Plant Floor Safety by CFE MEDIA

Plant Floor
Safety
SUM M E R ED I T I O N
Contents
3 — Benefits of using a control of work system in a
manufacturing facility
11 — Understanding ASHRAE Standard 199
12 — 10 Tips for Keeping Your Dust Collection System
Performing Optimally and Safely
22 — Benefits of a rack safety flywheel in warehouse,
manufacturing facilities
27 — Bolted Access Stairs: Code-Compliant Facility Stairs
28 — Code-compliant stair design for safety and ergonomics
54 — Select the right PPE to take control of electrical risks
61 — Therm-O-Mix Station: How it Works
62 — Selecting The Right Tepid Water Solution
69 — Why you should consider using steel conduit and tubing
73 — Seven clean-in-place design best practices
2
Benefits of using a control of work
system in a manufacturing facility  Back to TOC
Many plant managers and environmental, health and safety (EHS)

professionals can manage regulatory requirements for dangerous
environments more easily as part of a larger control of work system.
M any facility managers, plant engineers and environmental, health and safety
(EHS) professionals know there are regulatory requirements for safe work prac-
tices and procedures for permit-required confined space entry or “hot work.” This
includes welding, cutting, grinding, torching, brazing or other slag or spark producing
activities. However, workers may not understand how these requirements fit into and
are more easily managed as part of a larger control of work system. They may not real-
ize the wider benefits of control of work for safety management which builds the foun-
dation for environmental, social and governance (ESG) maturity.
What is control of work?

Control of work is an essential element of a comprehensive EHS management program
that ensures hazardous work only occurs when safety preconditions are met. It also
helps with management of multiemployer worksites by ensuring all temporary workers
and contractors (as well as the staffing agencies and contractor providers who employ
them) meet the organization’s qualifications and safety standards, support safe facility
operations and align them with safety performance goals.
Companies with robust control of work programs can reduce risk and improve relation-
ships with key stakeholders such as employees and contracted workers. It also provides
an important building block for ESG maturity.
3
Benefits of using a control of work system in a manufacturing facility
How control of work improves EHS management and  Back to TOC

regulatory compliance
An element of a control of work program is especially useful for managing the risks
associated with high hazard activities is a permit to work (PTW) system. This formal
documentation system establishes safe work practices and procedures to control when
certain hazardous work tasks are performed, who can perform them, and the condi-
tions and controls that need to be in place before work can proceed.
Systems involving spreadsheets and paper documents are often cumbersome and
tedious; modern EHS software can simplify the process, improving efficiency and mini-
mizing management time. The right software gives organizations all the benefits of an
effective system without the headaches.
A PTW system can improve key areas of regulatory compliance and EHS management.
Permit-required confined spaces

Many workplaces have “confined spaces,” which are spaces big enough for a person
to enter and work in but have limited means of entry and exit. Some confined spaces
pose significant risks to the safety and health of employees who would work in them. In
the U.S., the Occupational Safety and Health Administration (OSHA) requires employ-
ers to use a permit system for confined spaces that have one or more of the following
characteristics:
• It contains or has a potential to contain a hazardous atmosphere.
• It contains a material with potential for engulfing an entrant.

4
• It has an internal configuration such that an entrant could be trapped or asphyxiat-  Back to TOC
ed by inwardly converging walls or by a floor which slopes downward and tapers to
a smaller cross-section.
• It contains any other recognized serious safety or health hazard.
OSHA sets requirements for “permit-required” confined spaces at 29 CFR 1910.146 for
general industry, and a similar standard at 1926.1206 for construction. These regula-
tions define which confined spaces are “permit required” confined spaces and define
the information that needs to be included in the permit. This includes the permit space
to be entered, the date, the length of time the permit is valid, name of entry supervi-
sor, methods of assessing air contamination hazards and more.
There is no specific European Union requirement for confined spaces, although Direc-
tive 89/391/EEC from June 12, 1989, covers all aspects of safety and health at a work-
place and places a duty on employers to consider the specific characteristics of every
workplace. A formal PTW system, even when not specifically required in a regulatory ju-
risdiction, is an effective way to limit and monitor access to hazardous confined spaces.
Controlling hazardous energy

The term “control of hazardous energy” refers to a process of protecting workers from
unexpected startup of equipment that could release any form of energy such as elec-
tricity, heat, hydraulic energy or stored energy such as gravity, and other energy sourc-
es The system for managing control of hazardous energy is often known as lockout/
tagout (LOTO), which involves both physical prevention of activating equipment as
well as visual identifications, aka “tags,” indicating employees should not activate the
equipment until the tags are removed.
5
In the U.S., OSHA has a regulatory standard addressing LOTO at 29 CFR 1910.147.  Back to TOC
In Canada, there’s no specific regulatory framework for enforcing control of hazardous

energy, although it’s considered an employer obligation and CSA Z460-13, which is
based on ANSI/ASSP standard Z244.1-20 which establishes specific characteristics and
requirements for lockout programs. In the United Kingdom, British Standard BS 7671
“Requirements for Electrical Installations” covers electrical installation and the safe-
ty of electrical wiring in domestic, commercial, industrial and other buildings, and in
special installations and locations. It states “every employer shall ensure that, where
appropriate, work equipment is provided with a suitable means to isolate it from all its
sources of energy. Every employer shall take appropriate measures to ensure that re-
connection of any energy source to work equipment does not expose any person using
the equipment to any risk to their health or safety.”
None of these standards explicitly state employers should use a PTW system, but in
practice, many employers do use one because it provides better assurance employees
don’t activate dangerous equipment by accident.
Permit to work systems are crucial to general safety

management
There are many job tasks, such as working at heights, where using a permit system
could help mitigate risks of employees performing tasks without proper training, au-
thorization or personal protective equipment (PPE) such as fall arrest or protection
systems. Energized electrical work or troubleshooting may expose employees or con-
tractors to hazardous energy when lockout-tagout is not possible. “Hot work” like
cutting, welding and brazing is another slag or spark activities are often managed with
hot work permits which are often driven by property insurance companies.
6
OSHA’s hot work regulations in the U.S. require a prework inspection and authoriza-  Back to TOC
tions assuring the work is performed by a competent individual.
PTW is part of a proactive, risk-focused approach to safety management. As business-

es move from a compliance-focused approach to a more mature approach based on
employee engagement and best practices, this is why they tend to expand their use of
control of work systems.
Managing temporary worker and contractor safety

Control of work systems are especially important in today’s workplaces, because
“traditional workforces” are being supplemented by temporary workers and on-site
contractors.
For example, temporary employment in manufacturing is much higher compared to

other industries.
With contractors always entering and exiting workplaces, it can be challenging to track
them, and even to know which specific individuals are on-site at any given time.
Consider this situation involving a Chicago Fire Department hazardous materials

manager, who relayed a story about arriving at a chemical manufacturing facility in
response to an emergency call. Upon their arrival, site representatives informed fire
department first responders that contractors had been on-site working on some de-
commissioned chemical processing tanks, and while in the process of working, one of
the contractors got trapped inside the tank.
7
While site representatives knew the person inside the tank was a male contractor —  Back to TOC
that’s all they knew. They didn’t know his name or what time he’d entered the tank. This
real-life example highlights the horror of how badly things can go wrong when organiza-
tions lack efficient and effective control of work processes tracking who’s on-site, tightly
controlling access to dangerous places and processes and ensuring everyone on-site has
the right knowledge, pre-qualifications and competencies before starting work.
Formal control of work and PTW systems provide an effective communication frame-
work that promotes collaboration and coordination between host and temporary em-
ployers and between host employers and contractors. This makes it easier to ensure all
parties to the employment contract are aware of their obligations for worker safety and
verify all necessary training, hazard controls, PPE and other job-specific precautions are
in place before work. This understanding and communication are a crucial, yet often
overlooked component of contractor and temporary worker safety, the lack of which
has been shown to be a significant factor in temporary worker injuries and illnesses.
Modern control of work software is configurable to the specific PTW processes in

place at the organization and helps manufacturers and employers across all industries
manage complete contractor journeys and electronic permit-to-work processes across
locations through a centralized system. Providing greater transparency, strengthening
compliance with EHS policies and structuring the PTW system in a way that prompts
workers to accurately complete permits helps electronic PTW systems can save signifi-
cant time and headaches with day-to-day tasks while minimizing EHS risks.
Control of work helps build, sustain ESG maturity

