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Welcome

Contractor
Safety Meeting
2016

Waupaca Foundry, Inc.


Contractor Safety Program
This program has been established to provide
Waupaca Foundry, Inc. with a screening process
for all potential Contractors and Subcontractors.
The selection process allows Waupaca Foundry,
Inc. to hire companies that will accomplish the
desired job tasks without compromising the Health
and Safety of our employees and visitors, as well
as the contractors themselves, while at our facility.

Contractor Definition:
A Contractor is an individual, service firm, company, or other
non-WF employee, performing on-site work for Waupaca
Foundry, Inc. at our discretion through contracts, subcontracts, purchase orders or other directives.

Examples of contractors are:

Mechanics, millwrights, plumbers, and electricians.


Heating, ventilating, and air conditioning services.
Compressed gas cylinder suppliers and bulk chemical suppliers.
Bulk fuel and oil delivery companies.
Building and grounds maintenance.
Equipment maintenance personnel (computers, telephones, fork trucks,
crane rental etc.)

Subcontractor Definition:
Companies that are hired by the contractor,
sometimes referred to as subcontractors
must also complete the Waupaca Foundry,
Inc. safety program.
Subcontractors must meet the same
requirements as contractors.
Subcontractors must also be pre-approved
for work at Waupaca Foundry, Inc.
It is the responsibility of the Contractor to
ensure all sub-contractors are trained in this
program and have completed all of Waupaca
Foundry, Inc.s requirements.

Objectives of the Waupaca Foundry,


Inc. Contractor Program
The major objectives of the Contractor
Safety Program:
Inform Contractors and Sub-Contractors of
their responsibilities when working on
Waupaca Foundry, Inc. property.
Protect employees, visitors, property and the
environment from potential hazards.
Comply with all federal and local safety and
environmental regulations.

Contractor Responsibilities

Contractors are expected to implement their own


Environmental, Health and Safety programs.
Prior to starting a project, each contractor is required to review the work site
and identify hazards that may occur while performing the job.
The contractor shall ensure proper Environmental, Health, and Safety
precautions are followed in accordance with the Occupational Safety and
Health Administrations (OSHA) and the Environmental Protection Agencys
(EPA) Code of Federal Regulations (CFR).
The contractor shall ensure individuals working at the site are trained and are
aware of potential hazards. Contractors shall also ensure these individuals
are provided with proper safety equipment to prevent incidental injury in
accordance with OSHAs CFR.
The contractor shall ensure all personnel follow the guidelines of OSHA,
EPA and Waupaca Foundry, Inc.s policies, in addition to any guidelines of
the jurisdiction(s) in which the operations will be performed.

Waupaca Foundry, Inc. EHS Staff


Each WF location is staffed with Environmental, Health and
Safety personnel. This includes Environmental and Safety
managers, Behavior Based Safety leaders, and Occupational
Health Nurses.
Corporate Staff for the oversight of EHS are also in place.

Waupaca Foundry, Inc. EHS Staff

OSHA Temporary Workers : Both HOST and


Staffing Agency are responsible for providing and
maintaining a safe work environment
It is a fundamental principle that temporary workers are
entitled to the same protections under the OSH Act as all
other covered workers.
The staffing agency and host employer must work together to
ensure that OSH Act requirements are fully met and that the
temporary worker is provided a safe workplace.
https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=NEWS_RELEASES&p_id=26586

OHSAS 18001.2007
OHSAS 18001 is an
Occupational Health and Safety Assessment
Series for Health and Safety Management
Systems.

OHSAS 18001 is intended to help organizations


identify and control Occupational Health and
Safety risks. It was developed in response to a
widespread demand for a recognized standard
to be used for system assessment.
All Waupaca Foundry, Inc. sites have been
certified in the OSHAS 18001.2007 assessment.

OHSAS 18001 Risk Management Hierarchy


After determining a Job Risk the following Hierarchy shall be used:
1. Elimination of the hazard.
2. Substitution to eliminate or reduce the hazard.
Examples of substitution may be using water based solvents, vacuuming material vs.
blowing with air; electric powered vs. gas powered fork trucks.

3. Engineering Controls
Examples of Engineering Controls: Machine guarding, Noise reduction baffles or
enclosures, ventilation, and ergonomic tools.

4. Administrative Controls
Exampled of Administrative Controls: Documented work procedures, training, safety
signs, limitation of employee exposure, job rotation and scheduling, and temporary
barriers.

5. Personal Protective Equipment (PPE)


PPE should be used as the last option. Although some protection is given, the hazard
remains right next to the person.
The Higher the level of Hazard Control used,
the more distance is placed between the hazard and the person affected!

Environmental, Health and Safety Policy:


Waupaca Foundry, Inc. uses the acronym CAST
C Commitment to Environmental, Health and Safety (EHS) excellence
through compliance with EHS regulations and other requirements.
A Always strive for continuous improvement and prevention of
incidents, injuries, and pollution.
S Set and review EHS Objectives and Targets.
T- Train employees on their EHS responsibilities.

Total Recordable Rate


35

31.48

# Incidents x 200,000* Divided by Actual hours worked


(Represents 100 Full Time Employees)

CAST
C: Commitment to Environmental, Health &
Safety excellence through compliance with
EHS regulations and other requirements.

30

A: Always strive for continuous


improvement and prevention of accidents,
injuries & Pollution.

26.64
25

S: Set and review EHS objectives & targets.


T: Train employees on their EHS responsibilities.
20
18.1
15.56
15

14.9

15.5
14.4
12.4
10.2

10
8.1

[VALUE]

0
2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

Environmental,
Health, & Safety
Management
ISO 14001
OHSAS 18001
2016 Meeting

ISO 14001

ISO 14001 is the Management


System for Environmental
Controls.
Contractors must be aware of the
Impact their services may
have on the Environment.
The recognized Significant
Impact of WF Contractors is
their potential to cause
Chemical and or Petroleum
spills which may contaminate
the air, soil and/or water.

ISO 14001
The ISO 14001 Certification is awarded by a 3rd party auditing
company. The auditors will ask three main questions of any contractor
representatives they see:
1. Are you aware of Waupaca Foundry, Inc.s Environmental Policy
and, in general, what does it say?
2. Are you aware of any significant aspects for your area?
3. What do you do in the case of a spill/fire?

Pocket cards with this information have


been developed for your use and are
available at the guardhouse check-in.

14001 - 18001: Consequences of


Program Departure
Examples of Consequences:
A consequence may be the contamination of the air, the soil, or
water from spills and neglected clean up of spills.
A consequence would also be the failure of Waupaca Foundry, Inc. to
maintain the elements of our Environmental, Health and Safety Policy.

These consequences could result in the


loss of our 14001 and/or 18001 certification.
Gross departure will affect a contractors
employment status with Waupaca Foundry, Inc.

Environmental Safety
Management of Hazardous
Substances and Empty Containers

Remove all chemical wastes/residues from Waupaca Foundry, Inc.


property when the work is complete.

If any onsite storage of chemicals is necessary, provide an appropriate


storage location with secondary containment.

Practice good housekeeping with all materials brought on site.

Special precautions should be in place when using chemicals near


drains or the sewer.

Contractors shall be aware of the Waupaca Foundry, Inc. spill response


plan. Contact the Emergency Response Team to clean up a spill.

Bulk Liquid Loading and


Unloading
Contractors responsible for delivering bulk liquids must adhere to
the following during delivery/pick up service:
Turn off all unnecessary engines.
Chock wheels prior to loading or unloading.
Check the receiving tank level by visual gauge or other means
to determine quantity of liquid needed.
Tanks must be supervised during pumping activity.
Confirm hoses are disengaged before driving away.
Be prepared to contact ERT for response to non-routine spills
as needed.

Environmental Safety Air


and/or
Water Emissions
Any project resulting in the discharge of significant hazardous
air emissions or wastewater discharges must gain preapproval by the Environmental Dept. PRIOR to initiation of the
project. It is the responsibility of the contractor to provide this
notification to the Plants Environmental Engineer.
Any Contracting Company working with CFCs
(Chlorofluorocarbons) must provide Technician Certification
for all on-site technicians.

