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Motor Pool and Maintenance
Safety and Accident Prevention
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Maintenance-Related Accidents
Maintenance-related accidents are responsible for 20 percent of all military on-duty injuries
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References
• 29 Code of Federal Regulations (CFR) 1910, General Industry Standards
• AR 385-10, The Army Safety Program
• AR 750-1, Army Material Maintenance Policy
• DA Pam 750-1, Commanders’ Maintenance Handbook
• DA Pam 750-3, Soldiers’ Guide for Field Maintenance Operations
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Terminal Learning Objective
Action:
Explain requirements for motor pool and maintenance safety and accident prevention.
Conditions:
During group discussions regarding motor pool and maintenance operations.
Standard:
Requirements include responsibilities, standing operating procedures, and safety precautions.
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Lesson Data
• Safety Requirements
• Risk Assessment
• Environmental Conditions
• Evaluation
– Oral questions
– Participation during class discussions
5
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Overview
• Responsibilities of key maintenance personnel
• Standing Operating Procedures (SOPs)
• Precautions for hazards found within or around a motor pool and/or maintenance facility
• Hazards of specialized equipment and procedures
66
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Enabling Learning Objective A
Action:
Identify the responsibilities of key maintenance personnel within a unit maintenance program.
Conditions:
Given the titles of key maintenance personnel
Standard:
Identification must include a minimum of three responsibilities for each as outlined in AR 385-10, AR-750-1, and DA Pam 750-1.
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Commander’s Responsibilities
• As an Army leader, commander’s responsibilities include:
– Protecting personnel, equipment, and facilities
– Establishing accountability for safety and occupational health
– Implementing safety and occupational health policies
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Commander’s Responsibilities
• Commander’s responsibilities also include:
– Integrating Composite Risk Management (CRM) process into mission activities
– Emphasizing the importance of safety and maintenance
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Continued
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Safety Officer/NCO Responsibilities
• Responsibilities include:
– Serving as principal advisor to the commander in all safety / occupational health related matters related to mission
– Advising and assisting the commander in ensuring CRM is an integral part of the unit’s operations and training
– Assisting with hazard identification and assessment tools
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Supervisor’s Responsibilities
• A supervisor’s responsibilities include:
– Maintaining a safe and healthful workplace
– Inspecting the work area for hazards
– Using CRM during planning, preparation, and execution of all operations
– Preventing accidents
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Supervisor’s Responsibilities
• A supervisor’s responsibilities also include:
– Attending, leading, and supervising preventive maintenance operations
– Checking and updating SOPs
– Enforcing Army Maintenance Standards
– Training operators and crews to operate equipment and perform PMCS properly
– Enforcing safety12
Continued
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Operators’ and Crews’ Responsibilities
• Operator and crew responsibilities include:
– Detecting and reporting malfunctions
– Operating equipment properly and safely
– Knowing their responsibility in achieving the Army Maintenance Standard
– Performing Preventive Maintenance Checks and Services (PMCS)
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Performing PMCS
• Cornerstone of the Army Maintenance System
• Required by all printed, electronic, and interactive electronic technical manuals (TM)
• Must be performed from the applicable TM
• Faults detected that violate a safety directive must be corrected
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Enabling Learning Objective B
Action:
Describe the requirements for maintenance standing operating procedures (SOPs).
Conditions:
During group discussions.
Standard:
Requirements must include the description for the need of SOPs and at least 10 areas that should be addressed in detail as specified in DA Pam 750-3.
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Why have a Maintenance Standing Operating Procedure (SOP)?
• Required by AR 750-1 which states:
– “SOPs will be established and maintained by all Army organizations and activities performing maintenance operations.”
