PREFACE

These "AK Steel Safety and Health Rules & Instructions"

apply to all AK Steel employees, visitors and contractors.

Your cooperation
in preventing injury and non-injury incidents
is an absolute necessity.
The success of our Safety and Health Program
requires everyone to accept the responsibility
for their own safety and the safety of their fellow employees.

"THE BEST SAFETY DEVICE KNOWN IS A SAFE WORKER "

- THINK BEFORE YOU ACT-

Updated: 8/29/14
Refer to the AK Steel Website (http://www.akst.com/newhome.htm) for the most current version of the
AK Steel Safety and Health Rules & Instructions

00

Health and Safety Policy

HEALTH AND SAFETY POLICY

AK Steel is committed to providing and maintaining a safe and healthy
workplace for all employees and any other persons who may be directly
affected by the activities of AK Steel.
Recognizing the importance and commitment to the Occupational
Health & Safety Management System, the policy of AK Steel is to:

Commit necessary resources to comply with all applicable legal

and other requirements, as well as incident prevention and
necessary continuous improvement.
Reduce and eliminate risks through safety and health procedures
and emergency preparedness programs.
Develop, implement and maintain OH&S procedures.
Evaluate on a routine basis compliance with all applicable OH&S
procedures.
Strive for continual improvement in the effectiveness of its OH&S
management efforts.

Origination Date: 6/6/2012

01
General Instructions
1.0 KNOW AND FOLLOW THE GENERAL SAFETY AND HEALTH RULES AND
INSTRUCTIONS. Plan and think of the safe way to do a job, act and work safely. Get in the
habit of asking "What If" before taking that next job step. If not sure, ask someone who knows.
1.1 Violation of any General, Plant, or Departmental Safety and Health Rules, Orders or
Safe Practices may be cause for disciplinary action.
1.2 Report all injuries, illnesses, near miss and incidents to your supervisor immediately.
1.2.1 The supervisor is responsible for investigating every incident or exposure
that occurs in his/her department, even though the /incident/exposure may not
result in personal injury, illness or property damage.
1.2.2 The investigation shall be thorough and complete to determine the root
causes of the incident and prevent a recurrence.
1.2.3 Each plant shall develop specific procedures for reference to aid in incident
investigation.
1.2.4 All involved employees are required to cooperate with management, safety
coordinators, and other people investigating any incidents or exposures. When
asked about an incident with injury/incident/exposure, provide detailed factual
information of what was witnessed.
1.2.5 Do not disturb or remove evidence at the scene of the incident or exposure
until it has been investigated.
1.2.6 Do not leave the area until you are permitted to do so by your supervisor.
Exception: If the area is unsafe or there is a risk of injury or exposure.
1.3 Emergency Reporting Procedures and Emergency Action Plan must be followed
without deviation to prevent unnecessary and possible life threatening delays.
1.4 Ambulance Emergency Actions
1.4.1 Call the Emergency Injury Number.
1.4.2 Give the Door Number.
1.4.3 Give the Grid Number or other specific plant location.
1.4.4 Give the nature of the emergency.
1.4.5 Stay on the phone! Do not hang up until told to do so by the person taking
the call.
1.4.6 Send someone to the road to meet and direct the emergency vehicles.

1.5 Fire Emergency Actions

1.5.1 Call from a safe location that is not threatened by the fire or explosion.
1.5.2 Call the Emergency Fire Number.
1.5.3 Give the Door Number.
1.5.4 Give the Grid Number or other specific plant location.
1.5.5 Stay on the phone! Do not hang up until told to do so by the person taking
the call.
1.5.6 Send someone to the road to meet and direct the emergency vehicles.
1.5.7 Go to the designated emergency assembly area.
1.6 Report all unsafe conditions, such as tools, equipment, work areas and structures, to
your supervisor immediately. These conditions shall include all existing and predictable
physical, health, and ergonomic hazards.
1.7 Be alert to the safety of visitors, new employees, contractor employees and coworkers. Do not hesitate to tell them if they are in danger.
1.8 Crossing Railroad Tracks
1.8.1 Vehicle Operators and pedestrians shall be alert when crossing railroad
tracks.
1.8.2 Cross only at designated crossing points. Stop and look both ways for
engines and rolling railroad cars before crossing railroad tracks.
1.8.3 Do not climb across the rail car couplings or crawl under a rail car.
1.8.4 The railroad has the right of way.
1.8.5 Never assume the railroad crew sees you and never attempt to beat the
railroad equipment to the crossing.
1.8.6 Never place or set anything on a rail unless permission has been provided
and/or GSO #3 requirements have been met.
1.8.7 Never step on a rail always step over it.
1.8.8 If a designated railroad crossing is protected by positive track protection, in
accordance with GSO#3, and is posted as such, then stopping at the crossing is
not required. Once the positive track protection has been removed, stopping prior
to crossing is required and shall be designated with a positive device such as a
stop sign, crossing arms, red flashing, etc.

1.9 Entering Buildings or Other Departments

1.9.1 Do not go into any department, other than your own, unless your work
requires you to do so.
1.9.2 Sign in and out as required by the department prior to entering and after
exiting the operations area.
1.9.3 When going into other departments contact the appropriate department
person at the sign in location and comply with that department's safety rules,
including the wearing of all appropriate personal protective equipment.
1.9.4 Prior to entering a building, always read and observe warning signs.
1.9.5 Always enter through designated man doors. It is permitted to enter through
a roll-up door if the door has been pinned and posted as such.
1.9.6 When entering a building, stop and look around for possible movement of
overhead cranes or other mobile equipment before proceeding. Do not assume
that crane or mobile equipment operators can see you.
1.9.7 Warning signs and warning signal systems have been established in each
department. Know and obey the signs and signals of the department where you
work and those of any department that your work requires you to enter.
1.9.8 Signals - Make sure you know the Emergency Signals and Evacuation Plans
in each department where you work.
1.10 Horseplay, startling, teasing, throwing of objects, scuffling or distracting another
employee is strictly prohibited.
1.11 Always drink from approved water coolers. Water from any other source may be
unsuitable to drink. To assure water quality, only authorized personnel are to make
repairs to drinking water lines and equipment.
1.12 Molten metal can explode when it makes contact with a wet surface, particularly
where it may entrap moisture or water. All designated equipment and areas must be dry
before using them for molten metal. Do not throw materials into vessels that may or will
contain molten metal unless directed to.
1.13 Never lean against, sit, or stand, on temporary or permanent hand railings or guard
railings of any kind.
1.14 Rain, snow, ice or over-hanging icicles may represent slipping or struck-by hazards.
When such hazards exist in your work area, report them to your supervisor immediately.
1.15 Never dispose of empty aerosol cans or gas cylinders in dumpsters or containers in
which they could end up in molten metal, scrap, or be exposed to heat.

1.16 Disposal of Propane and Calibration Gas Bottles. Depressurize each bottle to
atmospheric pressure and clearly mark the bottle EMPTY with a Semi Permanent
Marker. The bottles can then be placed into a trash disposal container, or returned to the
vendor for re-use.
1.17 Only trained and authorized employees may use fire extinguishers, fire hoses, SCBA
(self-contained breathing apparatus) and other emergency equipment.
1.18 Intercoms, PA Systems and Two-way radios are to be used for business purposes
only. Non-essential communication and inappropriate language are prohibited.
1.19 The use of cellular phones and laptop computers in operating areas is prohibited
unless authorized by your supervisor. All other personal electronic or audio/video
equipment is prohibited in operating areas or mobile equipment.
1.19.1 Cell phones and laptop computers provided by the company and used to
conduct business may be carried on the plant property and into operating areas.
Personal cell phones or laptop computers shall not be carried into any plant
operational area or mobile equipment.
1.19.2 Cell phones with photographic or video capabilities shall not used for
taking photographs or videos on company property unless authorized by AK Steel
management.
1.19.3 When operating a company-owned vehicle, rental vehicle, leased vehicle
or personal vehicle, while performing company business, drivers shall not operate
a cell phone, electronic communication device or any other electronic equipment,
that is NOT "Hands-Free" equipped.
a. The term Hands-free" equipped is defined as an attachment, add-on,
built-in feature or addition to a mobile cellular telephone that, when used,
allows the driver to maintain both hands on the steering wheel when
receiving, talking and terminating a cellular call. The hands-free accessory
can be either permanently installed in the vehicle or may be portable.
b. This rule shall apply to company-owned/issued devices or ones owned
by the employee.
c. If an employee must initiate or receive a cellular call, and their
equipment is NOT "Hands-Free" equipped, they shall drive to a safe
location and stop the vehicle prior to activating the device, remaining there
until the communication is completed.
d. If an employee must initiate or receive a text message, they shall drive
to a safe location and stop the vehicle prior to activating the device,
remaining there until the communication is completed.

1.20 Before sitting in a chair assure that it is in good repair (including all of the legs) and
that is placed on a flat level surface, with all of the legs making contact with the floor
surface.
1.20.1 While sitting in a chair, never tip the chair to cause one or more of the
chair legs to lose contact with the floor surface.
1.20.2 While sitting in a chair, never prop your feet on a surface above the level
of the seat or in any other way that will cause the chair to become unstable.
1.20.3 Never climb or stand on a chair to reach an upper surface or elevated
objects.
1.21 Never attempt to board or deboard any type of mobile equipment, vehicle, railroad
rolling stock, cranes or other mobile machinery that is in motion
1.22 Trailers (temporary, permanent office, tool, etc) and Storage Containers (Conex type
boxes)
1.22.1 Prior to staging a trailer or storage containers, a Request to Stage A Trailer
Or Storage Container Form (AKForm-01) shall be completed and requires
approval from the host Department Manager or designated representative and the
Safety Department.
1.22.2 The Request Form shall detail the proposed location, securement
procedures, utilities needed, intended use, materials to be stored (flammable,
acids, etc) and intended occupancy.
1.22.3 Prior to using the trailers or storage containers, a Safety Department or
designated representative must conduct an inspection and complete the Pre-Use
and Monthly Trailer/Storage Container Inspection Form (AKForm-02).
1.22.4 Monthly thereafter, the Pre-Use and Monthly Trailer/Storage Container
Inspection Form (AKForm-02) shall be completed by the occupants/owners and
faxed/or e-mailed to the Safety Department by the first day of the month.
1.23 Personal Vehicles
1.23.1 No open top vehicles (e.g. Jeeps, convertibles, sun roofs, etc.) shall be
driven onto plant roadway with the tops open. The vehicle tops shall be closed
before entering the gate.
1.23.2 Anyone on a motorcycle shall be wearing an approved motorcycle helmet
at all times while operating on AK Steel property.
1.23.3 Motorcycles are only permitted to be ridden and parked in AK Steel
approved locations.

1.23.4 If a personal vehicle becomes disabled on AK Steel property, employees

are not permitted to work on the vehicle, but must call an (outside) Road Service
to respond.
1.23.5 No personal trailers, boats, campers, etc allowed on property.
1.24 The use of prescription medication issued to you by your personal physician may
impair your ability to safely perform all parts of your job.
1.24.1 Medication, which causes drowsiness, reduced alertness or clarity of
thought, or slowed reaction times, can pose a serious threat to your personal
safety and to the safety of your fellow workers. Examples of medication, which
can have that effect, include, but are not limited to, mood altering drugs and
narcotic pain management drugs.
1.24.2 If you are currently taking or will be taking a medication with these or
similar side effects, or that instructs you not to drive or operate machinery while
taking, you must promptly notify the plant medical department or the Human
Resources department, for the locations without a medical department, for review
of the potential impact to your safety on the job. In appropriate circumstances, as
determined by the medical department, the Safety Sensitive Form will be
completed to assure that a safety sensitive prescription is not taken within six (6)
hours of starting work or during the work turn.
1.24.3 In addition to the use of prescription medication, other factors could also
impair your ability to safely perform all parts of your job. These factors include
emotional, mental, physical, or health related issues. If you are experiencing any
such factors that could impact your ability to safely perform your job, you must
promptly notify your supervisor for appropriate review of the situation.
1.25 Hazard identification. The use of temporary YELLOW Caution Tape and RED
Danger tape shall be used to control access to areas of the facility where hazards have
been identified.
1.25.1 RED Danger tape shall be used to limit access to areas where a hazard has
been identified or where hazardous activity is taking place. ONLY Authorized
Employees may enter RED Danger tape areas.
a. For the purpose of this section the term Authorized Employee means
employees that have been assigned a task to perform in the taped off area;
have been trained in the hazards associated within the area and have the
proper PPE to enter the area.
b. If the hazardous area cannot be completely encompassed with red
danger tape, a safety attendant shall be stationed at the opening to control
access to the area.

c. A safety attendant assigned to control entry into the Red Danger tape
area shall wear reflective clothing for identification and have an air horn
or other device to warn unauthorized people away from the area.
d. When RED Danger tape is used to establish an overhead work zone,
NO ONE is permitted inside the overhead work zone UNLESS all
overhead hazards that have the potential to fall or be dropped have been
secured.

1.25.2 YELLOW Caution tape shall be used to identify hazards or activities that
are less hazardous than RED Danger zones.
a. You may proceed with caution through YELLOW Caution zones if you
have a specific need to do so.
b. When entering any restricted area you MUST be aware of your
surroundings, paying special attentions to the hazards within the area.

1.26 Safety Task Assessment (STA) Cards

1.26.1 STA Cards are required for the following situations
1.26.1.1 A job specific written procedure does not exist, or
1.26.1.2 The job deviates from the existing written procedure, or
1.26.1.3 A new hazard is introduced into the job that was not identified in
the original written procedure

1.26.2 Cards shall be completed at the job site by the work group, reviewed by the
group and then signed by a manager or a crew chief before work commences.
1.26.3 Additional employees arriving after the job has started shall review the
STA Card and sign it.
1.26.4 Completed STA Cards shall be turned into the Shift Manager at the
completion of the job.
1.26.5 Jobs that are performed more often than once per month shall have a JSHA
developed for that specific job.
1.26.6 Any conditions or new hazards that were not initially identified on the
original STA card require a revision to the STA card and review by the work
group before work continues.

02

Housekeeping
2.1 Housekeeping is everyone's responsibility. The Departmental Program will give
specific details on housekeeping assignments for your job.
2.2 Keep your work area clean and clear. Pick up and dispose of debris as it accumulates.
Return hand tools and equipment to their proper storage places when finished with them.
2.3 All work areas including passageways, storage areas and service rooms are to be
maintained in a clean and orderly manner and free of debris and in a sanitary condition.
2.4 Keep all walkways, aisles, stairs, and platforms clear of obstructions. Do not pile
materials in any area where people must walk. Be sure that materials which are stacked or
piled near walkways do not project into aisles, stairs or platforms and that they are
properly stacked so they will not topple or fall.
2.5 Do not obstruct access to emergency exits, fixed ladders, stairways, electrical
switches, shutoff valves, fire fighting or rescue equipment and safety eyewash fountains
or safety showers. Do not store any material in, on, or in front of switch boxes or other
electrical equipment.
2.6 Keep floors clean and clear. Clean up oil, grease, water and other liquids which can
cause slips or falls.
2.7 When you have completed repair, construction, or maintenance work of any kind,
take time to clean the area. Pick up and remove all waste and salvaged materials. Return
all hand tools and equipment to proper storage. Remove all loose objects after completing
overhead work. Replace all covers, guards and/or access panels.
2.8 Oily, greasy rags must be deposited in designated and properly marked, closed
containers to prevent spontaneous combustion.
2.9 Containers shall be provided for the collection and separation of waste, trash, and
other refuse. Containers used for garbage, oily, flammable, or hazardous wastes (such as
caustics, acids, harmful dust, etc.) shall be equipped with covers and labeled. Garbage
and other waste shall be disposed of at frequent and regular intervals. Never dispose of
trash or non-metallic waste in scrap metal containers.
2.10 Construction materials of all kinds will be stored in an orderly manner while work is
in progress. Scrap lumber, pieces of pipe, conduit, metal, and all other debris shall be
kept clear of work areas, passageways, stairs, and from around buildings or other plant
structures.
2.11 Wooden construction material (i.e.: scaffold boards) shall have the AK Department
or Contractor company name stenciled or stamped onto the wood. Nails protruding from
lumber shall be removed or re-driven. Wear gloves and avoid sliding hands when
handling lumber.

2.12 When working with, moving or cleaning materials such as metal, wood, glass, etc.,
do not use your hands, forearms, or other parts of your body to remove slag, slivers,
chips, dust, etc. from materials or surrounding areas. The appropriate brush, broom,
scoop, hammer, etc. is to be used for surface preparation and/ or cleaning.

03
Personal Protection
3.0 Personal Protective Equipment
3.1 General Requirements
3.1.1 AK Steel employees are responsible for the inspection and proper use of all
Personal Protective Equipment (PPE) issued to them.
3.1.2 Alterations of personal protective equipment in any way are strictly
prohibited.
3.1.3 Always inspect the PPE before use and replace if needed. Report defects to
AK Steel Management immediately.
3.1.4 The Job Safety and Health Analysis (JSHA), Safety Task Assessment (STA)
card or Department Rules, shall specify the PPE required for each job. If the PPE
is not identified, contact AK Steel Management to confirm PPE requirements
before starting the task or if the tasks conditions have changed and may require
additional PPE.
3.1.5 AK Steel employees visiting outside processor and/or vendor manufacturing
facilities are required to wear helmets, safety glasses with side shields, longsleeved shirts, ATA sleeves and metatarsal guarded boots. Additional personal
protection, such as hearing protection, must also be worn if required by the
facility.
3.1.6 AK Steel employees are not permitted to use PPE on AK Steel property that
were not approved and provided by AK Steel.
3.1.7 AK Steel employees shall always practice good personal hygiene is a
requirement in all jobs for theirs and their co-workers safety and health.
3.1.8 Employees with shoulder length or longer hair shall wear it tucked up and
under the protective helmet to avoid being caught on projections or being caught
in moving machinery.
3.1.9 Employees with facial hair (beards) extending below the upper edge of the
collar with the head held up right shall either trim the facial hair so that it does not
extend below the upper edge of the collar or tie and bind the beard into a single
strand and tuck it into the shirt front
3.2 Protective Helmets
3.2.1 Only AK Steel approved Protective helmets conforming to ANSI Z-89.1
Industrial Standard shall be worn by AK Steel employees. Your protective helmet
shall be worn:

i. With bill to the front.

ii. Without altering or wearing anything that would affect the suspension
system.
iii. Hats (e.g. baseball type hats, tossle caps, toboggans, etc.) that may affect
the fit of the helmet shall not be worn under the protective helmet. AK
approved welders caps are permitted to be worn under the helmets.
iv. Without painting, drilling, or otherwise altering the helmet shell.
v. With long hair tucked up and worn under the protective helmet. Hair shall
be considered long when it hangs to the shoulder.
vi. With your first and last name printed or labeled onto the front of the
helmet.
vii. The use of any other decal, sticker, or writing shall first be approved by
AK Steel Management.
viii. With reflective safety tape as follows:
At least a three (3) inch long strip on each side of the helmet placed
approximately one (1) inch up from the brim of the hat.
At least a three (3) inch long strip on the back of the helmet placed
approximately one (1) inch up from the brim of the hat.
3.2.2 Helmets cracked, chipped, burnt, or otherwise damaged shall be taken out of
service immediately.
3.2.3 Employees shall wear a helmet when operating or riding in powered
industrial or construction type mobile equipment, (i.e. forklifts, mobile cranes,
Euclid, front end loaders, motorized utility vehicle, etc.).
3.2.4 A red flashing light mounted on the hard hat near the top center is required
to enter designated coil fields, low visibility situations and/or as specified in
JSHA. (e.g. roll storage racks, slab yards, batch annealing operations, etc.)
3.3 Metatarsal Boots
3.3.1. Only AK Steel approved six inch or higher, hard toed, leather safety boots
with permanently attached or internal rigid metatarsal guards conforming to ANSI
Z-41 Industrial Standard in good repair, properly laced and tied shall be worn by
AK Steel employees.
3.3.2. AK Steel employees are only permitted to obtain metatarsal boots through
AK Steel approved metatarsal boot vendors.
3.3.3. AK Steel employees shall not wear slip-on, zippered or other non-approved
metatarsal boots unless specified in a JSHA and approved by the Plant Physician.

3.3.4. Rubber type metatarsal boots are not permitted unless required by the
JSHA.
3.3.5. Temporary metatarsal guards are not permitted.
3.4 Safety Glasses
3.4.1 Only AK Steel approved safety plastic framed glasses with permanently
attached side shields which meet the ANSI Z.87 Industrial Standard shall be worn
by AK Steel employees.
3.4.2 AK Steel employees are only permitted to obtain prescription safety glasses
through AK Steel approved eye glass vendors.
3.4.3 Additional eye protection, such as face shields, welding helmets, goggles,
etc., may be required for specific jobs. Always wear the type of eye protection
prescribed for the job as specified by the JSHA.
3.4.4 Employees operating or riding in fully enclosed crane cabs or mobile
equipment with all windows closed are not required to wear approved safety
glasses unless directed to do so by a specific JSHA.
3.4.5 Employees operating or riding in open cab cranes or mobile equipment with
open windows shall wear approved safety glasses.
3.4.6 Safety eyewear retainers (chums) or cable guards shall be worn to obtain the
best possible fit of the safety glasses/goggles to the face to maximize the
protection of the eyes.
3.4.7 Sunglasses, photo-sun, etc. are not permitted to be worn inside the plant.

i. Exceptions require, documented in writing, a medical condition by the

employee's doctor and approved by the Plant designated Physician and the
Safety Department.
ii. Employees performing tasks identified in the JSHA requiring dark
lenses shall be provided the appropriate clip-ons, flip downs, goggles, face
shields, or hoods.

3.4.8 Employees with vision in one eye only, or who are considered industrially
blind in one eye, shall wear approved eye protection at all times while on plant
property.
3.5 Face Protection
3.5.1 Only AK Steel approved face shields which meet the ANSI Z.87 Industrial
Standard shall be worn by AK Steel employees.

3.5.2 The material constructing the face shield shall be selected based on the
potential hazard. Solid material (polycarbonate, acetate, etc.) face shields shall be
worn when the hazards is either liquid, molten, arc flash or steam.
3.5.3 The face shield shall be designed to fit the face shield bracket without
modifying the bracket and/or face shield
3.5.4 Face shields shall be worn in addition to approved safety glasses or goggles.

3.5.5 A face shield shall be worn if the work activity includes one or more of the
following hazards:

i. Handling metal or plastic banding while banding coils or other

materials, picking up and carrying loose bands or when cutting bands from
coils, bundles, pallets, etc. (> 6 inches in length).
ii. Employees within an arms' length of metal ends, samples, scrap or other
materials that can whip or spring, striking the face (e.g. edge trim, weld
scarf, scrap bales, flashing).
iii. Handling full width samples or scrap.
iv. Exposure to flame, sparks, radiant heat, ultraviolet radiation (welding)
or arc flash.
v. Exposure to molten metal (zinc, aluminum, steel, iron, etc.).
vi. Exposure to acidic, caustic, hot and/or cryogenic fluids
vii. Spraying with pressurized (>25 psi) liquids and mixtures. (e.g.
refractory gunning, pressure washing, fire hose cleaning, abrasive blasting,
use of garden type hose, etc).
viii. Exposure to steam.
ix. When performing work that could cause deposited dust or metal fines
to drop down onto the employee(s).
x. Discharging fire extinguishers
xi. Grinding, chipping, striking or cutting operations that cause flying
sparks, chips or particles.
xii. While troubleshooting and/or performing maintenance on hydraulic,
pneumatic, steam, or any other line that is under pressure.

xiii. As required by the JSHA, STA or department rules.

3.5.6 When working in chemical areas where the procedure requires a chemical
barrier suit, the face shield shall be equipped with a chin cup protector to enhance
protection to the face and neck. In addition, goggles shall be worn under the face
shield for added protection to the eyes.
3.5.7 Employees assigned as a Fire Watch, Safety Watch or Confined Space
Attendant shall wear an appropriate face shield in the down position when
potentially exposed to the aforementioned hazards (i- xiii)
3.5.8 The Fire Watch shall also wear a face shield when the use of a fire hose or
fire extinguisher becomes necessary.
3.6 Respiratory Protection
3.6.1 Only AK Steel designated NIOSH approved respiratory protection shall be
worn by AK Steel employees.
3.6.2 If wearing a respirator is required, you must be medically evaluated, fit
tested and properly trained.
3.6.3 To ensure an adequate seal and proper function of the respirator, facial hair
or stubble shall be trimmed or shaved to conform to the AK facial hair policy of
less than 1 day of growth is permitted.
3.6.4 Employees shall inspect their respirators prior to use.
3.6.5 Employees shall conduct field verification (positive and negative) fit checks
prior to entering the respiratory required work area.
3.6.6 Voluntary use of respiratory protection requires the employee to be provided
a copy of Appendix D to Sec. 1910.134 (Mandatory) Information for
Employees Using Respirators When Not Required Under the Standard.
3.7 Aluminized Clothing
3.7.1 Only AK Steel approved aluminized clothing shall be worn by AK Steel
employees.
3.7.2 Approved aluminized jacket, completely buttoned, shall be worn to protect
the torso, arms and upper legs from radiant heat, molten metal and sparks or as
required by a JSHA and/or department rules and shall extend at least 2 inches
over the aluminized spats.

i. Approved aluminized spats shall be worn to protect from the top of the

foot to the knee from radiant heat, molten metal and sparks or as required
by a JSHA.
ii. The spats may be worn under the outer garment or over the outer
garment in the following manner:

a. Aluminized spats worn under approved flame retardant pants or

coveralls shall be worn over approved long underwear or long
stockings to provide additional protection from the hot work
hazards and to prevent skin irritation.
b. Aluminized spats worn over approved flame retardant pants or
coveralls shall have a minimum of one inch of the pant leg
blousing out and over the top of the main body section of the
leggings
3.7.3 Approved aluminized jacket, completely buttoned, shall be worn to protect
the torso, arms and upper legs from open, unprotected flames whenever the
employee is required to be within one arms length of the flames or as required by
a JSHA.
3.7.4 Approved aluminized jacket with reflective tape with hood, completely
buttoned and hood over helmet, shall be worn to protect the head, neck and torso
of the railroad crew within 30 feet of torpedo cars transporting molten iron.
3.7.5 The aluminized jacket requirements do not apply to burning or brazing with
a hand torch or hand held welding or air arcing unless specifically required by a
JSHA.
3.7.6 Approved aluminized neck shroud shall be properly worn in conjunction
with an approved face shield and Nomex type hood when there is a molten metal
splash hazard or as required by the JSHA.
3.7.7 Approved aluminized beehive type hood shall be worn when the
combination of a face shield, aluminized shroud and Nomex type hood does not
provide adequate protection from exposures to molten metal, sparks, radiant heat,
flame and/or steam or as required by the JSHA.
3.8 Hand Protection
3.8.1 Only AK Steel approved hand protection shall be worn by AK Steel
employees.
3.8.2 Before handling any object, substance, or tool, approved hand protection
shall be selected and worn to provide the required level of protection.

3.8.3 Hand protection shall be selected based on an evaluation of the performance

characteristics of the equipment relative to the job tasks to be performed and the
type of hazard/hazards associated with the tasks.
3.8.4 Approved and designated cut resistant gloves shall be properly worn when
the employee is within an arms length of cut hazard from coils, metal strips,
banding, scrap, etc. or as directed by the JSHA or Department Rules.
3.8.5 Approved and designated puncture resistant gloves shall be properly worn
when handling wire rope, wire slings or other materials with a potential puncture
hazard or as directed by the JSHA or Department Rules.
3.8.6 Hand protection shall be designated in a JSHA, on a STA card or by
Department Rules and shall be worn as required.
3.8.7 If you are unable to determine proper hand protection for a task, your
supervisor will determine and provide the proper protection.
3.8.8 Hand protection shall be worn as designed by the manufacturer and shall not
be altered from the original design.
3.8.9 When wearing gloves it is not permissible to turn the glove cuff down or to
cut the glove cuff off.
3.9 Arm Protection
3.9.1 Only AK Steel approved arm protection shall be worn by AK Steel
employees.
3.9.2 All AK Steel employees, contractors, and service providers, in all operating
and maintenance areas (both inside and outside of buildings), are required to wear
ATA sleeves. (Rule-of-Thumb: "If hardhat and/or safety glasses are required, then
so are ATA Sleeves")
3.9.3 ATA sleeves are not required in offices, lunchrooms, locker rooms,
restrooms, company or personal vehicles, and cabs of overhead cranes unless
required by JSHA.
3.9.4 Requests for exceptions for wearing ATA sleeves shall be submitted in
writing for review by the Plant Manager and the Safety Manager. If the exception
is granted, specific details shall be documented in all appropriate JSHA's.
3.9.5 ATA sleeves shall be worn with the thumb through the thumbhole and
finger(s) through the finger hole(s) and worn under gloves.
3.9.6 The ATA sleeve must be extended to the shoulder, where they shall be
secured with the clips in such a manner that the ATA sleeve will remain extended
to the shoulder area.

3.9.7 Specific tasks may require the removal of the metal ring/clips. Any/all
exceptions:

i. Requires review and approval by the Safety Department.

ii. Shall be documented in the appropriate JSHA's.
3.9.8 Employees performing any electrical work that requires Arc Flash PPE shall
use the plastic clips on the ATA Sleeves
3.9.9 Employees performing tasks that require an aluminized jacket may remove
the metal ring/clips on the ATA sleeves prior to donning the aluminized
jacket/coat.
i. Immediately upon completion of the task that requires an aluminized
jacket, the metal ring/clips shall be replaced and properly clipped in order
for the ATA sleeve to remain extended to the shoulder area.
3.10 Torso and Leg Protection Cut Protection
3.10.1 Only AK Steel approved torso and leg protection shall be worn by AK
Steel employees.
3.10.2 Full length cut-resistant chaps shall be worn when cutting or handling
metal strip, banding, metal scrap or metal sample pieces or as required by a
JSHA.
3.10.3 Full length cut-resistant chaps shall be worn whenever the employee is
within an arms length of coils, metal strip, scrap, banding, or other similar cut
hazards.
3.10.4 Full length cut resistant chaps shall be worn when walking/working in
designated coil fields or as required by a JSHA.
3.10.5 Cut-resistant aprons shall be worn when there is a potential to strike the
torso against protruding metal strip, scrap, banding, or other similar cut hazards or
as required by a JSHA.
3.10.6Aprons shall not be worn when there is a potential of being caught in
machinery.
3.11 Flame Retardant / Flame Resistant Clothing
3.11.1 Only AK Steel approved flame retardant / flame resistant clothing shall be
worn by AK Steel employees when in or exposed to:

i. Hot Metal Areas

ii. Annealing Areas

iii. High Radiant Heat
iv. Open Flames
v. Burning, Cutting, and Welding Activities
vi. Electrical Activities with Arc Flash Potential
vii. Operations designated by the Plant or Department Rules.

