Steel Erection Safety Manual

What Should a Steel Erection Safety Manual Include?

The contents of a Steel Erection Safety Manual should reflect the contractor’s operations.

A structural steel erector may have different hazards than a contractor primarily erecting systems-engineered metal buildings, installing steel joists and decking, or performing miscellaneous and ornamental ironwork.

Federal OSHA’s Steel Erection standard, 29 CFR 1926 Subpart R, establishes specific requirements for steel erection activities. The company’s manual should incorporate applicable steel-erection requirements along with other construction safety programs necessary for its work.

Core Safety Programs for Steel Erectors

A comprehensive Steel Erection Safety Manual may include core programs addressing:

• Accident and Incident Investigation.
• Emergency Action Plan.
• Fire Prevention.
• First Aid.
• Hand and Power Tool Safety.
• Hazard Communication.
• Housekeeping.
• Job Safety Analysis (JSA/JHA).
• Manual Lifting and Material Handling.
• Personal Protective Equipment.
• Slips, Trips and Falls.
• Walking-Working Surfaces.
• Electrical Safety.
• Ladder and Stairway Safety.

The manual should also establish responsibilities for management, supervisors, employees, competent and qualified persons, hazard identification, inspections, safety training, hazard correction, incident reporting, recordkeeping, and periodic program review.

Steel Erection Safety

Steel erection can include activities such as:

• Hoisting.
• Laying out structural members.
• Placing and connecting steel.
• Welding and burning.
• Bolting.
• Guying and bracing.
• Plumbing structural members.
• Rigging.
• Installing steel joists.
• Installing metal decking.
• Erecting metal buildings.
• Installing miscellaneous or ornamental metals.

Steel erection activities should be planned and performed in accordance with applicable OSHA requirements and project-specific conditions.

Pre-Erection Planning and Site Preparation

Effective planning before steel erection begins is essential because the erection sequence, crane operations, material deliveries, site conditions, and structural stability can affect employee safety throughout the project.

Pre-erection planning should consider:

• Construction sequence.
• Crane and derrick access.
• Material deliveries.
• Material staging and storage.
• Equipment operating areas.
• Pedestrian and vehicle movement.
• Ground conditions.
• Overhead hoisting.
• Structural stability.
• Temporary bracing and guying.
• Fall-protection methods.
• Coordination with the controlling contractor and other trades.

Conditions that could affect safe erection should be addressed before work begins.

Approval to Begin Steel Erection

Before steel erection begins, required conditions for supporting the structural loads imposed during erection must be satisfied.

The steel erector should receive required written notification concerning the strength of concrete or masonry supporting the steel erection and applicable repairs, replacements, or modifications to anchor rods.

Steel erection should not begin until required notifications have been received and conditions necessary for safe erection are established.

Controlling Contractor Coordination

Steel erection requires coordination between the steel erector and the controlling contractor.

Relevant responsibilities may include:

• Providing required written notifications before steel erection begins.
• Maintaining appropriate site access.
• Providing suitable areas for material storage and equipment operations.
• Coordinating work performed below steel erection.
• Addressing falling-object hazards.
• Coordinating perimeter safety systems.
• Communicating changing site conditions.

The steel erector should communicate hazards created by its operations when those hazards could affect other contractors or employees.

Site Layout and Access

The steel erector depends on suitable site conditions for delivery, staging, crane setup, material handling, and erection operations.

Work areas should provide adequate space for:

• Cranes and derricks.
• Trucks.
• Material deliveries.
• Steel storage.
• Rigging.
• Equipment movement.
• Employee access.

Ground and access conditions should be evaluated before heavy equipment is positioned or operated.

Preplanning Hoisting Operations

Hoisting operations used during steel erection should be planned before lifts begin.

Planning should consider:

• Crane selection and placement.
• Load weights.
• Rigging.
• Lift paths.
• Employee positioning.
• Structural sequence.
• Ground conditions.
• Power lines.
• Other contractors.
• Material staging.
• Communication.
• Potential critical or unusual lifts.

Changes in erection conditions should be evaluated before continuing affected hoisting operations.

Site-Specific Erection Plans

A site-specific erection plan may be required when an employer elects to use certain alternate means and methods permitted by OSHA’s Steel Erection standard.

Where applicable, the plan should be developed by a qualified person and be available at the worksite.