Another major advantage of a control of work system is it helps organizations navigate
the journey from EHS management to ESG maturity.
8
There are a couple of specific ways  Back to TOC

that control of work helps move
the needle on ESG performance.
The first pertains to shoring up the
essentials of EHS management by
giving better oversight of contrac-
tors and temporary workers and
having a sustainable process for
maintaining regulatory compliance.
To build and sustain ESG maturity,
companies first need to do EHS
right. Think of ESG management in
terms of a pyramid. Without a solid
foundation in EHS management,
the peak of the pyramid, ESG ma-
turity, will remain out of reach.
Another benefit of control of work

is it helps build good stakehold-
er relationships. A stakeholder is
anyone affected by, or who per-
ceives themselves to be affected
by, the business operations and
who affects them in turn. The or-
ganization’s employees are stake-
holders, but so are temporary
workers and contractors. 9
Control of work improves communications with these stakeholders, which helps or-  Back to TOC
ganizations maintain ESG programs and policies. Organizations may have great pro-
grams to avoid impacts to stormwater and wastewater, reduce wastes sent to landfill
and avoid use of chemicals that pose hazards to workers, the community and the value
chain. However, if contractors don’t know those policies, those sustainability efforts
may be negatively impacted and the organization’s reputation will be damaged.
The stakeholder relationships that control of work helps build can then help organiza-
tions advance their ESG initiatives by identifying and focusing on the issues that matter
most. The term for such an exercise is a materiality assessment, which is a stakehold-
er survey designed to assess the relative importance of various areas of ESG, such as
greenhouse gas emissions or supply chain stability.
Contractors, for example, may have important insights into aspects of business they’d
need to know about. Modern ESG software can then organize the survey results in the
form of a materiality matrix, which ranks ESG issues as a function of impact and impor-
tance and shows the most significant issues in the top right corner.
Putting everything together, a control of work system can help proactively reduce risk,
help maintain regulatory compliance and protect employees, temporary workers and
contractors. In a business environment where stakeholders demand higher levels of
ESG accountability and performance, control of work can be an important part of the
journey, helping organizations demonstrate proactive safety practices, improve value
chain relationships and gain competitive advantages by building ESG maturity.
Phil Molé
Phil Molé, MPH, EHS & sustainability expert for VelocityEHS. 10
Understanding ASHRAE Standard 199
 Back to TOC

Understanding ASHRAE Standard 199
ASHRAE developed Standard 199-2016 to test the performance
of a dust collection system under real-world conditions. Testing
involves six stages that measure a dust collector’s emissions,
pressure drop, and compressed air usage. This video explains
why the ASHRAE 199 testing process is a better measure of filter
efficiency than MERV ratings, what’s included in the ASHRAE 199
testing process and how testing results help you select the ideal
dust collector for your application.
11
10 Tips for When operating an industrial dust collector,
deflagration protection, venting, filter efficiencies
and safety monitoring are just a few elements
Keeping Your that can mean the difference between high-
efficiency performance or a production shutdown.
Dust Collection A dust collector is a key component in the safety
System of almost every manufacturing plant. When

properly maintained, it can keep workers safe,
maximize production uptime and help meet
Performing regulatory compliance.
Optimally and T hough a dust collector is a vital component in the

safety of almost every manufacturing plant, it is usually
Safely
a reluctant purchase. Few plant professionals get excited
about buying a dust collection system. As a result, they
will often select the lowest-cost equipment available for
the job. However, the solution with the lowest price tag
can prove to be the most costly in terms of worker safety,
production downtime, regulatory compliance and other
problems that plague companies when dust collectors do
not perform properly.
The total cost of ownership of a dust collector is impact-

ed much more by the cost of energy and consumables to
keep it operating. Also, not all collectors are created equal
10 Tips for Keeping Your Dust Collection System Performing Optimally
from a safety standpoint. Consider the following guidelines when selecting new equip-  Back to TOC
ment and when looking to improve an existing system.
1. Protect from Deflagration

If your dust collector handles combustible dust, you
must equip it with deflagration protection. Although
there are many forms of deflagration protection, a
common, cost-effective passive method is venting.
An explosion vent opens when predetermined pres-
sures are reached inside the collector, allowing the
excess pressure and flame front from the deflagra-
tion to exit to a safe area.
This minimizes damage to the collector and pre-

vents it from blowing up in the event of a defla-
gration, thereby reducing the hazard. A flameless vent is To minimize explosion and fire
risk, this collector is equipped
designed to install over a standard explosion vent and ex- with an explosion vent and a
tinguish the flame front exiting the vented area, not allow- large bin for safe storage of
discharged dust.
ing it to exit the device. This allows conventional venting to
be accomplished indoors where it could otherwise endan-
ger personnel or ignite secondary explosions. If you cannot vent the pressure wave and
fireball to a safe area, discuss another method with your dust collection professional.
Understanding the pressure capabilities of your collector is important in the specifica-

tion and selection of vent sizing. Comparing venting vessel strength to the deflagration
strength and vent burst pressure is key to effective deflagration protection. Some of
13
the combustible dust properties required to under-  Back to TOC

stand this concept are described by the Kst (bar
m/s – normalized rate of pressure rise) and Pmax
(bar – maximum pressure for an unvented dust ex-
plosion) values (Figure 1). As Figure 2 shows, burst
pressure of the vent is designed to be lower than
enclosure strength, which will relieve the pressure
of the deflagration before it can build to levels that
would destroy the collector enclosure. Figure 1
2. Protect the Ductwork

Even if a collector has rugged construction and
a properly sized explosion vent, you still need to
protect the ductwork that serves the dust collector
and processes upstream. This is a task that is often
overlooked.
The NFPA requires that ducting be equipped with

dampers and valves designed to minimize the risk
of explosion within these components. Here’s how
Figure 2
a flow-activated inlet isolation valve works in the event of a deflagration
event in the main dust collector housing. The pressure wave causes the
valve to close, which prevents flames and smoke from passing to areas upstream. The
valve latches shut and must be opened manually. The NFPA requires that the ductwork
between the dust collector and isolation valve be designed to withstand two times the
reduced pressure reached following the venting of the dust collector.
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3. Keep Hoppers Empty  Back to TOC

Factories and process manufacturers sometimes
store products in hoppers. However, the hop-
per required with a dust collector should not
be used to store dust. The hopper is only in-
tended to funnel process dust to a storage bin.
Dust that has accumulated in a hopper creates
a potential fire or deflagration risk. Dust in the
hopper may also diminish the collector’s perfor-
mance by clogging the system and preventing
the pulse cleaning system from doing its job.
Self-dumping hoppers provide easy dust dis-

posal while protecting against unwanted dust leakage This dust collector removes high
loads of concrete dust from
between the collector and hopper. A slide gate and flexible the air. Self-dumping hoppers
quick-disconnect hose connect the two components to- minimize worker exposure and
gether, and the hopper lid is fastened with rubber clamps handling of silica dust.
that create a gasketed seal to prevent dust from escaping.

When the hopper is full, you can detach it from the bottom of the collector, lift the
hopper onto a fork truck, and simply pull a lever to swing the lid open and dump the
contents into a larger disposal container.
Self-dumping hoppers are used for a range of dry dusts, including those that must be
reclaimed or recycled after the collection process.
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4. Use an Effective Pulse-Cleaning System  Back to TOC

The dust collector’s cleaning system design works in conjunction with filter design.
Selective cleaning controls provide an easy, maintenance-friendly way to keep filters
clean. You can select from three cleaning options:
continuous cleaning, on-demand cleaning and
downtime cleaning. Continuous cleaning is suited
for porous dusts, such as silica and other minerals,
high-dust-loading applications like thermal spray
or plasma cutting, or lightweight dust such as
fumed silica and paper fines.
On-demand cleaning is recommended for most

dust types. This setting monitors the differen-
tial pressure across the clean-air section and the
dirty-air filter section of the collector. On-demand
cleaning allows you to set a very narrow range of
This high-quality dust
differential pressures to activate and stop the cartridge clean- collector filter uses an
ing. This setting uses the least amount of compressed air and open-pleat design that
provides optimum filter cleaning efficiency and filter life. Note helps dust to release more
readily during pulse cleaning,
that the on-demand settings will need to be adjusted to com- extending filter life and
pensate for the slow but continual rise in filter pressure drop reducing energy usage.
over the life of the filter set.
Downtime cleaning allows for time-based pulsing at the end of a plant shift, after
completing a batch process or after an upset condition that may affect the filter’s per-
formance. Downtime cleaning allows you to shut off the fan and clean the filters during
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a set duration of time. After the cleaning period is finished, the unit will shut off com-  Back to TOC
pletely. This is an important feature because overcleaning the cartridges during op-
eration causes higher emissions, shorter cartridge life and higher energy costs due to
overuse of compressed air.
5. Use Safety Monitoring Filters