3.11.2 Flame retardant / flame resistant clothing must be laundered in an approved

and controlled manner to prevent damage to the garment that will reduce the
flame resistant performance.
3.11.3 Flame retardant / flame resistant clothing shall not be home laundered.
3.11.4 Insulated underwear and outerwear, when worn around sparks, molten
metal, high radiant heat devices, etc., must be fire resistant natural fiber (cotton,
wool, denim) or an approved fire retardant material.
3.11.5 Synthetic clothing including under clothing, that is not made of approved
fire retardant or fire resistant materials, shall not be worn in hot metal areas or
when exposed to burning, welding, flame, high radiant heat areas or potential arc
flash.
3.12 Miscellaneous PPE Requirements
3.12.1 Only AK Steel approved Green High Visibility vests shall be worn by AK
Steel employees when performing the following tasks:
i. Safety Lookouts
ii. Spotters
iii. Safety Watch
iv. Lock-Out Coordinator
v. Fire Watch
vi. Confined Space Attendants
vii Specified in the JSHA
3.12.2 Only AK Steel approved High Visibility Clothing shall be worn by AK
Steel employees when performing the following tasks:
i. In Coil Fields
ii. All crews working on or about the railroad
iii. Specified in the JSHA

3.12.3 Employees working or occupying an area within 10 feet of a body of water

which is 4 feet or more in depth and not protected by a standard guardrail system,
must wear a U.S. Coast Guard approved Life Jacket.

04

Personal Clothing/Jewelry
4.1 Employees bodies shall be covered during work hours to comply with department and
plant regulations. Only approved apparel, worn in the proper manner shall be permitted in
the plant.
4.1.1 Trousers must extend at least to the ankles.
4.1.2 Long sleeved shirts are required in all operating areas with the sleeves down
and buttoned at the wrist. The shirt shall be tucked into the trousers and fully
buttoned up the front to the first button below the collar button. The collar button
shall be buttoned when directed by specific Department Procedures.
4.1.2.1 Exceptions to this rule, permitting rolled up long sleeves in
operating areas (such as Machine Shops), shall be documented in writing
and approved by the Plant Manager and Safety Department.
4.1.2.2 This rule does not apply to non operating areas such as office
areas, break rooms, general office buildings, etc.

4.2 Work clothes shall not be cleaned in flammable liquids, such as gasoline, kerosene, or
similar fluids.
4.3 Do not wear clothing that is loose fitting, torn, or ragged, too long (pant legs/shirt
sleeves) or with attached hoods (i.e. hooded sweat shirts) to avoid being caught on
projections or in moving machinery.
4.3.1 Hooded outer clothing required by a JSHA or approved by your supervisor
(i.e. hooded aluminized coats, hooded rain coats) shall be worn as specified in the
JSHA.
4.4 Wearing of finger rings, loose-fitting wrist bracelets, exposed dangling necklaces, and
earrings, other than stud type earrings, is prohibited in all operating areas.

05

Use & Care of Hand Tools

5.1 All hand tools must be inspected each time before use. A documented hand tool
inspection will be performed monthly. Mushroomed, cracked, or chipped heads and
rough, splintered or badly worn handles must be turned in for repair or replacement.
Never use a defective tool or leave defective tools where others might use them.
5.2 If you use your own personal tools, repair or replace them as soon as they become
worn or defective. All tools are subject to periodic inspection by supervision and must be
replaced or repaired if found to be unsafe.
5.3 Use the right tool for the job and keep tools clean. Never use tools and equipment for
purposes for which they were not designed or intended.
5.3.1 Proper sized socket wrenches, box end wrenches and/or open end wrenches
shall be used to assure the maximum possible purchase (grip) when
loosening/tightening fastening
devices. Consideration shall also be given to hand and body position in relation to
potential pinch points when selecting the appropriate tool for the job.
5.4 Tools shall be transported in tool boxes, tool belts, tool pouches, etc. designed for
such use. Do not carry hand tools in pants or shirt pockets.
5.5 Never throw tools, equipment, or parts from one location to another, from one
employee to another, or from one level to another level.
5.6 Do not leave tools, equipment, or materials in elevated places from which they may
fall or be knocked off.
5.7 Maintain secure footing and balance, and position yourself while applying pressure
on a wrench or other tool, so that you won't fall if the tool suddenly moves or slips from
its bite. When possible grasp something that is firmly secure with your free hand to assist
in maintaining your balance. Always work away from your body and away from coworkers. If necessary reposition yourself and co-workers out of the working path of the
tool.
5.7.1 Hands shall not be used to hold or position a tool or object that is being
hammered by another employee. Holding tools, jigs, or other positioning devices
must be used for this task.
5.7.2 Hands shall not be used to hold a chisel, punch, or any other tool that is
being struck by a hammer. A holding tool, with a handle extension, specifically
designed to hold a chisel, punch, etc. shall be used whenever striking or
hammering.
5.7.3 Hand Tools (i.e. channel locks, vice grips, pliers) not specifically designed
to hold a chisel, punch or other hammered tools shall not be used for this purpose.

5.7.4 Holding tools with long handle extensions and hand guards shall be used
when striking the chisel, punch, etc. with a sledge hammer and/or when the
striking angle creates an additional hazard to the hand.
5.8 Do not force tools beyond their capacity or use "cheaters" to increase their capacity.
5.9 Do not fabricate hand tools. Do not modify or in any way alter the design of existing
hand tools.
5.10 Only AK Steel Safety approved lock blade pocket knives are permitted in the plant.
Always cut in the direction away from yourself. Kevlar gloves or kevlar lined leather
gloves and ATA sleeves must be worn when cutting with a pocket knife.
5.10.1 Wire stripping tools shall be used when preparing electrical wire.
5.10.2 Alternate tools, other than open blade knives, shall be used to cut materials
whenever possible.

06

Powered Hand Tools & Fixed Equipment

6.1 All powered tools and equipment must be inspected before each use. All tools must
be physically and mechanically sound, and appropriate for the job. If any defects are
detected, the tool must be removed from service immediately. Only properly trained and
authorized personnel are permitted to operate these types of equipment.
6.2 Electric tools or equipment with broken three-prong grounding plugs must be
replaced or repaired before use.
6.3 Double insulated portable electric tools must be identified as double insulated so they
will not be confused with grounded tools. All portable cord and plug electric tools must
be connected to G.F.C.I. (Ground Fault Circuit Interrupter).
6.4 Electrical power tools are not to be used in hazardous locations as defined by the
National Electric Code unless the tool is approved for service in that environment.
6.5 Guards, shields or safety devices specifically designed for portable power tools must
be installed before use. Never use tools and equipment when guards, shields or safety
devices are defective or have been removed. Report the condition to your supervisor
immediately.
6.6 Temporary electric extension cords must be of the three wire type and shall be
designed for industrial usage.
6.6.1 Temporary electric cords must be inspected for kinks, worn insulation, and
exposed strands of wire before use.
6.6.2 Temporary electric cords must be protected from physical damage and
installed to be out of walkways, stairways, aisles, and areas where they present a
trip hazard.
6.6.3 Temporary electric cords must be protected by G.F.C.I. (ground fault circuit
interrupters).
6.6.4 Temporary work lighting must be protected by G.F.C.I. (ground fault circuit
interrupters) and shall be protected from accidental contact or breakage.
6.7 Pneumatic Power Tools and Hose. Pneumatic power tools must be connected only to
designated plant air lines. They shall be secured to the hose by a positive means to
prevent the tool from becoming accidentally disconnected. Safety clips or retainers shall
be installed on pneumatic tools to prevent the attachments from flying off. When you are
finished with air-powered tools, disconnect the air hose, and release the air in the tool by
pressing the trigger.
6.7.1 All hoses, fittings, and clamps must be of specific design for the use of
pneumatic power tools and follow manufactures recommendations for their

assembly. Automotive radiator type hose clamps are not permitted on air hoses.
6.7.2 Pneumatic hose sections must be wired together at each coupling
connection.
6.8 AK Steel approved safety glasses with eyewear retainers and a faceshield in the
down position must be worn when using air operated drills, jack hammers, grinders,
sanders, and cut-off saws.
6.9 Compressed Air - Never direct compressed air toward yourself or anyone else for any
reason. Never connect, or allow others to connect, to plant air as a source of breathing air
unless it is connected through an approved breathing air purification system.
6.9.1 Compressed air used for cleaning purposes shall not exceed 30 PSI and then
only with effective chip guarding, personal protective equipment and a face
shield.
6.9.2 Never hook up to an unidentified line.
6.9.3 Never use compressed air to clean your person, clothing being worn, or that
of another person.
6.10 Never use fixed or portable grinders without the use of protective shielding and
proper eye protection. A pedestal grinder tool rest must not be more than 1/8" away from
the grinding wheel and the upper tongue guard not more than 1/4" from the grinding
wheel.
6.10.1 Prior to mounting, all grinding wheels shall be inspected for damage by a
trained and authorized person. This inspection will include a ring test when
appropriate.
6.10.2 The spindle speed of the machine shall be checked before mounting of the
wheel to be certain that it does not exceed the maximum operating speed marked on
the wheel
6.10.3 You should not use any grinding wheel unless you have been properly
instructed in its use and authorized by your supervisor.
6.10.4 Gloves and loose clothing (including ATA sleeves) shall not be worn when
using a pedestal or bench grinder. The handling of sharp or hot material before or
after grinding will require gloves or a tool.
6.10.5 When grinding with a pedestal or bench grinder:
i. Start the grinder and allow it to reach full speed. Never stand directly in front
of a grinder while it is coming to full speed.
ii. Slowly start grinding the piece and keep both hands a safe distance from the
grinding wheel. An alternative means of holding the piece (e.g.: vise grips,
channel locks, fixtures) shall be used if the hands cannot be positioned a safe
distance from the wheel.

iii. Grind on the face of the grinding wheel, not on the sides.
iv. When finished grinding, turn the grinder off and observe that the wheels are
slowing to a stop before leaving the area.
6.11 Hydraulic powered tools and jacks are required to be visually inspected before and
after each use.
6.11.1 Hydraulic powered tools and jacks shall have a documented thorough
inspection every 6 months. The inspection records will be maintained in the
department for the life of the tool or jack.
6.11.2 Hydraulic powered tools and jacks shall be permanently marked with a
department number and identification number.
6.11.3 The rated load shall be legibly and permanently marked in a prominent
location on the jack.
6.11.4 Hydraulic powered tools and jacks shall not be used in a manner that will
exceed the rated load or any other capacity of the tool.
6.12 Powered equipment being refueled must be attended the entire time during the
fueling process.
6.12.1 All fuel loading nozzles on AK Steel property shall have the trigger hold
down rack removed.
6.12.2 No object shall be placed in the handle that will defeat the automatic shutoff at any time during the fueling.
6.13 Powered hand tools equipped with side handles shall be operated with both hands
holding the tool to control kickback or twist. Do not use the tool if the handles are
defective or missing.
6.14 When using powered hand tools, the work piece shall be mechanically secured to
prevent movement while cutting, drilling, grinding etc.
6.15 When using fixed powered tools, the work piece shall be mechanically secured to
prevent movement; or the work piece shall be held/controlled using appropriate hands
free tool specified in the JSHA.
6.16 Gloves, loose clothing and ATA sleeves shall not be worn when operating powered
fixed equipment, such as drill presses, milling machines, lathes, pipe threaders or other
rotating equipment, where the point of operation, ingoing nip points or caught-on hazards
are accessible (within arm's reach) to the operator.
6.16.1 The requirement (i.e. specified by the equipment manufacturer) shall be
documented in writing and approved by the Plant Manager and Safety
Department.

6.16.2 Equipment that does not have adequate protection of the point of operation,
ingoing nip points or caught-on hazards shall have an established red zone around
the powered fixed equipment a minimum of 5 feet from the hazards. The red zone
along with signs shall clearly communicate to all employees the requirements
pertaining to gloves, loose clothing, ATA sleeves, long sleeve position, etc. while
the equipment is operating.
6.16.3 Gloves and ATA sleeves are required before or after machining when
handling any sharp and/or hot objects, such as drill bits, milling bits, cutting tools,
etc. and when handling the work piece being machined. The powered fixed
equipment must be shutoff and come to a complete stop prior to putting gloves
and ATA sleeves on and attempting to change the machining tool,
removing/repositioning the work piece or cleaning the machine.
6.16.4 Each operating fixed equipment shall be posted with a sign that indicates:
i.
ii.
iii.
iv.

Do Not Operate unless Trained on JSHA #_______

Review JSHA and PPE requirements prior to use
Do not use if guards, shields or safety devices are defective or missing
Work piece shall be mechanically secured or shall be held/controlled using
the appropriate hands free tool specified in the JSHA.

6.16.5 Maintenance activities require the powered fixed equipment to be shut-off

and LOTO and the employees performing the maintenance shall wear the
appropriate gloves and ATA sleeves.
6.16.6 Requests for exceptions of the aforementioned rules shall be submitted in
writing for review by the Plant Manager and the Safety Manager.

07

Walkways, Work Areas, Roadways, Stairs & Doors

7.1 Follow designated walkways and aisles to and from work. Walk, don't run. Be alert
for moving vehicles. Look where you are going. Do not walk backward. Always glance
at the walking surface ahead of you. Look both ways before crossing roads or railroad
crossings or tracks.
7.1.1 Employees shall have on their person an operable flashlight when entering a
basement, pit, or any area that may have insufficient lighting, poorly distributed
lighting and/or no emergency lighting.
7.1.2 Locations requiring employees to have on their person an operable flashlight
shall be posted with a sign indicating this requirement.
7.2 Driving your personal vehicle on company premises is a privilege. Do not abuse the
privilege by making unauthorized trips, speeding, reckless operation, or parking in an
unauthorized area. The driver and all passengers must wear safety seat belts while driving
in the plant and whenever driving outside of the plant while on company business. For
your own safety, wear your seat belt at all times while driving.
7.2.1 Do not make or take a cellular phone call or text message while driving your
personal vehicle or any company vehicle on company property. If using a cell
phone in your vehicle is necessary, pull off the road to a safe location
to make or take the call.
7.3 Use stairways and walkways as provided. Do not take short cuts through stocking
areas, over run-out tables or conveyors, or through any posted restricted areas.
Go around or use cross-over walkways where they have been provided. Do not climb
over handrails or equipment.
7.3.1 Designated storage/stocking areas shall be provided with adequate
walkways to permit passage through and/or access to the materials in the
storage/stocking areas.
7.3.2 Designated storage/stocking areas and walkways shall be marked using
paint, stanchions/chains, signs, etc. The designated walkways shall not be blocked
or obstructed by materials or equipment.
7.4 When walking on or alongside roadways, walk facing oncoming traffic. Be constantly
alert for vehicle traffic. Move to the side, do not force a vehicle to swerve to avoid
striking you.
7.4.1 When walking to and from the gates or locker rooms to your work location,
approved and authorized walkways must be used.

7.5 Use handrails when going up or down stairs. If carrying an object, one hand must be
free for the handrail. Walk, do not run. Do not go up or down more than one step at a
time.
7.5.1 Do not descend stairs backwards unless the JSHA for the job conditions
requires it.
7.5.2 If directed by the JSHA to descend stairs backwards, step cautiously to the
next level and maintain a 3-point touch using handrails, grab irons or other similar
hold devices at all times while descending.
7.6 When walking along conveyor ramps and inclines maintain your balance and use
handrails to assure that you do not come in contact with moving machinery or belts.
7.7 When coming out of buildings adjacent to roadways, be extremely cautious to avoid
being struck by an approaching vehicle. Always look both ways before stepping onto the
roadway.
7.8 Overhead Roll-up Doors
7.8.1 Entry/Exit man doors shall be used for routine entry or exit of buildings.
Roll-up doors shall only be used when there is no entry/exit man door present.
Never attempt to pass under a roll-up door while it is in motion.
7.8.2 Electrically operated overhead roll-up doors shall not be operated manually
unless directed to do so by management. The JSHA for opening and closing
overhead roll-up doors must also be reviewed before performing the work.
7.8.3 When attempting to electrically operate a jammed overhead roll-up door,
one or more safety lookouts shall be positioned to assure the area under the door
is clear.
7.8.4 When manually opening/closing, or performing maintenance on an overhead
roll-up door, a fork lift, or other appropriate mechanical equipment, shall be used
to control the unexpected movement of the door.
7.9 When entering dark or dimly lit buildings from the outside, allow sufficient time for
your eyes to adjust to become accustomed to the light change. Observe the interior of the
building in all directions to determine crane movement, mobile equipment movement and
any other potential hazards before proceeding.
7.10 Hazardous Locations - shall be defined as a location in the operating areas where
identifiable hazards exist as part of the operation. Examples are acid/caustic areas,
restricted visibility areas, designated coil fields, slab yards and other areas
where hazards exist that may not be readily identifiable to personnel not familiar to the
area.
7.10.1 Hazardous locations shall be identified and precautions shall be taken to
restrict access to unauthorized personnel.

7.10.1.1 All gates, doors, entry chains, or access points to the identified
Hazardous Locations shall be posted with sign/signs that will
communicate the following:
1. The specific hazard present.
2. Who is permitted to enter.
3. Procedures to be followed to enter.
4. Additional PPE/equipment required to enter.
7.10.2 Designated coil fields / coil staging areas shall be clearly delineated by
high visibility orange paint, high visibility orange stanchions, and/or by chain,
wire rope, rope, etc. In addition, permanent signs at entry points shall be posted.
The coil field/coil staging signs shall at a minimum contain the following
wording:
CAUTION
COIL FIELD / COIL STAGING AREA
AUTHORIZED EMPLOYEES ONLY
Do Not Enter
Unless Trained on: _____________________
Additional PPE Required:
High Visibility Clothing / Red Flashing Light Mounted on Hard Hat.
7.10.2.1 Only properly trained and authorized personnel with the proper
PPE are permitted to enter designated coil fields / coil staging areas.
7.10.2.2 The following PPE is required for an authorized employee to
enter a designated coil field/ coil staging area.
7.10.2.2.1 A red flashing light mounted on the hard hat near the top
center.
7.10.2.2.2 High visibility vest or jacket.
7.10.2.2.3 Full length cut resistant chaps shall be worn when
walking/working in locations where coil tails or edges are
protruding into the walking/working areas and a distance of at least
an arms length cannot be maintained.

7.10.2.2.4 At a minimum, cut-resistant gloves shall be worn. It is

not permissible to turn the glove cuff down when wearing gloves.
7.10.2.2.5 At a minimum, when a distance of at least an arms
length cannot be maintained, ATA sleeves shall be worn extended
from the cut resistant gloves

to the shoulder and be clipped or secured in such a manner that the

sleeve extends to the shoulder area.
7.10.2.3 Each plant shall develop and maintain standard
practices/procedures/JSHA's that shall be complied with prior to entering
and exiting a designated coil field/staging area which is serviced by a caboperated crane, RC crane, and / or mobile equipment.
7.10.2.3.1 Notification of the crane operators that may service the
designated coil field/ coil staging area.
7.10.2.3.2 Notification of the mobile equipment operators that
transport coils that may service the designated coil field / coil
staging area.
7.10.2.4 In addition to red flashing light mounted on the hard hat, an
operating light may be placed on a coil adjacent to where you will be
working that will further enhance visibility to the crane and/or mobile
equipment operators. Verify the lights are functioning properly prior to
entering the designated coil field/coil staging area and periodically while
in the designated coil field/coil staging area,
7.10.2.4.1 The light shall be a different color than specified in the
plant's GSO#2.
7.10.2.5 Cranes shall not make lifts or set a lift within two rows on either
side of an authorized employee working in the designated coil field /coil
staging area unless permission is given by the authorized employee
and the employee is in a safe location where the crane operator can see the
employee.
7.10.2.6 Mobile equipment operations shall not move coils within two
rows on either side of an authorized employee working in the designated
coil field /coil staging area unless permission is given by an authorized
employee and the employee is in a safe location where the mobile
equipment operator can see the employee.
7.11 Inspection of Supported Walking and Working Surfaces.
7.11.1 Floor grating, floor plate, support structure, fasteners and welds shall be
visually inspected monthly as part of the department housekeeping inspection.
7.11.2 Floor grating, floor plate, support structure, grating or plate fasteners and
welds shall be given a physical inspection to be scheduled at a frequency not to
exceed six months or immediately upon detection of damage, and/or substantial
corrosion.

08

Welding, Burning, & Cutting Equipment

8.1 Welding, Burning, and Cutting Personal Protective Equipment - Only trained and
authorized personnel are permitted to use gas cutting or electric welding equipment and
shall wear the following:
8.1.1 Approved welders' hoods, goggles, and/or face shields designated by the
JSHA and/or for the type of welding/burning shall must be worn for protection
from flashes or sparks.
8.1.2 Approved flame retardant (FR) clothing
8.1.3 Approved flame retardant (FR), aluminized or leather welding jacket
fastened up the front and closed at the collar
8.1.4 Approved burning/welding gloves
8.1.5 Approved Nomex, Carbonex or similar type flame retardant (FR) hood
8.1.6 Leather leggings, designed to protect the foot, ankle and lower leg. The
leggings may be worn under the outer garment or over the outer garment in the
following manner:
8.1.6.1 Leggings worn under approved flame retardant (FR) pants or
coveralls shall be worn over approved long underwear or long stockings to
provide additional protection from the hot work hazards and to prevent
skin irritation.
8.1.6.2 Leggings worn over approved flame retardant (FR) pants or
coveralls shall have a minimum of one inch of the pant leg blousing out
and over the top of the main body section of the leggings.
8.1.7 An aluminized jacket, aluminized gloves and aluminized leggings shall be
worn over approved flame retardant (FR) clothing when oxygen lancing.
8.1.7.1 Approved aluminized neck shroud shall be properly worn in
conjunction with an approved face shield and Nomex type hood when
there is a molten metal splash hazard or as required by the JSHA
8.1.7.2 Approved aluminized beehive type hood shall be worn when the
combination of a face shield, aluminized shroud and Nomex type hood
does not provide adequate protection from exposures to molten metal,
sparks, radiant heat, flame and/or steam or as required by the JSHA.
8.1.8 Helpers shall wear the exact PPE as the employee performing the welding,
burning and cutting.

8.1.9 Work must be shielded when welding or burning to protect others from the
arc, flash, or ultraviolet rays.
8.1.10 Always check burning equipment for leaks before use.
8.2 Hot Work Permit - Specific areas in the plant will be designated for hot work such as
burning, welding, and grinding. If an area is not designed and designated for hot work; a
hot work permit must be filled out before hot work can begin. The permit may require the
use of fire blankets, other means of spark containment, removal of fire hazards, air
quality tests, fire watch, etc, to protect other employees and surrounding property.
8.2.1 Supervision will designate an individual responsible for authorizing burning,
welding, grinding, and other hot work operations in areas not specifically
designed or approved for such operations. The work area must be inspected, all
portions of the Hot Work Permit completed, and the hot work permit signed by
the authorized employee.
8.2.1.1 Hot Work Permits for demolition projects shall be reviewed by the
demolition project manager with AK Operating and/or AK Engineering
personnel knowledgeable of the potential hazards associated with the
equipment or facility before Hot Work Permit is signed by the Authorized
Employee.
8.2.1.2 The Hot work Permit will specifically list the potential hazards
such as flammable/explosive liquids or gases, combustible/explosive
dusts, oxygen enrichment, utility lines or utility line support structures,
etc. The Hot Work Permit shall also include the precautions taken to
remove, eliminate or protect the potential hazards from the hot work
exposure.
8.2.1.3 All demolition Hot Work with any potential combustion hazards
shall have a minimum of one fire hose charged and positioned with the
Fire Watch during the hot work activity. The Fire Watch with the charged
fire hose shall be maintained for at least an hour after job completion to
detect and extinguish possible smoldering fires.
8.2.2 All completed Hot Work Permits shall be reviewed at the site of the
proposed work by a Safety Department representative or a designee approved by
the Plant General Manager. The work area shall be inspected to verify the
accuracy of the Hot Work Permit and the permit will be approved before hot work
begins.
8.3 If it is necessary for you to be in an area where welding or cutting is being done,
exercise caution. Never look directly at the intense light generated by welding or cutting.
Check your clothing to be sure you are not carrying sparks which might set your clothing
afire. Grease and/or oil on your clothes are especially dangerous if you are working
around oxygen. Oxygen can cause the grease or oil to ignite.

8.4 Cylinders Containing Compressed Gases - Oxygen, acetylene, and other compressed
gases must be considered dangerous fire hazards because they support or increase the rate
of combustion. When handling cylinders containing any kind of compressed gas, observe
the following rules and specific instructions of your supervisor: If clothes are
contaminated with grease, or oil, or solvents, they must be changed before performing
any burning or welding.
8.4.1 Transporting
8.4.1.1 Caps shall be in place on compressed gas cylinders unless they are
in use. Always replace the caps on full or empty cylinders after regulators
have been removed. It is especially important to have the caps in place
while transporting cylinders to protect the valve.
8.4.1.2 Compressed gas cylinders must be transported in special containers
or carriers provided for that purpose. At a minimum the carriers shall have
toe guards and a retainer system to secure the cylinder from falling during
transport. Do not handle cylinders with crane slings or magnets. Use good
judgment when handling or moving cylinders and do not lift beyond your
capabilities.
8.4.1.3 Compressed gas cylinders must always be securely tied off in a
vertical position.
8.4.1.4 Do not transport compressed gas cylinders in passenger elevators.
8.4.1.5 When burning, the torch shall be extinguished when it becomes
necessary to reposition yourself, the compressed gas cylinders or the hoses,
around or over obstructions.
8.4.1.6 When burning, the torch shall be extinguished when it becomes
necessary to remove the twist from the oxygen and fuel hoses.
8.4.2 Storage
8.4.2.1 Compressed gas cylinders shall be stored with regulators removed
and the cylinder caps installed and tightened.
8.4.2.2 Compressed gas cylinders shall not be stored near stoves, furnaces,
salamanders or in any area where they will be subjected to high
temperatures. They must not be stored where they can make unexpected
contact with electrical equipment or conductors if they should slip, roll or
fall. Do not store cylinders in entrance/exit areas, or in stair wells.
8.4.2.3 Oxygen cylinders must not be stored in a confined or enclosed
space with acetylene, liquid flammables, oils, or grease. A leaking
cylinder can cause spontaneous combustion of these materials.

8.4.2.4 Acetylene cylinders must always be stored vertically and used

vertically with the valve end up.
8.4.2.5 Oxygen shall be separated from fuel-gas cylinders or combustible
materials at a minimum of 20 feet or by a noncombustible barrier at least
five feet high having a one-half hour fire resistance rating.
8.4.3 Using Cylinders
8.4.3.1 Never use oil or grease to lubricate any part of an oxygen,
acetylene or other gas cylinder or regulator. Do not touch them if you have
oil or grease on your hands or gloves.
8.4.3.2 If a leaking cylinder is found, remove it to the outside immediately
and keep it away from any flames or combustible materials. Notify your
supervisor.
8.4.3.3 Hoses for Acetylene-Oxygen Rigs - GREEN hose is for oxygen;
RED hose is for all fuel gas. Never use compressed air to blow out these
hoses. To prevent tripping hazards and hose damage, keep excess hose
lengths coiled and lines arranged in orderly fashion.
8.4.3.4 Never bring cylinders into or store cylinders in confined spaces,
unventilated rooms, or other closed quarters. Storage areas must be open
or ventilated to prevent a build-up of gas.
8.4.3.5 All torches must have either flashback arrestors built into the torch
or units connected between the hoses and the torch.
8.5 Repair of cutting and welding equipment must be done only by authorized personnel.
8.6 Hoses which are damaged shall be cut in two and taken out of service to prevent
injury. Branching or using T-fittings in oxygen or fuel gas hoses is prohibited.
8.7 Oxygen hoses and fuel gas hoses shall be inspected for leaks prior to each first use
by each user.
8.7.1 Prior to each first use by each user, the hose shall be visually inspected for
wear and loose connections. If defects are found the hose shall be removed from
service and not used.
8.7.2 Prior to each first use by each user, the working end connections and
fittings of the hose shall be tested for leaks by immersing or spraying the
pressurized hose with an approved leak detection solution. If bubbles, or leaking
is detected the hose shall be removed from service and not used.
8.8 Wire brushes, scrapers, or other appropriate hand tools shall be used to clean a
surface before or after burning, cutting, or making weld repairs. Do not attempt to clean
the work surface with your hand.

8.8.1 Oxygen, compressed air greater than 30 psi, or welding shield gases. (such
as Argon, CO2, etc.) shall not be used to clean surfaces before burning, cutting or
making weld repairs.
8.8.2 Prior to each first use by each user, the hose shall be visually inspected for
wear and loose connections. If defects are found the hose shall be removed from
service and not used.
8.9 Welding, Burning and Cutting Procedures
8.9.1 When welding, burning, or cutting (air arcing), or saw cutting, the material
shall be secured when the potential exists for unexpected movement. securing
methods may include clamping, binding, bolting, etc.
8.9.2 When material is being removed and it cannot be secured, the material shall
be cut into pieces to relieve any tension/stress or stored energy.
8.9.3 When welding, burning, or cutting (air arcing), or saw cutting, all pinch
points shall be identified and eliminated prior to performing the task
8.10 Wire brushes, scrapers, or other appropriate hand tools shall be used to clean a
surface before or after burning, cutting or making weld repairs. Do not attempt to clean
the work surface before or after burning, cutting or making weld repairs. Do not attempt
to clean the work surface with your hand.
8.10.1 Oxygen, compressed air greater than 30 psi, or welding shield gasses,
(such as Argon, CO2, etc.) shall not be used to clean surfaces before burning,
cutting or making weld repairs.

09

Operating, Repairing, Servicing and Inspection of Equipment

9.1 Only a trained operator or maintenance person may energize/de-energize and operate
a machine. Do not operate, repair or test any machinery, electrical apparatus, or other
equipment unless it is part of your assigned duties. Do not lubricate, clean, repair, inspect
or operate a machine you do not understand. When in doubt, ask your supervisor. If you
are authorized to operate machinery, follow all safe procedures including the Job Safety
and Health Analysis, Department Rules, and Manufacturers recommendations established
for the machine or equipment.
9.2 Energy control procedures, which include de-energize, lockout and tryout must be
performed by authorized employees before servicing and/or maintenance of machines
and equipment. Normal production operations (i.e. minor tool changes, adjustments and
other minor servicing) that are routine, repetitive and integral to the use of the machine
and/or equipment, do not require energy control, lockout/tryout procedures provided no
employee places themselves into a point of operation or associated danger zone on the
machine or equipment. All employees will comply with the provisions of General Safety
Order (GSO) #1 "Lockout/Tryout Procedures". See GSO #1 Lockout/Tryout Procedures
Section 28.
9.2.1 All employees shall be trained on GSO #1 "Lock Out / Tryout Procedures"
to ensure that each employee understands the purpose and function of the energy
control program and the knowledge and skills required for the safe application
usage and removal of energy controls.
9.2.2 All employees shall be retrained on GSO #1 "Lock Out / Tryout
Procedures" annually.
9.2.2.1 Retraining shall be provided for all authorized and affected
employees whenever there is a change in their job assignments, a change
in machines, equipment or processes that present a new hazard, or when
there is a change in the energy control procedures.
9.3 It is the Operator's responsibility to see that everyone is in the clear before starting
any machine.
9.4 Operators of machines, cranes, and other equipment must secure the equipment under
established procedure before leaving the job unless relieved on the job by another
operator.
9.5 Any machine that is unsafe to operate must be de-energized and locked out. Notify a
supervisor of any broken or unsafe machinery or equipment.
9.6 When opening an electric safety or disconnect switch, do not pull a switch under load.
Make sure the power is shut off to the equipment by pushing the stop button or otherwise
assuring that no current is flowing in the disconnect switch circuit. Pulling a switch under
load could result in an explosion or an electrical shock.