Depending on the operation, a site-specific erection plan may address:

• Project identification.
• Erection sequence.
• Crane selection and placement.
• Material deliveries and staging.
• Rigging procedures.
• Structural stability.
• Temporary bracing and guying.
• Steel joists.
• Decking.
• Fall protection.
• Falling-object protection.
• Special or non-routine tasks.
• Qualified and competent persons.
• Emergency and rescue procedures.

A site-specific erection plan should not be treated as universally required for every steel erection project; its applicability depends on the means and methods being used.

Structural Stability

Structural stability must be maintained throughout steel erection.

The erection sequence should account for the stability of columns, beams, joists, frames, and other structural members before employees rely on the structure for support or proceed with subsequent erection activities.

Temporary bracing, guying, connections, and other stabilizing measures should remain in place until they can be safely removed.

Employees should not alter structural members, connections, anchor rods, bracing, or other components without appropriate authorization.

Column Anchorage

Column anchorage is critical to structural stability during erection.

Columns should be anchored in accordance with applicable requirements and project specifications.

Procedures should address:

• Anchor rods.
• Column base plates.
• Required nuts and washers.
• Column stability.
• Repair, replacement, or modification of anchor rods.
• Engineering approval where required.
• Communication between the steel erector and controlling contractor.

Unauthorized modification of anchor rods or other structural anchorage should not be permitted.

Beams and Columns

Beams and columns should be installed and connected according to applicable steel-erection requirements.

Work procedures should address:

• Hoisting.
• Initial connections.
• Final connections.
• Employee positioning.
• Double connections.
• Structural stability.
• Fall exposure.
• Suspended loads.
• Connection points.
• Bolting and welding.

Employees should remain clear of locations where structural members could swing, shift, rotate, or fall.

Connecting Operations

Connectors can be exposed to significant fall, struck-by, caught-between, and suspended-load hazards while receiving and connecting structural members.

Connecting procedures should address:

• Employee positioning.
• Fall protection.
• Structural stability.
• Communication with crane operators.
• Rigging.
• Initial connections.
• Bolt placement.
• Tools and equipment.
• Access.
• Falling objects.

Only employees who have received appropriate training should perform connecting work.

Open-Web Steel Joists

Steel joists can become unstable during erection if they are not properly attached and bridged.

Procedures for open-web steel joists should address applicable requirements for:

• Joist placement.
• Attachment.
• Bridging.
• Erection bridging.
• Joist stability.
• Hoisting.
• Bundled loads.
• Employee access.
• Fall protection.

Employees should not place loads on inadequately secured joists or use unstable joists as walking-working surfaces.

Metal Decking

Metal decking operations can expose employees to falls, sharp edges, unstable material, wind, falling objects, and material-handling hazards.

Decking procedures should address:

• Deck placement.
• Deck attachment.
• Deck bundles.
• Bundle positioning.
• Fall protection.
• Controlled Decking Zones where permitted.
• Openings.
• Sharp edges.
• Wind conditions.
• Material storage.
• Falling objects.

Loose decking should be controlled to prevent displacement.

Controlled Decking Zones

Where permitted by applicable OSHA requirements, a Controlled Decking Zone may be used during certain leading-edge metal-decking operations.

Procedures should address applicable limitations and requirements, including:

• Employee access.
• Control lines.
• Boundaries.
• Decking operations.
• Employee training.
• Securing decking.
• Fall exposure.
• Supervision.

Controlled Decking Zones should only be used where permitted and should not become a general substitute for required fall protection.

Systems-Engineered Metal Buildings

Contractors erecting systems-engineered metal buildings may install columns, rigid frames, purlins, girts, joists, roofing, siding, and other structural components.

Safety procedures should address:

• Erection sequence.
• Structural stability.
• Temporary bracing.
• Hoisting.
• Connections.
• Fall protection.
• Roof and wall components.
• Wind conditions.
• Material handling.

Temporary bracing should remain in place until the structure has sufficient stability to permit its safe removal.

Cranes and Hoisting

Cranes are integral to many steel erection operations.

Crane procedures should address:

• Equipment inspection.
• Operator qualification.
• Ground conditions.
• Setup.
• Load capacity.
• Rigging.
• Power-line hazards.
• Lift planning.
• Communication.
• Swing radius.
• Employee positioning.
• Suspended loads.

Employees should remain clear of crane operating areas and suspended loads except where applicable steel-erection procedures specifically permit necessary work associated with receiving and connecting loads.