Environmental Safety Housekeeping

Clean up of trash and debris; dispose of it properly.

Remove ALL chemical containers (drums, pails) from


Waupaca Foundry, Inc. property.
Materials should NOT be put in Waupaca Foundry, Inc. trash
receptacles.

Clean up of BULK materials (cement, sand) to prevent


eventual storm water runoff and vehicle tracking.

Control of chemicals and oil-laden equipment to


prevent weather exposure.

Concept Review
True or False - Subcontractors are required to go
through the same training as contractor
What is Waupaca Foundrys Environmental, Health &
Safety Policy?
A. WF E.H.S
C. E.N.V.I.R.O.
B. S.T.O.P
D. C.A.S.T.
Who should be contacted in case of a spill?
A. Supervisor
C. No One
B. ERT
D. Co-Worker

ANY
QUESTIONS?
Contact Information
Bryant Esch
Bryant.Esch@waupacafoundry.com
Direct: (715) 258-6674

Pre-Job Meetings

Job Specific pre-job meetings will be held with WF personnel and the
contractor for major projects and other jobs with unusual risks.
Crane Operation, Confined Space Entry, Demolition, Excavation, Fall
Protection Use and Scaffolding Use ALL REQUIRE A PRE-JOB
MEETING!
Other Dangerous Work may also require a pre-job meeting Examples are hot work, work within 10 feet of an energized line, fire protection
impairment, and equipment lockout. In these examples additional procedures
and permits may be required.

The meeting involves a completed Hazard and Risk Assessment for the work
to be performed.
Specific Risk Controls will be reviewed and agreed upon prior to the work
starting.
It is the contractors responsibility to contact the plant safety department to
arrange a pre-job meeting as needed.

General Contractor Information

Forms & Permits section will need to filled out for;


Confined Spaces, Lockout, Fire Impairment, Chemicals, Demo, Excavation,
Cranes, hot Zones, Safety Suggestion, Hot Work, and Risk Ranking

Job Impacting Factors

Factors that would impact job are as follows;


Job stress - tight time schedules, multiple tasks, lack or resources, end of shift
Vague/Poor Work Guidance - instructions conflict with experience or are out of date, poor
communication
First Time/Infrequent Task - first time completing task, longer than 30 days since completing
task, unfamiliar, inexperience, overconfidence in abilities
Distractions - pulled from another job, not completing job, too many tasks, surrounding
environment, first day back to work >4 days
Communication - adequate with WF employees, other contractors, daily & follow-up meetings

Hazard Assessments

Hazards at Waupaca Foundry, Inc. include;


Troubleshooting, Falls, Lockout, Traffic, Chemicals,
Guarding, Ergonomics, Congestion, Repetitive Motion,
Heat, Noise, Dust, Toxins, Confined Spaces, Slips, Trips,
Excavation, Pinch Points, Hot Work, Heights Above 4,
Lifting, Pushing, Pulling, Scaffolds, Line of Fire, Struck
by, Electrical Exposures

Critical Steps/Acknowledgment
Considerations for each step;
What could go wrong?
Countermeasures Implemented
Who is Responsible?
Acknowledgment by both parties the document and information was reviewed.

Waupaca Foundry, Inc. is tearing down part of the office complex and
rebuilding a larger office space. You have been contracted to help with a
portion of this project.
Some jobs that are being completed;

Demolition
Excavation
Electrical
Landscape
Concrete
Wall/Siding
Mechanical
Plumbing
Roofing

Fill out the pre-job meeting form as if you were completing one of the
jobs above. Answer the questions to the best of your knowledge.
***This is a fictitious scenario; we arent looking for correct answers, merely
knowledge of how to fill out the form and requirements.

Training

Contractors are responsible for the proper training


of their employees in such areas as fire, explosion,
chemicals, uncontrolled energy, confined spaces,
fall protection and any other hazards related to
their work.
In certain circumstances, Waupaca Foundry, Inc.
will require proof of Contractor employee training.
It is not the responsibility of, nor will Waupaca
Foundry, Inc. provide any detailed training to a
Contractor Employee.

Behavior Based Safety

BBS Includes observation and feedback of employees behaviors and


performance with regard to daily safety.

Contractor employees may be observed and should expect this as well of


safety performance feedback.

All Waupaca Foundry, Inc. employees are encouraged to report unsafe


behavior.

In addition to BBS, contractors also may be included in compliance


inspections.

Contractors that are found to be non-compliant will be expected to provide a


written corrective action in a timely manner.

BBS Observation Procedure

Go to the work being performed


Observe Openly
Extend your Greeting
Observe the situation/work
Record all behaviors observed
Give feedback
*Communication is the KEY to the observation process!
Employees will talk to you about what they observed.
What actions were safe and which were at risk

Utilize this time for questions and improvements.

Reporting of All Incidents


All Injuries sustained on the job site, must be
reported immediately to the Waupaca Foundry, Inc.
Health Services or Safety department.
All incidents, including near miss and property
damage, must be investigated and a copy of the
investigation kept on file with Waupaca Foundry, Inc.

Preservation of equipment, vehicles, etc. involved in


an incident is required until investigation is complete.

Goes into effect January 1, 2015


Under the revised rule, employers will be required to notify OSHA of

work-related fatalities within eight hours, and


Any work-related in-patient hospitalizations,
Any amputations or
Any losses of an eye within 24 hours.

Previously, OSHA's regulations required an employer to report only


work-related fatalities and in-patient hospitalizations of three or more
employees. Reporting single hospitalizations, amputations or loss of
an eye was not required under the previous rule

Bloodborne Pathogens

Bloodborne Pathogens (BBP) are micro organisms that are


carried in the blood and may cause disease in humans.

There are many different BBPs, but the two most significant are
HIV and Hepatitis B (HBV).

Prevention:
The key to avoid being infected is to protect yourself! Treat ALL
body fluids as if they are contaminated. DO NOT touch or clean
up blood.

All Waupaca Foundry, Inc. nurses and medical responders have


specific training in the proper clean up and disposal of blood
spills.

If you are incidentally exposed to blood or other potentially


infected material, wash the areas immediately and contact Health
Services.

Concept Review
Name reasons why a pre-job meeting would be necessary.
A. Confined Space
C. Fall Protection Req.
B. Crane Operation
D. All the Above & More

Whose responsibility is it to train contracted employees?


A. Contractors
C. Waupaca Foundrys
B. Themselves
D. Supervisor
Who should you report injuries or incidents to?
A. Supervisor
C. No one
B. Health Services or Safety Dept.
D. Friend

Confined Space Entry


A confined space, generally speaking, is one in which an
individuals ability to move about or exit is limited or restricted.
Potential risks include oxygen deficiency, toxic atmosphere,
entrapment, engulfment, fire or other physical danger.
Some confined spaces are obvious, but others may not be
apparent. It is important for all workers to be aware of what
confined spaces are and the potential hazards they represent.
Confined spaces are deadly. It is imperative that contracted
employees are aware that only those individuals having
received specialized training are permitted to enter a confined
space regardless of circumstances.

Confined Space Entry


Confined Space A confined space is one that:
Limited means for entry and exit (*note - this may be more than one entry and/or exit
point) Limited means you cannot easily walk in and walk out, and rescue in an emergency
would be difficult, AND
Not meant for continuous human occupancy - when the area was engineered,
consideration was not given to human occupancy - for lighting, ventilation, heat, etc., AND
Large enough to enter and perform work Entry is considered to have occurred as soon
as any part of the entrants body breaks the plane of an opening into the space.

Over 200 Confined Spaces have been identified at


Waupaca Foundry, Inc. Examples of Confined Spaces
at Waupaca Foundry, Inc. include:
Sand Silos, Furnace, Furnace Pit, Cupola, Bag
Houses, Duct Work, Melt Recouperator, Hoppers,
Mullors, Casting Cleaning Blast Machines, etc.