9.6.1 When opening or closing electric safety or cut-off switches, use your left
hand. Whenever possible, stand to the right of the switch box, not directly in front
of it. In all cases stay away from the front of the box and keep your face turned
away as you throw the switch. There may be sparking or flashing.
Note: If it is not possible to stand clear from the front of the box, contact your
supervisor.
9.6.2 Only electrically qualified and authorized personnel are permitted to open a
disconnect switch to verify that the knife blades are in the open position.
9.7 Do not remove any personal safety lock unless you placed it. Remove only your lock
only after you are sure all personnel are in the clear. Do not remove any DANGER or
CAUTION signs unless you placed them and then only after you are sure the dangerous
condition has been corrected. If a lock must be removed and the person who placed it
cannot be found, contact your supervisor. The lock shall be removed by following GSO
#1 procedures.
9.8 Only authorized personnel are permitted to adjust machinery while in motion, and
then only when proper written procedures have been established. If you are authorized to
make minor production adjustments on machines, follow the procedures that have been
approved. Be sure to guard against unexpected movement of parts or machinery which
might injure you or others. Lockout/Tryout procedures must be followed during the
service or maintenance of the equipment.
9.9 Machinery must not be operated if guards have been removed for repairs or
adjustments. Do not remove locks or energize equipment until all guards and safety
devices are replaced properly secured and operable.
9.9.1 Machine guarding and safety devices shall be affixed to the machine or
secured elsewhere as designed by the equipment manufacturer or approved by a
Plant Equipment Safety Inspection Procedure.
9.10 Pressure must be bled off prior to repair or service work on hydraulic, steam, gas,
air, oil or water lines or connected equipment. Flow valves must be closed and locked
and pressure relief valves must be locked in the open position. Accumulators must be
discharged.
9.10.1 Valve lockouts must be made in accordance with GSO #1 before any repair
or service is done.
9.10.2 Before the flow of steam, gas, air, oil, or water is restored to a system, the
person doing so must make certain that no one is in a position to be injured as the
systems are activated.
9.11 Use only approved Red locks when locking out equipment.

9.12 Green locks shall be used only as equipment control for idled equipment and where
no work is being performed.
9.12.1 Idled equipment is defined as equipment that is no longer in use or that will
be out of service for a lengthy period of time.
9.13 Unauthorized persons shall not go into operating pulpits for any reason, other than
an emergency.
9.14 Use extreme caution when working around conveyor systems, especially conveyor
belts. Do not shovel onto moving belts unless authorized by specific written procedures
and all guarding is in place. Make sure the emergency stop is functioning properly.
9.15 Moving rolls shall not be touched at any time.
9.15.1 Work rolls shall not be cleaned or polished by hand while they are in the
mill and under power. If work rolls are installed in the mill and must be cleaned
or polished by hand, they shall be locked out.
9.15.2 Work rolls installed in the mill and moving or under power may be cleaned
or polished under the following conditions:
a. Tools will be provided to facilitate the cleaning or polishing of work
rolls with the hands at a safe distance from the moving rolls.
b. A procedure is in place directing the use of a tool or tools to be used to
keep hands away from the moving rolls.
c. The cleaning or polishing of the work rolls will be performed at the side
of the mill opposite of the work rolls in-running nip point. If necessary the
direction of rotation of the work rolls may be reversed to eliminate the inrunning nip-point hazard.
9.16 The strip shall not be touched with any part of the body when it is moving under
tension.
9.16.1 The strip may be positioned or worked on using extension/hands free tools
when the line is stopped or in the jog mode. Extension/hands free tools shall be
used when clearing jambs and removing scrap from the line, unless the scrap has
been cut into easily manageable, i.e. sample width or smaller pieces.
9.16.1.1 A variance to this rule may be granted by the Plant Manager after
all alternatives have been exhausted and a safe procedure for performing
the job has been developed.
9.16.2 Personal Protective Equipment required for handling or working in close
proximity to strip, scrap, samples, and/or steel banding shall include cut resistant
sleeves worn with cut resistant gloves. The sleeves shall, extend from the glove to
the shoulder and be clipped or secured in such a manner that the sleeves remain
extended to the shoulder area. Full length cut resistant chaps, aprons, or
equivalent cut protection shall be worn when there is a potential to strike the torso

or legs against protruding strip, scrap, samples, steel banding, or other similar cut
hazards.
9.17 Equipment Safety Inspection Procedures.
9.17.1 Each plant shall develop and maintain a standard practice / procedure to
protect employees from potential hazards involved in the start up and operation of
all newly purchased, constructed, installed, relocated and replaced; buildings,
structures, equipment, or machinery.
9.17.1.1 This practice / procedure shall designate an inspection committee
and persons responsible to conduct a final inspection of the subject
building; structure, equipment, or machinery prior to its release for use.
Members of the inspection committee shall, at a minimum, consist of
representatives from the Operations, Engineering and Safety Departments.
9.17.1.2 Results of the final inspection shall be documented to include
corrective actions required prior to the final release of the item for service.
9.17.2 Each plant shall develop and maintain a standard practice / procedure to
protect employees from potential hazards involved in the start up and operation of
equipment or machinery owned, installed, and operated by contractors.
9.17.2.1 This practice / procedure shall designate an inspection committee
and persons responsible to conduct a final inspection of the subject
equipment or machinery prior to its release for use. Members of the
inspection committee shall, at a minimum, consist of representatives from
the Operations, Engineering and Safety Departments.
9.17.2.2 Results of the final inspection shall be documented to include
corrective actions required prior to the final release of the item for service.
9.18 Thermography of Iron Transfer Ladles (Hot Pots)
9.18.1 Ashland and Middletown shall develop and maintain standard
practices/procedures to ensure all full iron transfer ladles have infrared
thermography conducted a full 360 degrees including the bottom and around the
trunnions prior to being transferred to the skimmer from the Desulfurization
station.
9.18.2 Each plant shall develop and maintain standard practices/procedures to
define the specific temperature thresholds that require immediate corrective or
preventative actions up to and including requiring the iron transfer ladles to be
emptied and taken out of service.
9.19 Thermography of Steel Ladles
9.19.1 Each plant shall develop and maintain standard practices/procedures to
ensure all full steel ladles destined for caster have infrared thermography

conducted a full 360 degrees including the bottom and around the trunnions prior
to going to the caster.
9.19.2 Mansfield and Butler shall develop and maintain practices/procedures to
ensure all full steel transfer ladles have infrared thermography conducted a full
360 degrees including the bottom and around the trunnions at a minimum of once
per day.
9.19.3 Each plant shall develop and maintain standards practices/procedures to
define the specific temperature thresholds that require immediate corrective or
preventative actions up to and including requiring the Ladle to be emptied and
taken out of service.

10

Electrical Hazards
10.1 Only properly trained personnel are allowed to make electrical connections or repair
electrical equipment and wiring. Before beginning work, always use a testing device to
determine if lines or equipment are live. The proper PPE, including diaelectric gloves and
face shield, must be worn while making these tests. All jewelry and metallic belt buckles
are prohibited when working on energized parts.
Caution: Make sure the testing device is properly rated for the voltage being tested and
that it is working properly.
10.1.1 Only properly trained employees may work in areas containing unguarded,
un-insulated energized lines or parts of equipment at 50 volts or more.
10.1.2 Only properly trained employees may work on energized parts that must be
worked on in an energized state or do not have the capability of being locked out.
10.1.3 Bypassing a safety device or interlock to open a bus bar protective shutter
in either a starter or breaker cubicle is prohibited unless the source of incoming
power to that cubicle is de-energized and locked out.
Situations requiring these safety devices or interlocks to be bypassed to open the
shutters while energized require an Electrical Hot Work permit to be completed,
reviewed and approved by Electric Dept. Manager or his designee.
10.2 Consider all wires live until it is positively known that they are dead. Do not touch
any exposed or dangling wires. Report exposed wires and open electrical components to
your supervisor.
10.3 Do not use extension cords that are defective. Examine them carefully for worn
insulation and exposed strands of wire before use. Connect extension cords only to
G.F.C.I. outlets or adapters. Do not place extension cords over sharp edges or across
aisles where mobile equipment can damage them. Do not create a tripping hazard with
extension cords.
Note: Extension cords are for temporary use only.
10.4 Do not overload electric circuits. When fuses blow continually or circuit breakers
kick out, report the condition to your supervisor.
10.5 Heed all warning signs and signals concerning the hazards of electrical equipment or
lines.
10.6 Unauthorized personnel are not permitted to enter rooms or vaults containing live
electrical lines or equipment, such as supply stations, substations, motor rooms, control
houses, or any room containing high voltage equipment, unless instructed to do so by
Supervision and accompanied by a trained and authorized individual.

Note: Only Electric Services personnel, qualified AK Engineers, qualified contractor

personnel, and qualified equipment suppliers are permitted to work with devices of 480
AC/250DC volts or more.
10.7 Nominal 460 VAC (i.e., 440 VAC, 460 VAC, 480 VAC) plug and receptacle
systems shall be de-energized before plugging or unplugging the equipment.
10.7.1 Nominal 460 VAC receptacles shall be integral to a disconnect switch or
facilitate de-energization and lockout.
10.8 Temporary Power Feeds - Electrical power being supplied from a second source or
different from the original design location.
10.8.1. Temporary Power Feeds shall be documented at the time of installation.
10.8.1.1 Documentation will include:
10.8.1.1.1 Tag ALL effected equipment
10.8.1.1.2 Tag the Temporary Power wire/cable at all termination
points.
10.8.1.1.3 Tag the original Power Feed that is being
removed/modified at all termination points
10.8.1.1.4 Tag all Breakers, Disconnects, Switches, etc. involved
in the Temporary Power Feed
10.8.1.1.5 Tag all Breakers, Disconnects, Switches, etc. involved
in the original Power Feed
10.8.2. Temporary Power Feeds and affected equipment shall be tagged with the
following:

10.8.3. Locks shall be placed on all equipment associated with the original Power
Feeds that are temporarily removed from service, whenever possible.
10.8.4. In addition to the locks and whenever locks cannot be applied, "Out of
Service-Do Not Use" tags shall be placed on all equipment and cables associated
with the original Power Feeds that are temporarily removed from service.
10.8.5. A SAFETY Work Order or equivalent tracking method shall be entered
for:
10.8.5.1. The restoration of the original Power Feed/equipment, including
removal of the Temporary Power Feed.
10.8.5.2. The permanent installation of the Temporary Power Feed and the
removal of the original Power Feed.

11

Crane Material Handling

11.1 Only trained and authorized personnel are allowed to operate any kind of crane.
Qualification as a crane operator shall be based on medical certification, training and
demonstrated ability to operate any crane to which the employee may be assigned. Cranes
shall be operated in a competent manner in strict compliance with government
regulations and all applicable crane safety rules.
11.1.1 Crane Boarding/De-boarding
11.1.1.1 Definitions:
11.1.1.1.1 Qualified Crane Operator is the operator that has been
assigned and deemed qualified as stated in section 11.1 of the AK
Steel Safety and Health Rules and Instruction Booklet by
management as the principal operator of the crane. Break-in or
extra crane operators are to follow same boarding procedures as
authorized employees.
11.1.1.1.2 Authorized Employee is an employee that has been
trained on the applicable procedure and has been classified as
"Authorized" by management.
11.1.1.1 No one shall ever board or de-board a moving crane.
11.1.1.2 Personnel, other than qualified crane operators, shall not be
permitted on cranes, crane runways or in crane cabs without the
authorization of management.
11.1.1.3 A documented JSHA for boarding and de-boarding occupied and
unoccupied overhead cranes shall be developed and implemented. The
procedure shall have, at minimum, the following instruction:
11.1.1.3.1 Boarding a crane that is occupied:
11.1.1.3.1.1. The authorized employee shall notify the
crane operator of their intention to board the crane and shall
receive acknowledgement from the crane operator.
11.1.1.3.1.2. The crane operator shall de-energize the crane.
11.1.1.3.1.3 The crane operator shall assure the red status
light (Green in Butler Works) is on and then place the
indicator light on yellow if the crane is so equipped.
11.1.1.3.1.4 The crane operator shall then exit the cab and
go to a position where they can be seen by the employee(s)
wishing to board the crane.

11.1.1.3.1.5 The crane operator may put the crane into

operation only after ensuring all employees are clear, the
green light (Red in Butler Works) is turned on, and sounds
the crane warning for at least five seconds.
11.1.1.3.2 Boarding or de-boarding a crane during planned
maintenance downturns and a crane operator is not scheduled.
11.1.1.3.2.1 If the hot rails are locked out and/or a lockout
box established, the employee can enter the crane after
putting their personal lock on the hot rail source or lockbox
for the hot rails and signing lockout control sheet.
11.1.1.3.2.2 If the hot rails are not locked out, the employee
shall gain permission by the supervisor in charge and/or the
maintenance crew leader prior to boarding the crane.
11.1.1.3.2.3 The crane must be de-energized prior to
boarding the crane.
11.1.1.3.2.4 The manual magnetic switch must be in the off
or open position and the indicator light on before the crane
can be boarded or exited.
11.1.1.4 Signs shall be posted at the bottom of the crane access stairs or
ladders and at each boarding location stating, at a minimum, the following
wording:

WARNING OVERHEAD CRANE BOARDING LOCATION

AUTHORIZED EMPLOYEES ONLY
Do Not Proceed
Unless Trained and Follow the Requirements
of: (JSHA).
11.2 The following rules apply to employees in areas where overhead travel cranes,
mobile cranes, locomotive cranes, and other hoisting equipment operate. There are
additional rules, regulations and special instructions for crane operators, floor personnel
and maintenance personnel listed in specific manuals and job procedures for each
position.
11.2.1 Crane operators shall not make or complete a lift where line of sight to the
load or lifting device cannot be maintained, unless directed by authorized
personnel. Signals shall be taken only from those authorized to give them. Only
one person shall be authorized to give signals for a given lift. Crane Operators
must not make a lift or move their crane in any way, regardless of signals, if their
judgment indicates someone is in a hazardous position or it is an unsafe lift.

11.2.1.1 Crane operators shall not lower or set a lift if floor personnel are
in a position to be struck or caught by the lifting or lift device.
11.2.1.2 Crane operators shall not relax tension on a lift, if in their
judgment, the lift is unstable or is in some other way creating a hazard.
11.2.2 Except for designated crane operations which are handled without a floor
person or signal person in accordance with department procedures, a crane
operator must not move a lift without standard hand signals or approved radio
communication from a designated person (see Appendix 1 for Standard Crane
Hand Signals).
11.2.2.1 A floor person must always verify the positive engagement of
crane J Hooks or bales on ladle trunions for all hot metal lifts. The crane
operator shall not hoist a hot metal lift until clearly signaled to do so by
the floor person.
11.2.3 Floor personnel must visually inspect below the hook lifting equipment
such as chains, cables, slings, tongs, forks, etc., before use to assure they are in
good condition. Never use a defective lifting device or overload a lifting device.
11.2.3.1 Lifting devices and slings with defective or missing safety latches
shall not be used.
11.2.3.2 Lifting devices shall have permanently affixed and legible
identification markings as prescribed by the manufacturer that indicate the
recommended safe working load.
11.2.3.3 Remove lifting devices that are noncertified, that don't have an
affixed, legible identification markings or unsafe from service and tag it as
defective, then report it to supervision immediately. Cable and sling eyes
shall be cut and the device scrapped when found to be defective.
11.2.3.4 Two or more slings (wire, chain, rope or synthetic) shall not be
connected to each other by means of choking, knotting, with shackles or
other unapproved mechanical means. The proper length slings shall be
used.
11.2.4 Floor personnel must assure that no one is in a hazardous position before
signaling a lift to be moved and must prevent personnel from entering the hazard
area during movement of the lift.
11.2.5 Tag lines, hand hooks or equivalent "hands free" tools must be used as
directed by the department for guiding and positioning lifts. Keep all parts of the
body in the clear of lifts while tension is being applied. Never use your feet to
hold cables or chains in place while the hoist is being raised or lowered or to
steady or guide lifts.

11.2.5.1 Floor personnel shall assure that lifts or lifting devices are set in
such a way to prevent movement when unhooked from the crane. Stands,
racks, blocking, or other devices shall be used to assure the stability of the
lift or lifting device.
11.2.5.2 Do not lean lifts or lifting devices against surfaces or other
objects without first providing some means to secure them from
movement.
11.2.5.3 Tag lines, hand hooks, or equivalent "hands free" tools shall be
used by the floor person to guide, position, and steady lifting devices when
placing or removing off of a lift. Once the lift is set and stable, the floor
person shall control the lifting device to assure it does not snag the lift or
surrounding objects as the crane operator hoists the lifting device from the
area.
11.2.6 Riding crane loads, lifting equipment, or crane hooks by employees is
strictly prohibited.
11.2.7 Never walk, stand, or work under loads suspended from cranes. Maintain a
safe distance from a suspended load.
11.2.7.1 Do not stand or walk under the empty hook of a crane.
11.2.7.2 Do not walk in the path of a moving crane load.
11.2.8 No lift shall be made with chains, cables, or slings while a magnet or other
auxiliary lifting device is still attached to the same crane hook.
11.2.9 Departmental Safety Rules shall identify specifically the type of lifts that
may not be handled with electromagnets. Do not carry magnet loads over
machinery unless such movement has been approved by supervision.
11.2.10 When a railroad car is being loaded or unloaded by either overhead crane,
gantry crane, mobile crane, or locomotive crane, workers in the car must keep a
minimum distance of 10 feet from the lift in motion until such time as the lift is
stationary and no higher than 6 inches above the blocking or the bottom of the car.
The position of the worker must be such that the lift is not moving toward them.
11.2.11 Where the minimum distance cannot be maintained, the worker is to get
out of the car until the lift has either cleared the car or is stationary no higher than
6 inches above the blocking or the bottom of the car.
11.2.12 To the extent possible, the movement of the lift being loaded or unloaded
must be made at right angles to the car. It must never be made directly toward the
worker in the car.
11.2.13 Workers shall not be permitted on the bed of trucks being loaded or
unloaded by a crane except for hooking and unhooking a lift. However, when

loading, once the lift is stationary and no more than 6 inches above the blocking,
the worker is permitted on the truck bed if necessary for final placement of the
lift.
11.2.13.1 When loading and unloading a truck by crane, ensure the driver
remains out of the cab and in the clear of the truck.
11.2.13.2 When loading, once the lift is stationary and no more than 6
inches above the blocking, the truck driver is permitted on the truck bed, if
necessary, for final placement of the lift.
11.2.14 Workers shall not be in the railroad car or truck while they are being
loaded or unloaded with crane magnets, dirt boxes, grab buckets, clam shells, or
similar equipment.
11.2.15 When using magnets, buckets, special hooks, etc., maintain distance and
control movement to avoid damage to railroad cars and trucks. Pay particular
attention to safety grab irons, steps, and brake wheels. Report any damage to your
supervisor.
11.2.16 Overhead cranes shall not be used for side pulls except when specifically
authorized by a designated responsible supervisor and then only after all possible
alternatives have been investigated.
11.2.16.1 A JSHA shall be written for each side pull situation and will
include: securing the load and hoist, evacuation of the area, conditions to
stop the side pull, and an inspection of the crane and cables immediately
upon completion of the side pull.
11.2.16.2 The side pull will not be made if the responsible supervisor
determines that the crane and/or the lifting mechanism will be over
stressed.
11.2.16.3 Overhead cranes shall not be used to move railroad cars.
11.2.17 Crane hook safety latches, chains, or devices shall be in good operating
condition and shall be latched or fastened before the lift is made.
11.2.18 Each Crane Operator must complete the Crane Safety Checklist at the
start of their turn. Do not operate the crane if an unsafe condition exists.
11.2.18.1 The crane operator shall test all limit switches before starting to
operate. No hoist shall be operated if the limit switch is found to be
defective.
11.2.18.2 Crane hoist upper limit switches shall never be used for
intentionally stopping the hoist during operations.
11.2.18.3 Crane operators shall inspect the condition of stairs, landing,

hand-hold/grab irons, and crane platforms prior to boarding and deboarding overhead cranes.
11.2.19 Crane Operators must not hoist loads exceeding the safe load limit of
their cranes. All EOT cranes, monorail hoists, jib cranes, crane blocks, and lifting
devices must have their lifting capacities clearly marked in a location visible to
the operator and floor personnel.
11.2.19.1 The weight of the load plus the weight of the lifting device must
be combined and be less than the capacity of the lifting equipment rating.
11.2.20 Crane Operators shall sound the crane signal at the initial movements of
the trolley, bridge, and hoist when lowering. Crane Operators shall sound the
crane signal when approaching any personnel in the area of the crane's travel.
Never carry any type of load over personnel. Avoid carrying loads over operating
equipment unless when necessary to service the equipment or when there is no
acceptable alternate route for the lift.
11.2.20.1 Suspended loads shall not be left unattended. Crane operators
shall not leave their position at the crane controls while the load is
suspended.
11.2.20.2 Crane operators shall not engage in any activity that might divert
their attention from a suspended load.
11.2.21 Prescribed routes must be followed to and from cranes.
11.2.22 When working in the area of Mobile Cranes or Locomotive Cranes, keep
clear of the lifting beam or boom and swinging crane cab or counterweight
identified by markings which signify the swing radius.
11.2.22.1 Barriers will be set up to prevent accidental access to the
hazardous area created by the swing radius of the crane cab or
counterweight.
11.2.23 Only employees who have been trained and are qualified shall be
permitted to operate overhead Radio Remote Control or Pendant Control Cranes.
11.2.23.1 Pay attention to all crane status lights. Employees working in
areas with overhead crane activity shall be trained to understand crane
status lights:
1. Green Light On - crane power is on.
2. Red Light On - crane power is off.
3. Blue Light On - magnet, or other electrical powered lifting device,
power is off and discharged

4. Blue Light Off - magnet, or other lifting device, power is on.

11.3 Mobile Cranes
11.3.1 Mobile cranes shall never be overloaded or otherwise used beyond their
designed capabilities. If the weight of the load cannot be determined or has the
potential to exceed the working load limits of the crane, do not attempt the lift.
11.3.2 Outriggers and appropriate outrigger cribbing shall be utilized as dictated
by the crane manufacturer's requirements, JSHA, and/or engineering procedures.
11.3.3 Surface conditions shall be evaluated to assure adequate stability before a
mobile crane is set up and lifts are made.

12

Working At Overhead Locations

12.1 If you are required to work overhead, you shall protect employees and/or contractors
below by designating a hazardous work area on the ground or at any level below the work
activity where there is potential for falling objects. Red Danger Tape (with identification,
i.e., department name, contractor name) and Overhead Work Warning Signs shall be
erected to completely encompass and block access to the Red Zone hazardous work area.
12.1.1 Entry into the Red Zone shall not be permitted until the following
conditions are met:
12.1.2 Entry into the Red Zone is absolutely required to complete the planned
jobs/tasks.
12.1.3 A safety attendant must be in position to control entry into the Red Zone.
12.1.3.1 The attendant shall not permit entry into the Red Zone until the
overhead work is stopped and communications are established between
the employees on the ground/lower level and the crew working above.
12.1.3.2 Overhead work may continue after the communications have
been established and the work procedures/protection are in place to protect
the employees on the ground/lower levels.
12.1.4 A safety attendant is also required when entry into the Red Zone is not
required but the hazardous work area cannot be completely encompassed with red
danger zone tape.
12.1.5 The overhead work area Red Zone entry permit must be completed, signed,
and posted at the Red Zone entry along with all attached written procedures.
12.1.6 A safety attendant assigned to control entry into the Red Zone shall wear a
fluorescent safety vest for identification and have an air horn or other device to
warn unauthorized people away from the area.
12.1.7 Entry is permitted when the overhead work has stopped or completed and
the "overhead" signs have been removed. If overhead work starts again,
"overhead" signs and red danger tape shall be installed.
12.1.8 When jobs are planned, consideration must be given to overhead work and
the potential for falling objects. Hole covers, nets, toe boards, screens, etc. must
be considered and written in the preplan, JSHA, and/or other work instruction.
12.1.9 The red danger tape shall be printed with Department or Contractor name,
or signs may be attached to the tape to identify the Department or Contractor that
established the Red Zone area.

12.2 Use approved ladders, scaffolding, or staging in good condition to reach overhead
work. Report defects to your supervisor. Do not use improvised or makeshift
arrangements. Loose materials, such as planks, scaffolding, pipe, bolts, nuts, tools, etc.,
must not be left overhead. Temporary scaffolding must be removed by authorized
personnel at the conclusion of the job. Materials are not to be dropped or thrown to the
ground but must be let down by hand lines or some other controlled method.
12.3 Overhead Work on Crane Runways
12.3.1 Crane movements may present special hazards. General Safety Order #2
and other safe working procedures for the job being done must be followed while
working on cranes or crane runways. This includes work on buildings, on top of
tall bins, high machinery, and other areas where employees may be struck by the
crane. See General Safety Order #2, Governing Persons Working on Overhead
Cranes, Crane Runways, and Buildings, Section 29.
12.3.2 Warning signs shall be posted on the floor below to alert others in the area
of the work being performed overhead. Red Danger Tape (with identification, i.e.,
department name, contractor name) shall be erected to completely encompass and
block access to work areas where there is the potential for objects to fall to the
area below. Entry into the Red Zone Shall Be prohibited until the conditions
specified in 12.1 are met.
12.3.2.1 A Safety Attendant shall be assigned to control the Red Zone if it
is not possible to completely encompass the hazardous work area with the
Red Danger Tape.
12.3.2.2 A Safety Attendant assigned to control entry into the Red Zone
shall wear a fluorescent safety vest for identification and have an air horn
or other device to warn unauthorized people away from the area.
12.3.2.3 When jobs are planned, consideration must be given to overhead
work and the potential for falling objects. Hole covers, nets, toe boards,
screens, etc., must be considered and written in the preplan, JSHA, and/or
other work instruction.
12.3.2.4 The Red Danger Tape may be printed with Department or
Contractor name, or signs may be attached to the tape to identify the
Department or Contractor that established the Red Zone Area.
12.4 Working on Roofs
12.4.1 All work on roofs shall apply 100% fall protection for both edge protection
and fall through protection. This includes traveling to the location on the roof
where the work will be done.
12.4.1.1 Exceptions to this rule will be:
1. Roofs that have a certification by Engineering that they are safe to walk

on, and the work does not require edge protection.

2. Office building roofs that are designed with edge protection.
12.4.2 Roof access points, such as ladders or stairways, shall display signs stating
"Access to Roof is Prohibited without Department Authorization".
12. 5 Working on Cranes
12.5.1 Prior to commencing any preventative, breakdown, or shutdown
maintenance on an overhead crane, a Red Pendant Flag (highly visible) must be
lowered from the crane 10 to 15 feet above the floor. The pendant shall have
"WARNING" displayed on both sides and shall easily be seen from the floor.
12.5.2 Warning signs shall also be placed on the floor (i.e., "Caution Overhead
Work") to alert others in the area of the work being performed on the crane
overhead.
12.5.3 The warning signs will be the maximum protection required if there is no
potential for tools, parts, or materials to fall to the area below. Employees and
contractors shall use caution when walking under any part of an overhead crane
that has the red pendant "WARNING" flag displayed and warning signs on the
floor indicating the crane is down for maintenance.
12.5.4 A Red Danger Tape Zone (with identification, i.e., department name,
contractor name) shall be erected to completely encompass and block access to
work areas on the ground when there is a potential for tools, parts or materials to
fall from the crane during the maintenance activity. Entry into the Red Zone shall
be prohibited during the maintenance activity. Entry into the Red Zone shall be
prohibited until all conditions of 12.1 through 12.1.9 are met.

13

Ladders, Scaffolding, & Staging

13.1 Ladders
13.1.1 Always inspect ladders before use. Defective ladders shall be tagged and
immediately removed from service. Notify your supervisor for a replacement.
13.1.1.1 Portable metal ladders including aluminum shall not be approved
for use on AK Steel Property.
13.1.2 Never paint or use painted wooden ladders. Paint will hide cracks, knots,
rot, or other defects.
13.1.3 Inspect the safety feet before using the ladder and be sure the safety feet
are positioned on a firm level surface when positioning the ladder.
13.1.4 Straight portable ladders, extension ladders, or non self-supporting portable
ladders, shall extend at least three feet above the top access level and be placed so
the distance from the base of the ladder to the wall or other supporting structure is
about one-quarter the length of the ladder from the floor to the top support point.
These ladders are to be tied in place, or held by a coworker whenever someone is
working on the ladder.
13.1.4.1 Both rails of the extension ladder must be tied off to a structure
capable of stabilizing and supporting the ladder from falling.
13.1.4.2 When working from straight, extension, or non self-supporting
portable ladders and over 4 feet from the ground you must wear a full
body harness fall arrest system and be tied-off to a proper anchor point
unless the following conditions are met:
13.1.4.2.1 The worker can maintain a 3-point touch, 2 hands and
one foot, two feet and one hand, or two feet and the midline of the
body. Examples are:
- Both feet and 1 hand - on the ladder, belt buckle or midline of the
body must be between the rails of the ladder, and the shoulders
below the top rail. Any stretching for position requires
repositioning of the ladder.
- Both legs and body leading against the ladder. The belt
buckle/midline of the body must be between rails. Any stretching
for position perpendicular to the ladder requires repositioning of
the ladder. Feet must be firmly on the ladder and the belt
buckle/midline of the body must be resting on the ladder. The
shoulders must be below the top rung. Worker may use two hands
for short duration work (changing light bulbs, opening hand

valves, etc.).
13.1.4.2.2 The ladder must be tied off as described above, or
ground person must be holding the ladder during climbing and
working activities.
13.1.5 Safety stepladders need not be held by another person if they are used with
all 4 legs on an even surface. The legs of stepladders shall be fully opened and
locked. Never stand on top of a stepladder. Work from a point at least two feet or
two steps from the top. When working on a safety stepladder 6 feet or less, which
is properly secured and stable and the worker is no higher than the 4th step, it is
not necessary to use fall protection.
13.1.5.1 When working on a safety stepladder over 4 feet you must wear a
full body harness fall arrest system and be tied off to a proper anchor point
unless the following conditions are met.
13.1.5.1.1 The worker can maintain a 3-point touch, 2 hands and
one foot, two feet and one hand, or two feet and the midline of the
body. Examples are:
A. 2 legs are braced against the opposite side rails of the ladder, 1
hand holding onto the ladder, and belt buckle/shoulders must be
between rails of the ladder. Any stretching for position
perpendicular to the ladder requires repositioning of the ladder.
B. 2 legs are braced against the opposite side rails of the ladder,
and the belt buckle is in contact with the ladder. The belt
buckle/shoulders must be between rails and the belt buckle must be
below the top rail. Any stretching for positions perpendicular to the
ladder requires repositioning of the ladder. Feet must be firmly on
the ladder and the belt buckle must be resting on the ladder.
Worker may use two hands for short duration work (changing light
bulbs, opening hand valves, etc.).
13.1.6 When climbing any ladder (portable or stationary), hold on with both
hands and always face the ladder. Use a hand line to raise or lower tools that you
will need. Do not overreach. Move the portable ladder as work progresses or, if
necessary, use another ladder to avoid overreaching. Never exceed the maximum
intended load of the ladder.
13.1.7 Never place a ladder against equipment which may move or rotate
unexpectedly or in the path of equipment that may move unless such equipment is
locked out.
13.1.8 Never extend an extension ladder full length. The overlap shall be at least
four rungs.
13.1.9 Wherever practical, rope off the areas at the base of a ladder while in use.