Rigging for Steel Erection

Rigging should be selected, inspected, and used according to the load and lifting operation.

Procedures should address:

• Slings.
• Shackles.
• Hooks.
• Below-the-hook devices.
• Rigging capacity.
• Inspection.
• Load control.
• Center of gravity.
• Sharp edges.
• Qualified riggers where required.
• Communication.

Defective rigging should be removed from service.

Multiple-Lift Rigging Procedures

Where multiple-lift rigging procedures are used, the operation should meet applicable steel-erection requirements.

Employees involved in multiple-lift rigging operations should receive required training, and the operation should be planned and conducted using appropriate equipment and procedures.

Multiple-lift methods should not be improvised or used outside the conditions permitted by applicable requirements.

Suspended Loads and Employee Positioning

Structural steel members can weigh thousands of pounds and may swing, rotate, shift, or descend unexpectedly.

Employees should avoid placing themselves:

• Beneath suspended loads.
• Between suspended steel and fixed objects.
• Within uncontrolled swing areas.
• In pinch points.
• In areas where loads could shift or fall.

When employees must receive or guide structural members as part of the erection process, the operation should be controlled and coordinated with the equipment operator.

Fall Protection in Steel Erection

Fall hazards are a major concern during steel erection.

Under Federal OSHA’s Steel Erection standard, employees engaged in steel erection activities on walking-working surfaces with unprotected sides or edges more than 15 feet above a lower level generally must be protected from fall hazards, subject to specific provisions for connectors and employees working in Controlled Decking Zones.

Applicable fall-protection methods may include:

• Guardrail systems.
• Safety-net systems.
• Personal fall-arrest systems.
• Positioning-device systems.
• Fall-restraint systems.
• Perimeter safety cables.

The company’s procedures should address the specific fall-protection requirements applicable to each steel erection activity.

Connector Fall Protection

Connectors are subject to specific fall-protection provisions under OSHA’s Steel Erection standard.

Procedures should address:

• Applicable height thresholds.
• Required fall-protection equipment.
• Employee access.
• Connection points.
• Personal fall-arrest systems.
• Positioning systems.
• Training.
• Rescue considerations.

The special provisions applicable to connectors should not be interpreted as eliminating fall hazards or preventing an employer from requiring additional protection.

Perimeter Safety Cables

On applicable multi-story structures, perimeter safety cables should be installed as required as metal decking progresses.

Procedures should address:

• Installation.
• Required locations.
• Maintenance.
• Turnover or use by other contractors.
• Inspection.
• Removal.

Perimeter systems should remain effective and should not be altered without authorization.

Floor Openings and Deck Openings

Steel erection may create temporary floor, roof, and deck openings.

Openings should be protected as required using appropriate covers, guardrails, fall-protection systems, or other permitted methods.

Covers should be capable of supporting applicable loads, secured against displacement, and appropriately identified where required.

Employees should not remove opening protection unless authorized and necessary for the work.

Falling-Object Protection

Tools, bolts, structural components, decking, welding equipment, and other materials can fall from elevated steel erection operations.

Falling-object procedures should address:

• Securing loose materials.
• Tool control.
• Barricading.
• Controlled access.
• Overhead protection.
• Material storage.
• Coordination with employees working below.
• Housekeeping.

Other construction processes should not be performed below steel erection operations unless appropriate protection is provided as required.

Welding, Cutting and Hot Work

Steel erection commonly involves welding, cutting, burning, grinding, and other hot work.

Procedures should address:

• Fire prevention.
• Combustible materials.
• Fire extinguishers.
• Fire watches where required.
• Welding leads.
• Electrode holders.
• Grounding.
• Compressed-gas cylinders.
• Ventilation.
• Welding fumes.
• Eye and face protection.
• Protective clothing.
• Fall protection.

Hot slag, sparks, and molten metal should be controlled to protect employees working below or nearby.

Compressed Gas Cylinders

Oxygen, fuel-gas, and other compressed-gas cylinders should be transported, stored, and used safely.

Procedures should address:

• Cylinder securing.
• Valve protection.
• Separation and storage.
• Regulators.
• Hoses.
• Leak detection.
• Transport.
• Fire hazards.
• Damaged cylinders.

Cylinders should be protected from falling objects, physical damage, and excessive heat.