Confined Space Entry


The company project supervisor and Plant
Safety Dept. (Waupaca Foundry, Inc.
employees) must be notified and approve
entry before a contractor enters a
Confined Space.
Confined Space entry requires a pre-job
meeting between the contractor and
Waupaca Safety.
Discussion to include the known hazards
Previous entry experiences
Precautions and procedures required for safe
entry.

A contractor must conform to all


requirements of the company confined space
entry permit before entry into the space

Required Information on a

Confined Space Entry Permit


Space Name
Date / Time
Names of Entrants,
attendants, supervisor
Known hazards and
Measures to remove
hazards
Equipment for entry
Rescue information
Air Monitoring results

Hazards may include:


oxygen enriched or
deficient atmosphere,
flammables,
combustible dust, toxic
vapors and gas,
Chemical contacts,
electrical and
mechanical hazards,
temperature extremes,
engulfment, or
entrapment

Material Handling, Hoists, Cranes &


Rigging
Authorized, Trained and
Certified Personnel
Mobile Crane Policy

OSHA Subpart CC; 19261400-1442 Cranes and


Derricks in Construction
Rigging Calculation

Critical Lift

Only trained, authorized and certified


personnel are allowed to operate
cranes.

Mobile Crane
Compliance Work
Instruction
Critical Lift definition, requirements,
documentation
Only trained personnel, using ASME Standard
Hand Signals may act as the signal person
Requirement for Pre-Job / Pre-Lift meeting
Lift Calculation worksheets are available from
Waupaca Foundry, Inc.

Critical Lift
Under no circumstances
shall a load be hoisted
over people or
occupied areas.
(unless specific critical
lift requirements have
been met)
A suspended load shall
not be left unattended!

Rigging Calculation
A Rigging Calculation Worksheet
must be completed prior to each lift.
Only trained personnel shall perform
rigging duties.

Operator Responsibilities
The crane operators
responsibilities include, but are
not limited to;
Securing & maintaining lift
zone & marks
If lift zone is disrupted, it is the
operators responsibility to
reestablish the zone

Preventing pedestrian and/or


vehicular traffic
Use barricades, cones, and/or signs
to warn people of crane operation

Aerial Lift Equipment


Contractors are required to
operate Aerial Lift Equipment in
compliance with :
ANSI/SIA A92.6-2006, SelfPropelled Elevating Work
Platforms
ANSI/SIA A92.5-2006, BoomSupported Elevating Work
Platforms

Selection of Lift Equipment


Waupaca Foundrys dust and dirt
environment must be taken into account
when selecting lift equipment
Pre-use inspection of lift control operations is
required
Problems have occurred with SkyJack controls due
to the dusty environment
It is the contractors responsibility to be aware of
these hazards and select appropriate equipment

When is Personal Fall Protection required?


You are required to wear Personal Fall Protection Equipment if
you are working in an ARTICULATING lift. This is a lift that
moves out and away, not just up and down.

No one is allowed to stand on


the railings!

The tie-off point designated


by the manufacturer of the
articulating lift is normally
on the floor or at the base
of the operator panel; this
is where you should tie-off
in a lift.

Concept Review
How many confined spaces are at Waupaca Foundry, Inc.?
A. Over 200
C. 50
B. 100
D. Very Few

Who is allowed to operate a crane?


A. Anyone
C. Trained, Authorized, Certified
B. Trained
D. Kids

Scaffolds
Contractor employees
will be aware of the
types of scaffolds,
including supported
scaffolds and
suspension scaffolds,
and the unique
hazards of each.

Scaffolds
Equipment and work process must
comply with OSHA Construction
CFR 1926 Subpart L.
A Pre Job meeting with Waupaca
Foundry, Inc. Safety must be
completed prior to the use of
Scaffolding.
Scaffold erection documentation
will be required.

Scaffolds
The Contractor shall have each employee who is
involved in erecting, disassembling, moving, operating,
repairing, maintaining, or inspecting a scaffold trained by
a competent person to recognize any hazards associated
with the work in question.
The Contractor shall have each employee who performs
work while on a scaffold trained by a person qualified in
the subject matter to recognize the hazards associated
with the type of scaffold being used and to understand the
procedures to control or minimize those hazards.

Scaffolds
Inspect and check scaffold before each use.
Begin with good footing on solid ground; scaffold should
be level.
Use adequate bracing.
Tie scaffold to a building or structure when possible.
Dont overload scaffolding.
Dont ride on moving scaffolding.
Dont climb on braces, instead use the designated steps.
Establish barriers around scaffold tower to prevent
unintentional contact with moving equipment.

Scaffolds
Basic scaffolding must be able to support,
without failure, its own weight and at least
4 times the maximum intended load
(people & supplies).

Ladder Safety
The #1 Violation of Contractors
regarding Ladder Use at Waupaca
Foundry is using a ladder not
appropriate for the job.
Contractors must have Waupaca
Foundrys Permission and a
Contractor Loan agreement if using a
portable ladder owned by WF.

Ladder Safety - Read your ladder!


The three points of contact
rule;
always maintain one hand
and two feet.
or
two hands and one foot

when climbing or
descending ladders

Demolition
ANSI 10.6-2006
Dismantling, razing, or wrecking of any
fixed building or structure or any part
thereof
Rehabilitation, repair, or remodeling
including those where no removal or load
supporting structural members takes
place
Examples at Waupaca Foundry, Inc.;
Wall Removal
Building Knock-Down
Equipment Decommission and Removal

Demolition
Engineering Survey
OSHA 1926 Subpart T
Prior to permitting employees to start
demolition operations, a documented
engineering survey shall be
conducted by a competent person,
to determine the condition of the framing,
floors, and walls and possibility of
unplanned collapse of any portion of the
structure.
Any adjacent structure where employees
may be exposed shall also be
considered during the survey.

Demolition
An example of a Demolition Checklist is available from
Waupaca Foundry, Inc. upon request.
The survey and demolition checklist should be completed by
the Contractor and will be reviewed during the required prejob meeting with Waupaca Foundry, Inc. Safety.

Excavation Work
OSHA Construction Standard 1926
Subpart P
Applies to all open excavations
made in the earths surface (may
be indoor or outdoor).
Excavations are defined to include
trenches.
*Note: Excavation may create a
Confined Space

Excavation Definitions
Excavation is any man-made
cut, cavity, trench, or
depression in an earth surface
that is formed by earth removal.
*Note: may be indoor or outdoor
Trench is a narrow
excavation (in relation to its
length) made below the surface
of the ground. The depth of a
trench is greater than its width.

Excavation of Work Site


It is the responsibility of the contractor to determine the
location of any underground electrical cables, water pipes,
etc. prior to excavation work beginning.

Original Evaluation / Documented - Before any work begins Comprehensive


Daily Evaluation / Documented -Each day before work begins, by a competent
employee, with the ability to make changes as needed.

Ongoing evaluation throughout the day

Excavation
A ladder or other means of escape,
such as a ramp shall be located every
25 feet for means of exit from an
excavation.
Sides of excavations 5 feet or more in
depth shall be shored, sheeted or
braced
Spoil piles* must be at least 2 feet
away from the edge of the excavation.
This prevents cave ins and debris from
falling in excavated area.
*Spoil Piles: Excavated materials consisting of topsoil or subsoils that have
been removed and temporarily stored during the construction activity

Concept Review
How many times its maximum load does scaffolding have to hold, this
includes people and supplies?
A. 1 Times
C. 3 Times
B. 2 Times
D. 4 Times

True or False - Three Points of Contact rule means always maintaining one
hand and two feet or two hands and one foot on the ladder at all times.

What is the Digger Hotline number?


A. 811
C. 5111
B. 911
D. 111
How far away from the edge of the excavation do
spoil piles have to be?
A. 0 Ft.
B. 2 Ft.
C. 4 Ft.
D. 6 Ft.