13.1.10 Ladders shall not be placed in front of doors opening toward the ladder
unless the door is blocked open, locked, or guarded.
13.1.11 Ladders shall not be placed on boxes, barrels or other unstable bases to
obtain additional height.
13.1.12 When raising or lowering an extension ladder, take extreme care to keep
your hands and fingers clear of pinch points.
13.2 Scaffolding & Staging.
13.2.1 Employees who perform work while on a scaffold shall be trained by a
qualified person to recognize the hazards associated with the type of scaffold
being used, the nature of any electrical hazards, fall hazards, and falling object
hazards in the work area.
13.2.2 Scaffolds and their components shall be capable of supporting without
failure at least four times the maximum intended load.
13.2.3 Any scaffold damaged or weakened from any cause shall be immediately
repaired or replaced and shall not be used until repairs have been completed.
13.2.4 Scaffolds shall not be loaded in excess of the working load for which they
are intended.
13.2.5 Tools, materials, and debris shall not be allowed to accumulate in
quantities to cause a hazard when working on a scaffold.
13.2.6 All scaffold planking must be approved and identified as scaffold grade.
13.2.7 Access to a scaffold shall be by secured ladder, or an equivalent safe
access shall be provided. Climbing the side of scaffolding is not permitted.
13.2.8 Scaffolding greater than four feet in height must be equipped with
handrails, mid-rails, toe boards, and be tightly planked.
13.2.9 Fall protection equipment including a body harness and shock absorbing
lanyard deceleration or self retracting device shall be worn and connected to an
approved anchorage point or lifeline when working on any scaffold platform
greater than four feet in height and not equipped with standard top rails and midrails.
13.2.10 A scaffold tag signed by a competent person is required prior to allowing
personnel to work on scaffolds. The tag certifies proper construction and that
safety features are in place. The scaffold inspection checklist must be completed
before accessing the scaffold.

14

Fall Protection
14.1 Employees working at any elevation greater than 4 feet above the floor, deck,
platform, or ground level, and not protected by standard top rails, mid rails, toe boards,
and/or equivalent protection shall be required to use personal fall protection. Employees
working in an aerial lift or on scaffolding not equipped with standard top rails, mid rails,
and toe boards shall be required to use personal fall protection. All employees shall
comply with the provisions of General Safety Order (GSO) #5 Fall Protection Program.
See GSO #5 Fall Protection Program, Section 32.
14.2 Personal Fall Protection is a system that is used to arrest an employee in a fall from
a working level. The fall protection must consist of a body harness, a lanyard with a
deceleration device, and an anchorage point or lifeline, with approved hooking devices as
specified in GSO #5.
14.3 Travel Limiting is a system consisting of a body harness, lanyard, and anchorage
that prevents a person from an exposure to a fall. The length of the lanyard must prevent
the person from reaching the free fall hazard.
14.4 Work Positioning is a system consisting of a body harness, lanyards, and anchorage
devices rigged to allow a person to be supported on an elevated vertical surface, such as a
wall or fixed ladder, and work with both hands free.
14.5 All fall protection equipment shall be visually inspected for damage and defects
prior to use. See GSO #5 Fall Protection Program Section 32 for correct procedures.
14.6 Fall protection equipment shall be adjusted to minimize the drop in case of a fall.
The potential free fall distances should never exceed 6 ft. The anchorage point for tie off
should be at or above the D-ring level on the body harness whenever possible.
14.7 In considering the most desirable anchorage for tie-off, any sharp object that the
lanyard may contact while at the work location or during a possible fall must be avoided.
Lanyards must never be tied off to shafts or other parts of machinery which are subject to
movement or rotation.
14.8 Anchorage Points must be capable of supporting 5,000 lb. per employee attached. If
there is any doubt about the strength of the anchorage point, do not tie off; notify your
supervisor and find an alternative anchorage point.
14.9 Anchorage locations should; reduce possible free fall distance, prevent swing fall
hazards, and provide clear space in the potential fall path to avoid striking an object.
14.10 Use caution while wearing a body harness and lanyard when you are not tied off.
Wear the lanyard in such a manner that it will not get caught on or in equipment,
structures, or moving machinery.

14.10.1 All adjustment straps of the body harness shall be kept snug against the
body.
14.10.2 No part of the lanyard shall be allowed to dangle freely when not tied off.
The lanyard shall be secured tightly against the user's body.
14.11 Do not climb, walk, or stand on building and/or machinery, piping, conduit or
structural support members. They are not designed to be climbing, walking, or working
surfaces. Alternate means (i.e. ladders, scaffolds, man lifts, etc.) shall be used to reach the
work area.
14.11.1 When directed by supervision to climb, walk and work on machinery or
equipment to perform a specific job, the following shall apply:
-Appropriate walking working surfaces will be established for both the
path or travel and the work area to avoid walking or standing on piping,
conduit, etc.
-Fall hazards will be assessed and tie off points designated for both the
work area and the path of travel.
-Appropriate personal fall protection (i.e. body harness, lanyard or
retractable) will be worn by all employees exposed to the fall hazard.

15

Vehicles: Operation & Care

15.1 Industrial Vehicles includes all powered industrial trucks (PIT), fork trucks, tractors,
platform lift trucks, trucks, cars, motorized personnel carts, material handling wheeled or
tracked Industrial Vehicles and other specialized industrial trucks powered by electric motors or
internal combustion engines used exclusively in the industrial setting.
The term "Industrial Vehicle" will be used to mean all of the above in Section 15.
Refer to the Mobile Equipment Safety Handbook for additional specific rules pertaining to
Powered Industrial Trucks (PIT).
15.1.1 Only employees authorized by the company as being physically fit and thoroughly trained
are permitted to operate Industrial Vehicles.
15.1.2 If riding in or operating this type of equipment is not your job, stay off of the equipment.
15.2 At the beginning of each work shift, operators shall inspect and test their assigned Industrial
Vehicle to determine if it is in safe operating condition.
15.2.1 A daily checklist shall be completed and signed by the operator.
15.2.2 If any inadequacies in the operation, non functioning safety devices or other deficiencies
effecting safe operation of the Industrial Vehicles are recorded or noted at inspection, the
operator will make immediate notification to the appropriate manager or designee..
15.2.3 The defective equipment shall not be operated until the repairs are made or operation is
authorized by the appropriate manager or designee
15.2.4 The following list is of the minimally required safety devices that shall be functioning
properly in order to operate the Industrial Vehicle:
15.2.4.1 Yellow Caution Light
15.2.4.2 Head Lights, if equipped
15.2.4.3 Tail Lights, if equipped
15.2.4.4 Turn Signals, if equipped
15.2.4.5 Back Up Alarm
15.2.4.6 Horn
15.2.4.7 Cameras, if equipped
15.2.4.8 Brakes, both parking and running
15.2.4.9 Seatbelts
15.2.4.10 Deadman switch (scissors lifts and articulating boom lifts)
15.2.4.11 Speed Control or governors
15.2.5 Operators shall not remove or make inoperative any safety device such as seat belts,
running lights, warning alarm, strobe lights, revolving lights, guards, back-up alarm speed
governor, fire extinguisher, etc.

15.2.6 Industrial Vehicles operators shall inspect the condition of steps and hand-holds/grab
irons prior to mounting and dismounting Industrial Vehicles equipment.
15.2.7 Yellow rotating or flashing beacons, and backup alarms will be used on all maintenance
and operations Industrial Vehicles operating within the plant. Industrial Vehicles include those
used for hauling work supplies, doing excavation, grading work, crew transportation, etc.
This policy includes personal Industrial Vehicles if they are used for such business purposes.
15.3 Authorized Industrial Vehicle operators shall abide by all traffic regulations and be alert for
pedestrians.
15.4 Do not stay in the cab or truck while loading or unloading with a crane.
15.5 Unattended Industrial Vehicles shall have the engine shut off and parking brake set or
block the wheels to prevent unexpected movement.
15.5.1 All Industrial Vehicles, including personal Industrial Vehicles, with automatic
transmissions shall be placed in park with the engine off and the parking brake set when leaving
the Industrial Vehicle unattended on plant property.
15.5.2 All Industrial Vehicles, including personal Industrial Vehicles, with manual
transmissions shall be placed in gear with the engine off and the parking brake set when leaving
the Industrial Vehicle unattended on plant property.
15.5.3 Industrial Vehicles not equipped with air brakes can be left running and unattended in
temperatures below 35 degrees F. with the emergency brake set and chocks set behind and in
front of a rear wheel. Air brakes must be set on Industrial Vehicles that are equipped with them.
15.6 Industrial Vehicle operators must not permit unauthorized riders on their Industrial
Vehicles.
15.6.1 Employees are permitted on Industrial Vehicles authorized to carry riders only when their
duties require them to become riders.
15.6.2 Riders are never permitted on Industrial Vehicles for which a "no rider" ban applies.
15.6.3 Riders are not permitted to ride in the back of pickup trucks or other l Industrial Vehicles
that do not have specifically approved seats and seat belts.
15.6.4 If you are authorized to ride in an Industrial Vehicle, do not allow any part of your body
to hang over the edge.
15.6.5 Do not jump off of a moving Industrial Vehicle.
15.6.6 Do not ride in an Industrial Vehicle with unsecured loads.
15.7 When riding in Industrial Vehicles always keep your body parts inside the running lines of
the Industrial Vehicle.

15.8 Pedestrians must be aware of plant Industrial Vehicle movement when walking through
buildings or yards.
15.8.1 Do not walk beside Industrial Vehicles equipment while it is in motion.
15.8.2 Do not assume the Industrial Vehicle operator can see you. Be prepared for sudden turns
or the Industrial Vehicle backing up.
15.9 Spotter (This rule does not apply to powered industrial trucks used for routine operations)
15.9.1 A Spotter shall be assigned to assist any AK Steel, Contractor, or "Over-the-road" trucks
or equipment that are required to back into an AK Steel Building.
15.9.2 A Spotter shall be assigned when operating equipment inside buildings and a minimum
of 10 feet cannot be maintained on both sides of the Industrial Vehicle.
15.9.3 A Spotter shall be assigned if the Industrial Vehicle has limited or restricted visibility in
the direction of travel.
15.9.3.1 A Spotter is required for Industrial Vehicles that are 8 feet or wider that are backing into
an outdoor location that is less than 30 feet wide between the structures, buildings or other fixed
obstacles.
15.9.3.2 A Spotter required for Industrial Vehicles that are 8 feet or wider that are backing into
an outdoor location that is greater than 30 feet wide between structures, buildings or other fixed
obstacles, if Industrial Industrial Vehicles, materials, equipment or other obstructions reduces
the width to less than 30 feet.
15.9.3.3 Signs indicating a Spotter is required for backing in shall be posted at the entrance to
each location meeting the requirements of 15.9.3.1 or 15.9.3.2.
15.9.4 A Spotter shall wear a high-visibility vest for identification and have an air horn or other
device to warn unauthorized people away from area.
15.9.5 The Industrial Vehicle operators shall maintain visual and/or radio communication with
the Spotter before initiating any movement of the Industrial Vehicle.
15.9.6 If visual contact and/or radio communication is lost or restricted, no movement shall
occur until contact and/or radio communication is restored.
15.9.7 The Industrial Vehicle operator shall not move the Industrial Vehicle until given direction
to do so by the Spotter and the Spotter is a minimum of 10 feet away from the equipment.
15.9.8 A Spotter shall assure that all equipment and people are in the clear before giving
direction to move the Industrial Vehicle.
15.9.9 A Spotter shall assure that all equipment and people are in the clear before giving
direction to move the Industrial Vehicle.

15.9.10 Each plant shall review shipping doors and if there is minimal risk of personal injury or
AK Steel property damage, the an exemption to the aforementioned requirements can be issued,
with the Plant Manager and Safety Manager approval.
15.9.11 Signs shall be posted at each truck door indicating the door number, the open height of
the door, sound horn prior to entering and a Spotter is required or not.
15.9.12 All truck doors shall have the lower inside and outside edge of the door (~ 18 inches)
and the sides of the door opening painted with high visibility paint.
15.10 Employees working in the area of mobile equipment must be aware of the movement
capabilities of the equipment to include the swing radius of Industrial Vehicles with rear
steering. Whenever possible, maintain a minimum distance of 10 feet from the mobile
equipment while it is moving.
15.11 Operators of plant Industrial Vehicles are not to transport loads which are unstable or
above the rated capacity of their Industrial Vehicles.
15.12 Mobile cranes are not to be used to transport materials on the hook to and from the job
site.
15.13 Never use a fork lift or similar Industrial Vehicle as a working platform or allow yourself
to be hoisted from one level to another unless a specially designed platform is provided and you
have been authorized to use the Industrial Vehicle in this way. The platform must be secured to
the fork lift, and the fork lift operator must remain
at the controls at all times while the platform is in use.
15.14 When a powered industrial truck is left unattended, the load lifting device shall be fully
lowered, controls neutralized, power shut off and brakes set. Wheels shall be blocked if the truck
is parked on an incline.
15.15 When an Industrial Vehicle is being refueled or serviced, the motor must be shut off.
Gasoline refueling is also to take place out of doors at a location which is well in the clear of
ignition sources. The Industrial Vehicle being refueled must be attended the entire time during
the fueling process.
The following sign must be attached to or next to the fuel pump.
WARNING: This is a designated "No Smoking" area.
15.15.1 All fuel loading nozzles on AK Steel property shall have the trigger hold down rack
removed.
15.15.2 No object shall be placed in the handle that will defeat the automatic shut-off at any
time during the fueling.
15.15.3 AK Steel employees shall use approved rolling step platforms with hand rails to climb
onto and off of truck and trailer beds.
15.15.4 Do not use a cell phone while refueling.

15.16 Operators shall use access ladders and provided steps and/or ladders to get on or off the
equipment. Do not jump from the Industrial Vehicle to the ground. Alertness, firm footing, and
firm grip on hand holds must be maintained when boarding and dismounting equipment.
Hand holds and steps shall be part of the daily inspection to assure their integrity.
15.17 Be alert for other moving equipment, debris, obstructions, product, or uneven ground
surfaces which may be in the area when boarding or dismounting the Industrial Vehicle.
15.18 Slow the Industrial Vehicle down and give adequate warning by sounding the horn or
audio warning alarm signal when entering or exiting buildings, or when approaching corners,
blind spots, cross aisles, pedestrians, or where employees are working. Operate the Industrial
Vehicle with caution.
Sounding of the horn or alarm does not give the operator of the equipment the right of way.
15.19 Industrial Vehicles shall not be parked closer than six feet from the outer rail of the nearest
operating railroad track.
15.20 Operators shall always keep their Industrial Vehicles under control and shall be required to
look in the direction of, and keep a clear view of, the path of travel.
15.21 Stunt driving and horseplay shall not be permitted.
15.22 Industrial Vehicles shall not be placed in motion until the operator makes certain the
Industrial Vehicle movement will not endanger another person's safety or damage material or
equipment. Loads will be secured in such a manner to prevent shifting before the Industrial
Vehicle is placed in motion.
15.22.1 When an authorized Industrial Vehicle operator leaves a plant Industrial Vehicle
unattended, they shall, upon returning to the Industrial Vehicle, perform a visual
inspection along all sides of the Industrial Vehicle before placing the Industrial Vehicle
in motion. This is to assure that changing conditions that might endanger the operator,
other persons, or damage material or equipment have not occurred while the Industrial
Vehicle was left unattended.
15.22.2 Employees working on, under, or in the path of parked Industrial Vehicles, must
assure the Industrial Vehicle will not move by; blocking the wheels, shutting down and/or
locking out, positioning a Safety Attendant, or a combination of these methods.
15.23 Operators shall be aware of overhead crane movements. Maintain a safe distance with your
Industrial Vehicle when crane movements are being made.
15.24 If a Industrial Vehicle operator is involved in an accident with their equipment, such as
injury to personnel or damage to a building, structure, machinery, equipment, products,
materials, etc., the operator shall immediately report the occurrence to their supervisor regardless
of how minor the injury or property damage may appear.
15.25 When following behind large Industrial Vehicles (Eucs, tractor/trailers, coil trucks, dump
trucks, flush trucks, spray trucks, sweeper trucks, front end loaders, etc.) stay back far enough to
allow you to see the mirrors of the equipment you are following at all times. If specific following

distances are established by Plant or Department Rules, they shall be complied with. A minimum
following distance of 100 feet shall be maintained behind moving large Industrial Vehicles and
at stop signs. Be prepared for the equipment in front of you to have to reverse its direction of
travel.
15.26 Parabolic mirrors shall be installed on all plant Industrial Vehicles equipped with side
mirrors.
15.27 Seat belts must be worn by Industrial Vehicle operators and passengers at all times on
company property. If the seat belt is damaged or missing, report it to your supervisor
immediately.
15.27.1 Industrial Vehicle operators and passengers driving off company property but on
company business must wear seat belts at all times.
15.27.2 In the event of a Industrial Vehicle tip over, seat belts shall not be released until
the Industrial Vehicle motion has stopped. Operators should never attempt to jump free
of a Industrial Vehicle that is tipping over.
15.28 Pneumatic filled, tube or tubeless tires with multi-piece and bolt-together rim wheels.
i. "Multi-piece wheel" means a Industrial Vehicle wheel consisting of two or more
parts, one of which is a side locking ring designed to hold the tire on the wheel by
interlocking components when the tire is inflated.
ii. "Rim wheel" means an assemblage of tire, tube and liner (where appropriate), and
wheel components.
iii. "Installing a rim wheel" means the transfer and attachment of an assembled rim wheel
onto a Industrial Vehicle axle hub. "Removing" means the opposite of installing.
iv. "Mounting a tire" means assembling or putting together of the tire and wheel
components to for a rim wheel, including inflation. "Demounting means the opposite
of mounting.
15.28.1 Servicing of pneumatic filled, tube or tubeless tires with multi-piece wheels on
large Industrial Vehicles such as Eucs, tractor/trailers, coil trucks, off-road machines, etc.
shall not be performed by AK Steel employees except as follows:
15.28.1.1 Removing the rim wheel assembly from a Industrial Vehicle. (DO
NOT demount the tire from the wheel assembly). Before loosening any nuts or
clamps that attach a rim wheel assembly to a Industrial Vehicle always
completely deflate the tire (or both tires of a dual assembly) with a standoff
device. Once the tire is completely deflated, the valve core(s) shall be removed..
15.28.1.2 Adding air to a tire on a Industrial Vehicle that is under inflated but has
more than 80 percent of the recommended pressure. The rim wheel installed on
an Industrial Vehicle shall be inspected to assure all clamps and lug nuts are in
place and properly tightened. The tire may be inflated while the rim wheel is on
the Industrial Vehicle provided remote control or stand-off inflation equipment is
used, and no employees remain in the trajectory during inflation.

DO NOT add air to a tire that is under inflated below 80 percent of the
recommended pressure. These tires must be completely deflated and
serviced by trained and competent contractors.
NOTE: Trajectory of the air or rim wheel is any potential path or route (basically along
the axis of the rim wheel) that a rim wheel components may travel during an explosive
separation, or the area into which the air blast may be released.
15.28.2 Servicing of pneumatic filled, or tubeless tires with multi-piece wheels on large
Industrial Vehicle such as Eucs, tractor/trailers, coil trucks, off-road machines, etc. shall
not be performed by contractor employees on AK steel property except as follows:
15.28.2.1 Trained and competent contractors may install pneumatic filled, tub or
tubeless tires with multi-piece rim wheels onto Industrial Vehicles using
equipment and procedures as set forth in Federal., State, local and manufacturers
standards.
15.28.2.1.1 Prior approval from the Plant Manager is required before the
contractor installs pneumatic filled, tube or tubeless tires with multi-piece
wheels onto Industrial Vehicles.
15.28.2.2 Trained and competent contractors may demount and mount tires onto
large Industrial Vehicle that have a rim assembly that cannot be readily removed
from the axle using equipment and procedures as set forth in Federal, State, local
and manufacturers' standards.
15.28.2.2.1 Prior approval from the Plant Manager is required before the
contractor demount and mount tires onto large Industrial Vehicles that
have a rim assembly that cannot be readily removed from the axle using
equipment.
15.28.2.3 Removing the rim wheel from a Industrial Vehicle. Before loosening
any nuts or clamps that attach a rim wheel to a Industrial Vehicle always
completely deflate the tire (or both tires of a dual assembly) with a standoff
device. Once the tire is completely deflated, the valve core(s) shall be removed.
15.28.2.4 Adding air to a tire on a Industrial Vehicle that us under inflated but
has more than 80 percent of the recommended pressure. The rim wheel installed
on a Industrial Vehicle shall be inspected to assure all clamps and lug nuts are in
place and properly tightened. The tire may be inflated while the rim wheel is on
the Industrial Vehicle provided remote control or stand-off inflation equipment is
used, and no employees remain in the trajectory during inflation.
DO NOT add air to a tire that is under inflated below 80 percent of the
recommended pressure. These tires must be completely deflated by
removing the valve core prior to being serviced by trained and competent
contractors.

NOTE: Trajectory of the air or rim wheel is any potential path or route (basically along
the axis of the rim wheel) that a rim wheel component may travel during an explosive
separation, or the areas into which the air blast may be released.
15.28.3 Bolt together rim wheels can be installed on AK Steel property by AK Steel
employees or trained and competent contractors using equipment and procedures as set
forth by Federal, State local and manufacturers' standards.
15.28.4 Rim wheels with foam or solid tires can be installed on AK Steel property by
AK Steel employees and trained and competent contractors using equipment and
procedures as set forth by Federal, State, local and manufacturers' standards.
15.29 Industrial Vehicle Tires
15.29.1 Tires on large Industrial Vehicles such as Eucs, tractor/trailers, coil trucks, offroad Industrial Vehicles etc. shall be given daily visual tire inspection and air pressure
check with the results documented in writing.
15.29.1.1 Procedures will also be developed for the weekly and monthly
inspections of large Industrial Vehicle tires with written documentation.
15.29.2 Patch repairs may be made to large Industrial Vehicle tires but those tires shall
then only be used as rear or non-steering tire on the Industrial Vehicle.
15.29.2.1 Section repairs shall not be permitted on AK Steel large Industrial
Vehicle tires.
15.30 Motorized Utility Industrial Vehicles (Cushman Carts, Golf Cart, Gators etc.)
15.30.1 Motorized utility Industrial Vehicles used for the transportation of employees,
tools, parts and materials shall be equipped with seat belts for the operator and all
passengers.
15.30.2 Motorized utility Industrial Vehicle operators and passengers shall be seated in
the Industrial Vehicle with their seat belts fastened before engaging the directional lever
on an electric Industrial Vehicle or starting the engine on an internal combustion
Industrial Vehicle.
15.30.3 Operators and passengers shall keep arms and feet inside the utility Industrial
Vehicle when the Industrial Vehicle is in motion. Do not jump off a moving Industrial
Vehicle.
15.30.4 Motorized utility Industrial Vehicles shall not exceed a speed of 5 mph when
being operated inside a building. Watch for pedestrians, pedestrians have the right of
way. Sounding the horn or alarm does not give the operator of the Industrial Vehicle the
right of way.
15.30.5 Be aware of crane movement, railroad switching, and other mobile equipment
while traveling inside a building.

15.30.6 Be aware of uneven floors, uneven or missing floor plates, and/or water, grease
or other debris on the floor that could cause a loss of control while driving a utility
Industrial Vehicle.
15.31 Self-Propelled Elevated Work Platforms (scissor lifts) and Boom-Supported Elevated
Work Platforms (JLG type lifts).
15.31.1 Leased, rented, or purchased aerial platforms shall have a nameplate indicating
that the units were constructed to meet applicable ANSI/SIA
standards for the particular units based on the manufacture or remanufacture date.
15.31.2 Leased, rented, or purchased aerial platforms shall be inspected and maintained
to meet owner/or user requirements according to the
applicable ANSI/SIA standard based on the manufacture or remanufacture date.
15.31.3 Leased, rented, or purchased aerial platforms shall be provided with Operator
Controls (upper directional controls) at the platform, and minimally shall:
i. Include an enabling device/control which:
ii. Shall be continuously activated by the operator for upper directinal controls to be
operational, and
iii. Shall render the upper controls inoperative when released by the operator.
iv. Automatically returns to the "off" or "neutral" position when released, if used to
control any movement of the aerial platform (Self-Centering type Controllers)
v. Be protected against activation other than that initiated by the operator.
vi. Be clearly marked.
15.31.4 Leased, rented, or purchased aerial platforms shall be equipped with clearly
marked emergency lowering means readily accessible from ground level.
15.31.4.1 It is not permitted to operate the elevated platform with employees on
the platform from the lower controls except to lower in an emergency situation.
15.31.5 Inspections
15.31.5.1 Pre-Shift (frequent) inspection shall be performed prior to using the
aerial platform. The inspection shall be in accordance with items specified for
owners and users of the aerial platform.
15.31.5.2 Annual Inspection shall be performed by a person qualified as a
mechanic on the specific make and model of the aerial platform. The inspection
shall be in accordance with items specified by the manufacturer.
15.31.6 The operating manual and maintenance manual shall be provided and shall be
stored in the weather resistant storage compartment on the aerial platform.
15.31.7 Prior to operating an aerial platform, the operator shall be properly trained by a
qualified trainer and shall be familiar with the controls and operations of the specific
aerial platform being used.

16

Railroad Equipment & Tracks

16.1 Obey all signs and always look both ways before crossing railroad tracks when
walking or driving - the railroad has the right-of-way. A burning Fusie is to be treated the
same as a Stop sign at railroad crossing points. Cross tracks inside or outside of buildings
at the regular crossing points. Do not step or stand on rails when crossing. If a railroad
crew is present, do not cross the rails until the crew directs you to cross.
16.2 Do not go under, over, on, or in a locomotive or other railroad car for any purpose or
work on or near any railroad track unless your work requires it. If you are authorized to
work on or near cars or tracks, follow General Safety Order #3, (Working on or About
Railroad Tracks Section 30).
16.3 When loading or unloading trucks on or close to railroad tracks, you must take the
responsibility for safeguarding yourself against being struck by railroad equipment by
using positive track protective devices as specified in General Safety Order #3.
16.4 Do not remove a working crew's protective devices unless you placed it. Crews
placing the protective devices shall remove them when the work is completed and the
protection is no longer required.
16.5 When piling materials near the track, allow at least six feet from the outer rail of the
track. Do not otherwise obstruct the view of train crews.
16.6 Unauthorized persons are not permitted to ride engines, locomotive cranes, or
railroad cars.
16.6.1 Radio Controlled Locomotive (RCL) Operators and brakemen are
permitted to ride in the cab or on the deck of the locomotive when no railcars are
coupled to the locomotive. Riding the steps of the locomotive is not permitted.
16.6.2 Radio Controlled Locomotive (RCL) Operators and brakemen are
permitted to ride in the cab, on the deck or on the upper steps of the locomotive
when coupled to railcars and Line of Sight/Head End Protection is being provided
from the locomotive.
16.6.3 Employees shall not ride the bottom step of a locomotive.
16.6.4 Prior to initiating movement, the Radio Controlled Locomotive (RCL)
Operators shall verify all personnel including themselves, are outside the running
lines of the railroad cars.
16.6.5 Radio Controlled Locomotive (RCL) Operators shall wear vest/body
harness systems specified by the radio control manufacturer and/or approved by
AK Steel Safety Department. Tear-away style vest/body harness systems shall be
required if a caught-on hazard exist during routine operations.

16.6.6 Radio Controlled Locomotive (RCL) Operators, Brakeman and Track

Crews shall wear high visibility jackets, vest or shirts while in the railroad
operational areas.
16.6.7 During low visibility conditions, fog, rain, snow and dusk to dawn, the
Radio Controlled Locomotive (RCL) Operators, Brakeman and Track Crews shall
wear an operating Red Flashing Light Mounted on Hard Hat.
16.7 Stay at a safe distance from equipment transporting any type of hot or molten
substances. Radiant heat and the erupting and/or splashing of molten substances on
railroad cars can occur, causing serious hazards.
16.8 When passing ends of railroad cars, engines or locomotive cranes, maintain a
distance of at least 20 feet from the cars.
16.9 Only authorized persons are permitted to move cars. Never release brakes or remove
blocking unless this is part of your regular job.
16.9.1 Railroad cars are not to be pushed or pulled with brakes set (air or hand)
while on AK Steel property or by authorized AK Steel employees.
16.9.1.1 Any/all exceptions to this rule are to be approved by the plant
manager and plant safety department and incorporated in a JSHA.
16.9.2 Railroad cars are not to be pushed or pulled over manufactured metal
chocks or oak wood chocks.
16.9.3 Gondola railcars shall not be loaded with loose scrap (P&S, shredded
scrap, etc.) piled higher than 18 inches in the center or above the railcar sides or
ends.
16.9.4 Gondola railcars shall not be switched with loose scrap (P&S, shredded
scrap, etc,) piled higher than 18 inches in the center or above the railcar sides or
ends.
16.10 Railroad crews must maintain control of their engines and trains at all times. The
practice of "kicking" cars is not permitted on AK Steel property.
16.10.1Railroad operations are permitted to move railroad cars that are not
positively controlled by the locomotive at Middletown Works Coal, Coke and
Ore Dumpers and Ashland Works Ore Dumper

16.11 Be especially alert in railroad track areas that have been posted "close clearance".
16.12 When walking close to railroad track the following additional rules shall be
observed.

16.12.1 Do not stand or walk parallel between rails of a track.

16.12.2 Observe both directions while walking close to a track.
16.12.3 Expect the movement of trains, locomotives, or cars at any time in either
direction.
16.12.4 Maintain a safe distance from passing trains to avoid injury from falling
objects or projecting materials.
16.12.5 Do not stand with your back towards passing cars, locomotives, or other
moving equipment.
16.12.6 Do not step in between railcars to release couplings while cars are
moving.
16.12.7 All movement of railcars shall be stopped and they shall be at least 20
feet apart before making adjustments to the drawheads.
16.12.8 Never use feet to adjust couplers and/or knuckles.

16.13 In addition to safety rules for railroad equipment and tracks, General Safety Order
#3., and Plant Instructions for Railroad Crews detailing safe practices are to be strictly
observed. See General Safety Order #3 Working On or About Railroad Tracks Section
30.
16.14 Manufactured metal chocks or oak woodchocks with handles shall be set under the
wheels of railroad cars to prevent the unplanned movement of the car/cars while being
worked on or when placed in storage.