You might also want to equip your collector with a safety monitoring filter. This is a
secondary bank of high-efficiency air filters that prevent collected dust from re-enter-
ing the workspace if there should be a leak in the dust
collector’s primary filtering system.
A safety monitoring filter is a required component in

a recirculating dust collection system that recycles air
downstream of the collector. By recirculating heated or
cooled air back through the plant, the cost to replace
that conditioned air is eliminated, with rapid paybacks
in energy savings. Another advantage of recirculating
systems is a reduction in regulatory paperwork. By con- A safety monitoring filter is
a required component in
taining the air indoors, you can avoid the time-consuming recirculating dust collection
permitting involved when contaminated air is exhausted systems that recycle air
downstream of the collector
outside.
when filtering hazardous or toxic
dusts. This large dust collector
6. Make sure you Comply with Emissions has an integrated safety
monitoring filter (iSMF) mounted
Requirements on top, a vertical explosion vent,
Using filter percentage efficiencies and minimum efficiency vertical vent ducting, a weather
cover, and an NFPA-rated airlock
reporting value (MERV) ratings to predict emissions compli-
on the discharge of the hopper. 17
ance isn’t enough. The MERV scale provides a good indicator of a filter’s initial efficien-  Back to TOC
cy; however, it does not measure pressure drop, emissions while pulsing, energy per-
formance or the other parameters that better reflect dust collector efficiency. The EPA
and OSHA want to know that emissions will be at or below their required thresholds.
Ask the filtration manufacturer for a written guarantee of emissions performance stated
as grains per cubic foot.
A good way to measure your dust collector’s emissions effectiveness is to test it ac-
cording to the recently published ANSI/ASHRAE Standard 199-2016, Method of Testing
the Performance of Industrial Pulse Cleaned Dust Collectors. This standard is designed
to help end users evaluate collection equipment effectively and accurately. The test
measures four key performance parameters: emissions, pressure drop, compressed air
usage and emission reading.
7. Change Out Filter Cartridges Safely

Ideally, your workers should never have to enter the dust
collector to change the filters. Dust collectors that require
entry during service put workers at risk and require com-
panies to file confined space entry permits and monitor
for gas. Many cartridge-style dust collectors offer ease
of filter change-out. For optimal safety, filters should be
positioned for ease of access and slide in and out of the
housing readily. This cartridge dust collector
features easy filter change-
out without entry into the
Simple, quick-open heavy-gauge doors can provide access to collector and extended-life
a fast cartridge change-out system that does not require entry filters for longer intervals
into the collector.

between service. 18
We recommend looking for doors that are fully reversible for access from either side  Back to TOC
and have an exclusive lock-out feature for worker safety.
Pulling out a dirty overhead filter that weighs 100 pounds can result in neck, back and
foot injuries. Avoid threaded connections on the filter access doors or hoppers be-
cause dust tends to build up in the threads and cause connections to stick.
Camlock-style devices are not subject to this problem and make for easier service.
8. Don’t Skimp on Filter Cartridges

A simple but important safety requirement is to change filters when airflow through the
system reaches a differential pressure limit as prescribed by the manufacturer or when
the pressure drop across the collector is negatively affecting the ability of the dust col-
lection system to capture the dust, thus allowing it to escape into the facility. Some long-
life cartridge filters can operate for two years or even longer between change-outs.
However, for heavy-dust-loading applications, filter replacement might be much more

frequent. Moreover, extended-life cartridge filters can reduce replacement frequency
and minimize worker exposure to dust. Reducing filter change-out frequency also saves
on maintenance and disposal costs and reduces landfill impact. Ask your filter supplier
for a written guarantee on filter life.
9. Test the System using ASHRAE Standard 199

Industry experts estimate that 80% of all dust collectors do not operate satisfactorily.
That’s because designing dust collection equipment requires a comprehensive analy-
sis of the dust or other airborne contaminants, system operating conditions and many
other factors.
19
Instead of using guesswork to select this equipment, use ASHRAE Standard 199  Back to TOC
testing. It compares dust collectors based on true operating conditions and real
world performance data on emissions, pressure drop, compressed air usage, energy
consumption and emission readings.
The standard applies to industrial dust collectors that use pulse cleaning to recon-
dition the filter media so the collector can continue to operate. Armed with this com-
parative data on operation, energy costs and
particle emissions, you can make more in-
formed long-term decisions to reduce main-
tenance, consumables and disposal costs.
10. Protect from Fires and Use

Safety Accessories
For spark-generating applications, a range of
features and technologies is available, from
flame-retardant filter media to spark arrestors
in the form of drop-out boxes, perforated
screens or cyclone devices installed at collec-
tor inlets.
Dust collectors that use vertically mounted cartridges also reduce fire and explosion
risks. With horizontally mounted systems on heavy-dust-loading applications, dust
becomes entrained at the top of the filters, and there is no pre-separation of heavy or
abrasive particles from the air stream. This situation can shorten filter life and provide a
dusty surface for sparks to ignite. Vertical mounting reduces heavy loading dust on the
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filters and helps eliminate these problems.  Back to TOC
OSHA-compliant railed safety platforms and caged ladders can prevent slips and falls
when workers access the collector for service.
Lock-out/tag-out doors prevent injury caused by inadvertent opening of doors during

a pulsing cycle and/or exposure to hazardous dust. Where highly toxic dust is being
handled, a bag-in/bag-out containment system may be required to isolate workers
from used filters during change-out.
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Benefits of a rack safety flywheel in
warehouse, manufacturing facilities  Back to TOC
Rack safety in warehouse and manufacturing facilities can have major

consequences if not properly maintained. Developing a consistent safety
and education program can help.
R acks in warehouses and manufacturing facilities are highly-efficient structures that

need to be free from damage to fully bear the loads placed on them. While con-
ceptually simple, everything falls apart if they aren’t properly built or take too much
damage said, Marc Rousseau, VP, national accounts at Damotech in his presentation
“The 6 Principles of a Best-in-Class Rack Safety Program” at ProMat 2023, March 20-
23 in Chicago, organized by MHI.
Damage isn’t limited to a careless forklift driver, Rousseau said. Like anything else that
requires maintenance, the brace or the column wears over time or too much weight is
placed and it degrades the structure.
“What’s unfortunate with racking is they’re all tied together so damage causes prob-
lems to all,” he said.
Benefits of a rack safety flywheel

The idea of a flywheel in business is where companies gain small wins on a project
or philosophy over time and building off those wins to the point where momentum
is happening by itself. The parts of the flywheel work with one another and become
a part of the culture. With rack safety, which is a part of maintenance culture in ware-
houses and manufacturing facilities, Rousseau said investing in portions of the fly-
22
Benefits of a rack safety flywheel in warehouse, manufacturing facilities
wheel and building over time  Back to TOC

will help companies achieve
safety.
The flywheel starts with em-

ployee well-being, operation-
al efficiency and compliance.
Rousseau said its important
companies keep their workers
happy and educated on best
practices.
“Fill the gaps with thought

Marc Rousseau, VP, national accounts at
leaders and use third-party expertise,” he said. “Let Damotech, highlighted the importance
the experts train your folks on how to do this and of rack safety and how a flywheel
program can help companies improve
don’t be complacent.”
their overall culture. Courtesy: CFE
Media and Technology
In-house knowledge is also valuable because the
people in the facility know the ins and outs better—or should know better—and can
point out flaws or characteristics in a facility. The benefit of an outsider is the de-
tached viewpoint and not having an agenda. The two perspectives, when done cor-
rectly, can catch many potential issues.
Four rack safety steps to better performance