Bolting and Hand Tools

Steel erectors may use impact wrenches, spud wrenches, torque tools, drills, grinders, hammers, and other hand and power tools.

Tools should be:

• Appropriate for the task.
• Inspected as necessary.
• Properly maintained.
• Secured where falling-object hazards exist.
• Used according to manufacturer instructions.

Employees should be trained in the hazards associated with the tools they use.

Aerial Lifts and Mobile Elevating Work Platforms

Aerial lifts and other mobile elevating work platforms may be used for connecting, bolting, welding, inspection, and other steel erection activities.

Procedures should address:

• Pre-use inspection.
• Operator training.
• Fall protection.
• Ground conditions.
• Overhead hazards.
• Power lines.
• Equipment positioning.
• Load limits.
• Emergency lowering.

Employees should not climb on guardrails or use makeshift devices to gain additional working height.

Ladders and Access

Ladders, stairs, aerial lifts, scaffolds, and other access methods may be used during steel erection.

Access equipment should be selected according to the task and inspected before use as required.

Employees should maintain safe access to elevated work areas and should not climb structural components unless the method is permitted and appropriate for the work being performed.

Overhead Power Lines

Cranes, aerial lifts, structural members, and other equipment can contact overhead electrical lines.

Electrical hazards should be identified during preplanning.

Required clearances and protective measures should be established before equipment or structural members are moved near power lines.

Employees should treat overhead electrical lines as energized unless their status has been appropriately verified.

Personal Protective Equipment

PPE should be selected according to the hazards associated with steel erection operations.

Depending on the work, PPE may include:

• Hard hats.
• Safety glasses.
• Face shields.
• Welding helmets.
• Protective footwear.
• Work gloves.
• Hearing protection.
• High-visibility apparel.
• Protective clothing.
• Fall-protection equipment.
• Respiratory protection.

PPE should be inspected and maintained as required and replaced when defective.

Weather and Wind Conditions

Wind, rain, ice, snow, heat, and other environmental conditions can significantly affect steel erection.

Wind can affect:

• Crane operations.
• Suspended loads.
• Decking.
• Structural members.
• Aerial lifts.
• Employee balance.
• Material storage.

Weather conditions should be evaluated throughout the workday, and operations should be modified or suspended when conditions create unacceptable hazards.

Heat and Cold Stress

Steel erectors may perform physically demanding work outdoors while wearing substantial PPE.

Procedures should address applicable heat and cold hazards, including:

• Drinking water.
• Rest periods.
• Acclimatization.
• Shade or warming areas.
• Protective clothing.
• Employee monitoring.
• Recognition of symptoms.
• Emergency response.

Environmental conditions should be considered during job planning.

Emergency and Rescue Planning

Emergency planning for steel erection should consider the elevated and changing nature of the work.

Plans should address as applicable:

• Emergency communication.
• First aid.
• Rescue from elevated locations.
• Suspension following a fall.
• Crane incidents.
• Structural instability.
• Fire.
• Electrical contact.
• Severe weather.
• Site access for emergency responders.

Employees should understand how to summon assistance and the procedures applicable to foreseeable emergencies.

Steel Erection Training

Employees performing steel erection work should receive training appropriate to their assigned duties and hazards.

Required steel-erection training should be provided by qualified persons as applicable and may address:

• Fall hazards.
• Fall-protection systems.
• Connecting.
• Controlled Decking Zones.
• Multiple-lift rigging procedures.
• Hoisting hazards.
• Structural stability.
• Falling objects.
• Tools and equipment.
• Emergency procedures.

Training should be provided in a manner employees can understand.

Job Safety Analysis for Steel Erection

A Job Safety Analysis (JSA/JHA) can help steel erection contractors identify hazards and establish controls before individual tasks begin.

Steel-erection JSAs may address:

• Crane setup.
• Rigging and hoisting.
• Unloading structural steel.
• Column erection.
• Beam installation.
• Connecting.
• Bolting.
• Welding.
• Steel joist installation.
• Metal decking.
• Aerial-lift work.
• Fall protection.
• Work near overhead power lines.
• Material handling.

The JSA should reflect the actual erection sequence, equipment, structural components, elevations, and site conditions.

Additional Safety Programs for Steel Erection Contractors

Not every steel erection contractor requires the same safety programs.