16.14.1 Manufactured metals chocks shall be equipped with handles that will
allow their placement and removal from the side of the wheel to avoid pinch
points between the wheel, chocks, and tracks.
16.14.2 Oak wood chocks with handles shall be manufactured to comply with AK
Steel Corporate Drawing Number CHQSA0001. The handle shall allow the
placement and removal of the chock from the side of the wheel to avoid the pinch
points between the wheel, chock, and track.

16.15 Separating Rails by Torch Cutting, Saw Cutting or Unbolting Joint Bars

16.15.1 ALL initial rail separations will be treated as a rail under tension.
16.15.2 A piece of mobile equipment shall be placed on the rails to secure
movement.

16.15.3 A Red Zone shall be established around the rail to be separated to prevent
access except for the employee cutting or separating the rail.
16.15.4 While burning or unbolting the rail, the employee shall not reach across
the rail to perform the task.
16.15.5 If torch cutting the rail, a 48" long torch handle at least shall be used to
cut the rail.
16.15.6 A Safety Task Assessment Card shall be completed at the job site by the
work group, reviewed by the group and then signed by a manager or a crew chief
before cutting or separating any rail.

17

Piling, Storing, Loading & Manual Material Handling

17.1 Always use good judgment when piling materials. A solid, level base is necessary.
Observe all height requirements for your area and be sure all material is piled straight. If
you must pile different sizes of lifts of flat steel, coils or other items, the wider material
must be on the bottom.
17.2 Follow the safe practice in your department for blocking materials to prevent rolling
or falling. Check blocking to make sure that removing material will not result in a spill or
shifting in other parts of the pile.
17.3 Designated aisles, walkways or passageways shall not be blocked or obstructed by
materials. Access to emergency devices, such as fire hydrants, extinguishers, stretchers,
control valves, electrical switch boxes, shall be maintained at all times and shall not be
obstructed by any materials.
17.4 When storing materials in bins or on shelves, put heavier items on the lower level.
Avoid overloading shelves and overhead storage areas. Never store materials on shelves,
roofs, or other flat structures unless they are rated and load posted. Shelves, cabinets,
lockers, tool boxes, etc. must be bolted to the wall or floor to prevent tip-over. Storage
capacity must be marked on all shelving designed for industrial storage.
17.4.1 Items in storage that weigh 50 pounds or more should be secured to a pallet
and accessible to a forklift or other mechanical means for safe handling and
storage.
17.5 Employees are not permitted to climb on piled sheets, slabs, scrap, coal, coke,
plates, coils, pipe, or other material except in the discharge of their regular duties under
the direction of supervision.
17.6 When piling, do not throw materials onto the pile. Place your materials into position.
Take care to avoid crushing fingers between materials and the top of the pile.
17.7 Loading & Unloading
17.7.1 Know the safe load limits and the approved methods of securing loads of
piled materials. Never load any material handling equipment such as trailers,
trucks, buggies, elevators, etc., beyond its safe limit. Tie or band material if
necessary to prevent shifting.
17.7.2 Always check the condition of the floor of trucks and railroad cars for
holes or weak spots. Report defective cars or trucks to your supervisor before
working in them.
17.7.2.1 Truck beds or railroad car beds that contain debris (i.e.: paper,
plastic, dunnage, etc.) must be cleaned to allow inspection of the integrity
of the floor before beginning work.

17.7.2.2 Employees shall not walk or work on a truck bed or in a railcar

while stepping on paper, plastic, or any other debris. Report trucks or
railcars with excessive debris to your supervisor to determine cleaning
requirements.
17.7.3 Only properly trained and authorized personnel are permitted to load or
unload tank cars and trucks containing flammable liquids. Open flames, spark
producing devices and unprotected electrical devices must be removed from the
area before proceeding with the loading or unloading of flammable liquids.
Specific job procedures must be developed for each chemical, a current SDS must
be available on site, and all required Personal Protective Equipment must be worn
during the operation. If in doubt, check with your supervisor.
17.7.4 Stay away from all tank cars or trucks if you are not trained and equipped
to work with the potentially hazardous chemical that they might contain.
17.7.5 Each plant/department shall develop specific procedures for the loading
and unloading of trucks, railcars, and bulk storage containing acids, caustics, or
other potentially harmful chemicals or materials designated by the department.
17.7.5.1 The plant/department shall develop procedures and assign
responsibilities for the acceptance of loading and off-loading of
chemicals/materials when shipped/received by bulk delivery truck. The
procedures shall at a minimum include the following.
17.7.5.1.1 Security shall notify designated AK personnel of
contract employees that a truck to be loaded/off-loaded has arrived.
17.7.5.1.2 Designated personnel shall be assigned to review the
truck driver's paperwork to include:
(a) Bill of lading of manifest.
(b) Placards/labels.
(c) SDS.
(d) Certificate of analysis (if applicable).
(e) Plant destination or Door number. The designated person shall
also verify that the driver has at a minimum, all PPE as outlined in
the SDS, and required by AK Steel, for the material to be
loaded/off-loaded.
17.7.5.1.3 The truck shall be directed or escorted to the specific
loading/off-loading area. A ground guide/operator shall assist the
truck driver when positioning the truck at the load/unload station to assure the truck does not strike the adjacent tanks, pipes,
structures, etc. Once positioned, the truck wheels shall be chocked
and the truck driver shall be instructed to not move the vehicle
without authorization and assistance of the guide/operator.

17.7.5.1.4 The loading/unloading area shall be secured by a

positive barrier (e.g. chains, cables, retractable straps, removable
standard railings, saw horses - RED DANGER TAPE SHALL
NOT BE USED FOR THIS PURPOSE) and designated by signs at
all potential entry locations. Signs shall warn all employees not
associated with the loading/unloading to stay out of the designated
area.
17.7.5.1.5 A positive verification shall be established to assure the
delivered material is off-loaded into the proper storage tank,
shipped material is loaded into the proper truck and that the
tank/truck capacity will hold the volume of the full loaded/offloaded product.
17.7.5.1.6 A two lock control system shall be developed by the
plant/department to prevent off-loading material into the wrong
storage tank or loading the wrong material into a truck.
17.7.5.1.7 The loading/unloading station safety shower eyewash
shall be verified operational, and a water hose for decontamination
purposes shall be charged and positioned in the immediate area,
before operating any valves or starting hook-up for the loading or
off-loading.
17.7.5.1.8 A designated AK or contract employee shall monitor the
truck hook up to the proper facility receptacle; verify that no leaks
exist at the start of loading/unloading and that the driver is wearing
all required PPE for the material being loaded/off-loaded. The
designated employee must understand which jobs are performed by
the truck driver and which jobs they must perform as specified by
JSHA and Department Procedures.
17.7.6 Employees, Contractors, or Vendor Truck Drivers shall not walk or work
on the top of trucks, trailers, and railroad cars unless protected by an approved
handrail system or a full body harness fall arrest system.
i. This rule applies to all tank or bulk material trucks and rail cars and any other
truck or rail car of a similar height or configuration.
ii. This rule does not apply to flat-bed or specialty coil trucks and rail cars
typically used to ship and receive steel product, production machinery, or
operating supplies.
17.7.7 Employees, Contractors, or Vendor Truck Drivers may climb and work
from permanently affixed truck and rail car ladders, without the use of a full body
harness fall arrest system, when the worker can maintain a 3-point touch (two
hands and one foot or two feet and one hand) on the ladder at all times.
17.8 Manual Material Handling

17.8.1 Learn to lift the right way to avoid strains. To safely lift and/or manually
transfer materials from one location to another:
17.8.1.1 Determine the weight of the object or material to be moved
before lifting. If the object or material weighs 50 pounds or more or by
the shape of the load is difficult to safely handle either use mechanical
lifting equipment or a second person to complete the lift. If an item
weighs 50 pounds or more and can only be lifted by 1 person and
mechanical lifting equipment is not capable of assisting, then the task shall
be reviewed and approved by Department Management prior to
performing the lift. This approval shall be documented in the applicable
JSHA and/or the Safety Tasks Assessment Card.
17.8.1.2 Position your feet before you lift to reduce twisting with the load
and to maintain your balance while lifting.
17.8.1.3 Bend your knees and hips when lifting. Bring the material in as
close to your body as possible and keep your back straight. Lift slowly
with your leg and arm muscles avoid jerking the load!
17.8.1.4 Dont twist or extend your torso while lifting or transferring
material. After lifting vertically, move your feet in the direction of travel.
If the load interferes with normal walking, GET HELP! Always have a
clear vision over the load.
17.8.2 Before you lift, examine the material to be lifted. Check for nails, sharp
edges, slivers or other objects which might injure you. Look over the ground for
obstacles and tripping hazards. Do not try to change positions or adjust your grip
on the load while you are carrying it. Rest the load against something for support
and then make the change. When you set your load down, be sure to allow for
finger clearance. Bring the object to rest on its edge or place it on a block until
you can get your fingers out from under.
17.8.3 When lifting or carrying materials with a co-worker, use good
communications and coordinate your actions.
17.8.4 Never over exert yourself when lifting, pushing, pulling or otherwise
attempting to move or position materials, tools, or equipment. Report the
condition to your supervisor and review the procedure to determine how to
complete the task in a manner that will eliminate over exertion.
17.8.5 Do not use a ladder for items that are stored in a location that requires two
or more persons to lift. Utilize the proper equipment to access (forklift, scissors
lift, etc.)
18

Excavations, Floors, & Pit Openings

18.1 Unless authorized by your supervisor, do not start digging or excavating in any plant
area and then, only after the completion of an excavation permit. Supervision must check
with the plant Engineering Department for existence of pipes or conduits in the area to be
excavated. Should the excavation come upon pipes, conduits, or red plastic tape, work
must be stopped at once and supervision notified.
18.2 Excavation work 4 feet or deeper shall be considered a confined space and shall
have a confined space permit.
18.2.1 Every excavation which is four feet or deeper shall be continuously
monitored with a gas monitor capable of monitoring at a minimum Oxygen,
Carbon Monoxide, and L.E.L. (Lower Explosive Limit).
18.3 Employees making excavations, openings in floors or removing covers from sewers,
manholes, valve pits, trenches, etc., are responsible for safeguarding them by erecting
proper guards or barricades with signs. At night, warning lights shall be used to warn
others of the danger. Deep trenches or excavations (over four feet) must be properly
shored, sloped, or braced to guard against cave-in. All excavated material must be piled
at least three feet back from the edge of the excavation.
18.4 Floor openings, such as pits, chutes, trap doors, manholes, and hatchways, shall be
guarded by a floor opening cover of standard strength and construction, or standard
railing. If the cover or standard railing are not in place, the floor opening shall be
protected on all exposed sides by removable standard railing capable of withstanding 200
pounds of lateral force.
18.4.1 If it is not feasible to guard the floor opening with a removable standard
railing, the opening shall be constantly guarded by an attendant. The use of an
attendant to guard a floor opening shall be approved by the Department Manager.
18.4.1.1 The attendant shall not be assigned or perform other job tasks
while guarding floor openings.
18.4.1.2 The attendant shall maintain a minimum distance of 6 feet from
the edge of the floor opening.
18.4.1.3 The department may use barrier tape, cones, flags, sawhorses, etc.
to increase awareness of the floor opening. The attendant shall remain
outside the established perimeter. Barrier tape, cones, flags, sawhorses,
etc. shall never be used as the only means of floor opening protection.
18.5 Never step, leap, or jump over excavations, trenches, manholes, etc. Observe all
barricades. Never remove a barricade unless authorized to do so.
18.6 Report any unguarded excavation, trench, open manhole, shaft, etc. to your
supervisor immediately.
18.7 Piping trenches, valve pits, sewers, enclosed tanks, pipelines, etc., are confined
spaces. Never enter a confined space without an entry procedure and specific written

permission. Whenever possible, label all confined spaces as "Confined Space".

18.8 All soil at AK Steel is considered to be Class C, (as defined in OSHA's Construction
Standards) unless otherwise designated by the Excavation Permit issuer on the
Excavation Permit.

19

Fire Prevention & Firefighting

19.1 Prevent Fires
19.1.1 Follow fire prevention rules for your area and be alert to potential fire
hazards throughout the plant. Be aware that the danger of fires is higher in certain
areas of the plant and special precautions must be taken. Know the proper way of
responding to a fire and how to turn in an alarm in the area where you are
working. Know the emergency escape routes and the designated assembly points
should evacuation become necessary.
19.1.2 Always obey smoking regulations. Smoking is permitted in approved
smoking areas only. Smoking is not permitted in motor control centers, computer
rooms, electrical distribution areas, or within 50 feet of any flammable liquid or
gas storage area.
19.1.3 Do not allow rubbish or flammable materials to accumulate. Oily waste,
rags, gloves, etc., shall always be placed in receptacles provided for them.
19.1.4 Never pour gasoline, kerosene, oil, etc., or other flammable liquids down
drains or sewers. Flammable liquids are to be kept in self-closing, properly
labeled containers. Never use flammable liquids on materials around open flames.
19.1.5 Change your clothes immediately if they become soaked with oil, gasoline,
kerosene, naphtha, or other flammable or combustible materials. Stay far away
from salamanders, heating stoves, welding sparks, hot metal, and other sources of
fire if your clothing has been exposed to flammable or combustible liquids.
19.1.6 Do not light oil or gas furnaces, stoves, salamanders, or other heating
equipment unless you have been properly instructed and authorized. Never
deviate from specific written procedures when lighting furnaces, stoves,
salamanders, and heaters.
19.1.7 Flammable liquids (flash point under 100F) may be used only where there
are no open flames or other sources of ignition within any possible path of a vapor
trail. Do not dispense a flammable liquid into another container unless the nozzle
and container are properly grounded. Flammable liquids shall be disposed from
approved safety cans only.
19.1.8 Flammable liquids must be stored in a building, cabinet, or area
specifically designed for such storage and remote from general access or traffic.
The storage area must be properly identified and have a fire extinguisher readily
accessible.
19.2 Firefighting Equipment
19.2.1 Firefighting Equipment must not be used for any purpose except to put out
fires. Using fire hose for such jobs as washing down floors, walls, etc. is
prohibited unless specifically authorized by the Safety Department. Do not

obstruct aisles or block the paths to fire plugs, extinguishers, hose stands, and
other firefighting equipment.
19.2.2 Learn the location of the nearest fire extinguisher or fire hose in the area
where you work. Learn how to operate them and which type of fire extinguisher
to use on different types of fires, in their incipient or early stages.
19.2.2.1 All Fire Extinguishers must have metal tops and be mounted with
metal brackets. Plastic tops and brackets are not approved for use in AK
Steel.
19.2.3 Fire Classes
19.2.3.1 Class A fires involves ordinary combustibles like paper, wood,
cloth. Water is recommended, but any extinguisher rated A B C can be
used with reasonable success.
19.2.3.2 Class B fires involve grease, flammable liquids, and flammable
gas. They require the use of a blanketing or smothering type of
extinguisher such as foam, carbon dioxide (CO2), dry chemical, or water
fog. Use any extinguisher rated B or multipurpose A-l B-l C.
Caution: never pour water from containers or use an ordinary water hose
on these fires.
19.2.3.3 Class C fires involve electrical equipment. Use non-conductive
extinguishers such as dry chemical or carbon dioxide (CO2). Use any
extinguisher rated C or multipurpose A-l B-l C.
Caution: never use foam or water; they can be very dangerous and may
cause electrocution. If possible, pull the main electrical control switch.
19.2.3.4 Class D fires involve combustible metals such as magnesium,
titanium, certain suspended metal powders, or finely divided iron or steel
dust. Use only extinguishers rated D. (Special Dry Compound
extinguishing agents.)
19.2.3.5 The PASS method shall be used when using a fire extinguisher Pull, Aim, Squeeze and Sweep.

19.2.4 If there are flammable liquids in containers, or pipe lines supplying gas or
oxygen in the area where a fire breaks out, make every effort within the bounds of
safety to remove the containers and shut off the valve controlling the gas or
oxygen supply to keep the fire from spreading or exploding.
19.2.5 If a fire extinguisher is used, take it to the fire extinguisher pick-up storage
rack. Do not replace it on a hanger or in a cabinet. Notify your supervisor, who
will have the extinguisher checked and refilled.

19.2.6 Automatic sprinkler systems: If you are in an area protected by a sprinkler

system, do not tamper with the equipment. Do not pile materials close to the
sprinkler valves or heads.
19.2.7 In case of fire:
19.2.7.1 Only do what you can do safely to control or contain the fire. Call
the fire emergency number (listed in back of book) immediately if there is
any doubt about the situation. Notify your supervisor as soon as possible
and alert other personnel in the area of the situation.
19.2.7.2 Be sure to give the exact location, by building and door number
or by grid number at plants/facilities in a grid system, of the fire and the
type of material that is burning. Speak clearly and answer any questions
that may be asked. Do not hang up until the communication is complete
and you are told to do so.
19.2.7.3 If possible, send someone to the roadway or door of a building to
direct the firemen when they arrive. In a major fire event, go to a
prearranged known safe area and report to your supervisor.
19.2.8 If your clothing should catch fire STOP, DROP and ROLL. If possible,
smother the flame with a blanket, coat, or anything available.

20

Gas Hazards / Carbon Monoxide

20.1 Some equipment and processes produce dangerous levels of hazardous gases,
oxygen, or carbon monoxide. This includes operations or procedures when the potential
exists for:
i.
ii.
iii.
iv.
v.

The release of toxic gas or vapors

An oxygen deficiency or enrichment atmosphere
High levels of carbon monoxide
Combustible or explosive gas/air mixtures
Gas Hazard Areas have been established and posted based on results of Industrial
Hygiene studies, department measurements, past experience, or predictable
potential for a gas incident.

20.2 Never enter a Gas Hazard Area without:

20.2.1 Receiving permission from supervision to enter the Gas Hazard Area.
20.2.2 Signing in and receiving specific Gas Hazard instructions.
20.2.3 Following all safety rules specific to the Gas Hazards in that area.
20.3 Do not enter or work in any location where a gas hazard may be present until proper
gas tests have been made with the required instrumentation.
20.3.1 All tests shall be made by a qualified and authorized employee.
20.3.2 All gas tests shall be made with instrumentation that has a current
calibration and has been "bump tested" as required.
20.3.2.1 The alarm functions of gas testing instrumentation shall be
inspected during calibration to assure proper operation. If so equipped, the
audible alarm shall be measured for volume output. If the volume drops
more than 5 dB below the specified range, the instrument shall be repaired
before placing back into service.
20.4 When it is necessary to enter an area where hazardous gases (toxic, oxygen
deficient, or enrichment, combustible/explosive and/or carbon monoxide) have
accumulated, it is the responsibility of supervision to formulate a specific safe procedure
and to direct the operation to assure the procedure is followed.
20.4.1 This procedure will require some or all of the following:
- Gas Testing / continuous Monitoring
- Additional Personal Protective Equipment
- Breathing Air (SCBA or Air Line)
- Body Harness and Tag Line
- Work Location Ventilation
- Emergency Escape Devices
- Additional Fire Fighting Equipment

- Emergency Rescue Team

- Stand by Fire Truck or Foam Truck
20.4.2 Non sparking tools shall be used in areas where explosive or combustible
gases have accumulated or have the potential to accumulate during the work.
20.5 Report promptly to your supervisor any indication of leaking gas, whether it be from
tanks, pipes, or fittings of any kind.
20.6 Carbon Monoxide
20.6.1 All areas where either Industrial Hygiene studies or past experiences
indicate that CO is likely to be present in significant concentrations, shall be
identified. Access to these areas shall be posted designating them as CO Hazard
Areas. No one is permitted in a CO Hazard Area without that departments
supervisory permission.
20.6.2 No one is permitted in a CO Hazard area without continuous CO
monitoring.
20.6.2.1 Personal CO monitors shall be inspected for current calibration
and bump tested with the appropriate calibration gas before entering the
CO hazard area.
20.6.2.2 Personal CO monitors shall be worn at the shirt pocket level or
higher to place them as close to the breathing zone as possible. The units
gas detecting sensor and alarms must not be covered by clothing to other
materials.
20.6.3 Carbon Monoxide Levels
20.6.3.1 Concentrations above 1200 ppm are considered to be immediately
dangerous to life and health.
20.6.3.1.1 No one is permitted in the area without a full face selfcontained breathing apparatus (SCBA) or a full face-piece air line
respirator with escape tank in pressure demand mode.
20.6.3.1.2 For entry and stand by rescue procedures: See (Carbon
Monoxide Hazard Procedures, Appendix 3).
20.6.3.2 Concentrations above 200 ppm but below 1200 ppm.
20.6.3.2.1 No one is permitted in the area without a full face selfcontained breathing apparatus or a full face-piece air line respirator
operated in the pressure demand mode.
20.6.3.3 Concentrations between 100 ppm and 200 ppm.

20.6.3.3.1 No person may work more than 2 hours without

appropriate respiratory protection: See (Carbon Monoxide Hazard
Procedures, Appendix 3).
20.6.3.3.2No additional exposure is permitted for the rest of the
day.
20.6.3.4 Concentrations between 50 ppm and 99 ppm.
20.6.3.4.1 No person may work more than 4 hours without
appropriate respiratory protection.
20.6.3.4.2 No additional exposure is permitted for the rest of the
day.
20.6.3.5 Concentrations below 50 ppm.
20.6.3.5.1 Employees may work in the area without a time limit.
20.6.4 For more detailed information (see Appendix 3 Carbon Monoxide Hazard
Procedures).

21

Confined Space Entry

21.1 Never open or enter a confined space without specific written permission and a
completed confined space entry procedure. All employees shall comply with the
provisions of General Safety Order (GSO) #4 Confined Space Entry Procedures. See
General Safety Order #4 Confined Space Entry Procedures Section 31.
21.2 Confined spaces include all sewers, tanks, bins, pits, manholes or other locations
that meets all the following criteria:
21.2.1 Is large enough and so configured that an employee can bodily enter and
perform assigned work; and
21.2.2. Has limited or restricted means for entry or exit (for example, tanks,
vessels, storage bins, hoppers, vaults, pits and sewers that may have limited
means of entry);and
21.2.3. Is not designed for continuous occupancy; and
21.2.4. Presents a hazard by meeting one or more of the following:
21.2.4.2 Contains, or has the potential to contain, a hazardous atmosphere;
or
21.2.4.3 Contains, or has the potential to contain, a flowable material that
could engulf; or
21.2.4.4 Has an internal configuration such that one could be trapped or
asphyxiated by an inwardly converging wall or by a floor which slopes
downward and tapers to a small cross section;
- or 21.2.4.5 Contains any other recognized serious safety or health hazard.
(An example of this situation would be exposed (un-insulated) electrical
wiring.)
21.3 Never go into a sewer, pit, manhole, or other enclosure where a condition of oxygen
deficiency (or saturation) may exist without first checking for such a condition. Oxygen
shortage (or saturation) is as hazardous as toxic gases. Refer to the Oxygen Level
Standard which states a minimum level of 19.5% and a maximum of 23.5% oxygen.
Never enter into a space with this type of hazard without the proper procedures,
safeguards, and PPE as required.
21.4 In places where known gas hazards or lack of oxygen (or saturation) can exist, do
not attempt rescue of a stricken worker without first seeking help from a rescue team.
Rescuers must be trained and wear the appropriate respiratory protection, before entering
the space.

21.5 If you discover an area that might be a confined space and it is not marked as such,
notify your supervisor.

22

Hazard Communications
22.1 Safety Data Sheets (SDS)
22.1.1 Safety Data Sheets give the chemical components and possible hazards
associated with each component of potentially hazardous materials. Additional
information is also given for Reactivity Data, Spill or Leak Procedures, PPE to be
worn while using, Fire and Explosion Data, and Emergency Medical First Aid.
22.1.2 Departments must have an SDS for each material used or stored in the
department. The data sheets must always be readily available for the employees.
22.1.3 Each department must also maintain a current inventory list of the
materials used or stored.
22.1.4 New materials, or old materials used in new ways must be evaluated before
use. Know how the materials are to be used and check the specific JSHA, Safety
Data Sheet, or Product Label.
22.2 Labels
22.2.1 Every fixed and portable container of hazardous materials must be labeled.
Tanks and process vessels are included as containers. Each container must be
marked, tagged or labeled with the following information:
- Manufacturer's name
- Exact trade name
22.2.2 Non-labeled containers - If you come upon a container that does not have a
label, report it to your supervisor. Do not use an unfamiliar chemical or substance
until a label is provided or a SDS is available for review.
22.2.3 Damaged Labels - If a label is torn, damaged or faded, ask your supervisor
to obtain a new one. The only safe way to handle a chemical is to know what it is,
its associated hazards, and proper handling procedures.
22.2.4 Transfer Containers - If an employee transfers a chemical from a labeled
container to a different container, the employee must be sure that the new
container is so labeled.
22.2.4.1 Labeling is not required for portable or transfer containers into
which hazardous materials are transferred when:
22.2.4.1.1 The material is intended for use within the same work
shift.
22.2.4.1.2 The material remains under the immediate control (at all
times) of the employee who performed the transfer.

22.2.4.2 Transfer or portable containers must be of a design and

construction appropriate for the hazardous material that it is intended to
contain. The use of coffee cans, plastic soft drink containers, etc. is
prohibited.

23

Hazardous Materials
23.1 Asbestos
23.1.1 AK Steel employees shall not work with, remove, or disturb, materials
containing or suspected of containing asbestos.
23.1.1.1 All suspect materials shall be considered asbestos until the
material is tested for the presence of asbestos, or other documented
information that shows asbestos is not present (e.g. Safety Data Sheet,
Manufacture Statement).
23.1.2 Only authorized, trained contractors approved by the Safety and Health
Department shall be permitted to perform work (removal or encapsulated)
involving asbestos.
23.1.2.1 All asbestos containing materials must be removed or
encapsulated prior to any activity that may disturb it.
23.1.3 Contact the person responsible for asbestos testing and removal or the
Safety and Health Department immediately if you suspect a material to be
asbestos. Report all damaged materials that may contain asbestos to your
supervisor.
23.2 Lead
23.2.1 Only authorized, trained employees shall be permitted to perform work
involving lead. This includes the removal of lead-based paint or performing
any task that could disturb lead-based paint. As a preventive measure, each time
you begin a task such as: cutting, grinding, welding, brazing, sanding, or burning
on a painted surface, suspect that it contains lead unless tested otherwise.
23.2.1.1 No employee shall be permitted to burn, weld, or grind on leadbased paint due to the potentially high levels of lead fume that may be
generated during these activities.
23.2.2 Lead can be absorbed into your body by inhalation (breathing) and
ingestion (eating). When lead is scattered in the air as a dust, or fume or mist it
can be inhaled and absorbed through your lungs. You can also ingest lead through
your digestive system if lead gets into your mouth and is swallowed. If you
handle lead, never consume food, cigarettes, chewing tobacco or use make-up
which have lead on them or handle them with hands contaminated with lead, this
will contribute to ingestion.
23.2.3 Department Planners shall make arrangements to test for lead before work
begins. Do not burn, weld, grind, sand, or cut any material that may contain lead

until the tests have been completed.

23.2.3.1 All paint at AK Steel is considered to contain lead unless, all
layers of the paint are tested negative for the presence of lead by an
approved laboratory or other confirmed and documented information (xray fluorescence analysis, Safety Data Sheets, etc.).
23.2.4 Contact the person responsible for lead testing or the Safety and Health
Department immediately if you suspect a material to contain lead.
23.3 Bloodborne Pathogens
23.3.1 Only authorized, trained employees shall handle, clean up , or dispose of
human blood or other infectious materials. This includes the handling of regulated
waste as defined by the OSHA Bloodborne Pathogen Standard.
23.3.2 The handling of these substances shall be controlled by the AK Health
Services personnel. For more information on Bloodborne Pathogens contact the
Safety and Health Department.

24

Hearing Conservation
24.1 The purpose of the Hearing Conservation Program is to protect employees from
occupationally related hearing loss and to meet federal and state health and safety
standards.
24.2 All employees included in the Hearing Conservation Program must use approved
hearing protection. The Safety and Health Department will utilize noise monitoring
results to determine which employees shall be included in the Hearing Conservation
Program.
24.3 All work areas that have sound levels above 85 dBA shall be posted with signs
indicating "Hearing Protection Required." Everyone entering these areas must wear
approved hearing protection which can be obtained from your supervisor.
24.4 In addition to specific work areas, specific tasks or jobs, (like operating a pneumatic
jackhammer), require the use of hearing protection. The hearing protection requirement is
to be included in the JSHA for the task or job.
24.5 All employees identified as being in the Hearing Conservation Program must have
yearly audiometric exams. Those who do not report as scheduled to the plant medical
department or designated testing facility for the audiometric exam, will not be scheduled
to work.
24.6 Employees shall be allowed to choose hearing protection from the approved hearing
protection equipment for the job or task.
24.6.1 The Safety and Health Department will furnish a list of the various types of
hearing protection with suitable noise reduction for each level of noise exposure.
24.6.2 Employees are responsible for the maintenance of their hearing protection
equipment.
24.6.3 Only hearing protection suitable for the job/task noise exposure shall be
used.
24.7 If hearing protection is not required, individuals may choose to use hearing
protection on an individual, voluntary basis. Employees who voluntarily wish to use
hearing protection will be provided with suitable hearing protection equipment approved
for use at AK Steel.
24.8 For a full explanation of the Hearing conservation Program, contact the Safety and
Health Department.

25

Radiation / Laser
25.1 Only authorized and trained personnel shall be permitted to work on equipment that
generates radiation X-rays or contains radioactive material. Work on or around these
devices is only permitted if:
a. Lockout/Tryout has been done. Specific training is required before LOTO is
done on radiation producing equipment.
b. The JSHA is followed.
25.2 Do not enter a Radiation/Laser area unless your job requires it.
25.2.1 Each Radiation/Laser area shall be posted with a sign(s) bearing the
Radiation Symbol or the Laser Radiation Symbol (see Appendix 4, Radiation and
Laser Symbols).
25.2.2 Where shutter station lights are present, "Red" means stop - radiation is
present; "Green" means the radiation beam is blocked.
25.3 Never look into a beam of radiation or laser or the path of a Laser Beam.
25.4 If you have any questions pertaining to Radiation/Laser, please call the Plant
Radiation/Laser Officer or the Safety and Health Department.
25.5 There are employee information notices from the Nuclear Regulatory Commission
(NFC), or the State, posted in the Plant. Read these notices.

26

Batteries
26.1 Lead-Acid batteries typically used in autos, trucks, mobile equipment, and backup
power sources, contain sulfuric acid and generate hydrogen an explosive gas. Keep
sparks, flames, burning cigarettes, or other ignition sources away from batteries at all
times. Wear a face shield when testing or charging batteries or jump-starting an engine.
26.2 Only authorized and trained personnel shall work near lead-acid batteries, either in a
vehicle, on a bench, or as part of an electric power source. The manufactures instructions
and all applicable JSHAs must be followed when using any equipment on or around
batteries such as battery chargers or testers.
26.2.1 Battery Charging
a. Always charge the battery on a properly matched charger.
b. Keep the battery top clean, dry and free of foreign objects.
c. Keep the battery and vehicle/equipment cover open curing charging.
d. Never overcharge the battery.
e. Allow the battery to cool down before placing it back into service.
26.3 Refer to your Plant Rules for how to properly dispose of used batteries.

