“What to look for?” GRATING INSPECTIONS. Why is this important? We KEEP experiencing learning’s many times! Worker fell through grating into sump. Grating

“What to look for?”

GRATING INSPECTIONS

Why is this important? We KEEP experiencing learning’s many times!

Worker fell through

grating into sump.

Grating was not secured.

Worker stepped on grating and it collapsed. Worker fell through

grating where grating clips had been removed.

Why is this important? We KEEP experiencing learning’s many times!

5 ft

10

in

Grating moved and employee fell to ground level and landed uninjured in a standing position

Is our historical inspection process good enough?

One of our leading indicators (near misses) is telling us something undesirable may be in the near future!

What Management System is available?

• Global Elevated Work Standard– Repetitive Compliance Task

• A0015 Inspect Grating, Guardrails, and Stair Rails Grating, Guardrails, and Stairs

» According to manufacturer’s instructions, or » At least every 36 months – Recommendation is to start

with annual inspection frequency then use inspection data to allow inspection frequency to go to a max of 36 months (like GMISS inspections)

– Are you customizing your plant’s compliance task for inspection to make sure all areas are inspected?

• Guidance on reference page

But, what should we look for ?

Grating Clip Design

What are the proper grating clip locations?

Grating Clip at each corner of grating panel

2 Grating Clips at each intermediate

support

Grating Clip at each corner of grating panel

2 Grating Clips at each intermediate

support

Every piece of grating restrained at each corner

by hold-down clips

What are the proper grating clip locations?

Two clips at each intermediate

support

This beam is not considered a grating support because of

direction of grating span

Let’s start with the first one

• Grating clips - Missing, broken, loose, or corrodedGrating clips - Missing, broken, loose, or corroded• Grating cut too short for openingGrating cut too short for opening• Large holes in gratingLarge holes in grating• Damaged or corroded gratingDamaged or corroded grating• Openings not coveredOpenings not covered• Inadequate material to cover openingsInadequate material to cover openings• Covers on openings are not securedCovers on openings are not secured• Inadequate grating supportsInadequate grating supports

Examples

• The following are pictures showing examples of each of these issues.

Note: The following pictures are of either staged issues, or actual issues that were field-identified and corrected.

Missing grating clips-Our internal audits/inspections/rounds should be catching this type of problems.

This grating fell in when it was shifted due to not being secured or having a stop on it.

Listen for movement when stepping on grating (a clanging noise) which can be an indication that the grating is not secured well.

Checking for clip tightness

Proper clip location where tightness

can be considered

Improper clip location where

tightness cannot be considered

Our internal audits/inspections/rounds should be catching this type of problems.Poor securing of grating

How to tighten and check for tightness

Use a T-handle or wrench type tool: Tighten the grating clip hand snug tight Ensure that the grating clip is in contact with the support below. The grating clip should be tight enough to prevent sliding of the grating.

• The G-clips and saddle clips should have hex heads, so you can use a conventional nut driver or socket drive with a long extension.

• The Grate-Fast Clips have Allen type socket heads that require a special wrench tip.

Tools for clip tightness

Ratchet with positive locking mechanism Recommend ¼” drive to prevent over-torquing of fastener

Extension(s) with positive locking mechanism Recommend 36” long overall length

for improved ergonomics

End attachment

• For grating clips with slight corrosion or paint buildup:

– use a rubber mallet/hammer– tap the clip horizontally to see if

any movement occurs– if the clip moves, then tighten

with a wrench if possible– if clip cannot be tightened, then

replace loose clip

How to tighten and check for tightness

Missing clip at corner of grating

panel

Missing clip at corner of grating

panel

Single clip incorrectly securing TWO grating

panels

Poor securing of gratingOur internal audits/inspections/rounds should be catching this type of problems.

Using wire to secure

No clip installed on corner of grating panel


Broken Clip

Broken and missing clip


• Each clip must be painted with a spot of paint at time of inspection. – The paint color shall be consistent across the site. A different

color shall be used on each subsequent 3-year inspection. If a clip can not pass inspection, it shall not be marked with the new inspection color.

• Where grating is fastened with welds to the support instead of clips, each weld shall be painted.

Painting of Grating Clips following the Inspection

Painting of Grating Clips following the Inspection

• Note: Painting of the clips and welds serve several purposes:– Assures visual verification that each clip or weld location has

been inspected.– Allows grating clips and welds to be more visible to grating users

and indicates to grating users the inspection status.

Grating Hazards to look for:

• Grating clips - Missing, broken, loose, or corrodedGrating clips - Missing, broken, loose, or corroded• Grating cut too short for openingGrating cut too short for opening• Large holes in gratingLarge holes in grating• Damaged or corroded gratingDamaged or corroded grating• Openings not coveredOpenings not covered• Inadequate material to cover openingsInadequate material to cover openings• Covers on openings are not securedCovers on openings are not secured• Inadequate grating supportsInadequate grating supports

Grating cut too short for opening

Grating is cut too short, and if it is

moved a little …..

… it comes off of the support.


• Grating clips - Grating clips - Missing, broken, loose, or corrodedMissing, broken, loose, or corroded

• Grating cut too short for openingGrating cut too short for opening• Large holes in gratingLarge holes in grating• Damaged or corroded gratingDamaged or corroded grating• Openings not coveredOpenings not covered• Inadequate material to cover openingsInadequate material to cover openings• Covers on openings are not securedCovers on openings are not secured• Inadequate grating supportsInadequate grating supports

Large holes in grating

Opening in

grating. It is

hard to see

when it is

under water.