What are they looking for and hoping to achieve? The next layer of the flywheel is
broken down into four sections:
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1. Inspection. Find  Back to TOC

the issues in the
warehouse through
a third party or
in-house or some
combination. Is a
collapse imminent
or is it something
that can be set
aside? While no
one can say exactly
when something
will collapse or
break, Rousseau
said it’s a good idea to have at least a yearly in-
The rack safety flywheel starts with
spection from a third party with on-site checks emphasizing small victories like
monthly or even more frequently, depending improving compliance and employee
well-being and expanding to inspections
on the intensity. that give companies actionable items
on what they need to repair or replace.
2. Insight. Regardless of who is performing the Courtesy: CFE Media and Technology
inspection, Rousseau said the report needs to

have actionable items. “There should be an executive summary and make sure
they can summarize so you can act on the critical items right away.”
3. Maintenance. A plan should be in place to fix high-priority issues as soon as

possible, Rousseau said. The kind of maintenance required depends on the situ-
ation. Some situations call for a total replacement if the damage is severe. Other 24
situations, though, may require  Back to TOC

custom, compliant solutions. an expert who can fix the prob-
lem and put in built-in protec-
tion. Rousseau said repair work is
often a better choice if possible
because it’s cheaper and has less
downtime.
4. Prevention. Rousseau said

companies should always be
looking to protect their assets.
This is especially true after
something has been repaired
or replaced. This can come
in the form of mesh cages or
protection to keep workers
safe. Prevention also means
better worker education.
Rousseau said safety educa-
tion provides benefits such
as fewer injuries and reduced
maintenance costs. It also re-
duces potential liability issues,
extends the life of the racks
and increases productivity.
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The key to long-term success, Rousseau said, is finding a reliable partner. “They can  Back to TOC
help you plan for the long term and you should look for someone who has your best
interests at heart.”
The partner, he said, should be able to provide a wide range of products and services,
has engineers on their staff who can leverage software to manage inspections and
track potential issues.
Rousseau said, “If you work at it and stay consistent and work with a partner and keep
working at the flywheel, you’ll get yourself in a better place.”
Chris Vavra
Chris Vavra, web content manager, CFE Media and Technology.
26
Bolted Access Stairs: Code-Compliant Facility Stairs
 Back to TOC

Bolted Access Stairs: Code-Compliant
Facility Stairs
Learn how to determine which code applies to your stair
application; identify design specifications for OSHA and IBC stairs;
and understand other factors that contribute to stair safety.
27
Code-compliant
stair design
for safety and
ergonomics
SUMMARY
Providing code-compliant stairs is the first step to ensuring
safe access in your facility. Additional measures of safety
and improved ergonomic factors are achieved by limiting
environmental, behavioral, and design factors that can
contribute to the risk of using stairs.
This white paper will help you to:
• Determine which code applies to your stair application
• Identify design specifications for OSHA and IBC stairs
• Understand other factors that contribute to stair safety

Code-compliant stair design for safety and ergonomics
INTRODUCTION  Back to TOC

The team of stair experts at Lapeyre Stair has been manufacturing precision-built ac-
cess solutions for virtually every industry and application since 1981. We operate two,
state-of-the-art facilities with a total of 182,000 square feet fully dedicated to stair
production.
Our 113 full-time employees have a combined 661 years of stair manufacturing
experience and we execute every step of each project with an unwavering commit-
ment to zero-defect manufacturing. All of our products undergo complete, struc-
tural analyses to ensure every stair we ship fully complies with all applicable codes
and standards.
This white paper is culmi-

nation of the combined
knowledge of our team
of stair experts. Our goal
in providing this informa-
tion is to help you make
informed decisions to
confirm the stairs in your
facility are code compli-
ant and meet the highest
standards of safety and
ergonomics.
29
PART ONE: CODE COMPLIANCE  Back to TOC

OSHA stairs versus IBC stairs
OSHA (Occupational Safety and Health Administration) is part of the United States
Department of Labor. OSHA sets and enforces standards related to working condi-
tions. Its priority is to reduce the number of safety and health hazards at places of
employment. OSHA-compliant, industrial stairs are intended for workplace areas that
are not publicly accessible.
IBC (International Building Code) is a model

building code developed by the International
Code Council (ICC.) IBC standards address
safety and health concerns for public build-
ings. Its priority is to protect public health
and safety. IBC-compliant stairs are intended
for areas accessible to the general public and
their design is based on building type and
occupancy.
OSHA-compliant stairs
OSHA standards are federally
regulated and apply to places
of employment in the United
States. OSHA-compliant stairs are intended
for use in facilities designated as employee
workspaces such as factories and manufac-
turing facilities. OSHA stairs can be used on
30
both the interior and exterior of these locations to access equipment, platforms, mez-  Back to TOC
zanines, pits, or other floors.
The information in this white paper that pertains to OSHA stairs is based on the stan-
dards for General Industry. OSHA has separate standards for Construction, Agriculture,
and Maritime. There are other standards that may also apply; always double check to
ensure your stairs comply with any and all applicable codes and standards.
IBC-compliant stairs
IBC standards apply to stairs
accessible by the general pub-
lic and focus on the safety of
all people, including children and the elder-
ly. IBC stairs are part of a building’s means
of egress. There are four IBC standards that
apply to stairs: Industrial Egress, Commer-
cial Egress, Accessible Commercial Egress,
and Commercial Residential Egress. IBC
stairs that are located in areas required to be handicap accessible must also comply
with ADA (Americans with Disabilities Act) Accessibility Standards.
Most jurisdictions in the United States have adopted IBC standards as their base code.
Always check with your local code enforcement to ensure your stairs comply with any
and all applicable codes and standards.
31
 Back to TOC
Typical applications for OSHA stairs
• Equipment access stairs
• Crossover stairs and platforms
• Operator work platforms and stairs
• Maintenance access stairs
Quick check: Which code applies to your stair?

Is the stair accessible only to specific workers as part of their work operations?
YES  OSHA stair
Is the stair accessible to the general public?

YES  IBC stair
Is the stair part of the building structure?

YES  IBC stair
32
 Back to TOC
Typical applications for IBC stairs
• Publicly-accessible egress stairs
• Mezzanine stairs
• In-plant office stairs
Stair components and definitions
OSHA Terminology & Definitions IBC Terminology & Definitions
33
OSHA Terminology & Definitions IBC Terminology & Definitions  Back to TOC
34
Design criteria for standard stairs  Back to TOC
35
Tread and riser design criteria  Back to TOC
36
Guardrail and handrail requirements  Back to TOC
37
OSHA’s fall protection requirement  Back to TOC

OSHA 1910.28 Employers duty to provide fall protection
1910.28(b)(1)(i) Except as provided elsewhere in this sec-

tion, the employer must ensure that each employee on a
walking-working surface with an unprotected side or edge
that is 4 feet (1.2 m) or more above a lower level is pro-
tected from falling by one or more of the following:
• 1910.28(b)(1)(i)(A) Guardrail systems;
• 1910.28(b)(1)(i)(B) Safety net systems; or
• 1910.28(b)(1)(i)(C) Personal fall protection systems, such as personal fall arrest, trav-
el restraint, or positioning systems.
38
Current OSHA handrail requirements  Back to TOC

Stairs installed prior to January 17, 2017 Stairs installed after January 17, 2017
1. Guardrail height of 36” to 38” 3. Guardrail height of 42” (± 3”)

2. Separate handrails are not required; 4. Separate handrails are required
the guardrail also serves as the handrail 5. Handrail height of 36”
39
PART TWO: NON-STANDARD STAIRS  Back to TOC

OSHA Terminology & Definitions IBC Terminology & Definitions
40
Applications with space restrictions  Back to TOC

Alternating tread stairs and ship stairs are often used in applications where space
restrictions prohibit the use of standard stairs; the steep-angle design of these devic-
es requires less floor space to install than a standard stair. The chart* below illustrates
the amount of space required to install non-standard stairs with angles of 68° and 56°
versus a standard OSHA stair with a 45° angle.
68° ALTERNATING TREAD STAIR

VERSUS 45° STANDARD STAIR
OSHA-compliant use of non-standard stairs §1910.25(b)(8)
• Applications where a standard stair is not feasible
41
 Back to TOC
IBC-compliant use of non-standards stairs §1011.14
• Access to unoccupied roofs
• Egress from mezzanines under 250 square feet with five or less occupants
• Egress from guard towers, observation towers, and control rooms under 250 square
feet
Use-case for non-

standard stairs
• Standard stairs are used to provide access from one

walkingworking surface to another when opera-
tions necessitate regular and routine travel between
levels, including access to operating platforms for
equipment OSHA §1910.25(b)(7)
• Spiral, ship, or alternating tread-type stairs are used

only when the employer can demonstrate that it is
not feasible to provide standard stairs OSHA §1910.25(b)(8)
68° ALTERNATING TREAD STAIR
 Typically, the use-case is space limitations. But, it could

be any theoretical reason as long as the employer can demonstrate that it is not
possible to use a standard stair. 42
 Back to TOC
“ OSHA believes that the language in the final rule gives employers greater
flexibility (than the previous language.) The final rule limits the use of non-standard
stairs to those circumstances where, based on specific case-by-case evaluations
and demonstrations, it is not possible to use standard stairs. ”
Federal Register / Vol. 81, No. 223
Ladders versus non-standard stairs
Fixed, vertical ladders are classified

separately from stairs; they are not
considered to be non-standard stairs.
Unlike stairs, OSHA does not speci-

fy the use of ladders for regular and
routine travel between levels
Part Four of this guide includes in-

formation about the safety and ergo-
nomics of ladders.
70° SHIP STAIR
43
PART THREE: STAIR DESIGN SAFETY FACTORS  Back to TOC