27

Contractor Safety and Health Rules

27.1 Definitions:
27.1.1 Contractor is defined as a company or organization that employs building
and construction craft personnel, union or otherwise, and provides physical labor
services on AK Steel property. These services can be classified as construction,
repair, maintenance, or renovation.
27.1.2 Sub-contractors are included in this definition provided they are governed
by their prime contractors CMA. However, Subcontractors must have their own
Safety Approval through ISNetworld (www.isnetworld.com) and their employees
must comply with the Contractor Employee Requirements.
27.1.3 Service Provider shall be defined as an organization or company that
provides services to AK Steel. Service providers shall not complete any hands
on type work and include, but not be limited to, the following:
i.
ii.
iii.
iv.
v.

Consultants
Engineers
Technicians
Start-up personnel
Other "non-physical service providers"

27.1.4 Visitors shall be defined as all other non AK personnel that do not provide
physical labor or services.
27.2 Contractor Requirement
27.2.1 All contractors shall have an approved CMA and Safety Approval through
ISNetworld (www.isnetworld.com) before performing any work activity for AK
Steel.
27.2.2 Contractors must complete the following requirements prior to entering
AK Steel to perform work:
a. OSHA 10 Hour Construction or General Industry Training. This card must
be presented before taking the plant specific training class.
b. AK Steel Core Safety Training
c. Plant Specific Safety Training
d. Valid documentation of drug/alcohol testing within the last year.
i.
Proof of this test, resulting in meeting AK Standards shall be
presented before taking the plant specific safety class
ii.
Check with each plant to determine what the location specific
requirements are for drug/alcohol testing
iii. AK Steel has the right to perform drug/alcohol testing on any
contractor at any given time.

e. Upon successful completion of the course the participants will be provided

a Photo ID Card.
i.
ii.
iii.

This card shall be carried by the contractor at all times during their
work at the facilities.
This card must be presented upon request by any AK Steel
employee or Security Personnel.
This card is valid for a two year period in which Core Safety
Training and Plant Site Specific Training must be renewed.

27.2.3 Service Providers must complete the following requirements, as a

minimum, prior to entering any AK Steel Facility to perform work:
a. AK Steel Core Safety Training
b. Plant Specific Safety Training
c. Valid documentation of substance testing within the last year. Proof of this
test, resulting in meeting AK Standards must be presented before taking
the Site Specific Class.
27.2.4 Visitors must complete the following requirements, as a minimum, prior to
entering any AK Steel Facility.
a. Visitors must be escorted at all times.
b. Visitor / Customer Safety Orientation (AKSF-16) must be completed with
the visitor and the AK Steel representative bringing them in.
c. When Visitor / Customer visit is complete, shall be forwarded to the
Safety Department for auditing and retention.
27.2.5 Any exception requests to any of the contractor, service provider, or visitor
entry requirements must be submitted in writing to the Occupational Safety and
Health Manager or his/her designee for approval.

27.2.6 Compliance - All Federal, State, and AK Steel Safety and Health Rules
shall be followed at all times.
27.2.7 Safety Representative - All contractors working at an AK Steel facility
with a staff of 12 or more employees must have a full-time safety
representative on site. The safety representative must meet all of the
following requirements/qualifications:
a. Capable of identifying existing and predictable conditions in the
surrounding work environment that is potentially unsafe and/or unhealthy
for their employees.
b. Authorized to take immediate action to eliminate unsafe/unhealthy
conditions.
c. Have a recognized safety and health degree, professional standing, or
extensive knowledge, training, and experience for the job.

d. Must be approved by the AK Steel site Occupational Safety and Health

Manager.
27.2.8 Observations, Tool Box Meetings, Safety Meetings, etc - All contractors
must satisfactorily perform safety related requirements including, but not limited
to, the following:
a.
b.
c.
d.
e.
f.
g.

Conduct and document pre-shift toolbox sessions

Conduct and document formal monthly or more frequent safety meetings
Conduct and document employee observations
Correct unsafe acts and conditions
Implement and maintain written safe job procedures
Conduct and document periodic safety audits and inspections
Submit a monthly Observation report to the AK Steel Sites Occupational
Safety and Health Manager
h. Attend and participate in the plants contractor safety meetings.

27.2.9 Plant Access

a. All contractor employees must enter the plant via the contractor
designated gate(s) provided unless the Plant and/or Safety Manager(s)
approve other arrangements through Plant Security.
b. Each Plant / Department shall adopt a procedure for contractors, service
providers and visitors for notification or sign in prior to entering the
operating areas.
c. Each Plant shall adopt a procedure on drive in permits for contractors,
service providers and visitors.
i
No person shall be permitted to drive into a plant without first
being issued a drive in permit.
ii No person shall be permitted to drive into a plant if their state
driving privileges are under suspension or have been revoked.
27.2.10 Any Injury, Incident, or Near Miss - shall be reported immediately to
the proper AK Steel Representative responsible for the job.
a. A complete investigation into root cause and corrective actions must take
place. The incident scene shall be left as is occurred, whenever possible,
until AK Safety Department clears the scene
b. A complete investigation including pictures, witness statements, and
supporting documents must be completed as to the root cause of the
incident as well as corrective actions to prevent reoccurrence of the
incident in the future.
c. Contact all appropriate AK personnel including AK Purchasing
Management.
d. The contracting companies management team is expected to be involved
on site for the investigation.
e. Completed incident investigation report shall be provided to the AK Steel
representative within 4 hours of occurrence.

27.3 Pre-Job or Pre-Task Requirements:

27.3.1 All contractor and service providers job activity must be reviewed with
the AK Steel employee (or representative) who requested the work to be
completed. For service departments bringing contractors into production areas,
the AK Steel representative must be familiar with the work areas and unique
safety requirements.
27.3.2 The specific job orientation must take place at the actual work site and
must include a pre-job walk-through to identify both direct and indirect hazards.
27.3.3 Job Site Orientation (JSO) (AKSF-03) - must be completed with the
contractor / service provider and the AK Steel Management representative or
approved designee who requested the work.
27.3.4The JSO shall be completed at the jobsite; there are no exceptions to
this rule.
a. All contract workers and AK Steel Management representative or
approved designee shall place name (printed and signed) in the appropriate
area on the JSO before work begins.
b. If another contract worker joins the work crew on the job described on the
JSO the AK Steel Management representative or approved designee must
review the hazards of the job, both direct and indirect, with them before
they start work.
c. The completed JSO shall remain at the job site until the job is completed.
d. Once the job is complete, all contractors shall sign out of the job by
placing the current time in the provided box and an AK Steel Management
representative or approved designee must complete the sign out
verification.
e. When all contractors are signed out of the job and the AK Steel
Management representative or approved designee has completed the sign
out verification, the JSO shall be forwarded to the Safety Department for
auditing and retention.
f. Any exception requested to the above mentioned requirements must be
submitted in writing to the Occupational Safety and Health Manager of the
facility for approval prior to any work being started.
g. If an exception is granted it must be granted in writing and shall meet
the following criteria to be exempt from requiring a JSO:
i.
Perform the same job(s) daily,
ii.
the jobs they are performing are not affected by any jobs being
performed by AK,
iii. conditions and hazards do not change,
iv.
hazard controls are in place at all times,
v.
does not require any type of permit to be issued,
vi.
AND, does not require controlling a hazard that falls under one or
more of the GSO's

27.3.6 Written Safety Procedures including but not limited to JSHAs, Pre-job
planning, Safety Task Assessments (STA), Etc must be completed. All tasks to be
completed by a Contractor shall have a written procedure or pre-plan. If there is
no formal written procedure a temporary such as an STA card or form shall be
used.
a. The form shall cover the hazards that are present.
b. The form shall cover the preventative measures taken to mitigate these
hazards.
c. Emergency contact numbers.
d. Personal Protective Equipment needed for the job.
e. Permits or Procedures needed for the task
f. This procedure must be readily available and presented upon request by
any AK Steel Management Representative.
27.3.7 General Safety Orders (GSO)
a. GSO #1 through GSO #5 AK Steel will instruct the contractor through
the JSO which GSOs apply to the job being performed.
b. GSO #1 through GSO #4 AK Steel will establish the initial compliance
with the specific GSO and then turn it over to the contractor.
c. The contractor will be required at all times to be compliant with all of the
GSOs requirements.
d. Any exception requested to the above mentioned requirements must be
submitted in writing to the Occupational Safety and Health Manager of the
facility for approval prior to any work being started. If an exception is
granted it must be granted in writing.
27.4 Powered Industrial Truck Operation
27.4.1 Powered Industrial Trucks (PIT) includes fork trucks, tractors, platform lift
trucks, all-terrain forklifts, motorized hand trucks, and other specialized industrial
trucks powered by electric motors or internal combustion engines.
27.4.2 Contractors whose job requires the operation of Powered Industrial Trucks
or mobile equipment must meet the following requirements.
a. PIT operators shall be physically fit in accordance with ANSI B56.1,
paragraph 4.18, which sets forth operator requirements for Powered
Industrial Trucks, requires employers to assure that operators are
"qualified as to visual, auditory, and mental ability to operate the
equipment safely."
b. PIT operators shall be trained on the specific type of mobile equipment
that they are operating.
c. PIT operators shall have a certification to operate Mobile Equipment that
shall include:
i.
Name of the operator
ii.
Date of the training
iii. Date of the evaluation

iv.
Identity of the person(s) performing the training or evaluation.
d. PIT operators shall have a current valid state driver or operator license
CDL.
27.5 High Pressure Water Jetting Operations
27.5.1 Contractors engaged in High Pressure Water Jetting shall comply with
ASTM E 1575-08 and ANSI 957-1987.
27.5.2 The term High Pressure Water Jetting covers all water jetting, including
the use of additives or abrasives at pressures above 100.5 psig.
27.5.3 All employees required to operate or maintain pressure water-jetting
equipment shall have been trained and have demonstrated the ability and
knowledge to do so in accordance with the original equipment manufacturers
instructions, specifications and training programs. The training and competency
shall be documented and be available at the worksite.
27.5.4 Personal Protection and Use of Protective clothing. In addition to the AK
Steel standard PPE requirements, the following shall be complied with:
a. All operators shall wear head protection capable of withstanding the
jet stream. This shall include a full face shield suitable for the type of
work performed.
b. Goggles or a full hood with shield are required when using caustic or
acidic liquids (see SDS sheets).
c. Plastic framed glasses with permanently attached side shields or
goggles which meet the ANSI Z.87 Industrial Standard shall be worn
under the hood or face shield.
d. All operators shall be supplied with suitable jet-resistant waterproof
clothing. Garments shall provide full protective cover to the operator's
feet, legs, torso, hands and arms.
e. All operators shall be supplied with waterproof metatarsal boots.
f. All operators shall wear hearing protection.
27.5.5 All Systems shall incorporate at least TWO emergency fluid shut off or
dump devices.
a. The Operator shall be able to shut down the water jet by releasing
pressure in the trigger or switch and the dead man foot valve pedal.
b. If the Operator is not utilizing a dead man foot control as the second
means to shut the system down, then the second Operator or the Safety
Lookout shall operate the dead man foot valve pedal.

c. The Safety Lookout shall not perform any other job functions when
lancing is being conducted.
27.5.6 Lances used to blast tubes/pipes shall be equipped with anti-withdrawal
device that shuts the flow of water off when withdrawn.
27.5.7 Erect suitable barriers to encompass the hazard area and post signs to warn
personnel they are entering a hazardous area.
27.5.8 Hearing Protection Required signs shall be posted at the pump and in the
location where the high pressure water jetting is occurring.
27.6 Vacuum Truck Operations
27.6.1 Contractors engaged in Vacuum Truck operations shall comply with
manufacturers recommended safety practices and applicable governmental
regulations.
27.6.2 All employees required to operate or maintain vacuum trucks shall have
been trained and have demonstrated the ability and knowledge to do so in
accordance with the original equipment manufacturers instructions,
specifications and training programs. The training and competency shall be
documented and be available at the worksite.
27.6.3 Employees involved in vacuum truck operations shall wear at least the AK
Steel standard personal protection equipment.
27.6.4 The vacuum tank shall be treated as a confined space. The contractor is
required is to have an established confined entry procedure to enter the tank for
cleanout or repair.
27.6.5 Procedures shall be written for dumping the vacuum truck onsite and
restrict access to the rear of the truck during the dumping process.
27.6.6 Safety Lookout shall be required for all vacuum truck operations.
27.6.7 All vacuum truck system shall incorporate at least TWO emergency safety
releases, which shall be verified that they function prior to commencing the
vacuuming job:
a. The vacuum truck controls shall be manned at all times by an operator that
is in radio and/or visual contact with the employee operating the hose.
b. Or the vacuum can be released remotely by the employee operating the
vacuum hose or the Safety Lookout..
c. All vacuum truck operations shall have an inline T vacuum breaker. The
inline T vacuum breaker shall be manned by either:
i.
The employee operating the vacuum hose shall have direct contact
with the inline 'T vacuum breaker.

ii.
iii.

Or the Safety Lookout shall have direct contact with the inline 'T
vacuum breaker.
The Safety Lookout shall be in visual contact at all times with the
employee operating the hose and is not permitted to perform any
other task.

27.6.8 Grounding - Static electricity can cause a dust explosion; therefore, all
vacuum trucks that are vacuuming dry material shall be properly grounded.
27.6.9 Material Mixing Do not mix wet and dry compounds in order to avoid
an adverse chemical reaction. Determine what the material is prior to vacuuming
and take the proper precautions.
27.6.10 Do not vacuum flammable liquids, combustible metals or reactive
materials.
27.6.11 Hearing Protection Required signs shall be posted at the truck and in
the location where the vacuuming is being performed.
27.6.12 Erect suitable barriers to encompass the hazard area and post signs to
warn personnel they are entering a hazardous area.

28

General Safety Order #1 - Lockout / Tryout Procedures

28.1 SCOPE
General Safety Order #1 has been authorized and approved to establish a lockout/tryout
policy that covers the servicing and maintenance of machines and equipment. This
includes installation, setting up, inspection, modifying, lubricating, cleaning, tool
changes, unjamming, repairing, servicing, and any other activity in which the unexpected
energization or start up of the machines or equipment, or release of stored energy could
cause injury to employees.
28.1.1 This General Safety Order/Lockout Program requires employees to lock
out machines or equipment to isolate them from all potentially hazardous energy
sources prior to any service or maintenance activities where the unexpected
energizing, start-up or release of stored energy could cause injury.
28.1.2 This Program establishes the minimum requirements for the locking out of
energy isolating devices before employees perform any servicing or maintenance
activities on machines or equipment.
28.1.3 This Program specifically outlines the purpose, responsibilities,
authorization, rules and techniques to be utilized by AK Steel employees to guard
against the unexpected energizing, or start-up of machines of equipment, or
release of stored energy which could cause injury to employees.
28.2 DEFINITIONS
The following definitions are provided to clarify language used throughout this Lockout
Program.
28.2.1 Affected Employee - An employee whose job requires him/her to operate
or use a machine or equipment on which servicing or maintenance is being
performed under lockout, or whose job requires him to work in an area in which
such servicing or maintenance is being performed.
28.2.2 Authorized employee - A person who locks out machines or equipment in
order to perform servicing or maintenance on that machine or equipment.
28.2.2.1 An affected employee becomes an authorized employee when
that employee's duties include performing servicing or maintenance.
28.2.3 Competent - One who is capable of identifying existing and predictable
hazards in the surroundings or working conditions which are unsanitary,
hazardous, or dangerous to employees, and who has authorization to take prompt
corrective measures to eliminate them.
28.2.4 Double Verification Rule - Each Lockout shall be verified by a second
authorized individual competent in the Lockout procedures for the equipment
being locked out.

28.2.5 Energized - Connected to an energy source or containing residual or stored

energy.
28.2.6 Energy Isolating Device - A mechanical device that physically prevents the
transmission or release of energy, including but not limited to the following:
28.2.6.1 A manually operated electrical circuit breaker,
28.2.6.2 A disconnect switch
28.2.6.3 A manually operated switch by which the conductors of a circuit
can be disconnected from all ungrounded supply conductors and, in
addition, no pole can be operated independently,
28.2.6.4 A Line valve,
28.2.6.5 A block; and
28.2.6.6 Any similar device used to block or isolate energy.
28.2.6.7 Push buttons, selector switches and other control circuit type
devices are not energy isolating devices.
28.2.7 Energy Source - Any source of electrical, mechanical, hydraulic,
pneumatic, chemical, thermal, or other energy.
28.2.8 Idled Equipment - Equipment that is no longer in use or that will be out of
service for a lengthy period of time.
28.2.9 Lockout - The placement of a lockout device on an energy isolating device,
in accordance with an established procedure, ensuring that the energy isolating
device and the equipment being controlled cannot be operated until the lockout
device is removed.
28.2.10 Lockout Device - A device that utilizes a positive means such as a keyed
lock, to hold an energy isolating device in the safe position and prevent the
energizing of a machine or equipment. Included are blank flanges and bolted slip
blinds.
28.2.11 Normal Production Operations - The utilization of a machine or
equipment to perform its intended production function.
28.2.12 Servicing and/or Maintenance - Workplace activities such as constructing,
installing, setting up, adjusting, inspecting, modifying, and maintaining and/or
servicing machines or equipment. These activities include lubrication, cleaning or
unjamming of machines or equipment and making adjustments or tool changes,
where the employee may be exposed to the unexpected energizing or startup of
the equipment or release of hazardous energy.

28.2.13 Zero Energy State - The state of a machine or system in which residual
energy in all forms has been dissipated to a safe level and lockouts have been
installed and verified.
28.3 WRITTEN LOCKOUT/TRYOUT PROCEDURES
Written lockout/tryout procedures shall be developed and maintained in each department.
These procedures will cover the steps to make sure equipment being serviced is isolated
and secured from ALL energy sources (including stored or residual) that could injure
personnel working on the equipment. These written procedures shall identify and
provide information on the following:
1. Type of machinery or equipment that is being locked out.
2. Type of energy sources, such as electrical, pneumatic, hydraulic, steam,
chemical, etc., that must be locked out.
a. Method and location to lockout.
b. Method and location where verification will take place.
3. Type of stored or residual energy sources, such as that in capacitors, springs,
elevated machine members, rotating flywheels, pressure in hydraulic,
pneumatic or steam systems, etc. that must be controlled.
a. Method and location to dissipate or restrain by grounding, repositioning,
blocking, pinning, bleeding down, etc.
b. Method and location of lockout of the dissipating or restraining device, if
applicable.
c. Method and location where verification will take place.
4. The method of verification that shall be used to assure that Zero Energy
State has been achieved and maintained for the machinery or equipment being
serviced.
5. The type or method of verification that will be used to assure the lock out was
successful.
28.4 FORMAL EMPLOYEE TRAINING/RETRAINING
28.4.1 Training will cover three classes of employees.
1. Authorized Employees -- Those who are allowed to perform energy
control procedures. Training will include company approved energy
control procedures, recognition of energy sources, and methods for
isolation and energy control.
2. Affected Employees -- Those employees that operate the equipment on
which work is being performed. Training will include the purpose and use
of the energy control procedures.
3. Other Employees -- All other employees that may work in an area where
energy control procedures may be used. Training will include instruction
on the energy control procedures and the prohibition relating to attempting
to restart or re-energize equipment that is locked out.

28.4.2 Employee retraining is required annually and:

1. Whenever there is a change in the location of an employee's job
assignment.
2. Whenever a new hazard is introduced due to a change in machines,
equipment, or process.
3. Whenever there is a change in energy control procedures.
4. Whenever a periodic inspection reveals inadequacies in the company
procedures or in the knowledge of an employee.
28.5 INSPECTIONS AND REVIEWS
28.5.1 Periodic Audits - Inspections and reviews of the energy control program
will be conducted at least annually.
28.5.2 The inspections and reviews will be designed to identify deviations or
inadequacies in the energy control (Lockout) program.
28.5.3 At least annually, all departmental written procedures will be reviewed by
designated employees to ensure that the procedures are current and
comprehensive.
28.5.4 Program audits (inspections) will be conducted annually through Works
Manager/Department Manager audits.
28.6 RESPONSIBILITY OF LOCK AND LOCK REMOVAL
28.6.1 The individual placing the lock on the energy isolation device is
responsible for removing the lock. If the repair work has not been
completed when the time comes for the individual to leave the job or
change turns, that individual must remove his/her individual lock or locks.
The incoming individual continuing the work must make certain that all
energy sources are secured and properly locked out.
28.6.2 When an employee who places a lock is not available to remove it, that
lock may be cut off only upon the approval of the Department Manager or
his/her designee. A reasonable effort will be made to assure that the
employee is not at the work site. A reasonable effort consists of attempting
to make phone contact, a physical inspection of the work site, a check of
the work schedule and, when possible, clock out records.
28.6.3 Prior to the employee resuming any work activity, he/she must be told that
his/her lock was cut off.
28.6.4 The lock removal shall be documented on a lock removal form with one
copy retained in the Department and one copy sent to the Safety
Department.
28.7 MULTIPLE LOCK DEVICES AND LOCKED KEY BOXES

28.7.1 When more than one person is working on machinery or equipment, a

multiple lock device shall be installed and used so that all individual locks
may be accommodated. When multiple energy sources must be secured,
each employee involved in the repair work must secure and verify the
lockout. The job supervisor will be contacted for additional locks or
multiple lock devices.
28.7.2 In some cases it may be practical to use locked key boxes rather than
multiple individual locks. When a locked key box is used instead of
individual locks the following is required:
28.7.2.1 As a job requiring locked key boxes is implemented, preplans
must identify which LOTO procedures will be needed. The
LOTO procedure will then be used to assure the equipment is
locked out correctly.
28.7.2.2 Keys to Control Locks shall be secured by the department
authorized competent employees. Control Lock Keys shall be
secured in a manner that allows only department authorized
competent employee(s) access to them.
28.7.2.3 It takes two departmental authorized competent employees to
lock out when using the Locked Key Box System. One
departmental authorized employee shall place the control lock or
locks. The other departmental authorized employee shall assure
the equipment lockout is verified. Verification can be
accomplished by the following:
attempting to operate equipment, visually verifying needed safe
guards are in place, or that the blades in the appropriate
disconnect box(s) are disengaged, using a voltmeter, or other test
device.
28.7.2.4 In some cases one, two, or all three methods must be used to
perform proper verification. Copies of all LOTO Procedures
covered by the locked key box must be available to employees
performing covered work. During shift change the oncoming
departmental authorized competent employee shall assure that
the locked key box is still in effect. A list with the following
shall be locked inside of the Locked Key Box. The list shall be
made available for viewing by each employee (if the list is not
readable from outside the Locked Key Box):
Covered jobs,
LOTO procedure identification,
Isolation devices and locations,
Lock numbers of control locks,
Identification of authorized employees who placed control locks

and completed verification steps,

Dates and times that verification took place,
Dates, times, and identification of authorized employees who
removed control locks.
28.7.2.5 The identity of the lock keys inside the box must be visible, or
the identity must be verified in writing by the authorized
competent lockout employee.
28.8 START UP OF EQUIPMENT
A thorough inspection must be conducted to assure all persons who may be affected by
the start up of the equipment are made aware that the equipment is to be started. Written
procedures shall be in place to assure all employees are in a safe position before
equipment is started. The written Start Up Procedures shall also specify any other
necessary steps which must be taken before equipment is started.
28.9 DOCUMENTATION
All activity within the scope of this General Safety Order shall be appropriately
documented. The Employee Contact Record Card will be used for documenting LockOut Procedure training, contacts, observations, violations, etc. Individual employee
safety training records shall be used to document:
Lock Out Procedure Training
Specific Lock Out Contacts
Observations of Lock Out Work Tasks
Violations of Lock Out Procedures
28.10 UNIQUE SAFETY LOCK, LOCK IDENTIFICATION

28.10.1 The designated locks shall be used only to secure hazardous energy
sources, and shall not be used for any other purpose.
28.10.2 Second or duplicate keys for designated locks shall be destroyed.
28.10.3 One key shall not open more than one designated lock.
28.10.4 Individually assigned red locks shall be further identified by permanently
marking with at least the employees name and one other form of identification
such as department number, check or badge number, or specific crew.
28.10.5 Red departmental locks shall have the department name and a sequential
number.
28.10.6 The only exceptions that may exist to the safety lock and lock
identification rule are specifically designed locking systems like the Kirk or

Castell Locking Systems. The Safety Department must approve all exceptions.
28.10.7 Green locks shall be used only as equipment control for idled equipment
and where no work is being performed.
28.10.7.1 Idled equipment is defined as equipment that is no longer in use
or that will be out of service for a lengthy period of time.
28.11 OUTSIDE PERSONNEL (CONTRACTORS)
When outside contractors are working within the plant, they will be required to have and
present to AK Steel a written lockout/tryout program. If no plan exists, the Contractor
will conform to AK Steel's Lockout/Tryout Procedure. The unique red safety lock and
lock identification, as defined above, applies to all non-AK personnel performing work
on AK Steel premises.
28.12 RESPONSIBILITY FOR HAZARDOUS ENERGY CONTROL
Although it is the responsibility of the company to provide this General Safety Order and
comply with the various provisions of federal, state, and local rules and regulations, the
ultimate responsibility to recognize, secure, test, and verify all hazardous energy sources
lies within each person who might be required to apply or abide by the provisions of this
program.
28.12.1 When a Locked Key Box System of LOTO is used it is the employees
responsibility to assure that he or she places their lock on the correct Lock Box.
28.13 LOTO PIPING SYSTEMS
Before any piping system is opened, procedures must be established to safely reduce to a
zero energy state, and verify that this has been done, for the section to be worked on.
28.13.1 System shut down to zero energy state is always preferred. If the work to
be done will affect the integrity of system valves, blanks, blinds, or other controls,
the system must be at zero energy.
28.13.2 Blank, blind, or bolted slip blind acceptable if there has been no previous
failure under same or like conditions.
28.13.3 Double Block and Bleed (aka Double Block and Vent).
28.13.3.1 Conditions for use of double block and bleed:
1. The bleed or vent has been confirmed to be open visually,
mechanically (rod), or by flow.
2. Release from bleed or vent will create no hazard.
3. System pressure will not exceed rating. Piping system rated by
pressure and temperature (most significant for steam).

4. The bleed off vent is large enough to release pressure.

28.13.3.2 Conditions under which use of double block and bleed is not
permitted:
1. There has been a previous failure under same or like conditions.
2. System pressure not known.
3. Piping rating not known.
4. The piping system is not rated.
5. System is susceptible to hammering or other uncontrolled
pressure surges.
6. IF during start-up, there is no procedure for bringing a system up
to pressure.
7. There have been changes, which could affect the flow off
material, made to the system since it was last in operation.
28.13.3.3 When locking out a double block and bleed or double block and
vent, the bleed or vent valve shall be locked in the open position.
28.13.4 Single Valve
28.13.4.1 Conditions for use of a single valve:
1. System pressure will not exceed 75% of rating. Piping system
rated by pressure and temperature (most significant for steam).
2. No defects or problems are detected by careful inspection of the
valve.
3. Stored energy and energy potential is extremely low/minimal &
the maximum system high pressure does not exceed rating. Piping
system rated by pressure and temperature (most significant for
steam).
4. The material being valved off creates no significant hazard.
28.13.4.2 Conditions under which use of a single valve is not permitted:
1. Has been a previous failure under same or like conditions.
2. System pressure not known.

3. Valve rating not known or the valve is not rated.

4. System is susceptible to hammering or other uncontrolled
pressure surges.
5. If during start up, there is no procedure for bringing a system up
to pressure.
6. There have been significant changes made to the system since it
was last in operation.
7. When the system contains acid, caustic, or poisonous material of
such strength or concentration that contact is capable of causing
injury.

29

General Safety Order #2 - Governing Persons Working on Overhead Cranes, Crane

Runways, and Buildings
29.1 SCOPE
General Safety Order #2 has been authorized and approved to provide protection
and warning to personnel working on or around overhead cranes and like
equipment, crane runways, and in building areas or other locations where there is
a need for special precaution from the hazard of moving cranes.
29.1.1 GSO #2 SHALL be enacted whenever the following occur:
29.1.1.1 Work, including installation of rail stops or hot rail grounds, is
going to be performed on the crane runway including supporting structures
above and below the crane rails that are within the Crane Envelope.
29.1.1.2 Work, including installation of rail stops or hot rail grounds, is
going to be performed on a crane whenever there are two one or more
cranes on the same runway.
29.1.1.3 Work, including installation of rail stops or hot rail grounds, is
going to be performed on the crane runway including supporting structures
above and below the crane rails that does not have a permanent barrier
between the immediately adjacent crane runways. GSO #2 is required for
both affected crane runways.
29.1.1.4 Mobile equipment with booms or other attachments are being
used within the building where overhead cranes are operating. GSO #2
SHALL be enacted for the following conditions:
a. The mobile equipment in the process of performing work
within the building is impinging on the overhead Crane
Envelope.
b. The mobile equipment in the process of performing work
within the building is capable of impinging on the overhead
Cranes Envelope.
NOTE: Mobile equipment with booms or other attachments are only
traveling within the building with overhead cranes and the boom or
other attachments are in travel position and will not impinge on the
Crane Envelope, then a GSO #2 is not required for the travel portion.
29.1.1.5 Mobile equipment with man baskets or elevated work
platforms are being used within the building where overhead cranes are
operating. GSO #2 SHALL be enacted for the following conditions:
a. The mobile equipment with man baskets or elevated work
platforms in the process of performing work within the
building impinging on the overhead Crane Envelope.

b. The mobile equipment in the process of performing work

within the building is capable of impinging on the overhead
Cranes Envelope.
NOTE: Mobile equipment with man baskets or elevated work
platform that are only traveling within the building with overhead
cranes and the man basket or platforms are in travel position and will
not impinge on the Crane Envelope, a GSO #2 is not required for the
travel portion.
29.1.1.6 If the fixed work locations, platforms, ladders or temporary
platforms within the building where overhead cranes are operating and
they impinge the Crane Envelope a GSO #2 must enacted.
a. Fixed work platforms/locations that require a GSO #2 to be
enacted to access must have proper signage and gates at all
entrance points that, at minimum, state what specific
procedures and a completed GSO #2 Form (AKSF-19)
must be in place to access the platform.
b. Temporary work platforms, such as scaffolding, that
require a GSO #2 to be enacted to access must be Red Tag
whenever GSO #2 is not in place to access. The Red Tag
must specify that a GSO #2 is required to access the
platform.
29.1.1.7 At the start of each turn or when erected or staged, a GSO #2
Form (AKSF-19) must be completed when temporary work platforms that
are erected or staged but do not impinge on the Crane Envelope.
a. The completed GSO #2 Form (AKSF-19) shall be
communicated with all affected crane operators prior to
start of shift immediately after erecting or staging
temporary work platforms.
b. Erected temporary work platforms that do not impinge on
the Crane Envelope shall be further highlighted by a
flashing Amber Light.
c. A crane shall proceed with caution past a flashing Amber
Light maintaining maximum distance as possible with
lifting devices and suspended loads.
29.1.1.8 EXEMPTED OVERHEAD CRANES
29.1.1.8.1 Appendix A contains a list of all cranes exempted
from implementing GSO #2 requirements due to
equipment and/or personnel being within the Crane
Envelope while on the main level during normal
operating conditions.