Night-time

would be

even worse.

These polyurethane collars are one alternative for enclosing the openings around piping. Intrepid, the company that manufactures ladder swing gates, also produces this model.

Hole in grating is too big.

Could cause a twisted ankle or someone could fall through.

Large holes in grating




These conditions could be an indication that the grating is not designed for the load intended. For instance, this grating would not be the proper selection for areas with forklift traffic.

This section of grating is upside down. This makes the grating surface much slicker, causing a slipping hazard.

Damaged grating

Check to ensure grating supports free of rust or

corrosion

Check to ensure grating is free from heavy corrosion or rust

Corrosion

Check to ensure grating supports free of rust or

corrosion

Corrosion

Check the step supports where the steps meet the

stair stringer (channel iron) on a flight of stairs




DOW RESTRICTED - For internal use only

Grating removedA “Life Critical Guard” will protect workers from fall hazards created when grating is removed.

Openings not covered

Potential Opening

How would this valve be accessed to operate it? If the grating is to be removed, what would have to be done first? What kind of engineering control could be put in place here?





Sump covered with plywood. It won’t remain in good

condition over time.

Note: Materials used must be robust to not only withstand the potential load but also withstand the environmental conditions.






Sump Covers

These sump covers can easily slide out of position leaving a gap. Needs to be secured by installing banding around the circumference.


Hatches, Accessways, Removable Panels

39DOW RESTRICTED - For internal use only

• Must be capable of carrying same design loads as rest of floor• Must be supported by beams underneath two load bearing

ends of panel – position so that panel will not fall if hinge fails• Must be secured by:

o Hinge if frequently openedo Grating clips if infrequently opened

Support beams under grating – position so that panel will not fall if hinge fails

Hinge

Hatches, Accessways, Removable Panels

40DOW RESTRICTED - For internal use only

• Consider latch or other device to prevent inadvertent closing of hatch on worker.

Latch to secure top of panel





Inadequate grating supports

Grating panel unsupported

Clipping to adjoining

grating panel is not acceptable

Missing clips on intermediate

support


Solutions

• The following are solutions that have been implemented to remedy grating and sump cover issues.

• Do some of these solutions need to be implemented at your facility?


Good job of securing issues identified with grating


Are you aware of any of these issues in your

facility?

• Grating clips - Missing, broken, loose, or corroded• Grating cut too short for opening• Large holes in grating• Damaged or corroded grating• Openings not covered• Inadequate material to cover openings• Covers on openings are not secured• Inadequate grating supports

What can you do so they don’t result in

an injury?


Here are some ideas

• When completing a grating audit, do it like your life depends on it.• Look, listen and feel for grating that is not secured as you walk over it. • Walk around or step over trench grating unless it is the only path available.• Walk around plywood, plates, etc. that are on the walking surfaces. You

don’t know what might not be under it.• Report Near Misses relating to grating so others can learn from them and to

better ensure that the root causes are identified and corrected.• Initiate work requests for any issues found during your rounds. If

appropriate, apply Life Critical Guards until issue is resolved. • Pre-plan for work that will leave openings in grating, i.e. removal of piping,

pumps, etc.• Remove grating and sump coverings only after fall prevention plan is in

place.


EMETL Practice Number Description

G2G-3315-40A Options LIGHT TRAFFIC TRENCH GRATING DETAIL

G2G-3315-40B Options LIGHT TRAFFIC TRENCH GRATING DETAIL

G2G-3315-41A Options HEAVY TRAFFIC TRENCH GRATING DETAIL

G2G-3315-41B Options HEAVY TRAFFIC TRENCH GRATING DETAIL

G2G-3315-42A Options PARTIALLY COVERED TRENCH GRATING

G2G-3315-42B Options PARTIALLY COVERED TRENCH GRATING

G2G-5530-01A Options GRATING DETAIL

G2G-5530-01B Options GRATING DETAIL

G2G-5530-02 Options N2 - REINFORCING FOR FIELD CUT OPENINGS

G2G-5530-05 Options GRATING PENETRATING COLLARS

G2G-5530-40A Options GRATING TO FLOOR PLATE DETAIL

G2G-5530-40B Options GRATING TO FLOOR PLATE DETAIL

EU2Y-5530-04 Options HEAVY DUTY SAFETY GRATING CLAMP

G2G-6500-30 Options FRP GRATING

What guidance is available?

Reference Slide 1


Divide Area segments to conform to the compliance task

• Divide your facility or area into sections that can be easily segmented and identified (i.e. structure levels, small process areas, etc.). The inspection of a section should be completed during one inspection task using one checklist per section (i.e. reactor area, catalyst area).

• Note: Points to consider when developing the task assignments for your facility:– Duration to complete an individual inspection– Dividing up tasks by Unit Operations Area– It is recommended that each area within a facility have its own

CTT/MTL task.

Reference Slide 2


Is your inspection process robust enough to identify grating issues that could result in an injury?


Documents

“What to look for?” GRATING INSPECTIONS. Why is this important? We KEEP experiencing learning’s many times! Worker fell through grating into sump. Grating