• Purpose
– To formally describe the way a unit performs maintenance
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Motor Pool and Shop Safety SOPs
• DA Pam 750-3 specifies
– Every unit SOP will address safety
– Motor pool operations and field maintenance are linked with safety
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Minimum Areas to Address in SOP
• Duties/responsibilities for key unit personnel
• How the maintenance platoon is organized
• The Army Maintenance Management System (TAMMS) information not covered in DA Pam 750-8
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Minimum Areas to Address in SOP
• Preventive maintenance checks and services (PMCS)
– Procedures for scheduled Field PMCS
– Army Oil Analysis Program (AOAP)
– Calibration of tools and Test, Measurement, and Diagnostic Equipment (TMDE)
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Continued
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Minimum Areas to Address in SOP
• Tool accountability and control procedures
• Safety requirements to include:
– All applicable safety guidance associated with equipment maintenance
– HAZMAT and PPE
– Lifting and holding device servicing
– Chemical Agent Resistant Coating (CARC)
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Continued
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Minimum Areas to Address in SOP
• Unit maintenance training programs and requirements
• Motor pool security
• Readiness reporting
• Publications
• Work order management
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Continued
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Minimum Areas to Address in SOP
• Equipment classifications
• Battlefield damage assessment and repair/recovery (BDAR/R)
• Repair parts (Class IX) management
• Warranty Management Program
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Continued
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Minimum Areas to Address in SOP
• Army Record Information Management System (ARIMS) filing system
• Equipment winterization/extreme climate program
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Continued
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SOP Development Considerations
• Maintenance Operations
• Safety and protection plans such as:
– Fire Prevention Plan
– Ground Pre-accident Plan
• Past accidents
– Lessons learned
– Preventive measures24
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Motor Pool and Shop Safety Sample SOPs
• Army Knowledge Online (AKO)
• U.S. Army Combat Readiness/Safety Center
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Enabling Learning Objective C
• Action: Recommend precautions for hazards found within or around a motor pool and/or maintenance facility.
• Condition: During group discussions and viewing photographs of maintenance areas.
• Standard: Recommended precautions must be feasible and effective.
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Recognize Motor Pool andMaintenance Facility Hazards
• Walk around outside areas of the facility to notice:
– Surface conditions
– Use of ground guides
– Use of wheel chocks
– Protective railings
– Hazardous substances
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Ground Guides
• Required when wheeled and tracked vehicles are:
– Backed
– Moved within an assembly area or motor pool
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Ground Guides
• Will be properly trained
– FM 21-60 Visual Signals
– FM 21-305 Manual for the Wheeled Vehicle Driver
– TC 21-306, Tracked Combat Vehicle Driver Training
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Continued
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Ground Guides
• Tracked vehicle movement within an assembly area requires ground guides front and rear
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Continued
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Wheel Chocks
• Army vehicles will be equipped with properly sized chocks when:
– Vehicles are parked on an incline
– Maintenance is being performed
– Vehicle is parked and a trailer is attached
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Proper Wheel Chock?
Slope
Wheel Chock?
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This is wrong -- why?
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Protective Railings
Elevated platforms (4 feet and above) should be equipped with proper railings and work platforms
29 CFR 1910 General Industry 35
Correct OSHA required platform and railings
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Report this Hazard to be Corrected
29 CFR 1910 General Industry 36
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Hazardous Substances
Ensure:• Proper storage, storage
containers, and markings• Inventory listing of all
hazardous materials• Material Safety Data
Sheets (MSDS) are located in area
• Signs are posted
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3838
Material Safety Data Sheets (MSDS)
• Must be maintained in the work area where hazardous chemicals are stored or used
• Post an inventory list of all chemicals on-hand and MSDS
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3939
Hazardous substance?
Know What’s Stored
Secondary containment needed?