29.1.1.8.2 GSO #2 would apply in the cases if any conditions

described in 29.1.2 are being performed other than
traveling through the building with the exempted
overhead crane.
29.1.1.8.3 Fork trucks, ram trucks, etc. performing normal
operation type lifts that will not impinge into the
path of the crane or crane cab are exempted from
GSO #2 requirements.
29.2 DEFINITIONS
29.2.1 Work Group Supervisor or Leader - is the individual in charge of the work
that is to be performed. In most cases this is not the operations supervisor but the
repair group supervisor doing the work activity.
29.2.2 GSO #2 trained and certified AK Steel Management or designees
employees trained and certified to complete and implement the GSO #2 Form
(AKSF-19). A list certified AK Steel Management or designees shall be
maintained by each department that may fall under the requirements of GSO #2
29.2.3 Safety Lookout - a person whose sole responsibility is to look out for the
crew or crews being protected and to prohibit the crane operator from operating
the crane too close to the personnel being protected. The Safety Lookout is
assigned to the group doing the repair or maintenance activity. This person reports
to and is relieved with the work group. The Safety Lookout may be positioned in
the crane cab or on the ground with the work crew based on the circumstances of
the work to be done.
29.2.4 Blue Flashing Lights - rotating or blinking warning lights visible to the
crane operators shall be used to draw attention to a planned work zone. A crane
shall never go past a flashing Blue Light.
29.2.5 Amber Flashing Lights - rotating or blinking warning lights visible to the
crane operators shall be used to draw attention to temporary work platforms,
ladders or mobile equipment erected or staged that do not impinge on the Crane
Envelope. This does not apply to normal storage of ladders in the upright position
or wooden access platforms that provide access to equipment such as stairs or
decking. A crane shall proceed with caution past a flashing Amber Light
maintaining maximum distance as possible with lifting devices and suspended
loads.
29.2.6 Hot Rail - Electrical conductors (runway conductors) located along a crane
runway to provide power to the crane.
29.2.7 Rail Stop (Rail dog) - A device attached to a crane bridge rail or fixed
structure to limit the travel of the crane bridge.

29.2.8 Crane (Cab Operated, Remote Operated, Pendant Operated and Automatic
Cranes) includes bridge, trolley, end trucks, cab and permanently attached (wire
rope reeved) lifting devices (block, heppenstahl, J-hooks, etc).
29.2.9 Crane Envelope Crane runway, area above the crane bridge, 10 feet
below the bridge and cab. If the lowest part of the permanently attached lifting
device in the nested position is below the bridge, then the envelope is 10 feet
below the lowest part of the nested lifting device and across the length of the
bridge. For example: if a set of J-hooks when nested extend 15 feet below the
bridge, the envelope is 25 feet below the whole length of the bridge.
29.2.10 Elevated temporary work platform - a scaffold, pick boards, or temporary
structures used to elevate personnel to a work locations.
29.2.11 Crane Travel Isolation Zone (Sick Bays, Split Power Feeds, Programmed
Work Zone) Zones were crane travel can be restricted either by isolation of the
power feeds or electronically prohibiting the crane travel into a specified area.
1. Sick Bay Isolation locations typically set up at the end of the crane
runway that is fed from a separate power feed that can be isolated from the
main crane power feed
2. Split Feed Crane Runway Isolation runways that are fed from two main
crane power feeds that can be isolated individually.
3. Programmed Work Zone - Computer program restrictions by the department
and/or Automation Engineers that sets crane(s) operational boundaries for
automatic cranes.

29.3 RESPONSIBILITY
The work group supervisor or leader shall be responsible to determine the means of
protection that will be used, and the implementation of the protection before the work
begins. This will include an understanding by all crane operators, look outs, and affected
employees of the level of protection to be implemented and the communications to be
used during the work.
29.4 PROTECTION PROCEDURES
29.4.1 The means of GSO #2 protection shall be implemented in the following
order of effectiveness to eliminate the hazards of crane movement. The level of
GSO #2 protection selected will be determined by GSO #2 trained and certified
AK Steel Management or designee.
a.
b.
c.
d.

Lock Out of Cranes

Positive Rail Stops
Crane Power Feed Isolation
Planned Work Zones

29.4.1.1 Lock Out of Cranes

29.4.1.1.1 Lock Out of overhead cranes that the work activity,

mobile equipment, work platforms, etc are or potentially are in the
Crane Envelope shall be implemented at all times unless it
absolutely infeasible. The decision to not Lockout shall be made
by GSO #2 trained and certified AK Steel Management or
designee.
a. Lock Out shall be completed for all cranes on the same
runway.
b. Lock Out shall be completed for all cranes on the adjacent
runway if the crane movement presents a potential hazard
to the work being performed on the adjacent crane, crane
runway or in the crane envelope.
c. GSO #2 Form (AKSF-19) shall be initiated by a GSO #2
trained and certified AK Steel Management or designee
and communicated with all affected employees prior to the
commencement of the job requiring the GSO #2 and at the
start of each subsequent shifts impacted by the GSO #2
29.4.1.1.2 Lockout or rail stops are required when work activity
involves rail breaks, rail replacement, or work on rails where there
is no safe clearance for cranes to pass.
29.4.1.1.3 When Lock Out has been determined by AK
Management as not feasible for the full length of the job, then
Positive Rail Stops shall be the next GSO #2 protective measure to
be evaluated.

29.4.1.2 Positive Rail Stops

29.4.1.2.1 GSO #2 Lockout or rail stops are required when work
activity involves rail breaks, rail replacement, or work on rails
where there is no safe clearance for cranes to pass
a. GSO #2 Form (AKSF-19) shall be initiated by a GSO #2
trained and certified AK Steel Management or designee
and communicated with all affected employees prior to the
commencement of the GSO #2 LOTO and installation of
the positive rail stops.
b. GSO #2 Lock Out with verification shall be completed for
denergization of the crane runway for the installation of the
rail stops.
29.4.1.2.3 Positive rail stops shall be placed on crane rails between
the crew doing the work and the active cranes to effectively protect
the work zone. A specified distance for the rail stop placement will
be determined by the AK Management.
29.4.1.2.4 Blue Flashing Lights shall be positioned below 35 feet

or 1 bay in advance of the rail stops on a position readily visible to

the crane operators to provide adequate warning of the position of
the rail stops.
29.4.1.2.5 A new GSO #2 Form (AKSF-19) shall be initiated by a
GSO #2 trained and certified AK Steel Management or designee
and communicated with all affected employees prior to the
commencement of the job requiring the GSO #2 and at the start of
each subsequent shifts impacted by the GSO.
a. The previous GSO #2 Form (AKSF-19) for LOTO and
installation of the Rail Stops is in effect until the new GSO
#2 Form (AKSF-19) for the use of positive rail stops is
completed and communicated with all affected employees.
b. At the commencement of the job requiring use of Positive
Rail Stop for GSO #2 protection, a new GSO #2 Form
(AKSF-19) shall be initiated by a GSO #2 trained and
certified AK Steel Management or designee and
communicated with all affected employees prior to the
commencement of the removal of the positive rail stops.
c. GSO #2 Lock Out with verification shall be completed for
denergization of the crane for the removal of the rail stops.
d. Once the rail stops have been removed, the GSO #2 Form
for the Rail Stops and the GSO #2 Form for denergization
of the crane for the removal of the Rail Stops can be
cancelled and all affected employees shall be informed that
the GSO #2 protection has been discontinued.
29.4.1.2.6 When Rail Stops for GSO #2 protection has been
determined by AK Management as not feasible for the full length
of the job, then Crane Power Feed Isolation shall be the next GSO
#2 protective measure to be evaluated.

29.4.1.3 Crane Power Feed Isolation

29.4.1.3.1 GSO #2 Protection through Crane Power Feed Isolation
of a specified part of the crane runway shall be evaluated whenever
it has been determined by AK Management that GSO #2 Lock Out
of the complete runway and installation Rail Stops are not feasible.
29.4.1.3.2 If grounding straps need to be installed, a GSO #2 Lock
Out with verification shall be completed for all cranes on the same
runway for the installation of the grounding strap.
a. GSO #2 Form (AKSF-19) shall be initiated by a GSO #2
trained and certified AK Steel Management or designee
and communicated with all affected employees prior to the
commencement of the GSO #2 LOTO for the installation of
the grounding strap .

b.

GSO #2 Lock Out with verification shall be completed for

denergization of the crane runway for the installation of the
grounding straps

29.4.1.3.3 The Crane Power Feed that is being isolated will need to
isolated, LOTO and verified to be at Zero Energy State. All
employees performing work that is being protected by the GSO #2
Crane Power Feed Isolation shall lock out on the established Lock
Box or LOTO location for the isolation.
29.4.1.3.4 Blue Flashing Lights shall be positioned one crane bay
ahead of the Crane Travel Isolation Zone (both end where
applicable) and at a position readily visible to the crane operators
to provide adequate warning of the position of the Crane Travel
Isolation Zone. The visibility of the Blue Flashing Lights shall be
verified by the crane operator.
29.4.1.3.4.1 If it is determined that the crane operator may
need to impinge on the one crane bay zone protected by the
Blue Light, then a Safety Lookout, wearing Hi-vis green
vest, will be required.
29.4.1.3.4.2 If it becomes necessary for crane(s) to pass
into the one crane bay zone protected by the Blue Light, the
following shall be done:
a. The crane operator notifies the safety lookout of
the need to pass into the one crane bay zone
protected by the Blue Light the safety lookout
notifies the work crew to exit the work area and
assures that the employees and equipment are in a
safe position
b. The lookout shall then turn off the flashing Blue
Lights and signal the crane to travel into the one
crane bay zone protected by the Blue Light.
c. After the crane has exited the one crane bay zone
protected by the Blue Light, the flashing Blue
Lights shall be reactivated.

29.4.1.3.5 A new GSO #2 Form (AKSF-19) shall be initiated by a

GSO #2 trained and certified AK Steel Management or designee
and communicated with all affected employees prior to the
commencement of the job requiring the GSO #2 and at the start of
each subsequent shifts impacted by the GSO.
a. The previous GSO #2 Form (AKSF-19) for LOTO and
installation of the grounding strap is in effect until the new
GSO #2 Form (AKSF-19) for the job requiring the GSO #2

b.

c.

d.

e.

is completed and communicated with all affected

employees.
Once the new GSO#2 Form has been completed and
communicated, the GSO #2 Lock Out can be discontinued
and the crane runway can be energized. This will permit
closing out of the initial GSO #2 for LOTO and installation
of the grounding strap.
At the commencement of the job requiring the CRANE
TRAVEL ISOLATION ZONE for GSO #2 protection, a
new GSO #2 Form (AKSF-19) shall be initiated by a GSO
#2 trained and certified AK Steel Management or designee
and communicated with all affected employees prior to the
commencement of the removal of the grounding strap
GSO #2 Lock Out with verification shall be completed for
denergization of the crane for the removal of the grounding
strap.
Once the grounding strap have been removed, the GSO #2
Form for the grounding strap and the GSO #2 Form for
Lock Out can be cancelled and all affected employees shall
be informed that the GSO #2 protection has been
discontinued.

29.4.1.3.6 When GSO #2 Crane Power Feed Isolation has been

determined by AK Management as not feasible for the full length
of the job, then Planned Work Zones shall be the next GSO #2
protective measure to be evaluated.

29.4.1.4 Planned Work Zones

29.4.1.4.1 The work group supervisor or leader shall conduct a
meeting with the crane operator(s) to determine the location of the
lookouts(s) and flashing warning beacon(s).
29.4.1.4.2 The work group leader or supervisor shall then hold a
meeting with the lookout to instruct them and position them as
required. (Note: The meeting can be held with all parties in
attendance as well.)
29.4.1.4.3 When a job continues into the next turn, relief personnel
shall have the same specific meeting to be advised of the details of
the areas being protected.
29.4.1.4.4 Planned work zones with flashing warning beacons and
safety lookout control provides 3 levels of control:
a. First the crane operator is responsible for the safe
operation of the crane. The operator shall perform the

regular inspection of the crane at the beginning of the

turn to assure proper functioning.
b. Second, flashing Blue Lights controlled by the work
crew shall identify the planned work zone. The crane
operator shall verify that the Blue Lights are visible and
that he has radio communication with the Lookout(s).
c. Third, a safety lookout with a green HiVis safety vest
positioned by the crew, and working under the crew
supervisor or leaders direction shall constantly monitor
crane activity for protection of the work crew. The
safety lockout lookout is not permitted to perform any
other tasks.
29.4.1.4.5 There shall be voice or radio communication between
the safety lookout and the crane operator(s) prior to the beginning
of the work and at all times. If a loss of communication occurs, the
crane operator or lookout shall immediately notify the work crews
to stop, move equipment and personnel out of the travel path of the
crane until communication can be re-established.
29.4.1.4.6 The safety lookouts sole duty shall be to keep a sharp
lookout
of crane activities for the crew being protected.
29.4.1.4.7 When this method is used GSO #2 Form (AKSF-19)
shall be completed by a GSO #2 trained and certified AK Steel
Management or designee
29.4.1.4.8 The safety lookout will hold the GSO #2 Form (AKSF19) until the job has been completed and the crew being protected
relieves the safety lookout.
29.4.1.4.9 It is the responsibility of the GSO #2 trained and
certified AK Steel Management or designee to be sure this GSO #2
Form (AKSF-19) is completed and understood by all affected
personnel.
29.4.1.4.10 In all cases involving the safety of the work crew the
crane operator shall follow the directives of the crew being
protected or the crews safety lookout person.
29.4.1.4.11 During the course of work it may be necessary for
crane(s) to pass into or through a work zone, the following shall be
done:
a. The crane operator notifies the safety lookout of the need to pass
into or through the work zone the safety lookout notifies the work
crew to exit the work area and assures that the employees and
equipment are in a safe position

b. The lookout shall then turn off the flashing Blue Lights and
signal the crane to pass or travel into the protected work zone.
c. After the crane has exited into out of the protected work zone,
the flashing Blue Lights shall be reactivated.
29.4.2 Riding outside the cab or landing platform is prohibited except for
inspection and adjustment of parts, or where necessary in the performance of
maintenance work. Riding on the trolley while the crane is in motion is never
permitted.
29.4.3 Persons required to check the performance of the crane while it is in
operation shall have:
29.4.3.1 Department clearance accompanied with a written procedure
signed by the maintenance shift supervisor.
29.4.3.2 A clear understanding and communication with the crane operator
of the position(s) of the service people
29.4.3.3 All other motions other than the one being checked shall be
locked out, or the crane operator in the cab in communication with the
repair person, and instructed by the repair person.
29.5 TRAINING
29.5.1 All employees shall be trained at least to an awareness level on the
aforementioned requirements annually.
29.5.2 AK Steel Managers and designees shall be trained initially prior to
assignment and whenever there is a significant change in GSO#2 and shall be
trained in the following:
a. GSO #2 requirements
b. Specific Situations requiring GSO #2
c. Proper Implementation of the procedures within GSO #2
d. How to properly complete and implement GSO #2 Form (AKSF-19)
e. Must successfully pass the GSO #2 quiz. (>90%)
29.5.3 Safety lookouts shall be trained in the following:
a.
b.
c.
d.

The location and boundaries of the work area

Specific responsibilities, duties, and obligations to the work crew
The signs and signals of the job
Responsibility of not leaving the job until relieved by the work crew
supervisor or leader
e. Interpretation of the sign-off sheet

APPENDIX A
The following is the list of the overhead cranes exempted from implementing GSO #2
requirements when equipment and/or personnel are within the Crane Envelope while on
the main level during normal operating conditions
Butler Works:

Department

Crane #

Department

Crane #

Silicon
Silicon
Silicon
Silicon
Silicon
Cold Mill
Cold Mill
Cold Mill
Cold Mill
Shipping
Shipping

C-23
C-24
C-25
C-26
C-27
D-106
D-130
D-142
D-147
D-17
D-18

Shipping
Shipping
Hot Mill
Hot Mill
Hot Mill
Hot Mill
Hot Mill
Hot Mill
Melt Shop
Melt Shop
Melt Shop

D-20
D-37
C-1
C-87
F-2
F-3
C-66
F-1
R13
R17
R36

Middletown Works:

Location

Crane #

Location

Crane #

#5 Temper Mill
#5 Temper Mill
Zincgrip Mtc
Zincgrip Entry End
Terne Coat Mtc
Terne Coat
Terne Coat
Blast Furnace W
Blast Furnace E

C-110
C-145
C-67
C-84
C-155
C-71
C-71
C-2
C-5

Shipping Door #187

Shipping Door #191 A
Shipping Door #191
Shipping Door #191
Shipping Door #167
Shipping Door #166
Annealing
#3 ZG

C-169
C-113
C-114
C-146
C-131
C-133
C-105
C-158

Zanesville Works:

Crane #

Crane #

#3 Crane
#4 Crane
#5 Crane
#7 Crane

#9 Crane
#21 Crane
#22 Crane

30

General Safety Order #3 - Governing Anyone Working On or About Railroad

Tracks
30.1 SCOPE
General Safety Order #3 has been authorized and approved to provide for the protection
of anyone working in or about standard railroad cars or railroad track areas. These areas
include, but are not limited to, areas where a rolling car could: contact other cars being
worked on or in, enter a building, and/or enter a work or traffic area.
30.2 DEFINITIONS
The following definitions are provided to clarify language used throughout this General
Safety Order.
Note: Working on or about railroad track areas is defined as:
Standard Gauge = within 6 ft from outer railroad track.
30.2.1 Derail - A device placed on a rail and designed to cause the wheels of
rolling rail stock to run off the rail into the ground.
30.2.1.1 This device is utilized as a positive protection device for
protected work areas and is capable of being locked.
30.2.1.2 This device shall be positioned in such a manner that the derailed
stock does not strike an adjacent building, utility structure, or other
facilities.
30.2.2 Flashing Red Light - A visual warning device used in conjunction with red
signs after daylight hours.
30.2.3 Head End Protection - Riding on, proceeding ahead, or positioned to view
area of travel of the lead car, or locomotive on foot, to afford protection to
vehicular, pedestrian, mobile equipment traffic, other rail movement, or other
obstructions.
30.2.3.1 May also be referred to as Point Protection or Front End
Protection.
30.2.3.2 Railroad operating areas requiring Head End Protection will be
specifically designated by the Plant and/or Department.
30.2.4 Positive Track Protection - A physical means of protecting workers in a
protected work area that may be achieved by one or more of the following (The
means of protection used shall also be prioritized in the following order):

30.2.4.1 Switch aligned against the protected area, locked out and
designated with a warning device.
30.2.4.2 Switch aligned against the protected area and spiked in that
position to prevent movement. The spiked switch will be designated with a
warning device.
30.2.4.3 A derail placed a specified minimum distance from the work area.
The distance is to be determined by Plant and/or Department rules and
procedures.
When the minimum distance is not attainable, derail(s) shall be placed
between the working crew and any rolling stock and be designated with a
warning device.
30.2.4.4 Bumpers or track blocks and designated with a warning device.
30.2.5 Protected Area - An area where work is or will be performed on or near rail
tracks and has all access tracks, and if necessary adjacent tracks, blocked with
positive track protection.
30.2.5.1 On or near Standard Gauge Railroad Track shall be within 6 ft
from the outer rail of the track.
30.2.6 Red Sign - Visual warning device used to warn rail movement of a
protected work area.
30.2.6.1 Red Signs shall be constructed of plastic or metal.
30.2.6.2 Reflective markings shall be attached to the front side of the sign.
30.2.6.3 Red Signs shall be permanently marked and legibly identified
indicating the department or contractor name and phone number on the
back of the sign.
30.2.6.4 Red Signs shall be a minimum of 36" high.
30.2.7 Switch - Railroad track device utilized to change the direction of travel
from one track to another.
30.2.7.1 Switch types can be manual, automatic (self-aligning), or
electrically operated.
30.2.8 Switch Alignment Against Protected Area - Aligning and locking or
spiking a switch to a position that directs the movement of rail stock away from a
Protected Area.
30.3 PROCEDURE

30.3.1 Positive Track Protection Specifications

30.3.1.1. Positive track protection including warning devices designating
the positive track protection device shall conform to standards in use on
the railroads and shall be approved by the Department Managers of the
Transportation and Safety Departments. They shall be permanently
marked and identified legibly, showing the name and phone number of the
department or contractor to which the device belongs.
Note: use positive track protection and warning devices identified with
your home department's or contractor's markings only.
30.3.2 Warning Devices
30.3.2.1 Red signs in daylight hours, and red signs with red flashing lights
from dusk to dawn or inclement (rain, fog, etc.) weather, shall be used as
warning signals by all departments where persons are working in, on, or
about railroad equipment, or nearer than 6 feet from the outer rail of any
railroad track.
30.3.2.2 Warning devices shall be placed within clear view of rail
equipment operators at a minimum distance designated by the Plant and/or
Department, or at the nearest switch aligned and locked against the
protected work area.
30.3.2.3 Warning devices shall be permanently marked and legibly
identified indicating the department or contractor name and phone number
on the device.
30.3.2.4 A protected area being guarded by positive protection and
warning devices shall not be entered by any railroad equipment.
30.3.2.5 No car or cut of cars shall be placed to obscure a warning device
without first notifying the person who placed the warning device, so that
person may relocate it at the head end of the new car or cut of cars.
30.3.2.6 Warning devices shall only be removed by authorized personnel
from the protected group.
30.3.3 Railroad Switches and Derails
30.3.3.1 When employees are working on or about railroad cars or railroad
tracks, within 6 feet from the outer rail of the track, positive track
protection shall be in place prior to worker exposure.
30.3.3.2 When permanent and temporary derails are installed, they shall be
locked for positive protection in conjunction with warning devices.

30.3.3.2.1 Permanent derails shall be locked in the open position

when NOT in use.
30.3.3.3 Permanent and temporary derails shall have the appropriate
warning device.
30.3.3.4 All buildings shall have Positive Track Protection at the
entrance/exit end(s).
30.3.3.5 All building railroad signal light switches shall be equipped with
guards that shall be locked out to prevent signal changes while
maintenance or service personnel are working on or near railroad tracks
within a building protected by building light signals.
30.3.3.6 When a cut of cars or railroad track work area is located so it can
be accessed from either direction, both ends of the car, cut of cars, or both
sides of the work area shall have Positive Track Protection.
30.3.3.7 When more than one crew is working on or about railroad cars or
track areas, each crew must protect itself by ensuring that positive track
protection is maintained until completion of their work.
30.3.3.8 When material is being loaded or unloaded and carried across
tracks parallel to the track on which the car stands, all involved tracks
shall have positive track protection.
30.3.3.9 Malfunctioning track lights shall be considered red, and entry into
a building by transportation or maintenance crews shall be made only
under the direction of an authorized person who is physically located at
the track entrance of the building. NO LIGHT IS A RED LIGHT.
30.3.4 ROLLING STOCK
30.3.4.1 Buildings
30.3.4.1.1 Railroad stock shall not be moved in or out of buildings
with mobile equipment or overhead cranes, or when personnel are
on the track, and
30.3.4.1.2 Railroad stock shall not be kicked, bumped, or dropped
into buildings or across crossings.
30.3.4.2 Yard Areas
30.3.4.2.1 In yard areas, if it is necessary to move railroad cars
with approved and authorized mobile equipment, such movement
shall be supervised.

30.4 RESPONSIBILITY
30.4.1 The supervisor or designated leader will be assigned for work crews being
protected and will be responsible for:
30.4.1.1 Requesting permission to enter the work area and requesting
approval for use of warning devices and derails, or locking or spiking out
switches to restrict track areas from the from the Yardmaster or other
designated supervisor who has responsibility for the track areas for the
following:
Entering the Work Area
Approval for Use of Warning Devices and Derails
Approval to Lock Out or Spike Switches.
30.4.1.2 Notifying the Yardmaster or other designated supervisor if a track
switch cannot be lined and locked against the work area.
30.4.1.3 The protection of the crew from rolling railroad stock when
working on or about railroad cars or tracks (within 6 feet from the outer
rail of the tracks), both inside and outside buildings.
30.4.1.4 The proper use of positive track protection by the crew(s).
30.4.1.5 Notification of the Yardmaster or other designated supervisor
when the job is complete and signs/warning devices have been removed.
30.4.2 The person placing the positive track protection is responsible for its
removal.
30.4.2.1 When the person who placed the positive track protection is not
available to remove it, the device may be removed under the direction of
the Department Manager having responsibility for the tracks under the
following guidelines:
30.4.2.1.1 Call the Department Manager or his department
designee of the person who placed the device to ascertain the
circumstances and state the reason removal of the device is
necessary;
30.4.2.1.2 Department Management shall conduct a thorough
inspection with the railroad supervisor (Yardmaster or other
designated supervisor) to assure that the area is clear and to alert
any individuals who may enter the area that the device will be
removed;
30.4.2.1.3 Notify the person who placed the device prior to his/her
return to work.

31

General Safety Order #4 - Confined Space Entry Procedures

31.1 SCOPE
General Safety Order #4 has been authorized and approved to establish the general
procedures necessary to eliminate, control, or mitigate the safety and health hazards
unique to confined spaces. It is based on developing specific procedures for each space.
This Confined Space Program applies to AK Steel personnel and to all contractors who
may enter a confined space.
31.2 DEFINITIONS
31.2.1 Attendant or Safety Standby - an individual stationed outside a confined
space who monitors the authorized entrants and performs all the attendant's duties
assigned in the confined space program.
31.2.2 Confined Space - a space that:
31.2.2.1 Is large enough and so configured that an employee can bodily
enter and perform assigned work; and
31.2.2.2 Has limited or restricted means for entry or exit (for example,
tanks, vessels, storage bins, hoppers, vaults, pits, and sewers that may
have limited means of entry); and
31.2.2.3 Is not designed for continuous occupancy.
31.2.3 Entrant - an employee authorized by the entry supervisor to enter a
confined space.
31.2.4 Entry - the action by which a person passes through an opening into a
confined space.
31.2.4.1 Entry includes ensuing work activities in that space and is
considered to have occurred as soon as any part of the entrant's body
breaks the plane of an opening into the space.
31.2.5 Entry Supervisor - the person responsible for determining if acceptable
entry conditions are present at a permit space where entry is planned, for
authorizing entry and overseeing entry operations, and for terminating entry.
31.2.6 Immediately Dangerous to Life or Health (IDLH) - any condition that
poses an immediate or delayed threat to life or that would cause irreversible
adverse health effects or that would interfere with an individual's ability to escape
unaided from a permit space.
31.2.7 Retrieval System - the equipment (including a retrieval line, chest or full

body harness, wristlets, if appropriate, and a lifting device or anchor) used for
non-entry rescue of persons from the permit space.
31.3 ENTRY ALTERNATIVES
Whenever feasible, design changes or work practice will be developed to
eliminate the need for entry into confined spaces. Non-entry work practices will
be covered by a JSHA.
31.4 CONFINED SPACE PERMIT
The Confined Space Permit will be used as written documentation to assure that all
hazards or potential hazards are dealt with appropriately (see section d below). Until
the Confined Space Permit is completed the Confined Space shall be considered to
contain a hazard (section d below).
For AK Steel, all sewers and any other location that meets all the following criteria
are to be considered as a CONFINED SPACE:
a. Is large enough and so configured that an employee can bodily enter and
perform assigned work; and
b. Has limited or restricted means for entry or exit (for example, tanks,
vessels, storage bins, hoppers, vaults, pits, and sewers that may have limited
means of entry); and
c. Is not designed for continuous occupancy; and
d. Presents a hazard by meeting one or more of the following:
1. Contains, or has the potential to contain, a hazardous atmosphere; or
2. Contains, or has the potential to contain, flowable material that could
engulf;
3. Has an internal configuration such that one could be trapped or
asphyxiated by an inwardly converging wall or by a floor which slopes
downward and tapers to a small cross section;
4. Contains any other recognized serious safety or health hazard. (An
example of this situation would be exposed un-insulated electrical wiring.)
31.5 INVENTORY
A complete list of all known confined spaces within a department will be made and
reviewed annually. Additional spaces will be included upon discovery. It is the
responsibility of the department to generate this list and keep it current.
31.6 POSTING

All accessible entrances to inventoried confined spaces shall be posted with the following
or other approved warning:
DANGER: CONFINED SPACE AUTHORIZED ENTRY ONLY
REVIEW CONFINED SPACE ENTRY PERMIT WITH DEPT SUPERVISION
BEFORE ENTRY
31.6.1 Posting Exception: Manholes in roadways.
31.6.2 Employees that may be affected by the spaces must be alerted to the
presence of the confined space and appropriate actions taken to prevent
unauthorized entry.
31.7 ENTRY PROCEDURES
Safe entry procedures for confined spaces must be developed and written in standard
format.
31.7.1 These step by step procedures must be created with enough detail that a
person preparing to enter a confined space can verify that the actions required and
conditions specified do exist and that the actions required have, in fact, been done.
31.7.2 It is AK Steel's responsibility, specifically the department controlling the
confined space, to create, maintain, review, revise, and approve the entry
procedure. Approval of new and revised entry procedures must be approved by
the Department Manager or Section Manager and the Safety Department.
31.7.3 Confined spaces entered at least once a year must have specific entry
procedures preplanned and in writing. Whenever possible these must be created in
advance of any entry to allow thorough review by operations, maintenance, safety
and likely entry groups.
31.7.4 Spaces entered less frequently than once per year, shall have their
procedures developed prior to entry as soon as the need to enter the space is
recognized.
31.7.5 Multiple spaces may be covered by a single procedure only if the spaces
are within the same department, are functionally identical, do not vary with
location and do not have varying conditions.
31.7.6 Current copies of any referenced documents and Safety Data Sheets
(SDS's) must be attached to the Confined Space Permit at the time of use. This
includes SDS's for materials that may already be present in the space and for
materials that entrants might introduce into the space. SDSs must be reviewed to
assure all hazards are eliminated or controlled.
31.7.7 Confined Space Entry permits do not include, cover, or take the place of

hot work permits.

31.8 SAFETY ATTENDANT/STANDBY
A Safety Stand-by, also called an attendant, wearing a Hi-Vis Green Vest, is required for
any entry that has one or more of the following characteristics:
31.8.1 Contains or has the potential to contain a hazardous atmosphere;
31.8.2 Contains a material that has the potential for engulfing an entrant;
31.8.3 Has an internal configuration such that an entrant could be trapped or
asphyxiated by inwardly converging walls or by a floor which slopes downward
and tapers to a small cross-section;
31.8.4 Contains any other recognized serious safety or health hazard.
31.9 RESCUE
If hazards within a confined space cannot be eliminated and if rescue cannot be done
from outside the space, or the conditions in the space are Immediately Dangerous to Life
and Health (IDLH), a rescue team is required. If rescue is provided by a non-AK Steel
source, advanced access to the confined space and training on associated hazards must be
provided. Confined spaces that require rescue teams must have the rescue team and
required equipment on-site, and within range of the air horn (or other pre-determined) n
emergency signal.
31.10 RESCUE FROM OUTSIDE THE CONFINED SPACE
If it is determined that rescue can be performed from outside the confined space the
person(s) responsible for rescue must be trained in the following:
a. Use of the mechanical hoist or other equipment that will be used to retrieve the
entrant.
b. Any hazards that exist outside of the confined space that could interfere with
rescue.
c. The necessary emergency numbers and how to access communications.
31.10.1 Rescue personnel must be provided quick access to communications
equipment so that emergency personnel can be contacted immediately if rescue
operations are put into effect.
31.11 TRAINING
Procedures and duties will be reviewed with all affected employees prior to confined
space entry. Training in job duties and the proper use of needed equipment, such as air

monitoring equipment, will be given and proficiency established prior to entry.