Minimum/maximum stair angles
Minimum projected tread depths
 KEY TAKEAWAY: Steep-angle stairs require less floor space to install but also
provide less usable tread depth to users
44
Design-induced risk factors of stairs  Back to TOC

Risk factors related to tread depth
• Missteps become increasingly more frequent

as tread depth decreases below 12”
• Inadequate tread depth provides insufficient

foot support and causes postural instabilities
Risk factors related to tread design
• Inconsistent dimensions of tread or rise cause

missteps
• Inappropriate combinations of tread depth

and riser height cause awkward walking mode
and missteps
• Slippery and rough treads cause missteps
• Confusing color patterns on the tread
• Poor visibility of tread nosing
• Nosing strips that project above the tread
45
Additional design-induced risk factors  Back to TOC
• One or two isolated steps without cues to

their presence
• Lack of a graspable, reachable handrail
• Presence of a discontinuous handrail
SOURCE: Fall Prevention and Protection

(Human Factors and Ergonomics)
Risk factors of decreased tread depth

Missteps increase as tread depth
decreases
Ergonomic studies show that missteps and

the likelihood of falls increase on stairs that
have less usable tread depth:
• Missteps increase as tread depth de-

creases Templer, 1975
• Treads that are too short force the stair user to either rest only part of the foot on
each tread or to twist the foot unnaturally; both of these cases increase the risk of a
misstep Jackson and Cohen, 1995
46
 Back to TOC
 KEY TAKEAWAY: Adequate tread depth = more stability and comfort
47
Virginia Tech conducted a study comparing alternating tread stairs to ship stairs and  Back to TOC
concluded that alternating tread stairs have a clear comfort and safety advantage
over ship stairs
48
PART THREE: ADDITIONAL SAFETY FACTORS  Back to TOC
“Lack of user-stability accounts for 55.2% of all cases of ladder-related falls from
self-supported ladders that are associated with the main ladder-use interactions and
fall mechanisms (slip, trip, loss of balance, stuck by object, lost hand grip.) ”
Fall Prevention and Protection (Human Factors and Ergonomics)
 KEY TAKEAWAY: When adequate tread depth is present, face-forward descent

on stairs provides safety and ergonomic benefits over backing down ladders
49
Falls from ladders  Back to TOC
“Falls from ladders account

for 20% of all fatal and lost
work-day injuries in
general industry ”
Bureau of Labor Statistics
50
MSDs and ladders  Back to TOC
“The National Institute for Occupational Safety and Health (NIOSH) defines a
musculoskeletal disorder (MSD) as a soft-tissue injury caused by sudden or
sustained exposure to repetitive motion, force, vibration, and awkward positions. ”
1,680
Diagnosed MSDs due to ladders that
resulted in lost workdays
2,500
Lost work-day injuries caused
by overexertion due to ladders
38
Median days away
from work
45
Median days away
from work
51
Stair design for safety and ergonomics  Back to TOC

This flowchart was developed to help you make decisions about the stairs in your facili-
ty. Following these guidelines will ensure your stairs are designed to provide users with
maximum safety and ergonomics.
52
References  Back to TOC

• Occupational Safety and Health Administration (OSHA.gov)
• Bureau of Labor Statistics (BLS.gov)
• Center for Disease Control (CDC.gov)
• The National Institute for Occupational Safety and Health (CDC.gov/NIOSH)
• Acting Director Directorate of Enforcement Programs Patrick J. Kapust to Amanda Edens Act-
ing Deputy Assistant Secretary, September 23, 2019, Subject Correspondence, Enforcement of
29 CFR 1910.29(f)(1)(ii)(B) and 1910.29(f)(1) (iii)(A): Heights of Handrail and Stair Rail Systems
• Jackson, P.L. & Cohen, H.H. (1995). An in-depth investigation of 40 stairway accidents and the
stair safety literature. Journal of Safety Research, 26(3), 151-159.
• Templer, J.A. (1992). The staircase: Studies of hazards, falls and safer design. Cambridge, MA:
Massachusetts Institute of Technology.
• Templer, J. A. Stair Shape and Human Movement, doctoral dissertation. New York, NY: Colum-
bia University (1975)
• Jorna, G.C., Mohageg, M.F., & Snyder, H.L. (1988) Performance, Perceived Safety, and Comfort
of the Alternating Tread Stair. Human Factors Engineering Laboratory, Virginia Polytechnic
Institute
• Fall Prevention and Protection: Principles, Guidelines, and Practices. CRC Press. 2017 22
53
Select the right PPE to take
control of electrical risks  Back to TOC
Employers and employees must ensure proper personal protective

equipment is in use to keep workers safe and lower risk.
M aintenance employees are exposed to more electrical hazards than in the past.
Technology advances have caused an increased risk to maintenance employees
due to the number of devices using electricity as an energy source. Most of the electri-
cal incidents employers investigate are caused by an employee’s lack of understanding
on how to protect themselves from a hazard that they cannot readily see.
According to the most recent United States Bureau of Labor Statistics data from the
Census of Fatal Occupational Injuries, 126 workers died due to exposure to electricity
in 2020. This was the lowest level since the survey started in 1992. But that is not to say
the risk is going away anytime soon.
Another factor that increases employee electrical safety risk is the current labor market
conditions. Employers rely on our people to work more hours and do more with less.
The lack of electrical preventive maintenance programs, fatigue and subsequent hu-
man error are factors employers cannot ignore. Employers cannot forgo an equipment
PM, qualified employee training, a hazard analysis for the task or situational awareness
to recognize when a condition is unsafe just to keep our facilities running.
The problem is that electrical energy creates an unseen opportunity for exposure that
increases the risk of injury. For example, exposure to electrical shock can range from
internal organ and muscle damage to burns and possible death. Arc flash events can
54
Select the right PPE to take control of electrical risks
 Back to TOC
cause death due to an explosive projection of molten material, Figure 1: Electrical hazards
hierarchy. Courtesy:
concussive blast, toxic gas exposure, fire or falls.
Schneider Electric
Consensus standards such as NFPA 70E: Standard for Electrical Safety in the Work-
place have been in existence for more than 40 years and have been incorporated by
reference into regulations for more than 30 years.
Therefore, it is not enough for a maintenance employee or their supervisor to plead ig-
norance for not providing or wearing personal protective equipment after an electrical
incident. Employees working with electrical systems must understand the proper shock
and arc flash PPE to wear when working around exposed energized conductors operat-
ing at or greater than 50 volts alternating current or direct current. 55
Whether an employee is working on  Back to TOC

a 120 Vac light switch, a 480 Vac heat-
ing, ventilation and air conditioning
unit, power distribution panels or any
other type of equipment with ex-
posed energized conductors, it is im-
perative that they protect themselves
and their co-workers from the hazards
of electricity.
Understanding electrical
hazards
First, let’s look at the electrical hazards
hierarchy to understand when mainte-
nance employees are at a higher risk
Figure 2: Electrical current
(see Figure 1). Each step of the electrical hazards hierarchy path through the human body.
has equal importance to overall safety, with risk reduction Courtesy: Schneider Electric
varying between the steps.
For example, levels 1 to 3 are designed to control the risk before it gets in close prox-
imity to the employee. Levels 4 to 6 assume that the employee is already exposed to
the electrical energy and needs to be kept safe while he or she is close to the hazard
by using the appropriate PPE.
PPE is the least effective risk control method and should only be used as a last resort.
Employers should first eliminate the hazard by creating a zero-energy state using
56
lockout tagout (level  Back to TOC

3). But even the act of
de-energizing to create
an electrically safe work
condition and reener-
gizing to return to nor-
mal operation (level 4)
requires employees to
wear the appropriate
shock and/or arc flash
PPE before performing
maintenance work.
Shock protection PPE

Employers know that high voltages are dangerous,
and low voltages can be extremely dangerous as
well. Shock injuries are dependent on the magni-
tude, frequency, path and time duration of elec-
trical current through the body. All other factors be-
ing equal, the degree of injury increases the longer
the body is in contact with the circuit.
As long as there is voltage present, it will try to

push any available current (as low as 5 to 10 milli-
Figure 3: Rubber insulating
amps) through the body. When making contact with an ener- gloves and leather protectors.
gized conductor electricity will travel throughout the body – Courtesy: Schneider Electric
57
looking for a path to return  Back to TOC

to the source, which in most
cases is via the ground. (see
Figure 2). The path it takes
is critical. When it travels
through the chest area, in-
cluding the lungs and heart
ventricular fibrillation (stop-
ping of rhythmic pumping
action) may cause a very
serious injury.
For shock protection PPE, NFPA 70E section 130.7 requires:

Figure 4: Example of arc-rated
personal protective equipment
• Rubber insulating gloves (tested up to the voltage the category 2, up to 8 cal/cm2.
Courtesy: Schneider Electric
technician is working with) and leather protector gloves
(gauntlets) over the top of the insulating gloves.
• Electrical hazard rated footwear (as needed).
• Class F or E rated hard hat (as needed).
• Safety glasses or goggles (as needed).
• Rubber insulating sleeves (as needed).
58
In addition, to protect against  Back to TOC

electric shock, it is important to not
wear any conductive items (jewelry,
belt buckles, etc.) that could come
into contact with exposed ener-
gized electrical conductors.
Arc-rated PPE
In addition to the shock protection
PPE noted above, if the hazard
analysis indicates an incident ener-
gy of 1.2 cal/cm2 or more, the use
of arc-rated PPE is required. NFPA
70E Table 130.7(C)(15)(a and b)
specifies arc flash PPE category 1,
2, 3 or 4.
The higher the category number,

the more protective the PPE is to
prevent a burn injury. In addition,
any underlayers that are worn
beneath the arc-rated PPE must
also be arc-rated or nonmelting
untreated natural fiber. If the risk
assessment determines the level of
hazard is greater than the available
59
PPE, even if the work is  Back to TOC

allowed, it should not
be carried out.
Why do workers
need PPE?
The electrical hazards
that exist can cause
serious injury or death
to maintenance workers.
Employers should have
very strict expectations
and requirements for
anyone that is working around electricity. Despite years of Figure 5: Example of arc-rated
personal protective equipment
experience and training, maintenance workers still suffer category 4, up to 40 cal/cm2.
injuries related to electricity on the job. Courtesy: Schneider Electric
Many employees who work with electricity don’t believe that an accident will happen
to them, but records prove otherwise. Employers and employees must work together
to make improvements to electrical safe work practices. Automobiles did not always
have seatbelts, but because we do, traffic-related fatalities have declined significantly
since these inventions have been implemented.
Tom Pitts
Tom Pitts is director of safety and environment for Schneider Electric Global Supply Chain.
60
Therm-O-Mix Station: How it Works
 Back to TOC

Therm-O-Mix Station: How it Works
The Therm-O-Mix® Station instantly delivers tepid water to
emergency safety showers and eyewash stations, using only
a facility’s existing steam and water supplies. The unit is
completely mechanical and requires no outside electricity or
air to function, making it particularly ideal for explosion-proof
industrial environments.
61
Tepid Water Delivery Systems for Safety Shower
Selecting The and Face/Eyewash Stations
Right Tepid Water I ndustrial manufacturing facilities are often inherently

unsafe environments – working machines, heavy equip-
Solution ment, and a fast pace of operation combined in a perfect

storm for accidents to occur. Due to this, safety regulations
are a primary concern for oil refineries, chemical/ petro-
chemical facilities, and nuclear power plants to maintain
proper working conditions for their employees.
Safety showers, facewash, or eyewash stations are critical

in facilities where employees may encounter debris or haz-
ardous materials.
Compliance Requirements for Emergency

Wash Equipment
There are a variety of standards and regulations govern-
ing emergency eyewashes and showers to ensure worker
safety in industrial environments. The most often cited
regulations are from OSHA 1910.151, ANSI Z358.1, and
ASSE 1071.
OSHA’s 1910.151 sets the groundwork and mandates that

“where the eyes or body of any person may be exposed
to injurious corrosive materials, suitable facilities for quick
Selecting The Right Tepid Water Solution
drenching or flushing of the eyes and body shall be provided within the work area or  Back to TOC
immediate emergency use.”
This states that a safety shower, facewash, or eyewash station is required in facilities
where employees are exposed to injurious corrosive materials but do not specify de-
tails concerning the equipment’s location, installation, nature, and maintenance.
The ANSI Z358.1 standard, published by the International Safety Equipment Associ-
ation (ISEA), establishes “minimum performance and use guidelines for eyewash and
shower equipment.” This standard is a widely accepted guideline for properly select-
ing, installing, operating, and maintaining emergency equipment.
Key features of this standard include the maximum distance from a worker’s station
to the emergency fixture and the required temperature range. For a facility to com-
ply, the emergency equipment must be installed in a location that “should take [no]
longer than 10 seconds to reach” when walking at an average pace of about 55 feet
per 10 seconds.
The standard also mandates that the station’s water be tepid, defined as between
60°F-100°F (15.6-37.8°C). The tepid water must be available for at least 15 minutes at
30 PSI (pounds per square inch) and a flow of 20 GPM (gallons per minute) for drench
showers, 0.4 GPM for eyewash stations, and 0.3 GPM for face/eyewash systems.
Water below this range will be too cold, inhibiting the user from using the equip-
ment for the full 15 minutes; water that is too hot can cause burns and/or a worsened
chemical reaction.
63
ASSE 1071 adds additional regulations in the event of system malfunction. Should the  Back to TOC
water supply be dangerously overheated, the “device shall have the means to limit the
maximum outlet temperature.” In addition, the station should “provide full cold-water
flow” in the event of a valve or supply failure (also known as ‘failing cold’) and automat-
ically stop flow “in case of cold-water loss” to prevent accidental scalding.
These regulations governing tepid water delivery systems keep workers safe and steer
the development of new products in a more safety-conscious direction.
Tepid Water Delivery Solution Considerations

A common misconception about tepid water supply for safety fixtures is that merely
heat-tracing water supply lines and shower piping eliminates the need for a proper
tepid water delivery system. This is incorrect as this setup would not provide sufficient
gallons per minute (GPM) flow and may result in water temperature spikes or drops,
making it difficult for the user to use the station for the required length of time.
Selecting the appropriate system depends on various factors, including installation con-
ditions and restrictions, available energy (steam, electricity, etc.) sources, and budget.
Currently Available Systems and Solutions

There are a variety of tepid water delivery options currently available, including ASSE
1071 mixing valves, turnkey systems, instantaneous electric heaters, and steam-fired
heaters.
ASSE 1071 mixing valves mix existing hot and cold water supply lines to produce tepid
water. They are offered in a variety of sizes, making them suitable for installations with
64
space restrictions. These mixing valves may support multiple shower and face/eyewash  Back to TOC
stations but will require a source of hot water with sufficient GPM flow. When placed
outdoors, ASSE 1071 mixing valves will require freeze protection.
For facilities that do not have an available source of hot water, turnkey systems can be
used to provide one. Typically comprised of a pre-packaged, self-contained heater and
mixing valve, turnkey solutions are simple to install but often have a large footprint,
usually requiring dedicated areas for the unit to occupy. If installed outdoors, the unit
may need freeze protection.
Instantaneous electric systems are also used for facilities that do not have an available
source of hot water. Typically installed on the wall, this option has a small footprint but
extremely high electric requirements. While the unit only uses energy when there is de-
mand, this can result in higher utility costs and may require special insulation in hazard-
ous or explosion-proof locations.
Instantaneous electric systems typically support only a single

combination shower and face/eyewash station and require
additional freeze protection precautions if installed outdoors.
Instantaneous steam-fired heater systems, such as Ther-

mOmegaTech’s Therm-O-Mix Station, utilize a plant’s exist-
ing steam supply to heat water to appropriate temperatures.
Compactly designed, these stations have a small footprint
and are simple to install onto new equipment or retrofit onto
existing showers or eyewash stations.
65
These tepid water delivery systems provide 3 to 25 GPM while maintaining a constant  Back to TOC
80 degrees Fahrenheit output regardless of inlet water temperature. The units use
steam only when there is demand and function 100% mechanically with no external
power source, making them ideal for explosive-proof environments.
These stations also have built-in freeze protection and can be placed outdoors with-
out additional insulation or spark protection. Self-purging, there is no requirement
for an elaborate drainage system or an expensive recirculation system. Instantaneous
steam-fired heaters support one activated combination shower and face/eyewash
station at a time.
Additional Points to Consider

