding and other hot work performed outside of work.

8 Budget / Approval Process

8.1 It is the responsibility of each jobsite to procure and provide all materials and PPE required and to provide necessary training.

9 Related Documents

9.1 See attachments.

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9.1 Appendix A Minimum Respiratory Protection for Cutting and Welding Processes Minimum Respiratory Protection for Cutting and Welding Processes

Welding Process and Base Metal Adequate Ventilation: Local exhaust ventilation is Inadequate Ventilation: Local exhaust used to capture fumes or in open area with ventilation not used or inside enclosed spaces Comments adequate air movement or adequate dilution with inadequate air movement or air movement ventilation with directional air flow away from team draws contaminant through breathing zone of member. The fume cannot be drawn through the team member. team member’s breathing zone. Shielded Carbon Steel Not required 1/2 face respirator with 100 efficiency cartridges Manganese Metal Arc Welding Other alloys and Not required. Air sampling required to verify 1/2 face respirator with 100 efficiency cartridges Manganese (stick) galvanized Carbon Steel Not required Air supplied respirator required Ozone Gas Tungsten Arc Welding Other alloys and Not required. Air sampling required to verify Air supplied respirator required Ozone especially with (TIG) galvanized aluminum

Carbon Steel Not required 1/2 face respirator with 100 efficiency cartridges Fume capture guns considered adequate Flux Core Arc ventilation, Manganese Welding Other alloys and Not required. Air sampling required to verify 1/2 face respirator with 100 efficiency cartridges Manganese galvanized Carbon Steel Not required Air supplied respirator required Ozone, Manganese Gas Metal Arc Welding (MIG) Other alloys and Not required. Air sampling required to verify Air supplied respirator required Ozone especially with galvanized aluminum, Manganese Sub- Arc Not required 1/2 face respirator with 100 efficiency cartridges Creates minimal fume Welding Air Supplied Respirator Required (unless using local Air supplied respirator required Ozone may be able to control exhaust ventilation and sampling is being done for exposure with directed Plasma ozone – can use 1/2 face respirator with 100 ventilation (fan) for 100% Cutting efficiency cartridges with ozone protection) water immersion table. Sampling required.

Carbon Steel Not required 1/2 face respirator with 100 efficiency cartridges Oxy- Fuel Cutting Other alloys and Not required. Air sampling required to verify 1/2 face respirator with 100 efficiency cartridges galvanized Air Arc/ 1/2 face respirator with 100 efficiency cartridges PAPR or full face respirator quantitatively fit, both Large amounts of fume Carbon Arc with 100 efficiency cartridges generated Lance Rod 1/2 face respirator with 100 efficiency cartridges Air supplied respirator required Typically used on demo jobs Cutting with coated steel present. See #3 below Cad Welding Not required 1/2 face respirator with 100 efficiency cartridges Should be able to provide adequate ventilation in most cases

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9.2 Appendix B Exposure Guidelines for Welding Fumes and Gases Exposure Guidelines for Welding Fumes and Gases 8-Hour Time-Weighted Average (TWA) Material (Fumes) Exposure Limit Potential Effects and Symptoms From Overexposure3

OSHA PEL1 TLV2 (mg/m3) (mg/m3) Aluminum 5 (respirable) 5 Skin irritation, respiratory system irritation, pulmonary fibrosis

Arsenic 0.01 0.01 Respiratory irritation, lung cancer, dermatitis Beryllium 0.002 0.002 Lung disease (), lung cancer, eye irritation 0.005 (C)4

Cadmium 0.005 0.002 Respiratory irritation, lung congestion, abdominal pain, kidney damage, 0.01 STEL5 yellow ring on teeth Chromium II & III Compounds and metal 0.5 0.5 Lung disease, nasal irritation, sensitization, eye irritation

Chromium VI compounds (insoluble) 0.005 0.01 Lung cancer, nasal irritation and perforation, liver and kidney effects

Cobalt 0.1 0.02 Lung disease, wheezing, hypersensitivity, asthma, cardiovascular system effects, eye irritation

Copper 0.1 0.2 Metal fume fever, respiratory irritation, skin and hair discoloration Fluorides 2.5 2.5 Respiratory irritation, mottling tooth enamel, bone changes, kidney effects Iron oxide 10 5 Siderosis (pigmentation of the lung) Lead 0.05 0.05 Central nervous system effects, , reproductive system effects fume 15 10 Metal fume fever, eye and nose irritation

Manganese fume 5(C)4 0.2 Nervous system effects(Parkinson’s), , reproductive system effects, metal fume fever

Mercury 0.1(C)4 0.025 CNS effects, kidney and reproductive effects, eye irritant, cough, chest pain Molybdenum 5 5 Respiratory irritation, liver and kidney effects Nickel 1 0.2 Asthma, congestion, lung disease, carcinogen, sensitization

Tin 5 (respirable) 2 Stannosis-benign lung disease Titanium dioxide 5 (respirable) 10 Lung fibrosis, potential carcinogen

Vanadium 0.05 0.05 Respiratory irritation, , emphysema, pneumonia, green tongue, cough fume 5 (respirable) 5 Metal fume fever, cough, chest pain Welding fumes – not otherwise classified 5 (respirable) 5 Depends on components of fume, metal fume fever, irritation, cough, pulmonary edema

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9.3 Appendix C Associated Guidelines for Gases Associated with Welding and Cutting Exposure Guidelines for Gases Associated with Welding and Cutting Material (gases) PEL (ppm) TLV (ppm) Potential Effects and Symptoms From Overexposure3 Argon None None Simple asphyxiant

Carbon dioxide 5000 30000 STEL5 Mild narcotic effects, respiratory effects,

Carbon monoxide 50 25 Headaches, drowsiness, asphyxiation, anoxia

Hydrogen chloride 5(C)4 5(C)4 Strong irritation, dermatitis

Hydrogen fluoride 3 3(C)4 Skin, eye, respiratory irritations, bone effects

Nitric oxide 25 25 Cyanotic effects, anoxia, eyes and skin irritation

Nitrogen dioxide 5(C)4 3 Eye, nose, throat irritant, chronic bronchitis, lung congestion, chest pain, 5 STEL5 cough Ozone 0.1 Light work 0.1 Respiratory irritation, lung congestion, bronchitis, headache, dry throat, premature aging Moderate 0.08 Heavy 0.05 Any work 0.2 Phosgene 0.1 0.1 Lung congestion, chronic lung changes, anoxia, eye irritation

1 OSHA Permissible Exposure Limit (PEL) as listed in 29CFR 1926.55 and accompanying standards as of 2/1/2000.

2 Threshold Limit Value (TLV) as published in the 2000 TLV and BEI booklet by the American Conference of Governmental IndustrialHygienists (advisory guidelines only).

3 Primary reference sources: 1997 NIOSH Pocket Guide to Chemical Hazards and the TLV Basis-Critical Effects as published in the 2000 TLV and BEI booklet2.

4 Ceiling Limit, not to be exceeded without respirator use.

5 Short Term Exposure Limit.

Policy: 015 Welding and Cutting Hazard Rev. 06/03/11 Page 12 Assessment Program