Fall Hazards
Specific to Waupaca Foundry, Inc.

Working on top of machinery and equipment such as Molding machines,


Core machines, casting coolers, conveyors, or overhead cranes.
Working on overhead plant facilities equipment such as heaters, blowers,
exhaust equipment, air conditioners, and piping systems.
Working on building roofs including hazards from roof openings,
unsupported surfaces, or working near the roof edge.
Working at heights on conduit, wiring, cable trays, ductwork, piping, lighting
fixtures.
Walking or working on overhead I-Beams or H-Beams.
Exposure to falls into or onto tanks, scrap pits/containers, moving conveyors
or compactors.
Working in High Reach equipment (Raymond lift) , or on Aerial work
platforms.

Fall Protection
The use of appropriate fall protection
equipment must be utilized whenever
personnel are at a risk of falls from
heights at or above 4 feet.
It is the responsibility of the Contractor
to select, maintain and use the most
appropriate fall protection when
located at a height at or above 4 feet.
A pre-job meeting is required if fall
protection is needed
Determine access
Tie-off points

Three components of a
Personal Fall Arrest System are:

Anchor point
Body harness

Shock absorbing
lanyard

Fall Protection

One form of fall protection is a


standard guardrail.
This consists of three main components:
Top rail
Mid-rail
Toe-board

Fall Protection Summary


General Industry requires Fall Protection at 4 feet
Fall protection can include: personal equipment,
guardrails, designated areas

CAUTION TAPE is NOT Fall protection!

Fire Safety
Burning and Welding equipment shall be
routinely inspected to ensure it is in good
working order.

All contractors are required to have


Flashback Arrestors on welding and/or
torching equipment used at
Waupaca Foundry, Inc.
No hot work is to be performed in areas
containing Flammables or Combustibles.

Fire Safety
Distance on permit states
flammables and
combustibles cannot be
within 35 ft. of hot work
Reminder: Filling out a
permit requires contractor
to check the area

Fire Safety
Fuel & Oxygen Cylinders
Must be secured in an upright position at all times.
Fuel and Oxygen must be stored 20 feet apart
or separated by a 5 fire wall.
Cylinders shall not be stored in areas of high
heat or molten iron.

Caps should be in place on unused cylinders.


Cylinders shall never be lifted by the cap. Approved transport
carriers/carts must be used when moving cylinders that have
been secured.

Fire Safety
Prior to using any welding, Burning, open torch soldering equipment
on company property, a HOT WORK permit must be completed.
Portable open flame heaters (salamanders) also require the
completion of a Hot Work Permit before use.

No hot work is to be performed in an area where the sprinklers are


out of service.
Areas in designated fabrication and maintenance shops are the only
places where a welding, burning or hot work permit is not required.
Housekeeping must be maintained in these areas!

Fire Safety
Hot Work Permits
A permit must be completed if you are
not in a designated maintenance shop.
**Maximum length of permit is 1 week
with prior safety dept. approval.
Review of permit conditions, including
housekeeping in the area, and
equipment inspection, is required prior
to each work shift no matter the length
of the permit approval.

Fire Watch
Only Fire Extinguisher trained
personnel shall be assigned to
maintain Fire Watch.
Fire watch must sign off on hard
copy(Back) of the Hot Work permit
when work is completed.
Return the completed permit to the Safety
Department.

Fire Watch
A Fire Watch should be provided during and for
one (1) hour after hot work, including break
activities.
Fire watch shall be completed with an adequate
number of suitable fire extinguishers.
The personnel completing fire watch shall be trained
to use the fire extinguisher, and aware of the means
to sound the fire alarm.
The hot work area shall continue to be monitored for
three (3) additional hours after the one (1) hour fire
watch.

Fire Safety
Fire Extinguishers
Most fire extinguishers at Waupaca Foundry, Inc. are
type A,B,C
They contain approximately 8-10 seconds of
extinguishing agent when full.
Remember - PASS:
P Pull the pin
A Aim the nozzle
S Squeeze the handle
S Sweep at the base of the fire

Fire Extinguishers
Locations & Markings
Signs shall be posted to show the location
and identification of fire extinguishers.
Leave Clear shall be posted on the fire
extinguisher sign or marked on the floor near
the base of the wall or column.
If not equipped with wheels, portable
extinguishers weighing more than 39
pounds should be installed so that the top is
no more than 3.6 feet above the floor.
Those weighing less than 39 pounds, should
not be mounted more than 5 feet above the
floor.

Fire Safety
Fire Extinguishers
If you have a Waupaca Foundry, Inc.
extinguisher that has been used you
should alert a supervisor and the Plant
Safety Department.
An incident report must be completed any
time an extinguisher is used.

Replace it with a FULL extinguisher.

Flammables

Contractors shall post warning signs, if using Flammables, that state:


Danger - No open flame, no smoking, etc.

Flammables used by the contractor need to be dispensed from safety cans


with flash arrest protection, and that area clearly marked with contents &
hazards
Plastic gas cans and containers are not allowed.

Non sparking tools & processes (drills & cutting)


should be used whenever possible around flammables.

Flammables shall be stored properly in flammable cabinets, in the


contractors work trailer, or vehicle when not in use.

Fire safety
Reporting a Fire
At Waupaca, Dial 9 911
At Marinette, Dial 9 911

When in doubt,
Call the Fire Dept.

At Tell City,
1st - Contact any WF employee with a radio
2nd - Call the Guardhouse at 812-547-0799
Last Step: dial 9-911

At Etowah, Dial 9- 911

Fire Safety
Sprinkler System Shutdown
When necessary to shut off fire protection equipment for
changes or repairs (regardless of length of time):

The designated operator


shall complete this form and
take it to the plant safety/fire
coordinator for approval
prior to the start of the
impairment.
Notify all persons in the area
of impairment, including
department
foremen/supervisors.
Minimize the length of
impairment by preparing
everything before shutdown.

Restrict hot work and smoking


in the area of impairment.

If shutting down Fire Detection


system, allow Extinguishing
systems to remain active if
safe.

Ensure fire extinguishers are


available in impairment area.

Avoid shutting down multiple


extinguishing systems at the
same time.

Fire Safety
Sprinkler Systems
A permit must be
obtained from the
safety dept. before
disabling any sprinkler
systems.

A copy of the Fire


System Down permit
must be displayed at
the work site.

Do not stack materials


within 18 inches of a
sprinkler head or
directly in front of a
sprinkler riser.

Sprinkler heads shall


be covered with paper
if painting in the area
will take place. Paper
must be removed when
painting is completed.

Concept Review
Fall protection is required at or above what
height?
A. 5 Ft.
C. 6 Ft.
B. 4 Ft.
D. 3 Ft.

True or False - Caution Tape is a form of Fall Protection.

What is the acronym for using a fire extinguisher?


A. F.I.R.E.
B. There is none

C. H.E.L.P
D. P.A.S.S.

Stretching Break
Waupaca Foundry, Inc. has implemented a Stretch It
Out program for all production and office employees.
If you see these stretching groups, please feel free to
join!
Not only does stretching assist your job functions, it
helps relieve strain on muscles when completing tasks at
home.
Please feel free to join us in stretching at this time.

Electrical Safety
CWI 3-0031 Safe Electrical Work Practices , written
in line with NFPA 70E, 2015.
Effective for safety-related work practices for qualified
persons who work on or near exposed energized
electrical conductors or circuit parts.
Host employer (Waupaca Foundry, Inc.) and Contract
employees must communicate with each other regarding
hazards.

Electrical Safety
Contract employer shall ensure that each of his/her employees
follows the work practices required by NFPA 70E, and safety
related work rules required by the host employer (Waupaca).

Contract employer shall advise the host of the following:


Any unique hazards presented by the contract employers
work.
Hazards identified during the course of work by the contract
employer that were not communicated by the host employer.
The measures the contractor took to correct any violations
reported by the host employer to prevent it from recurring.
New conditions related to contracted work.