Cold weather can freeze water-carrying pipes, leading to burst lines or interrupted sys-
tems. This can create a very hazardous situation for personnel at a plant if a worker is
unaware that the lines are frozen and tries to operate the safety shower or eyewash sta-
tion after exposure to a harmful substance. This prevention or delay in cleansing could
cause serious harm.
Mixing valves, instantaneous electric heaters, and some turnkey systems will typical-
ly require freeze protection when placed outdoors or in non-temperature-regulated
environments to ensure successful operation. In addition to protecting the tepid water
system, protecting the emergency fixtures themselves from freezing is also recom-
mended. Many shower manufacturers offer heavily insulated and electrically heat-
traced shower designs. The danger with this method is that electrical tracing cannot
always be used safely due to explosion hazards, and exposed water lines are still at risk
of freezing if there is a power outage.
66
An alternative solution is to install mechanical  Back to TOC

freeze protection valves, such as the ThermOme-
gaTech® HAT/FP or IC/FP valves, either as backup
freeze protection on traced units or directly onto
the safety equipment. These valves monitor ambi-
ent or water temperatures and automatically bleed
off the cold water in the lines before freezing occurs. Once the resupply water is 5
degrees Fahrenheit above the valve’s set point again, the valve will modulate closed to
minimize water waste.
Water-carrying pipes can also quickly become overheated by solar radiation or mal-
functioning heat tracing. If this hazard is not prevented, workers could be exposed to
over-temperature water resulting in burn injuries and worsening chemical reactions.
Instantaneous steam heater systems utilize built-in over-temperature protection, but it

is recommended that other tepid watery delivery solutions implement scald protection
valves if the supplier has not already.
Common devices used for over-temperature/

scald protection by shower manufacturers and
retrofitted by users are thermostatically con-
trolled scald protection valves, such as the Ther-
mOmegaTech ® HAT/SP or IC/SP valves. These
valves are installed at the highest point on an emergency safety station to sense
continuously and automatically bleed off hot water to prevent excessively high tem-
peratures at the point of use.
67
 Back to TOC
Cooler water from the supply will backfill the line and cause the valve to modulate
closed once the water temperature falls to 10 degrees Fahrenheit below the open set-
point. These valves can also be used as backup scald protection on traced units.
Selecting the correct tepid water delivery system is vital to ensuring a safe working en-
vironment for your personnel. It is not a decision to be made without thoroughly con-
sidering your facility’s capabilities and restrictions. However, with appropriate planning
and research, your facility will have the proper system to meet your OSHA and ANSI
approved tepid water delivery needs.
68
Why you should consider using
steel conduit and tubing  Back to TOC
Steel conduit is a versatile and safe wiring method to choose when building
commercial and industrial buildings.
T here are many options contractors have while selecting wiring methods; howev-
er, steel conduit and electrical metallic tubing, are versatile wiring methods often
used as electrical raceways for power, data and communication throughout commercial
and industrial buildings. These are the safest materials to use when choosing building
wiring methods. Steel conduit and EMT are non-combustible, have long lifespans, are
extremely resilient, in addition to being completely recyclable.
Steel conduit and EMT are viable options in fire safety design, yet they sometimes
don’t make the list because they do not have a fire rating. When request for propos-
als or project bids require fire resistance scores, while conduit and EMT have none,
contractors or specifying engineers may not include these valuable choices in their
specifications.
To better understand why steel conduit and EMT are excellent choices when prioritiz-
ing fire safety, there are many factors to consider like fire resistance ratings, building
codes and thermal protection.
Learn the facts about steel conduit

Before working with steel conduit and EMT, it’s important to consider building codes
and fire ratings. Steel conduit and EMT are both considered non-combustible by build-
ing codes. Because of this, they do not have fire ratings. This can possibly confuse con-
69
Why you should consider using steel conduit and tubing
tractors and installers who do not have  Back to TOC

experience with steel conduit and EMT.
If builders require a fire rating or if
project bids evaluate or score based on
this, they may miss out on the chance
to evaluate steel conduit and EMT.
Because fire resistance ratings only

apply to assemblies in their entirety,
using steel conduit or EMT as part of
a fire-rated assembly can improve the
fire resistance rating because the con-
duit and EMT have a zero score and
zero combustibility, supporting the fire
resistance of the overall assembly. Even
with a zero score, it remains important
to be sure to review all local codes for
penetrations, emergency circuits and fire pump Steel Conduit protects against fire and
explosion and ideal in high-risk areas like
circuits before installation.
gas stations, grain elevators and refineries.
Courtesy: Steel Tube Institute
Penetration of fire-resistance rate
assemblies
The National Electric Code and building codes require that openings around race-
ways which penetrate a fire-resistance rated assembly be sealed so that the possible
spread of fire or products of combustion will not be substantially increased from one
area to another. This can be accomplished by the use of a listed penetration firestop
70
system or by use of annular space  Back to TOC

filler in accordance with building
code exceptions. As steel conduit
and EMT are noncombustible, it
Protect is not required that they have a
Your fire-resistance rating but the area

around the conduit or EMT must
Personnel be properly filled with materials,
such as cement, mortar or grout
With Temperature Control
Products For Safety Showers so that the fire-resistance rating
and Eyewash Stations of the building is maintained.
Always refer to local codes prior
to installation.
OUR APPLICATIONS
Scald Protection Thermal protection of
Our HAT/SP thermostatic valves
prevent excessively hot water from
being released from emergency safety
steel raceways
equipment, protecting personnel
from scalding and/or worsened Using steel conduit or EMT cre-
chemical reactions.
ates a fire-safe system with many
Tepid Water Delivery other benefits. Using conduit or
The steam and water Therm-O-Mix® station
provides an instantaneous and reliable source
of tepid water for emergency equipment.
EMT in fire-rated enclosures pro-
It requires no electrical power and can easily
be retro�tted into an existing drench system. vides a safe solution. Steel con-
Freeze Protection duit and EMT can also be embed-
Our self-operating HAT/FP valves
protect water lines to safety showers
ded in concrete, adding flexibility
and face/eyewash stations from freezing.
They eliminate the human errors of design and safety, as concrete
associated with manual valves and
minimize water waste. resists combustion. Buildings
www.thermomegatech.com/protect-personnel | (267) 609-8867 can also use a listed wrap system
71
which further protects the integrity and safety of a steel raceway. Wrap systems can be  Back to TOC
easy to install and cost effective.
Using steel conduit or EMT in a listed circuit integrity system is another way to have
an effective fire resistive installation. Circuit integrity systems are listed to UL 2196
and use circuit integrity cables within systems such as those with steel conduit or EMT
to achieve fire ratings of one or two hours. The system must be installed as listed to
achieve the fire rating meaning the size and type of cable, conduit and fittings must
match what is included in the listing. Refer to the listing requirements of the system,
the NEC and local codes to be sure of installation requirements on circuit integrity
systems
Although routinely installed in fire-rated assemblies, steel conduit and EMT do not
have a fire rating and are considered non-combustible by most building codes. Before
using steel conduit or EMT, however, be sure to check all NEC and local codes to be
sure the commercial or industrial assembly is admissible by local standards.
Fire safety is an essential part of any specifying process and engineers can amplify
building effectiveness by recognizing all their choices and tools as they select and rec-
ommend their installations.
Dale Crawford
Dale Crawford is the Executive Director and Director of conduit of the Steel Tube
Institute where he is responsible for the organization’s activities to promote the growth
and competitiveness of steel pipe and tubular products throughout North America.
72
Seven clean-in-place design
best practices  Back to TOC
An effective clean-in-place design should be built with a facility’s specific

needs in mind while reducing contamination and water consumption.
A clean-in-place (CIP) system is a cost-effective and time-saving tool that rinses

and washes the inside surfaces of food processing piping and equipment without
mechanical disassembly. When designed well, a CIP system improves sanitation and
enhances food safety while simplifying the cleaning process for plant operators and
reducing downtime. It automates what has traditionally been a laborious and time-con-
suming manual process of disassembling the piping, hand-cleaning each component
and reassembling equipment.
In addition to lost revenue from halted production, improperly cleaned equipment can
spread foodborne contaminants from batch to batch, which is dangerous to consumers
and can lead to recalls that directly impact a company’s bottom line and reputation.
If you’re considering investing in a CIP system for your facility, it’s important to en-
sure you’re getting a design that is reliable and up-to-date. Your process design team
should consider the overall needs of your operation, including changeover efficiency,
water conservation and how the design will affect the complexity of the system.
For a CIP system to be effective, equipment and piping should be designed for easy
cleaning and installed to hygienic standards. Piping should be free draining, free of
“dead legs,” and the water used for the final rinse should meet product contact speci-
fications.
73
Seven clean-in-place design best practices
Seven essential design tips and considerations  Back to TOC

It’s important to consider a few things when designing a CIP system to fit a facility:
1. Understand your facility’s specific sanitation needs.

