Imagine the result Bayer Material Science LLC Health and Safety Plan May 2009 Health and Safety Plan Dave Kingsley Hicksville, New York Project/Task Manager Greg Ertel, CIH Health and Safety Manager Prepared for: Bayer Material Science LLC Prepared by: ARCADIS 295 Woodcliff Drive Third Floor Suite 301 Fairport New York 14450 Tel 585.385.0090 Fax 585.385.4198 Our Ref.: B0032305.0002 Date: May 2009 This document is intended only for the use of the individual or entity for which it was prepared and may contain information that is privileged, confidential and exempt from disclosure under applicable law. Any dissemination, distribution or copying of this document is strictly prohibited. Table of Contents Approvals and Acknowledgments viii 1. Introduction 1 1.1 Objective 1 1.2 Site and Facility Description 1 1.3 Relevant Site History 2 1.4 Policy Statement 3 1.5 References 4 1.6 Definitions 4 1.7 Acronyms 5 2. Roles and Responsibilities 8 2.1 All Personnel 8 2.2 ARCADIS Personnel 8 2.2.1 Project Officer (PO) 8 2.2.2 Health and Safety Officer (HSO) 8 2.2.3 Project Manager (PM) 8 2.2.4 Health and Safety Supervisor 9 2.2.5 Site Supervisor 10 2.3 Subcontractors 10 2.4 All On-Site Personnel 11 2.5 Visitors 12 2.6 Stop Work Authority 12 2.7 Short Service Employee (SSE) Program 12 2.8 Near-Miss Reporting Hotline 13 3. Project Hazards and Control Measures 15 3.1 Scope of Work 15 3.2 Field Activities, Hazards and Control Procedures 15 099911807.doc i Table of Contents 3.2.1 Mobilization 15 3.2.2 Construction Observation 16 3.2.2.1 Excavation Hazards and Control Procedures 17 3.2.2.2 Inspections by a Competent Person 19 3.2.2.3 Soil Classification 19 3.2.2.4 Overhead Electrical Clearances 21 3.2.2.5 Excavation Entry Procedure 21 3.2.2.6 Heavy Equipment Materials Handling 23 3.2.3 Air Monitoring 29 3.2.3.1 Hazards 29 3.2.4 Soil Sampling 30 3.2.4.1 Hazards 30 3.2.4.2 Control 31 3.2.5 Demobilization 31 3.3 Chemical Hazards 32 4. General Safety Practices 34 4.1 General Safety Rules 34 4.2 Loss Prevention System (LPS) 35 4.2.1 Safe Performance Self-Assessment / TRACK Process 36 4.2.2 Incident Investigation 37 4.2.3 Loss Prevention Observation 37 4.2.4 Near Miss Reporting 38 4.2.5 Job Safety Analysis 39 4.3 Buddy System 39 4.4 Heat Stress 40 4.4.1 Heat Rashes 40 4.4.2 Heat Cramps 41 099911807.doc ii Table of Contents 4.4.3 Heat Exhaustion 41 4.4.4 Heat Stroke 42 4.4.5 Heat Stress Safety Precautions 43 4.5 Cold Stress 45 4.6 Biological Hazards 48 4.6.1 Ticks 48 4.6.2 Mosquitoes 49 4.6.3 Poisionous Plants 50 4.6.4 Snakes 52 4.6.5 Spiders 52 4.7 Noise 53 4.8 Spill Control 53 4.9 Sanitation 54 4.9.1 Break Area 54 4.9.2 Potable Water 54 4.9.3 Sanitary Facilities 55 4.9.4 Lavatory 55 4.10 Emergency Equipment 55 4.11 Lockout/Tagout Procedures 55 4.12 Electrical Safety 56 4.13 Lifting Safety 57 4.14 Elevated Work Safety 58 4.14.1.1 Fall Protection 58 4.14.1.2 Ladders 59 4.15 Heavy Equipment Materials Handling 61 4.15.1 Audible Alarms 62 4.15.2 Equipment Inspection and Maintenance 62 099911807.doc iii Table of Contents 4.15.3 Equipment Parking and Loading 63 4.15.4 Equipment Fueling 64 4.15.5 Flaggers 64 4.15.6 Additional Safety Requirements 65 4.16 Hot Work Safety Program 67 4.16.1.1 Designated Hot Work Areas 67 4.16.1.2 Conditions Prohibiting Hot Work 67 4.16.1.3 Hot Work Permits 68 4.16.1.4 Fire Watch Procedures 70 4.17 Confined Space Entry 70 4.17.1 Duties of Personnel 71 4.17.1.1 Duties of Entrants 71 4.17.1.2 Duties of Attendants 72 4.17.1.3 Duties of Entry Supervisors 73 4.17.2 Procedures for Permit Space Entry 74 4.17.3 Training 77 4.18 Crane Hazards and Control Procedures 78 4.19 Traffic Safety 82 5. Personal Protective Equipment 83 5.1 Levels of Protection 83 5.1.1 Level D Protection 83 5.1.2 Modified Level D Protection 84 5.1.3 Level C Protection 84 5.2 Selection of PPE 85 5.3 Site Respiratory Protection Program 85 5.4 Using PPE 86 5.4.1 Donning Procedures 86 099911807.doc iv Table of Contents 5.4.2 Doffing Procedures 87 5.5 Selection Matrix 88 6. Air Monitoring 89 6.1 Air Monitoring 89 6.2 Noise Monitoring 90 6.3 Monitoring Equipment Maintenance and Calibration 90 6.4 Action Levels 91 6.5 On-Site Monitoring Plan and Response Activities 91 6.6 Odor Control 91 7. Work Zones and Decontamination 93 7.1 Work Zones 93 7.1.1 Authorization to Enter 93 7.1.2 Site Orientation and Hazard Briefing 93 7.1.3 Certification Documents 93 7.1.4 Entry Log 93 7.1.5 Entry Requirements 94 