NFPA 70E-2015
Pre Job Meeting (documented)
Exchange of electrical safety programs
Means/methods for reporting violations
Requirement for energized work permit
11.2 Energized Electrical Work Permit (HSF 4-0234): When
working within the limited approach boundary or the arc flash
boundary of exposed energized electrical conductors or circuit
parts that are not placed in an electrically safe work condition,
work to be performed shall be considered energized electrical
work and shall be performed by written permit only. The intent
of the permit is to ensure that all appropriate safety precautions
have been taken prior to starting energized electrical work

Required additional PPE

Electrical Safety
Contractor employees need to
understand safety practices
needed when working around
overhead, buried, or concealed
electric lines.
Awareness will include an
understanding of working
clearances around energized
lines and safety practices related
to conductive equipment (e.g.,
back hoes, cranes, aerial lifts)
and platforms and scaffolds.

Electrical Safety
Except for double
insulated tools, ground
fault protection must be
used for all electrical
devices in wet or outdoors locations.
All temporary lighting
service must be Ground
Fault Protected.

Electrical Safety
Electrical hand tools shall be
maintained is good operating
condition by the contractor.
Other electrical equipment, such as
job site radios, and extension cords
shall also be inspected prior to use
and maintained in a safe operating
condition.

Energy Control and Lockout


Contractor employees will be aware of the importance
and function of lockout programs in electric safety.
They will be aware that only qualified people may work with
exposed live conductors and electrical parts.
They will also be aware of the importance of safe
procedures, including circuit tests that are followed whenever
equipment is de-energized and re-energized.
They will be aware a pre-job meeting is required before a
machine can be locked-out

Energy Control and Lockout


Lockout / tagout programs protect
employees from the potential hazards
created by incidental release of energy.
Contractor employees will understand
equipment lockout including:
Responsibilities of affected and authorized
employees
Procedures for controlling energy sources
Importance of verification: try, lock and try.

Energy Control and Lockout


Contractor employees will be
aware of the risk presented by
hazardous energy, including:
incidental (intentional, unintentional)
start-up
Electric shock
Unexpected release of stored,
residual or potential energy which
may include:
-Electrical, mechanical, thermal, hydraulic,
pneumatic, steam and water or other types of
energy

Energy Control and Lockout

Lockout shall be used before any service or


maintenance is performed in order to ensure that
machines and equipment are isolated from any
hazardous energy sources.

Contractors need to provide individual locks for their


employees and label them properly.

Contractors must CO-LOCK with a knowledgeable


Waupaca Foundry, Inc. employee.

Contractors may NOT cut off locks that have been


placed on equipment by someone else.

Energy Bus Bar/HMC Power Rail


Hoisting that is required near
energized power sources, such as
the Hot Metal Carrier track (480v),
requires additional precautions.

The minimum distance from the


hoist, hoisting cable and the load
being lifted to the Hot Metal Carrier
track must be 10 feet.

If hoisting must be performed closer


than 10 feet, the Hot Metal Carrier
track must be de energized and
locked out before work can begin.

Pacemakers & Charge Crane


High powered industrial equipment,
such as the charge crane magnet,
have the potential to affect the
function of pacemakers.
It is the contractors responsibility to
avoid assigning employees with
pacemakers to work in the charge
yard.
If work situation cannot be avoided,
contractor must have individual
undergo a risk assessment prior to start
of work

Tool Safety
Power Tools
Maintain tools in a safe working condition.
Tools and extension cords must be
insulated and graded for industrial and
construction use.
Damaged cords must be removed from
Waupaca Foundry, Inc. property.
Pneumatic power tools shall be secured to
prevent incidental disconnection.
When refueling a gas powered tool, shut
the tool off and allow to cool down before
using again.

Tool Safety
Powder Actuated Tools
Powder actuated fasteners are used to bond various construction
materials together, such as wood and concrete, or steel and
concrete.
Powder actuated fastening is a unique and very cost-efficient
method that is used in a variety of construction situations from home
building to large urban structures.
An example of a Powder Actuated Tool that may be used at
Waupaca Foundry is a NAIL GUN.
Employees using the tool must be trained and inspect the equipment
prior to use.
Notification of use must be given to Waupaca Foundry Safety
personnel prior to use.

Tool Safety
Non Powered Hand Tools
General Condition
Chisels/Punch equipment
should not be mushroomed.
Hammer handles should not be
split and should be attached
firmly.
Screwdrivers should not be
rounded.

Concept Review
True or False - Ground fault protection does not need to be
used for electrical devices in wet or out-doors locations.
Who must a contracted employee co-lock with when de-energizing
a machine?
A. No One
C. Knowledgeable WF Employee
B. Co-worker
D. Supervisor
What must an individual with a pacemaker undergo before
working in the charge yard?
A. Risk Assessment
C. Nothing
B. Health Screening
D. Magnet Exam

Hazard Communication
It is the contractors responsibility to inform and
train their employees on the chemicals in the
work area.
An inventory of Waupaca Foundry, Inc.
chemicals and SDS are available from the plant
safety department.
Reminder Request a copy of SDS for chemicals
commonly used by contractors can be provided
to Waupaca Foundry, Inc. prior to work.
*Just the ones used at Waupaca, not complete filing cabinets!

Safety Data Sheets


SDS need to be retained by Waupaca Foundry, Inc. for any
hazardous material used by the contracting company.
Examples would be cleaning products, roofing materials, painting
materials, floor repair/installations involving sealants or adhesives,
insecticides, etc.

This includes materials that are essential to the project or


job at Waupaca Foundry, Inc.

Solvents & Paints


Maintain adequate ventilation and
use respiratory protection when
using solvents and paints.
When painting ceilings, all sprinkler
heads must be marked off to avoid
clogging or damage. Remove paper
when job is complete.
It is the contractors responsibility to
dispose of any remaining solvents or
paints at the completion of a project.

OSHA GHS Hazard Communication

Q. What is the phase-in period in the revised Hazard Communication


Standard?
A. The table below summarizes the phase-in dates required under the revised
Hazard Communication Standard (HCS):
Effective Completion Date

Requirement(s)

Who

December 1, 2013

Train employees on the new label elements and


safety data sheet (SDS) format.

Employers

June 1, 2015*
December 1, 2015

Compliance with all modified provisions of this


final rule, except:
The Distributor shall not ship containers labeled
by the chemical manufacturer or importer
unless it is a GHS label

June 1, 2016

Update alternative workplace labeling and


hazard communication program as necessary,
and provide additional employee training for
newly identified physical or health hazards.

Employers

Transition Period to the effective completion


dates noted above

May comply with either 29 CFR 1910.1200 (the


final standard), or the current standard, or both

Chemical manufacturers, importers, distributors,


and employers

Chemical manufacturers, importers,


distributors and employers

More information about Modification of the Hazard Communication Standard (HCS) to


conform with the United Nations' (UN) Globally Harmonized System of Classification and
Labeling of Chemicals (GHS) can be found at;
https://www.osha.gov/dsg/hazcom/hazcom-faq.html

OSHA GHS Hazard Communication


Q. What are the major changes to the Hazard Communication Standard?
A. The three major areas of change are in hazard classification, labels, and
safety data sheets.
Hazard classification: The definitions of hazard have been changed to provide specific
criteria for classification of health and physical hazards, as well as classification of mixtures.
These specific criteria will help to ensure that evaluations of hazardous effects are
consistent across manufacturers, and that labels and safety data sheets are more accurate
as a result.
Labels: Chemical manufacturers and importers will be required to provide a label that
includes a harmonized signal word, pictogram, and hazard statement for each hazard class
and category. Precautionary statements must also be provided.
Safety Data Sheets: Will now have a specified 16-section format.

The GHS does not include harmonized training provisions, but recognizes that training is essential to an
effective hazard communication approach. The revised Hazard Communication Standard (HCS)
requires that workers be re- trained within two years of the publication of the final rule to facilitate
recognition and understanding of the new labels and safety data sheets.