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Recognize Motor Pool andMaintenance Facility Hazards
• Walk around inside areas of facility to notice hazards associated with:– Roof leaks– Exhaust/Carbon Monoxide– Bay areas– Mezzanine storage areas– Noise exposure– Electrical– Housekeeping and general requirements
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4141
Roof Leaks
• May be common, yet still present a multitude of problems
– Slippery work surfaces
– Electrical hazards
– Health hazards
– Pests
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Exhaust / Carbon Monoxide
• Carbon monoxide poisoning may result from exhaust gases
• Avoid operating vehicles in a maintenance facility
• Use ventilation system
• Conduct annual carbon monoxide tests
42AR 385-10, 11-4k
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Bay Areas
• Pits must be fully covered when not in use
• An opening can be no larger than one (1) inch
43
4-ft hole isstill considered a pit
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Bay Areas
• When the cover is not in place
– Opening must be constantly attended by someone
– Or be protected by removable standard railings
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Mezzanine Storage Areas
• Structure must be approved by a building official
• Post sign showing the load limit and date inspected
45
Non-approvedNon-approvedstructurestructure
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4646
Unsafe Overhead Mezzanine
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Noise Exposure Surveillance Program
• When noise equals or exceeds an 8-hour time-weighted average of 85 decibels, the employer shall:
– Develop and implement a monitoring program
– Establish and maintain an audiometric testing program
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No Cover
Exposed Wiring
Broken Cover
48
Electrical
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Electrical Panels
• Each circuit on the panel must be clearly identified and prominently labeled
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Symbol for double insulated
50
Electrical Ground Protection
Plug with ground prong
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5151
Housekeeping and General Requirements
Violations result in hazards
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Exits
5252
Must provide quick, safe egress
UNSAFE!!
UNSAFE!!
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5353
Hard to Reach Safety Board
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5454
Blocked Emergency Eyewash Station
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eyewash stationeyewash station
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Blocked Again
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Requirements for Emergency Eyewash Stations
• Work areas that may require Emergency Eyewash Stations include:
– Battery charging areas
– Spraying operations
– High dust areas
– Dipping operations
– Hazardous substances dispensing areas
5656
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Eyewash Stations Accessibility
• Locate as close to the hazard as possible
– Be on the same floor as the hazard
– Not separated by a partition from the hazardous area
– Easily seen by workers
• Ensure path is unobstructed between the workstation and the hazard
5757
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5858
Work Surfaces – Water on Floor
Hazardous
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First Aid Kits
Ensure safe for use
• Inspect contents regularly
• Discard outdated items
• Refill kit
– Complete
– Current
59
Check Exp. Dates
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Display Signs
6060
“A picture is worth a thousand words”
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Personal Protective Equipment
First-line leaders should be involved in personal protective equipment (PPE) selection for their personnel
6161
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Personal Protective Equipment
• When PPE is necessary
• What PPE is necessary
• How to don, remove, adjust, and wear PPE
• The limitations of the PPE
• Proper care, maintenance, useful life and disposal of the PPE
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Enabling Learning Objective D
Action:
Identify hazards of specialized equipment and procedures.
Condition:
Given the name and/or photo of equipment or procedure used within maintenance facilities.
Standard:
Recommendations must be provided with hazard identification.
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Machine Guarding
• Recognize and control hazards
• Protect from exposure to unguarded or inadequately guarded machines to avoid:
– Amputations
– Lacerations
– Crushing injuries
– Abrasions
– Death6464
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Machine Guarding
• 29 CFR 1910 Requirements
– When blades of a ventilation fan are less than 7 feet above the floor or working level, the blades will be guarded
• Guard shall have openings no larger than ½ inch opening
6565
Continued
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6666
Machine Guarding Hazards
Not Guarded
Faulty Guarding
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Securing Abrasive Wheel Machines
67
Must be bolted to a surface area – work bench or floor
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Adjusting & Testing Abrasive Wheel Machines
6868
NOTE: Full face shields, hearing protection, and gloves must be used
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Air Compressors
• Require scheduled maintenance
– Drain water to help protect relief valve
– Avoid dangerous pressure levels
• Locate outside if possible(noise hazard)
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Compressed Air
• Air receiver shall be equipped with an indicating pressure gage
– Do not allow air pressure to exceed 30 pounds per square inch (PSI)
– 30 PSI is the maximum for cleaning
7070
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Compressed Air
• Use rubber or other insulating material for hose lines to blow out equipment
• Do not use compressed air for cleaning floors