7.1.6 Emergency Entry and Exit 94 7.1.7 Contamination Control Zones 94 7.1.7.1 Exclusion Zone 94 7.1.7.2 Contamination Reduction Zone 94 7.1.7.3 Support Zone 95 7.1.8 Posting 95 7.1.9 Site Inspections 95 7.2 Decontamination 95 7.2.1 Personnel Decontamination 95 7.2.2 Equipment Decontamination 96 7.2.3 Personal Protective Equipment Decontamination 96 099911807.doc v Table of Contents 8. Training and Medical Surveillance 97 8.1 Training 97 8.1.1 General 97 8.1.2 Basic 40-Hour Course 97 8.1.3 Supervisor Course 98 8.1.4 Site-Specific Training 98 8.1.5 Daily Safety Meetings 99 8.1.6 First Aid and CPR 99 8.2 Medical Surveillance 99 8.2.1 Medical Examination 99 8.2.2 Pre-placement Medical Examination 99 8.2.3 Other Medical Examinations 100 8.2.4 Periodic Exam 101 8.2.5 Medical Restriction 101 9. Emergency Procedures 102 9.1 General 102 9.2 Emergency Response 102 9.2.1 Fire 102 9.2.2 Contaminant Release 102 9.3 Medical Emergency 103 9.3.1 Emergency Care Steps 103 9.4 First Aid – General 104 9.4.1 First Aid – Inhalation 104 9.4.2 First Aid – Ingestion 104 9.4.3 First Aid – Skin Contact 104 9.4.4 First Aid – Eye Contact 105 9.5 Reporting Injuries, Illnesses and Near Miss Incidents 105 099911807.doc vi Table of Contents 9.6 Emergency Information 105 9.6.1 Directions to North Shore University Hospital 106 Tables 1 Key Personnel 2 Maximum Allowable Slopes (29 CFR 1926 Subpart P, Appendix B) 3 Minimum Overhead Electrical Clearances (All Equipment) 4 Screening Criteria for Heat Stress Exposure 5 Examples of Activities within Metabolic Rate Categories 6 Chill Temperature Chart 7 Minimum Overhead Electrical Clearances (Aerial Lifts) 8 Acceptable Entry Conditions for Confined Spaces 9 Minimum Overhead Electrical Clearances (Cranes) 10 PPE Selection Matrix 11 Airborne Contaminant Action Levels 12 Emergency Contacts Attachments A Addendum Page B Visitor Acknowledgement and Acceptance of HASP C Utility Location Policy and Procedure D Material Safety Data Sheets E Incident/Near-Miss Investigation Report F Loss Prevention Observation Form G Real Time Air Monitoring Data Collection Form H Site Activities Tailgate Safety Briefing Sign-in Log 099911807.doc vii Table of Contents Approvals and Acknowledgments Approvals I have read and approved this Health and Safety Plan with respect to project hazards, regulatory requirements, and ARCADIS procedures. Project Name: Bayer Material Science Facility, Hicksville, New York Project Number: B0032305.0002 _______________________________5.20.09 ____________________________5.20.09 Project/Task Manager/Date Health and Safety Manager/Date _______________________________ Health and Safety Supervisor/Date Acknowledgments The final approved version of this Health and Safety Plan (HASP) has been provided to the Site Supervisor (SS). I acknowledge my responsibility to provide the SS with the equipment, materials and qualified personnel to implement the safety requirements in this HASP. I will formally review this plan with the Health and Safety Staff every six months until project completion. ________________________________ Project/Task Manager/Date I acknowledge receipt of this HASP from the Project Manager (PM), and that it is my responsibility to explain its contents to all site personnel and cause these requirements to be fully implemented. Any change in conditions, scope of work or other change that might affect worker safety requires me to notify the PM and/or the Health and Safety Officer. ________________________________ Site Supervisor/Date 099911807.doc viii Health and Safety Plan Hicksville, New York 1. Introduction 1.1 Objective This Health and Safety Plan (HASP) has been prepared in support of Interim Corrective Measure Additional PCB Soil Removal Work Plan (ICM) removal activities to be performed at the Bayer Material Science LLC (Bayer) facility located at 125 New South Road in Hicksville, New York (Site). ICM activities conducted by ARCADIS for this project will consist of construction observation during the soil removal, being completed by the client’s contractor, from the Plant 1 and Pilot Plant footprint and other areas at the site that contains polychlorinated biphenyls (PCBs) at concentrations greater than 50 parts per million (ppm) and removal of certain soil that exhibits volatile and semivolatile organic compounds at concentrations exceeding New York State Department of Environmental Conservation (NYSDEC) soil guidelines.