31.11.1 If rescue is to be done by a rescue team that will enter the space they will
receive:
a. Training as required for equipment such as self-contained breathing
apparatus and testing devices.
b. Confined space hazard training the same as those entering the space.
c. Annual rescue training to include both actual confined spaces or appropriate
simulated confined spaces.
d. First-aid and Cardiopulmonary Resuscitation (CPR).

31.11.2 Training must be documented with employee's name, date of training, and
the signature or initials of the person conducting the training.
31.12 PERMISSION TO ENTER
31.12.1 No person is allowed to enter a confined space without permission.
31.12.2 Entry means any part of a person's body passing into the space.
31.12.3 A copy of the complete Confined Space Permit, with attachments, must
be posted or otherwise made highly visible at the entrance to a confined space
before permission to enter is given.
31.12.4 Permission to enter a space can only be given after all aspects of the
written entry permit, including attachments, have been met or completed and
employees have completed training.
31.12.5 The supervisor of employees entering a confined space must grant
permission for their entry by verifying required entry conditions and signing the
permit.
31.13 CANCELING AN ENTRY PERMIT
Permission to enter a confined space is canceled when:
31.13.1 The task for which the permit was issued has been completed.
31.13.2 A condition not allowed under the permit arises in or near the space. Any
such problems or conditions and their resolution will be noted on the entry
permit.
31.13.3 The permit time limit has expired.

31.14 MONITORING
31.14.1 Initial monitoring:
31.14.1.1 Initial monitoring will be performed from outside the confined
space prior to entry.
31.14.1.2 Oxygen (O2), Lower Explosive Limit (LEL), and Carbon Monoxide
(CO) levels must be tested in ALL confined spaces at AK Steel.
31.14.1.3 Monitoring must also be performed on any other contaminant that
may be present in the space.
31.14.1.4 All entry operations shall be prohibited when any atmospheric level
exceeds AK Steel's requirements (<19.5% Oxygen, > 23.5% Oxygen, > 5%
LEL, >50ppm Carbon Monoxide).
The level of other air contaminants allowed will be evaluated by the Safety
Department.
31.14.1.5 The air monitoring must be representative of the entire confined
space including monitoring at the top, middle, and bottom of the space in
order to detect any stratification of the gases.
31.14.2 Continuous monitoring: Oxygen (O2), Lower Explosive Limit (LEL), and
Carbon Monoxide (CO) levels must be continuously monitored with a direct
reading instrument equipped with an alarming device during ALL confined space
entry operations at AK Steel, regardless of classification.
31.14.2.1 All entry operations must cease when any atmosphere level
exceeds AK Steel's exposure limits.
31.14.2.2 The levels of monitored materials must be recorded every 15
minutes.
31.14.3 Results of the monitoring must be immediately provided to each entrant
or their authorized representative.
31.14.4 Each entrant or their authorized representative must be provided the
opportunity to observe the pre-entry and any subsequent monitoring of the
confined space.
31.15 CONTRACTORS
All contractors that participate in any aspect of confined space entry operations must, at a
minimum, follow AK Steel Confined Space Entry Procedures. Contractors must comply
with all AK Steel documentation requirements involving Confined Space Entry
Procedures.

31.15.1 The AK Steel person responsible for bringing the contractor on site must
notify the contractor about hazards of the confined space, AK Steel monitoring
requirements, and AK Steel Confined Space Entry Procedures. This notification
must be documented.
31.15.2 The AK Steel person responsible for bringing the contractor on site must
assure that the required debriefing is completed at the conclusion of the confined
space entry.
31.15.3 Contractors shall furnish their own monitors with proper calibration and a
current bump test prior to the issue of a confined space permit.
31.16 REVIEW/REVISION
Confined Space Entry Procedures must be reviewed, and revised as necessary. This must
be done annually or before the next entry, following any unplanned event, and after any
change which may affect the entry. It is the responsibility of the department "owning" or
controlling the confined space to maintain the Confined Space Entry Procedure, keep
canceled permits, and keep contractor notification and debriefing records for at least one
year.
31.17 AUDITS
The Confined Space Entry Program and entry procedures are subject to annual review
and periodic audit to ensure proper program direction and execution.
31.17.1 Each department must review their program annually.

32

General Safety Order #5 - Fall Protection Program

32.1 SCOPE
General Safety Order #5 has been authorized and approved to establish policy relative to
the scope and use of Fall Protection Systems by AK Steel Employees in all AK Steel
facilities. This policy shall establish a means to analyze elevated work tasks and
determine appropriate personal protection against elevated fall hazards. It is the
expectation that all AK Steel employees and all contractors shall/will follow and comply
with all standards in this policy as it has been developed to meet or exceed all applicable
OSHA regulatory requirements.

32.2 DEFINITIONS
32.2.1 Anchorage: A secure point of attachment for lifelines, lanyards, or
deceleration devices, capable of supporting 5000 lbs. per person..
32.2.2 Arresting Force: The force generated by arresting the test weight that is
transmitted through the fall arresting system components to the anchorage or load
cell.
32.2.3 Body Harness: A design of straps which may be secured about the
employee in a manner that will distribute the fall arrest forces over at least the
thighs, pelvis, waist, chest and shoulders with means for attaching it to other
components of a personal fall arrest system.
32.2.4 Deceleration Device: Any mechanism, such as a rope grab, rip stitch
lanyard, specially-woven lanyard, tearing or deforming lanyard, automatic selfretracting lifelines/lanyards, etc., which serves to dissipate a substantial amount of
energy during a fall arrest, or otherwise limit the energy imposed on an employee
during fall arrest.
32.2.5 Free Fall: The act of falling before a personal fall arrest system begins to
apply force to arrest the fall. (Must be limited to less than or equal to 6 feet)
32.2.6 Free Fall Distance: The vertical displacement of the fall arrest attachment
point on the employee's body harness between onset of the fall and just before the
system begins to apply force to arrest the fall. This distance excludes deceleration
distance, and lifeline/lanyard elongation, but includes any deceleration device
slide distance or self-retracting lifeline/lanyard extension before they operate and
fall arrest forces occur.
32.2.7 Lanyard: A flexible line of rope or strap, which generally has a connector
at each end for connecting the body harness to a deceleration device, lifeline, or
anchorage.
32.2.8 Lifeline: A component consisting of a flexible line for connection to an

anchorage at one end to hang vertically (vertical lifelines), or for connection to

anchorages at both ends to stretch horizontally (horizontal lifeline), and which
serves as a means for connecting other components of a personal fall arrest
system to the anchorage.
32.2.9 Low-Slope Roof: A roof having a slope less than or equal to 4 in 12
(vertical to horizontal).
32.2.10 Personal Fall Arrest System: System used to arrest an employee in a fall
from a working level. It consists of an anchorage, connectors, full body harness
and may include a lanyard, deceleration device, self-retractable lifeline/lanyard,
rope grab or suitable combination.
32.2.11 Qualified Person: One who, by possession of a recognized degree,
certificate, or professional standing, or who by extensive knowledge, training, and
experience, has successfully demonstrated his ability to solve or resolve problems
relating to the subject matter, the work, or the project.
32.2.12 Self-Retracting lifeline/Lanyard: Deceleration device containing a drumwound line which can be slowly extracted from, or retracted onto, the drum under
slight tension during normal employee movement, and which, after onset of a fall,
automatically locks the drum and arrests the fall.
32.2.13 Shock Absorber: A deceleration component of a fall protection system
which allows the dissipation of energy after a free fall.
32.2.14 Steep Roof: Roof having slope of greater than 4 in 12 (vertical to
horizontal).
32.2.15 Tie off: The act of an AK Steel employee wearing personal fall protection
equipment, connecting directly to an anchorage point. It also means the condition
of an AK Steel employee being connected to an anchorage point.
32.2.16 Travel Limiting (Work Positioning): The process of utilizing a anchorage
point, connecting means and full body harness to prevent access to a fall hazard.
The anchorage shall be capable of withstanding, without failure, a force of at least
200 pounds in any outward or downward direction.
32.2.17 Unprotected Sides or Edges: Any side or edge (except at entrances to
points of access) of a walking/working surface, e.g., floor, roof, ramp, or runway
where there is no wall or guardrail system at least 39 inches high.
32.2.18 Walking/Working Surface: Any surface, whether horizontal or vertical on
which an employee walks or works, including, but not limited to , floors, roofs,
ramps, bridges, runways, frame work and concrete reinforcing steel.
32.3 APPLICATION

AK Steel employees working at any elevation greater that four (4) feet from the floor,
deck, platform, or ground level not protected on all sides by standard handrails shall be
required to use personal fall protection. Any AK Steel employee working, in an aerial lift,
(excluding scissors lifts) on scaffolding without standard handrail, or around an
excavation (4 feet or deeper) are also required to use personal fall protection.
32.3.1 Every effort must be made by departmental supervision to eliminate fall
hazards from leading edges and open pits by installing a standard handrail or
other approved method of protection.
32.3.2 All AK Steel employees working at an elevation greater than four (4) feet
without a standard handrail shall be required to wear a full body harness, lanyard
and/or deceleration device attached to a secure anchorage. Body belts are not
permitted for use at AK Steel.
32.3.3 All roofs at AK Steel require fall off and fall through protection. Fall
through protection must be used unless the roof is certified for structural integrity.
Fall off protection must be used anytime an employee is within 6 feet from any
leading edge of the roof with more than a four (4) foot fall hazard. When working
on a roof, employees shall be protected in the following manner:
i. Fall through protection unless certified for structural integrity
ii. Fall off protection when working on a steep roof or within six feet from
the leading edge of a low sloped roof.
iii. If an employee is working on a low-sloped roof that is certified for fall
through protection, a warning line system may be used in strict accordance
with 29 CFR 1926.502(f)&(h).
32.3.4 All AK Steel employees shall use a retractable lanyard when working at
any elevation of fifteen (15) feet or less. A retractable lifeline will be used at this
elevation to prevent contact with any lower level in the event of a free fall. A
retractable lanyard is designed to "lock-up" within 2-24 inches of a free fall. The
retractable lanyard shall be attached directly to the "D" ring on the employee's
body harness. in the middle of the back of the employee's body harness.
32.3.5 Travel limiting may be used in the following manner:

i. Employee shall use a full body harness

ii. Employee shall use a non shock absorbing lanyard
iii. Lanyard must be of a length that will not allow access to the fall hazard
iv. Anchorage must support at least 200 pounds in horizontal & vertical plane

32.3.6 When a lanyard is used for fall protection (above 15 feet) it shall comply
with the following:
i. Shall only be of the shock absorbing type
ii. Shall only be made with nylon webbing material
iii. Shall not exceed six (6) feet in length
iv. Never tie a lanyard back into itself
32.3.7 When a retractable lanyard is used for fall protection (15 feet and below) it
shall comply with the following:
i. Shall be used directly overhead
ii. Shall not walk more than six (6) feet away from the device
iii. Shall be connected directly to the "D" ring in the middle of the back
iv. Shall not be used with a lanyard or other lengthening device
32.3.8 All lanyards, connecting means and harnesses shall have a minimum
breaking strength of 5400 pounds.
32.3.9 All lanyards, deceleration devices and connecting means shall have double
locking snap hooks.
32.3.10 All lanyard, deceleration device and full body harness connecting means
shall be made of drop forged or pressed steel and cadmium plated. The surfaces
shall be smooth and free of sharp edges.
32.3.11 All lanyards, deceleration devices, full body harnesses and associated
hardware shall be inspected before and after each use. (see section V-8 for
additional details).
32.3.12 The anchorage (tie off point) shall be capable of supporting 5000 lbs. per
employee attached. If there is any doubt about the strength of the anchorage point,
DO NOT TIE OFF; find an alternate attachment point.
32.3.13 If any part of a fall protection system is subjected to a free fall, all
components shall be taken out of service immediately and given to the Safety
Department for disposition.
32.3.14 If any employee experiences a free fall, the Safety Department shall be
notified immediately.

32.3.15 Only a "qualified" person may design a fall protection system or certify
an existing system or anchorage point.
32.3.16 Third party fall protection systems (Gemtor, Railmaster, etc.) must be
pre-approved by the Safety Department. The need for review of third party
systems by a qualified engineer shall be as determined by the Safety Department.
32.4 TIE OFF PROCEDURES
32.4.1 When using a full body harness for fall protection, connecting devices shall
be attached to the "D" ring in the middle of the back. Side "D" rings are for travel
limiting, or work positioning, only and shall never be used for fall arrest
connections. Always try to tie off to an anchorage point at or above the "D" ring
of the harness.
32.4.2 Workers shall tie off in a manner that ensures no lower level is struck
during a free fall. A retractable lanyard is required to be used when the
walking/working surface contains a fall hazard less than or equal to 15 feet. A
shock-absorbing lanyard will elongate 3 to 3.5 feet in the event of a free fall. If
you add this to the length of the lanyard and the height of the employee, it could
take up to 15 feet to stop the free fall. A retractable lanyard is designed to stop a
free fall in 2 to 24 inches. The employee shall not walk more than six (6) feet
away from the retractable in any direction. This is necessary to prevent a free fall
of more than six (6) feet.
32.4.3 Lanyards shall never be wrapped back into themselves. This can weaken
the lanyard by 75 percent. Beams wraps and other engineered devices shall be
used. Do not allow a lanyard to contact any sharp or rough edges.
32.4.4 When using a full body harness and lanyard for travel limiting, The lanyard
shall be of a length that will not permit the employee to reach the fall hazard. The
anchorage point shall support at least 200 pounds.
32.4.5 When using horizontal lifelines for fall protection on crane runways, the
employee shall make sure the lifeline is certified for that purpose. Certified
horizontal lifelines will be identified with an orange metal tag with the following
information:
1. Building Number
2. Crane Number
3. Date Installed
4. Installation Ref. Drawing #
5. Inspection Ref. Drawing #
6. Maximum # of Users Per Bay
7. Maximum Lanyard length
8. Installation PO/WO #

THIS TAG IS TO BE INSTALLED AT EACH END OF THE NOTED

HORIZONTAL LIFELINE AND AT EACH LOCATION BETWEEN
THE ENDS FOR WHICH A PERMANENT ACCESS TO THE
HORIZONTAL LIFELINE EXISTS OR THE HORIZONTAL LIFELINE
USAGE REQUIREMENTS CHANGE. PAPER COPIES OF ALL TAGS
ARE TO BE KEPT ON FILE BY THE MAINTENANCE SECTION
MANAGER.
32.4.6 When working in or around excavations or trenches, all employees shall be
protected from fall hazards greater than four feet. This can be accomplished by
using a warning line system erected at least six feet from the leading edge of the
fall hazard. Deviations from this section may be made by the competent person on
site as long as it provides equal or greater protection. This may be necessary to
evaluate the excavation for fall hazards, scope of work and/or integrity of
excavation.
32.5 INSPECTION AND MAINTENANCE
32.5.1 Full body harness inspection: Personal fall arrest systems shall be
inspected prior to each use for wear, damage and other deterioration and defective
components shall be removed from service.The employee shall inspect all fall
protection equipment for damage or excessive wear before and after each use.
32.5.1.1 Harness straps should be inspected by beginning at one end,
holding the body side of the harness towards you, grasp the harness with
your hands 6 to 8 inches apart. Bend the harness strap in an inverted "U".
The surface tension resulting makes damaged fibers or cuts easier to see.
Follow this process the entire length of harness. Watch for frayed edges,
broken fibers, pulled stitches, cuts, or chemical/burn damage.
32.5.1.2 Check the "D" ring and "D" ring metal wear pad (if any) for
distortion, cracks, breaks, and rough or sharp edges.
32.5.1.3 Attachment of buckles and "D" rings should be given special
attention. Note any unusual wear, frayed or cut fibers, or distortion of the
buckles or "D" rings. Rivets should be tight and unmovable with fingers.
Body side rivet base and outside rivet burr should be flat against the
material. Bent rivets will fail under stress.
32.5.1.4 Inspect for frayed or broken strands. Broken webbing strands
generally appear as tufts on the webbing surface. Any broken, cut or
burned stitches will be readily seen.
32.5.1.5 The tongue or billets of the leg straps receive heavy wear from
repeated buckling and unbuckling. Inspect for loose, distorted or broken
grommets. Straps should never have additional holes punched into it.

32.5.1.6 Any additional inspection procedures required by the equipment

manufacturer shall be observed.
32.5.2 Lanyard Inspection: When inspecting lanyards, begin at one end and work
to the opposite end. Slowly rotate the lanyard so that the entire circumference is
checked. Stitched (spliced) ends require extra attention.
32.5.2.1 The double locking snaps should be inspected closely for hook
and eye distortions, cracks, corrosion, or pitted surfaces. The keeper
(latch) should seat into the nose without binding and should not be
distorted or obstructed. The keeper spring should exert sufficient force to
firmly close the keeper. Keeper locks must prevent the keeper from
opening when the keeper closes.
32.5.2.2 The thimble must be firmly seated in the eye of the splice, and the
splice should have no loose or cut strands. The edges of the thimble must
be free of sharp edges, distortions or cracks.
32.5.2.3 While bending a web lanyard over a pipe or mandrel , observe
each side of the webbing. This will reveal any cuts or breaks. Swelling,
discoloration, cracks, or charring are obvious signs of chemical or heat
damage.
32.5.2.4 Shock absorption devices should be examined for burn holes and
tears of the outer portion. Stitching on areas where the pack is sewn to "D"
rings or lanyards should be examined for loose strands, rips and
deterioration.
32.5.2.5 Any additional inspection procedures required by the equipment
manufacturer shall be observed.
32.5.3 Inspection of Retractable Lanyards:
32.5.3.1 Anchorage connectors shall be checked for any bent, cracked or
distorted components.
32.5.3.2 With the device in the mounted position, test the lanyard
retraction and tension by pulling out several feet of the lanyard and allow
it to retract back into the unit. Always maintain a light tension on the
lanyard as it retracts. The lanyard should pull out freely and retract all the
way back into the unit.
a. If the lanyard does not pull out smoothly or sticks when
retracting, pull the entire lanyard out of the housing and allow it to
retract slowly under tension.
b. The lanyard should be checked for signs of damage. Inspect for
cuts, burns, corrosion, kinks, frays, or worn areas. Inspect any
sewing for loose, broken, or damaged stitches.

32.5.3.3 The braking mechanism shall be tested by grasping the lifeline

above the impact indicator (if equipped) and applying a sharp steady pull
downward which will engage the brakes. There should be no slippage of
the lifeline while the brakes are engaged. Once tension is released, the
brakes will disengage and the unit will return to the retractable mode.
32.5.3.4 Check the snap hook to be sure that it operates freely and locks.
Inspect the snap hook for any signs of damage to the keepers and any bent,
cracked or distorted components.
32.5.3.5 Load indicators, if equipped, will be located above the snap hook.
A label will be exposed when subjected to fall arresting forces.
32.5.3.6 Any additional inspection procedures required by the equipment
manufacturer shall be observed.
32.5.4 Visual Indications of Damage to Webbing and Lanyards:
32.5.4.1 Nylon & Cordura:
Heat Damage - In excessive heat, nylon becomes brittle and has a
shriveled brownish appearance. Fibers will break when flexed. Nylon
should never be used above 200 degrees Fahrenheit.
Chemical Damage - Change in color usually appearing as a brownish
smear or smudge. Transverse cracks when harness or lanyard is bent over
a pipe. There will also be a loss of elasticity in the harness or lanyard.
Flame/Molten Metal Damage - Webbing strands fuse together. Hard shiny
spots and brittle feel but will not support combustion.
Paint/Solvent Damage - Paint, which penetrates and dries, restricts
movement of fibers. Drying agents and solvents in some paints will appear
as chemical damage.
32.5.4.2 Polyester & Dacron:
Heat Damage --Same as nylon above except do not use above 180 degrees
Fahrenheit.
Chemical Damage --Same as nylon above.
Flame/Molten Metal Damage -- Same as nylon above except will support
combustion.
Paint/Solvent Damage - Same as nylon above.
32.5.5 Cleaning and Storage:
Wipe off all surface dirt with a sponge dampened in plain water. Squeeze the
sponge dry. Dip the sponge in a mild solution of water and commercial soap or

detergent. Work up a thick lather with a vigorous back and forth motions. Wipe
the belt dry with a clean cloth. Equipment shall hang freely to dry thoroughly
without close exposure to heat, steam, or long periods of sunlight. Refer to the
manufacture recommendations for additional cleaning and storage considerations.
32.5.6 Annual Inspection:
A competent person shall inspect the fall protection equipment at least once a year
and document the results of the inspection.
32.6 TRAINING
32.6.1 Each employee who might be exposed to fall hazards shall be trained to
recognize the hazards of falling and procedures to be followed in order to
minimize these hazards. The employee shall be trained by a competent person
qualified in the following areas:
Nature of fall hazards in the work area; The correct procedures for erecting,
maintaining, disassembling, and inspecting fall protection equipment;
The use and operation of guardrail systems, personal fall arrest systems and other
protection to be used; Limitations of fall protection equipment; and Policies set
forth in this program
32.6.2 The employee shall be retrained when the employee does not demonstrate
the understanding and skill required to follow these procedures, workplace
renders the training obsolete or the type of fall protection used changes.
32.6.3 The training shall be documented on the employee's contact card or other
equivalent means with the name of the employee, date(s) of training, and the
signature of the person conducting the training.

33

Appendix 1: Standard Crane Hand Signals

Hoist: With forearm vertical,

forefinger pointing up, move hand in small
horizontal circle.

Lower: With arm extended

downward, forefinger pointing down, move hand
in small horizontal circles.

Bridge Travel: Arm extended forward,

hand open and slightly raised, make pushing
motion in direction of travel.

Trolley Travel: Palm up, fingers

closed, thumb pointing in direction of motion, jerk
hand horizontally.

Stop: Arm extended, palm down,

move arm back and forth horizontally.

Emergency Stop: Both arms

extended, palms down, move arms back and forth
horizontally.

Multiple Trolleys: Hold up one

finger for block marked "1" and two fingers for
block marked "2." Regular signals follow.

Move Slowly: Use one hand to give

any motion signal and place other hand
motionless in front of hand giving the motion
signal.

Magnet is Disconnected: Crane operator spreads

both hands apartpalms up.

34

Appendix 2: Carbon Monoxide Hazard procedures

CARBON MONOXIDE HAZARD PROCEDURES

PURPOSE
This procedure establishes the general requirements to enter known Carbon Monoxide areas.
Carbon Monoxide is an odorless, colorless, tasteless gas, generated in some of our operations,
which can be fatal in sufficient concentration.
SCOPE
These requirements apply to AK Steel personnel and contractors whose job duties may require
them to enter known Carbon Monoxide Hazard Areas.
EXPOSURE ALTERNATIVES
Whenever feasible, design, process, or work practice changes will be developed to eliminate
Carbon Monoxide hazards or the need to enter Carbon Monoxide Hazard Areas.
DEFINITION
All areas shall be identified where Industrial Hygiene studies, Department measurements, or past
experience indicate that Carbon Monoxide (CO) is likely to be present in concentrations of
50ppm and higher.
POSTING
Access to these areas shall be clearly posted, designating them as CO Hazard Areas. When
feasible, this posting will include a physical barrier such as a removable cable, entryway, fence,
or other impediment to prevent people from accidentally entering a CO Hazard Area.
ENTRY PROCEDURES
1. No one will be permitted in a CO Hazard Area without supervisory permission.
2.A) Each group, (AK or Contractor) which enters a CO hazard area must contain at least one
person, or be accompanied by someone, who is, experienced and familiar with the CO gas hazard
area and the dangers of Carbon Monoxide.
2.B) Each person or group will not enter a CO Hazard Area without a properly functioning CO
meter with requirements referenced from #5 of this (CO) S.P.I..
3. Any department having a Carbon Monoxide Hazard Area, will develop and implement a plan
to keep track of all individuals entering and leaving CO Hazard Areas. This plan must include
the following elements:

A) Prior to entering, at least one designated responsible individual will be notified of the
area to be entered. This must be documented so it can be determined who is in the CO
Hazard Areas at any given time. This may be done by sign-in/sign-out sheets, a system of
tokens, electronically, or by any other means that positively identifies each individual and
their location.
B) Each department will develop a method to monitor the well being of each person or
group.
C) In areas where concentrations are likely to be above 1200 ppm, the monitoring method
must be able to detect problems in a timely manner so emergency action is effective.
Because of the fast action of high levels of Carbon Monoxide, the method developed
must detect problems and cause emergency action to begin quickly. This may be done
visually, audibly, electronically or by any other method that does not depend on those in
the CO area to initiate actions. In other words, even if everyone in the CO Hazard Area
were totally incapacitated, the method chosen must still function to show they are in
trouble.
4. No group will enter a CO Hazard Area unless properly serviced Self-contained breathing
apparatus is readily available for use in the event an accident should occur.
5. Carbon Monoxide Monitoring: All monitors must show the current (instantaneous)
concentration of CO in Parts Per Million (ppm) and be equipped with an alarm. The alarm may
be either visual, tactile, or audible or any combination. (Detector tubes are no longer acceptable.)
A) Fixed Monitors: Carbon Monoxide fixed monitors may be installed. If these are to be
the sole means of detection, they must be supplied with:
1. un-interruptible power supplies and
2. have an alarm indicator detectable in an area unlikely to be affected by the
same Carbon Monoxide source. This may be done by remote display, or by
audible or visual alarms.
B) Portable Monitors: Where CO work areas are not effectively covered by fixed
monitors, use of portable monitors is required. Prior to entering a CO Hazard Area, the
individual or group will obtain a correctly functioning Carbon Monoxide Meter. The
meter must be on and functioning before entering any CO Hazard Area. Exception: where
the area is already treated as IDLH (see "1200ppm" below) and the alarm is detrimental
to communication or job function it may be turned off.
If meters are also equipped to calculate and display a Time-Weighted Average (TWA),
Peak, or Short Term average they must:
1. Clearly indicate if the display is showing current (instantaneous) reading, TWA, Peak,
or Short Term average.
2. The TWA must be calculated on a projected 8-hour basis. This means calculating the
average for the exposure that has already occurred and assuming zero exposure for the

remainder of an 8-hour shift.

6. Alarm Set Points:
Current (instantaneous) concentration alarms will be set at 100 ppm. If equipped with second
level alarms they will be set at 200 ppm.
TWA for 8 hours: if equipped, will be set at 50 ppm.
Short Term alarms: if equipped, will be :
A) Disabled - orB) Set at the maximum instrument set point.
7. When the test results indicate the current CO concentration to be:
Above 1200ppm
Considered to be Immediately Dangerous to Life and Health (IDLH) No one is permitted
in the area without a full face Self-contained breathing apparatus (SCBA) or a full facepiece air line respirator with escape tank, in pressure demand mode. (Air line respirators
without escape tanks are not acceptable.) One employee or, when needed, more than one
employee is located outside of the IDLH atmosphere. Visual, voice, or signal line
communication is maintained between the employee(s) in the IDLH atmosphere and
those outside the IDLH atmosphere. Those outside the IDLH atmosphere must signal a
gas emergency before providing emergency rescue. Those outside the IDLH atmospheres
must be equipped with: Full face-piece SCBA to be operated in the pressure demand
mode. Appropriate retrieval equipment for removing incapacitated employees where such
equipment would contribute to the rescue and not increase the overall risk, or an
appropriate equivalent means of rescue.
Above 200ppm but below 1200ppm
No one is permitted in the area without appropriate respiratory protection. Appropriate
protection is full face-piece Self-contained breathing apparatus, or a full face-piece
supplied air respirator (with or without escape provision), operated in the pressure
demand mode.
100 - 200ppm
Work no more than 2 hours for any person without appropriate respiratory protection. No
additional exposure for the rest of the day. Appropriate protection is a full face-piece
Self-contained breathing apparatus, or a full face-piece supplied air respirator (with or
without escape provision), operated in the pressure demand mode.
50 - 99ppm
Work no more than 4 hours for any person without appropriate respiratory protection. No
additional exposure for the rest of the day. Appropriate protection is a full face-piece
Self-contained breathing apparatus, or a full face-piece supplied air respirator (with or
without escape provision), operated in the pressure demand mode.
Below 50ppm

Employees may work in the area without time limit.

8. Controlling exposure by use of a Time-Weighted Averaging meter:
A) Employee 8 Hour Time-Weighted Averages to Carbon Monoxide may not exceed
50ppm. Once a TWA of 50ppm is reached the employee is allowed zero additional
exposure to CO.
B) If the concentration in an area is less than 200 ppm, employee work time may be
controlled by use of an 8-Hour TWA Meter instead of the timed work shifts listed above.
C) If this method is selected, the meter must be assigned to a single individual and
monitoring started at the beginning of a shift or before any possible CO exposure.
D) All readings will be assumed to be without regard to respiratory protection. In other
words, if TWA control is used it cannot be ignored or circumvented by using appropriate
respiratory protection intermittently and adjusting the TWA value.
9. Anyone who has a Carboxyhemoglobin level (blood poisoned by CO) which has been raised
above baseline by 10% or more may not return to Carbon Monoxide Hazard areas without
Medical approval.

35

Appendix 3: Radiation and Laser Symbols

Radiation Symbol
a. Cross-hatched area is to be Magenta or Purple.
b. Background is to be Yellow.

Where shutter station lights are present:

a. Red means stop - radiation is present
b. Green means the radiation beam is blocked

Laser Symbol
a. Symbol and Border are to be Black.
b. Background is to be Yellow.

LASER RADIATION

EMERGENCY PROCEDURE
FIRE - Call 313-317-8888
IN CASE OF FIRE:
Phone: Give Bldg/Door/Grid Number
Use Radio Channel
Fight Fire - Use proper extinguisher
Report Fire - Notify your supervisor about the fire as soon as possible.

SERIOUS INJURY - Call 313-317-8888

Phone: Give Bldg/Door/Grid Number
Report Injury - Notify your supervisor promptly.
Do Not Move Injured - Unless absolutely necessary to prevent further injury or death.
Do Not Treat Injured - EMT or Trained Personnel may respond to:
Severe bleeding - apply pressure.
Stoppage of breathing - use artificial respiration.
Chemical burns - use plenty of water.
Send someone to the roadway or a door to direct emergency vehicles to the scene. Know the
location of the safety station in your work area.

Receipt for
AK STEEL SAFETY AND HEALTH RULES & INSTRUCTIONS
(AK Steel Safety Handbook)
In acknowledging receipt of the AK Steel Safety Handbook presented to me, I
agree to read the safety rules and instructions and, to the best of my
understanding, do all possible to prevent injury to myself and others.

Print Name

Signature

Check/Clock No.

I provided the above employee a copy of the AK Steel Safety Handbook.

Print Name

Signature

Check/Clock No.