• Do not direct air toward others or self
7171
Continued
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Lifting Devices
• Reference: TB 43-0142 Safety Inspections and Testing of Lifting Devices
– Cranes
– Hoists
– Slings
– Trucks, Forklift
– Jacks and Stands
• Inspect every 6 months
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Lifting Devices Load Testing
• Load tests will be clearly marked on the device
• Slings, wire ropes, hooks, etc., used for lifting, must be tagged with due date
• Load rating shall become a part of the maintenance records
7373
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Jack Stands and Floor Jacks
• Daily and/or before use inspections
– Ensure item is safe for use
– Follow appropriate checklist, technical manual (TM) and other information to ensure safety
• Periodic inspectionsevery 6-months
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Fork Lifts
• Train and certify operators
• Do not modify or make attachments
• Examine for defects
• Know the capacity of the truck
• Wear seatbelts
• Ensure reverse alarm works
• Avoid traveling with elevated load
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Welding Requirements
• Obtain hot work permit before welding operations
• Area must be deemed safe for welding
• Place shield to protect those passing by the area
• PPE includes gloves, apron boots head shield with protective lens
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Welding Operations
• Know what materials are being welded
• Certain metals produce fumes that produce a serious health threat to the welder
• Wear respiratory protection as needed
• No contact lens
7777
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Improper Procedures
• Missing PPE for welding
• Lack of fall protection – No :
– 3-point stand
– Guardrail system
– Guardrail system, or
– Personal fall arrest system
7878
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Compressed Gas Cylinders
• All personnel who work with or handle pressurized gas cylinders will review AR 700-68 annually
• Maintenance activities will maintain a record of these reviews
• Large number of tanks should not be stored in work areas
79
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Compressed Gas Storage
• Storage areas must be clearly marked and properly secured
• Separate cylinders by hazard class
– Flammable gas
– Nonflammable gas
– Poison gas
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Cleaning Solvents
• Use approved, environmental safe cleaning solvents
– Not highly toxic or flammable
– Consult applicable TM
• Ensure MSDS for solvent used is available
• Wear required PPE
8181
What’s wrong
What’s wrong
with this picture?
with this picture?
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Asbestos and Ceramic Fibers
• Inhaling asbestos and ceramic fibers can cause serious fibrotic lung disease and lung cancer
• Some brake shoes, clutch linings, and engine gaskets contain asbestos or ceramic fibers
• Take precautions to reduce exposure
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Working with Batteries
• Army battery program IAW AR 750-1, Paragraph 8-20
– Commanders will ensure that all battery shops are operated in an Occupational Safety and Health Organizations/ Environmental Protection Agency compliant manner
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Working with Batteries
• Charge batteries in a well-ventilated, clean, and uncluttered area
– Wear chemical splash goggles or a full face shield
• Filling Storage Batteries
– Wear acid-resistant gloves, chemical-splash goggles, rubber aprons, and rubber boots with non-slip soles
– If available, use a fume hood8484
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Storing Batteries
• Batteries must have secondary containment to prevent acid leaks
• If stored outdoors, they must have overhead cover
8585
Improper Storage
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Lockout – Tagout
• Affixed to energy isolating devices
• Prevent start up or releaseof stored energy in order to prevent injury to employees
• Prevent activating equipment while it is being worked on
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Painting Vehicles
• Minor paint operations can be conducted indoors
• Minor paint operations may be conducted outdoors
• As long as repeated operations is not more often than once a week and no more than one body panel
• Use proper PPE
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Tire Cages• Cages should not be bolted down
• Training and instructions must be provided
• Correct air hose must be used, that is, use a 10-foot extension with clip on chuck
8888
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Does Not Meet Specifications
8989
UNSAFE FOR USE!
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90
Check on Learning
Name a Commander’s responsibilities relating to maintenance facilities.
– Protecting personnel, equipment, and facilities
– Implementing safety and occupational health policies
– Integrating the composite risk management process into their mission activities
90
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91
Check on Learning
What must operators know to have a successful maintenance program?
– Operators must know how to detect and report malfunctions as well as operate equipment properly and safely.
91
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92
Check on Learning
What is the objective of the Army’s PMCS program?
– The objective is the observation of equipment performance and condition.
92
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93
Check on Learning
Name requirements regarding an open pit?
– It must be covered when not in use, constantly guarded by someone, or guarded by removable rails
93
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Summary
• Responsibilities of key maintenance personnel
• Standing Operating Procedures (SOPs)
• Precautions for hazards found within or around a motor pool and/or maintenance facility
• Hazards of specialized equipment and procedures
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95
Conclusion
Follow the standards!
Protect yourself and others!
Get the job done safely!
95