For a side-by-side comparison of the current HCS and the final revised HCS please see OSHA's hazard
communication safety and health topics webpage at: http://www.osha.gov/dsg/hazcom/index.html.

OSHA GHS Hazard Communication

Video is approx. 3 minutes

OSHA GHS Hazard Communication

The Basic Personal Protective Equipment


Required to be worn by Contractors is:
The Contracting Company shall provide all protective
equipment. At minimum Contractors shall wear the following
equipment on Waupaca Foundry, Inc. property (indoors and
outdoors):

Clear (not tinted or mirrored), foam-lined safety glasses


Hard hat
Steel toed shoes
Hearing protection
T-shirt and long pants
Gloves

Areas of Waupaca Foundry, Inc. may require respiratory protection; these


areas include the shaker system, millroom areas and the pelletizer
buildings

The Basic Personal Protective Equipment


Required to be worn by Contractors is:
Gloves shall be worn at all times, except where the hands are not
used or exposed to hazards (i.e. walking, standing, writing, or
computer entry). It is presumed by Waupaca Foundry, Inc. that all
employees' hands are exposed to hazards (laceration, abrasion,
puncture, crushing, chemical contact, electrical, etc.) when being used
to touch or handle tools, equipment, materials, or debris.
Employees may be over exposed to silica in some areas. It is the
responsibility of the contractor to provide employees with respirators,
training and health evaluations related to working in these areas.
The HOT ZONE requires additional PPE such as fire resistant clothing
and training.

Industrial Hygiene Testing


Results of testing are posted at each
plant location.
Results may require additional PPE
such as double hearing protection and
respirators/dust masks.
Areas commonly requiring respirators
include; casting shakeout, dust
collection systems, grinding
stations.
It is the responsibility of the contractor
to review and protect their employees.

Double Hearing Protection


Double Hearing Protection is REQUIRED in areas with sound
levels in excess of 100 dB. Currently these areas include:
Plant 1: Millroom cooler, Shakeout lines, Upper shaker, Dry Ice
Pattern cleaning area.
Plant 23: P2: BMD line, Spinner Grinding line, RBM lines, Dry Ice
Pattern Cleaning P3: Grinding Line 4, 5,6, Upper Deck CC lines ,
Pattern Cleaning, Shake out booths, VMM Operator #2-3
Plant 4: Shakeout lines and Dry Ice Pattern Cleaning area
Plant 5: Ductile Millroom Shake out (production) & cut off saw operator,
Dry Ice Pattern Cleaning, Operator of the KT 30.
Plant 6: Shakeout and Dry Ice Pattern Cleaning area

Ear Plugs VS. Earbuds


Section 2.3: Employees are not allowed to
use unapproved audio equipment with
headsets, ear jacks, Ipods/Mp3 players etc.
while in the plant.
Using unapproved ear buds may affect hearing of
horns/warnings from forklift, Raymond, HMC, etc.
All employees, contractors and visitors are required to
wear appropriate hearing protection in designated
areas, including but not limited to all production areas.
Only approved hearing protection is allowed in the
plant

Ear Plugs = Okay

Earbuds =
Not Okay

Automated External Defibrillator (AED)


Locations
The AED will be used in
conjunction with CardioPulmonary Resuscitation (CPR)
in cases of sudden cardiac arrest
on Waupaca Foundry, Inc.
property, in accordance with
accepted protocols, including
those developed by the American
Red Cross and the American
Heart Association
The AED devices are placed in
areas that are easily accessible

Plant

Location

First Aide
Room

2
3

First Aide
Room

P2 Electrical Maintenance Shop

0-2-3

Plant 3 Coreroom
Breakroom
Plant 23 Stockroom (Old trailette)

1st AED Outside First Aid Room & 2nd


AED In the Metallurgy Lab Hallway

1st in First Aid Room


2nd in North Breakroom

First Aid Room


Millroom Office

Signs, Signals & Barricades


Warnings / Postings
Confined Space

High Noise
Hazardous Chemicals
Housekeeping
6S

Emergency Planning
In the event of a plant evacuation, contract
employees should report to the GUARDHOUSE
and remain there until an all clear has been
announced.

Designated Take Cover Areas


Plant 1 Waupaca: Main offices & adjoining
hallways and 1st floor restrooms
Plant 2/3 Waupaca: Locker rooms, Basement
conference area, R&D, Stockroom, Warehouse
A/B- in department restrooms
Plant 4 Marinette: Shower rooms or
compressor room, Metal Lab, Melt control office,
Main office hallway, Stockroom restrooms.
Plant 5 Tell City: Locker rooms, in plant
restrooms.
Plant 6 Etowah: Shower rooms, plant
bathrooms, melt lab, men and womens shower
rooms

Emergency Response
Medical Care, Blood Spill, Fire, Chemical Spill, Confined
Space Rescue
When calling Emergency Responders, state the following;
State what you need (medical, fire, etc.)
State your location (plant, dept., area)
State type of incident

Contacting Medical First Responder &


ERT
Plant 0, 1 & 23
To Page a Medical First Responder dial 6699-630- "state
message" then wait for a beep before hanging up
To Page an Emergency Response Team Member (spills,
rescue, fire) dial 6699-690-"state message" then wait for a
beep before hanging up

Plant 4
Use Radio Channel #10

Plant 5
Call Guardhouse 812-547-0799 or
Use Radio Channels #1-8

Plant 6
Call Guardhouse on Radio Channel #1 or dial ext. 5999

Red Emergency Phone


Hard Line telephones in the event of power loss are
located in strategic areas of the facility.
They are RED and labeled as Emergency Phones.
Red Emergency Phone Locations:

Plant 1 - 1st aid room, East guard house, front


reception, Melt control, Maintenance Shop and Disa
diner
Plant 23 - P3 west/Guardhouse, P3 Core, P3 Mill,
P3 Maintenance, P23 Melt control, P2 Electrical
Plant 4 -1st aid room, Guardhouse, and Melt control
Plant 5 - 1st aid room, Guardhouse, front reception,
Melt control
Plant 6 - 1st aid room, Guardhouse, Melt Control,
VMM/Core office

Railroad Safety
A minimum 8 foot right-of-way clearance must be
maintained at all times on each side of track.
No unattended equipment should be left on the track
at any time.
Unusual work on or near the tracks must be pre
approved.
A moving train ALWAYS has the Right of Way
Railway employees shall not ride
a car ladder that is in front of a moving
set of wheels.

Concept Review
True or False - Two additions to required PPE
implemented in 2014 are foam-lined safety glasses and
gloves.

Where should contractors be meeting in the event of an evacuation?


A. Their Car
C. Stay where you are
B. Guardhouse
D. Parking Lot
What is the minimum clearance required for each side of the
railroad tracks?
A. 2 Ft.
C. 6 Ft.
B. 4 Ft.
D. 8 Ft.

Overhead Doors Vs. Pedestrian Walkways


Always stay in
pedestrian aisles

Correct!

Use personnel
doors only!!!
NEVER walk
through overhead
doors
Dont Do!

Security
Doors locked from the inside are not to be
propped open without prior approval from the
company.
Report suspicious behavior and vehicle
accidents to the Guardhouse.
You are advised to lock your personal equipment
& vehicles when left unattended.
Waupaca Foundry property may be under video
surveillance.

Cafeterias, Break Areas, Telephones


and Restrooms
Use of these areas is permitted for approved contractors
who have signed in and have proper identification.
Public pay telephones are located near break areas.
Contractors use of the shower and locker facilities is
prohibited, unless used for Emergency Take Cover.

Sign-In Process
One Sign-in for Competent Persons
(i.e.: foremen, leaders, safety rep , etc.)
One Sign-in for workers
OSHAS DEFINITION OF A COMPETENT PERSON:
One who is capable of identifying existing & predictable hazards in
the surroundings, or working conditions which are unsanitary,
hazardous, or dangerous to employees, and who has the
authorization to take prompt corrective measures to eliminate the
hazards.