Ask yourself the following questions: How often are you going to clean? What are you
going to clean? Are there any specific requirements? There is no one-size-fits-all ap-
proach to sanitation because some manufacturers produce food products that present
more difficult cleaning challenges than others. For example, a product with high lev-
els of sweeteners and artificial colors may require a longer wash sequence at a higher
temperature than a sugar-free beverage. Therefore, identifying exactly what substance
is being cleaned is critical.
2. Balance system design and production schedule.

It’s important to identify the size of the CIP system needed and how it will impact a
production schedule. Size refers to more than just the capacity of the tanks; it also
includes the number of process lines, tanks and areas (referred to as “circuits”) that
can be cleaned simultaneously. Consider the number of circuits that must be cleaned,
the frequency of cleaning, the total volume of the circuit, the flow rate required and
the types of chemicals needed to properly do the job. Different systems have varying
numbers of steps to achieve proper cleaning based on the product being cleaned. It’s
crucial to factor cleaning frequency into the production schedule.
It’s also important to consider any required changeover processes in your CIP
planning. In some applications, such as making fruit juice, a facility may be able
to switch from Flavor A to Flavor B without any cleaning because Flavor B is more
pungent than Flavor A; but switching from Flavor B back to Flavor A may require
74
running a rinse cycle or other method of cleaning. If the following product is dis-  Back to TOC
similar, such as going from a carbonated soft drink to an energy drink, this typically
requires a full system cleaning.
Cleaning is also needed when allergens are involved to avoid cross-contamination.

Operating with a production schedule that takes cleaning requirements into consider-
ation can reduce the burden on the CIP system and increase production time.
3. Mitigate the risk of cross-contamination.

If your food and beverage facility produces different types of products, you must take
extra precautions to mitigate cross-contamination, especially when handling allergens
or switching from raw to ready-to-eat (RTE) products. Many facilities install separate
CIP systems for RTE and raw production areas. When cleaning for allergens, it’s import-
ant to ensure water and chemicals are not reused, which can potentially spread aller-
gens to other portions of the processing facility.
4. Reduce water and chemical consumption.

Water usage has become an increasingly critical consideration in facility operations
as natural resources become more scarce. Introducing product recovery methods into
CIP can increase product yield and reduce rinsing times and water usage. These meth-
ods can include pigging, where a pressurized plug is pushed through the line, and air
blows, using dust-free air to clear a line. Adding a recovery tank to reuse the final rinse
as a first rinse is another opportunity to save water with CIP.
Some CIP systems employ alternatives to the traditional chemical wash step such as
ionized water, ozone or other disinfecting agents. These chemical alternatives vary in
75
usefulness based on cleaning requirements but are expected to become more widely  Back to TOC
used in the future.
5. Ensure adequate flow and drainage.

CIP flow rates are based on piping size to ensure turbulence in lines. Turbulence
improves the cleaning action of the fluid in the system, but requires high flow veloci-
ties. It’s common to see inadequately sized drainage on CIP systems, especially when
multiple circuits are being cleaned simultaneously. Typically, drain valves on the pro-
cess lines are opened for short bursts during CIP. For this reason, it is important that
field drains are routed to properly sized hub or floor drains to prevent flooding and/
or operators from getting sprayed with water and chemicals during the cycle. Flow
rates through drain valves are reduced from the full CIP flow rate and can be sized
accordingly.
6. Consider spatial limitations.

A plant can have a centralized CIP system that feeds to multiple locations with many
circuits, or the system can be comprised of multiple smaller systems spread out across
different areas of the plant. It often depends on the piping of the facility and what
makes sense as far as budget and system complexity. While size and layout vary from
plant to plant, it’s often better to have a single, central CIP system when possible. If
you have two systems, for example, and need a 1,000-gallon tank for each of them, it
may be less expensive to have a single 2,000-gallon tank at one location. Configuring
all CIP circuits in one system can provide capital cost savings.
7. Understand cleaning and pipe configuration compatibility.

Once you identify how you will clean, ensure your cleaning solutions and pipe con-
76
figuration are compatible. Elastomers (natural or synthetic elastic polymers) are often  Back to TOC
present in piping systems and process equipment, and can be damaged by the use of
certain chemicals. You may need to upgrade your piping or elastomer if using a harsh-
er cleaning solution. When planning to develop a CIP system from scratch, consider
compatibility from the start.
Choosing the right partner

The right partner can mean the difference between an effective, durable CIP system
and one that does not meet your needs and requirements. The first step should always
be identifying all aspects of the process where CIP may be a value-added application.
You should then discuss:
• The spatial and infrastructure requirements of the facility.
• All equipment and piping that must be cleaned, the flow rate and volume of each
circuit.
• Available timeframes for cleaning based on the plant’s production schedule.
• Cleaning requirements based on past experience, industry standards and custom-

er specifications. In the case of novel products, consult with chemical suppliers to
prescribe the best cleaning parameters.
• Designing a CIP skid that can accomplish all equipment cleaning in the selected
time frame.
77
Bring success to a facility through a well-designed CIP  Back to TOC

There are many advantages to investing in a well-designed CIP system for your facili-
ty, including improved sanitation and food safety, as well as more efficient cleaning in
general. Manual cleaning can quickly become a time-consuming task that results in lost
revenue from halting production and creates a risk of spreading foodborne contami-
nants. The right CIP system, on the other hand, can improve the safety and efficiency
of any food processing facility.
Thomas Burley and Mason Marriner

Thomas Burley and Mason Marriner are process engineers at Stellar.
78
Plant Floor
Safety
Content Archive Thank you for visiting the Plant Floor Safety eBook!
2023 Spring Edition
If you have any questions or feedback about the contents
2022 Fall Edition in this eBook, please contact CFE Media at
2022 Summer Edition
[email protected]
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Plant Floor

Many plant managers and environmental, health and safety (EHS)

What is control of work?

How control of work improves EHS management and  Back to TOC

Permit-required confined spaces

• It contains or has a potential to contain a hazardous atmosphere.

• It contains a material with potential for engulfing an entrant.

• It contains any other recognized serious safety or health hazard.

Controlling hazardous energy

In Canada, there’s no specific regulatory framework for enforcing control of hazardous

Permit to work systems are crucial to general safety

PTW is part of a proactive, risk-focused approach to safety management. As business-

Managing temporary worker and contractor safety

For example, temporary employment in manufacturing is much higher compared to

Consider this situation involving a Chicago Fire Department hazardous materials

Modern control of work software is configurable to the specific PTW processes in

Control of work helps build, sustain ESG maturity

There are a couple of specific ways  Back to TOC

Another benefit of control of work

System of almost every manufacturing plant. When

Optimally and T hough a dust collector is a vital component in the

The total cost of ownership of a dust collector is impact-

1. Protect from Deflagration

This minimizes damage to the collector and pre-

Understanding the pressure capabilities of your collector is important in the specifica-

the combustible dust properties required to under-  Back to TOC

2. Protect the Ductwork

The NFPA requires that ducting be equipped with

3. Keep Hoppers Empty  Back to TOC

Self-dumping hoppers provide easy dust dis-

that create a gasketed seal to prevent dust from escaping.

4. Use an Effective Pulse-Cleaning System  Back to TOC

On-demand cleaning is recommended for most

5. Use Safety Monitoring Filters

A safety monitoring filter is a required component in

7. Change Out Filter Cartridges Safely

into the collector.

8. Don’t Skimp on Filter Cartridges

However, for heavy-dust-loading applications, filter replacement might be much more

9. Test the System using ASHRAE Standard 199

10. Protect from Fires and Use

filters and helps eliminate these problems.  Back to TOC

Lock-out/tag-out doors prevent injury caused by inadvertent opening of doors during

Rack safety in warehouse and manufacturing facilities can have major

R acks in warehouses and manufacturing facilities are highly-efficient structures that

Benefits of a rack safety flywheel

wheel and building over time  Back to TOC

The flywheel starts with em-

“Fill the gaps with thought

Four rack safety steps to better performance

1. Inspection. Find  Back to TOC

inspection, Rousseau said the report needs to

3. Maintenance. A plan should be in place to fix high-priority issues as soon as

situations, though, may require  Back to TOC

4. Prevention. Rousseau said

This white paper will help you to:

• Determine which code applies to your stair application

• Identify design specifications for OSHA and IBC stairs

• Understand other factors that contribute to stair safety