Depending on the company’s operations, additional programs may include:

• Aerial and Boom Lift Safety.
• Compressed Gas Cylinder Safety.
• Crane Safety.
• Driving and Fleet Safety.
• Electrical Safety.
• Fall Protection.
• Fire Prevention.
• Forklift Safety.
• Hand and Power Tool Safety.
• Hearing Conservation.
• Heat Stress Prevention.
• Heavy Equipment and Mobile Equipment.
• Ladder and Stairway Safety.
• Lockout/Tagout.
• Manual Lifting and Material Handling.
• Overhead Power Line Safety.
• Personal Protective Equipment.
• Respiratory Protection.
• Rigging and Material Handling.
• Scaffolding.
• Silica Exposure.
• Welding, Cutting and Hot Work.
• Working Over or Near Water.
• Other programs applicable to the company’s operations.

Programs should be selected because they reasonably apply to the contractor’s work, equipment, employees, and workplace exposures.

Structural Steel Contractors

Structural steel contractors may erect steel frames for commercial buildings, industrial facilities, bridges, platforms, support structures, and other projects.

A Structural Steel Safety Manual should address the actual erection activities performed by the contractor, including applicable requirements for cranes, rigging, structural assembly, fall protection, welding, decking, aerial lifts, and other hazards.

Structural steel terminology can therefore be incorporated within a comprehensive Steel Erection Safety Manual rather than requiring a separate generic manual for every type of steel structure.

Ironworkers

Ironworkers may perform connecting, bolting, welding, decking, reinforcing, miscellaneous-metal installation, and other work depending on the contractor’s operations.

Safety procedures should reflect the employee’s actual work rather than relying solely on a job title.

Employees should receive the training, PPE, fall protection, tools, and equipment necessary for the tasks they are assigned.

Metal Building Erection

Contractors erecting systems-engineered or pre-engineered metal buildings may require procedures addressing:

• Structural stability.
• Temporary bracing.
• Columns and frames.
• Purlins and girts.
• Metal roofing.
• Wall panels.
• Cranes and hoisting.
• Aerial lifts.
• Fall protection.
• Wind exposure.

These operations can be incorporated into the Steel Erection Safety Manual when they are part of the company’s work.

Steel Erection Toolbox Talks

Toolbox talks can reinforce safe work practices and address hazards relevant to current erection activities.

Useful topics may include:

• Fall protection.
• Connector safety.
• Crane and rigging safety.
• Suspended loads.
• Structural stability.
• Metal decking.
• Falling objects.
• Welding and cutting.
• Aerial lifts.
• Power lines.
• Hand and power tools.
• Weather and wind.

Toolbox talks supplement required safety training but do not replace training specifically required by applicable OSHA standards.

Steel Erection Safety Manual vs. Site-Specific Erection Plan

A Steel Erection Safety Manual establishes the contractor’s overall safety policies, programs, and procedures.

A site-specific erection plan, when applicable, addresses conditions and erection methods associated with a particular project.

The company manual may contain Steel Erection, Crane Safety, Rigging, Fall Protection, Welding, PPE, and other procedures, while project-specific planning addresses the actual erection sequence, crane locations, structural configuration, material staging, temporary stability, and other conditions unique to the project.

The two documents therefore serve different purposes.

Building a Steel Erection Safety Manual

A practical Steel Erection Safety Manual should reflect the operations the contractor actually performs.

When determining which programs and procedures to include, consider:

• Structural steel erection.
• Connecting and bolting.
• Welding and cutting.
• Steel joists.
• Metal decking.
• Systems-engineered metal buildings.
• Miscellaneous and ornamental metals.
• Cranes and hoisting.
• Rigging.
• Aerial lifts.
• Fall protection.
• Structural stability.
• Work over water.
• Power-line exposure.
• Weather conditions.
• Applicable OSHA requirements.
• General contractor and controlling-contractor requirements.
• Contractor-prequalification requirements.

Selecting programs according to actual operations produces a safety manual that addresses the contractor’s real hazards without filling the manual with unrelated safety programs.

Customized Safety Manuals for Steel Erection Contractors

Steel erection and structural steel contractors can request a customized Construction Safety Manual containing the Core Safety Programs and additional programs applicable to their steel erection, crane, rigging, welding, decking, fall-protection, aerial-lift, and other operations.

Programs can be selected according to the company’s actual work so the manual addresses relevant steel erection hazards without including large numbers of unrelated safety programs.

Individual safety programs can also be selected when a contractor needs to add or update a particular program within an existing manual.