Visiting Multiple Plants

If signed in at P2/3,
please sign out before
heading over to P1, and
then sign in at P1 to
show you are in the
building (and vice versa).

Parking Lot
Do not park in the designated Visitor places.
Designated parking for contractors is the same as WF employees

Do not park at your work area, unless you have a permit


from the guardhouse, and can demonstrate a need to be
parked there.
Riding on the tailgate or back of truck is prohibited.
Speed limit is 15 MPH or LESS!

Equipment Loan Agreement


Loaned Equipment: Such as, but not limited to,
portable ladders, cranes, man-lifts, forklifts,
torch equipment, etc.
Due to liability Waupaca Foundry, Inc. prefers NOT to borrow
equipment to contractors.
If equipment will be used by contractors, an Equipment Loan
Agreement must be completed and signed FIRST !
Equipment, such as aerial lifts, forklifts, and cranes will
require training records of employees along with the
Equipment Loan Agreement.

Cell Phone Use


If cell phones need to be used, they
have to be used outside of production
areas and out of vehicular traffic!

Contractor Incident Review


Most cited problems among plants and contractors
PPE
Not wearing the foam-lined safety glasses and gloves

Ladder Use
Not selecting/using appropriate ladder for the job

Fall Protection
Not choosing the fall protection appropriate for the length of drop

Garage Doors
Contractors walking under overhead doors instead of using
pedestrian service doors

What is the Hot Zone?


The Hot Zone is the area(s) in our facility where
molten iron is being produced, transported or
poured.

Departments included in the Hot Zone are the Melt


and Molding Departments and the travel route of the
Hot Metal Carrier/Bull Ladle throughout the plant.

Molten Metal in contact with any water or


liquid-bearing material, turns the water
instantly to steam, causing it to expand 1600
times its original volume and producing a
violent explosion.

Three KEYS to Personal Safety in the Hot Zone


Distance: is a very straightforward form
of protection. The further you are away
from the furnace, or molten metal, the
safer you are from being splashed.
Protective Barriers: An example
would be a screen or wall around a
pouring deck.
Personal Protective Equipment: This
is the most important step you can take
as an individual to protect yourself from
metal splash.

General PPE in the Hot Zone

High Heat Resistant hard hat


Foam-lined Safety glasses with side protection
Hearing protection
Gloves
Fire/Flame Resistant FR Uniform: Long sleeve shirt
and pants covering boot top. No open pockets, or cuffs.
FR Jeans OK.
100% cotton underclothing is recommended.

Safety shoes with steel toe, made from natural materials


such as leather.

Fire Resistant FR clothing

FR Fire Resistant, not Fire PROOF.


- Nothing can withstand 2800F iron
FR why important? Reduces injury by not
allowing fire to spread
Common Brand Names:
Bulwark (Excel FR Cotton & Comfort Touch)
Red Kap (now owns Bulwark)

FR Clothing
FR : Fire Resistant treated to self-extinguish
upon the removal of the ignition source.
Must be laundered properly NO bleach, NO
fabric softener. (Bleach/Fabric Softener add a
flammable to the fabric)
Must be maintained in good condition. Limited
repairs, no frays etc.

FR Clothing
The higher the weight of the fabric the more
protection it will give you.
FR Jeans are 14 oz; FR uniform pants 9oz
As clothing wears it becomes thinner, losing some of
its protection.
Base cloth may be 100% cotton, or a cotton/nylon
combination. They both provide the same
protection. The combination cloth is softer/more
comfortable.
NOMEX NOT for Molten Iron!
- Molten iron will stick to Nomex like glue

FR Clothing (contd)

Loaning of FR jackets
- Waupaca will loan an FR jacket to a visitor on a
temporary basis.
- Contractors that will be performing work in the
Hot Zone, must supply FR clothing to their
employees.

Shoes / Boots
Kick off boots are not recommended for pouring
/ molten iron areas. (elastic sides can melt, or
sag causing injury)
6-8 lace up, with tight lacing; spats/shoe covers
if needed.
Bottom of pants to cover boot top.
No man-made materials.
Built-in metatarsal is best.

Additional Precautions in the


Hot Zone

Equipment and Material Storage


Equipment and Material storage shall be minimized
within the Hot Zone in order to prevent equipment
damage and fire.
Contractors shall contact their Waupaca contact or
the Safety Department to determine the proper
storage location of their equipment and material.
Powered Equipment shall be removed from the
active Hot Zone when not in use.

Warning Signals
Hot Metal Carrier/Bull Ladle warning horns,
lights, etc.
- Spotter must be present if working in path of travel to warn
others to clear area as needed.
- Spotter maintains ongoing communication with Hot Metal
Carrier operator, and the workers in the area.
- All personnel need to remain Clear by a minimum of 20 feet
when the Hot Metal Carrier is operating.

Warning Signals
Safety gates activate during the Hot Metal Carriers
movement.
- Similar to a RR crossing: be prepared to stop at the gate as
you approach.
Stop, look, listen and never attempt to bypass or go around a
gate.
Pedestrian aisles
- Stay within the designated aisle way to maintain a safe
distance.
Stop & Go Lights
Adhere to these lights like you would while walking across a street

Emergency Procedures
Contacting EMS Medical Assistance and
ERT Fire Assistance
- Any Waupaca employee can summon help
- Contact the local guardhouse

Emergency 1st Aid Equipment


- Fire Blankets in area to be used by anyone
- Fire Extinguishers may be used by trained personnel only
- All other emergency equipment is to be used by Waupaca
personnel only

Additional Recommendations
Shoulder-length or longer hair should be tied back or
covered.
- Susceptible to sparks or being caught in machinery

Having metal objects, or items such as lighters in shirt or


pants pockets is not recommended.
Wearing jewelry may be hazardous and is not
recommended.
- Traps sparks
- If burned, will hold and transfer heat of iron to body

Concept Review
What is the maximum speed limit in the parking lot?
A. 80 MPH
C. 15 MPH
B. 20 MPH
D. Whatever you want
True or False - Additional PPE is required to work in the hot zones.
True or False - Horns, lights, safety gates and pedestrian aisles are
forms of safety precautions for the Hot Metal Carrier.

Who can use a Fire Blanket?


A. Only WF Employee
B. Supervisors

C. Only ERT
D. Anyone

Legal
Review
2016 Meeting

Affirmative Action
As your firm is well aware, Waupaca Foundry, Inc., Inc. is an equal
opportunity employer.
Pursuant to Executive Order 11246, as amended, the Rehabilitation Act of 1973, as
amended, and the Vietnam Era Veterans Readjustment Assistance Act of 1974, as
amended, you are advised that under the provisions of government contracting and
in accordance with these laws, contractors and subcontractors are obliged to take
affirmative action to provide equal employment opportunity without regard to race,
color, religion, national origin, age, sex, physical or mental disability, or status as a
disabled veteran, recently separated veteran, Armed Forces Services medal
veteran or other protected veteran .
We expect to see our commitment to equal opportunity employment reflected in the
racial and sexual composition of your firms workforce and urge a vigorous
Affirmative Action Program to overcome underutilization.

Harassment Policy
Waupaca Foundry, Inc. has a written policy of Equal Employment Opportunity.
This policy is designed to extend equal opportunity in employment to
qualified applicants and employees without regard to an individual's
membership in a legally protected class, such as age, race, color, sex,
religion, national origin or disability. Illegal harassment is a form of
discrimination. Waupaca Foundry, Inc. has long regarded the harassment
of any employee on the basis of his or her membership in a protected
class, for example sexual or racial harassment, as a violation of the Equal
Employment Opportunity Policy. Harassment based on protected class
membership is a form of misconduct that undermines the integrity of the
employment relationship and negatively impacts upon the morale and
productivity of our employees. All employees are expected to deal fairly
and honestly with one another and to respect the rights and integrity
of all persons. Accordingly, Waupaca Foundry, Inc. has adopted a
ZERO TOLERANCE policy toward harassment. Consistent with
Waupaca Foundry, Inc.s policy, sexual harassment or harassment of any
employee on the basis of his or her membership in a protected class, is
STRICTLY PROHIBITED.

Union Officials
It is also our policy, that if an occasion should arise,
that a contracted employee is to meet with his/her
Union Official, the Union representative shall identify
themselves at the plant guardhouse and request that
the foreman bring the individual/s to the
guardhouse.
The contractors employee and the union official may
then meet either in the guardhouse, the union
officials automobile, or off of Waupaca Foundry, Inc.
property.

Workplace Violence
Waupaca Foundry, Inc. has ZERO tolerance to any threats or acts
of violence in our workplace.

Unacceptable behavior includes, but is not limited to the following


acts; explicit or implied threats, including written threats,
intimidation or physical assault.
*Notice: Waupaca Foundry, owner prohibits the carrying of firearms
or other weapons inside this facility.

Weapons: switchblade, stun gun/taser, explosives, machete,


hatchet, billy-club. Excluded: knifes with blades 3 or less.
Firearms & Ammunition: Lawfully possessed, locked in vehicle
and out of sight.

Drug Testing
Waupaca Foundry, Inc. tests our employees:
All contractors and subcontractors performing Safety Sensitive work at
Waupaca Foundry, Inc. will be required to participate in the Drug & Alcohol
Program.
Safety Sensitive work is any job position determined have such
risk, by the nature of the work involved, that even a momentary lapse
of attention could have serious consequences to the safety of the
employee, coworkers, customers, the company, or the general public.

ALL CONTRACTOR WORK IS SAFETY SENSITIVE!

The contractor is financially responsible for this testing.


Waupaca Foundry, Inc. only requests documentation stating compliance, not
the actual results, we want documentation (for example a company letter, or
Union card).

Smoking
Smoking is not permitted in any of our
facilities.

Designated smoking areas have been


identified outside the buildings.

Insurance
Requirements
What you need to know
What you need to supply
2016 Meeting

What is the Name of The Company


You Are Doing Business With?

Waupaca Foundry, Inc.


The Proper Name is Important. Waupaca Foundry, Inc.
is the name that is on our Purchase Orders and
Contracts
If the Certificates do not match the contracts, the
insurance company can deny coverage, especially for
additional insured coverage and the Waiver of
Subrogation.
Ask your insurance Agents to remove all ThyssenKrupp
Waupaca mailings from their systems.

Certificates of
Liability Insurance
Only Proof that your Company has the
minimum Insurance Requirements of
Waupaca Foundry, Inc.
No Rights or Obligations created without
an endorsement on the Certificate
Insurance Companies utilize the Accord
Form 25.

Insurance Requirements
For projects with Waupaca of $100,000 or
greater, your company will need to carry a
minimum of $5,000,000 liability coverage
on a per occurance basis with Waupaca
Foundry, Inc. listed as an Additional
insured.
For all companies who provide trucking
services, Waupaca Foundry will have to
be named as an Additional Insured for
Automotive liability policies.

Insurance
Requirements Cont.
Waupaca is also requiring all
contractors to complete the Waiver of
Subrogation with regard to Workers
Compensation Coverage where
allowed by State Law.
If you have multiple WC policies in
different states, Waupaca will need
the Waiver or the Letter depending on
the State law.

Contractor Environmental, Health


& Safety Record
This document will need to be signed by an
OFFICER of the company.
An officer is an individual who is appointed
by the board of directors to carry out the day
to day operations of the company. If you are
not a corporation, for example an LLC, the
equivalent position is a person appointed by
the owners to run the day to day operations
of the Business.
Examples of officers are President, COO,
CEO, Vice President, Secretary, CFO,
Treasurer, Chief Compliance Officer or Chief
Information Officer.

2016 Insurance
If you have submitted renewed
insurance for the 2016, you do not
need to send in an updated
Certificate of Liability
If your insurance is near the date of
expiration, however, remember to
send an updated/renewed copy of
the insurance to Waupaca Foundry,
Inc.

Concept Review
True or False - Waupaca Foundry, Inc. is an equal
opportunity employer.

What kind of policy does Waupaca Foundry, Inc. have


towards harassment, threats, violence, etc.?
A. Minimal Tolerance
C. Its Tolerated
B. Zero Tolerance
D. Its up to you
Can you be an approved contractor if your insurance is expired or
missing the Workers Compensation?

YES

or

No

ANY
QUESTIONS?
Contact Information
Jeremy R. Dobbe
Jeremy.Dobbe@waupacafoundry.com
Direct: (715) 258-6787

Additional Health and Safety


Information
www.osha.gov
Standards

Interpretation
Help

www.waupacafoundry.com
Environmental, Health and Safety Recap
Todays Meeting
Power Point Presentation
Visitor Safety Protocol (HSF 4-0033)
Contractor Environmental, Health & Safety Meeting
Record ( HSF 4-4.4.2-4)
Contractor Environmental, Health & Safety
Agreement (HSF 4-4.4.2-3)
Equipment Loan Agreement (HSF 4-4.4.2-6)

ALL of the following documents must be


completed and returned to Waupaca
Foundry, Inc. in order for your company to
become an Approved Contractor
Health and Safety Meeting Record
Contractor Health & Safety Agreement - signed by a
company official, and returned by Jan. 1st, 2016
Current Certificate of Insurance as outlined today.
Chemical SDS if not listed by Waupaca Foundry, Inc.
Equipment Loan Agreement (if requested, needs to be
pre-approved by WF Safety Personnel)

Environmental, Health and Safety


Compliance Work Instructions (CWI):

Aerial Lift Equipment (CWI 3-0059)


Bloodborne Pathogens (CWI 3-0003)
Confined Space Entry (CWI 3-0006)
Drug and Alcohol Abuse Testing and Rehabilitation (CWI 3-0010)
Safe Electrical Work Practices (CWI 3-0031)
Energy Control & Equipment Lockout (CWI 3-0011)
Fall Protection (CWI 3-0013)
Inergen Fire Suppression System (CWI 3-0046)
Hazard Communication (CWI 3-0015) & Chemical Inventory
Hearing Conservation (CWI 3-0029)
Hoist Equipment (CWI 3-0016)
Incident Investigation (HSP 2-4.5.3-1)
Lead Exposure Plan (CWI 3-0017)
Mobile & Overhead Crane Safe Operation (CWI 3-0008 & CWI 3-0009)
Personal Protective Equipment General Requirements (CWI 3-0018)
Powered Vehicle Operation (CWI 3-0014)
Respiratory Protection (CWI 3-0028)
Fire Prevention Welding, Torching, Burning, Hotwork (CWI 3-0020)
Workplace Violence Prevention (CWI 3-0021)
Emergency Preparedness & Response (HSP 2-4.4.7)

Environmental, Health and Safety Forms

Aerial Lift Inspection (HSF 4-0055)


Excavation Check List (HSF 4-0005)
Demolition Check List (HSF 4-0004)
Confined Space Permit (HSF 4-0023, 4-0037, 4-0039, & 4-0040)
Confined Space Identification Logs
Energized Electrical Work Permit (HSF 4-0234)
Fire Protection Shutoff/Impairment (HSF 4-0063)
Forklift Inspection (HSF 4-0058)
Hot Work Permit (HSF 4-0031)
Mobile Crane Critical Lift Plan (HSF 4-0065)
Mobile Crane Personnel Basket (HSF 4-0061.WM)
SDS inventory
Cable Tray Pre Entry Checklist (HSF 4-0331)
Portable Electrical Equipment Inspection (HSF 4-0062)
Pre Job Meeting Form (HSF 4-0278)
Respirator Protection Matrix (HSF 4-0021)
Visitor Safety Protocol (HSF 4-0033, 4-0116, 4-0117, 4-0118)
Spill Emergency Response Decision Chart (HSF 4-0173)

www.waupacafoundry.com

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