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Curb Extraction

Curb Extraction
A. Start-of-Shift Activities B. Workplace Examination C. Extraction D. Shipping E. End-of-shift activities F. Unusual conditions/Emergency Situations
1. A. Start-of-Shift Activities
Approach quarry entrance from main road with turn signal on
Enter mine property with caution
observe posted speed limits
10 or 15 mph as posted Notes
adjust based on weather conditions Notes
observe for mobile equipment in area
observe for foot traffic in area
Turn am/fm radio off
Arrive at quarry
Park in designated parking area
Clock in at office
Obtain Personal Protective Equipment
hard hat Notes
safety glasses w/side shields Notes
steel-toed safety shoes/boots Notes
harness Notes
hearing protection Notes
gloves Notes
respirator (if needed) Notes
Travel to work shack
company work truck Notes
personal vehicle w/prior permission Notes
walk Notes
Obtain job assignments from foreman
Check/Start forklift
Follow checklist for conducting pre-op on forklift Notes
Walk to saw block
2. B. Workplace Examination
Crane Level
Check walkways for tripping hazards
rocks, tools, other debris Notes
Check walkways for snow/ice accumulations
shovel or plow area Notes
use sand/cal mixture from drum to remove accumulations Notes
Check that kick boards are in place
replace if necessary Notes
Check that railings/guard rails are in place
replace if necessary Notes
Check ladder
Ensure ladder is tied off at the top and pinned in at the bottom
check for broken or missing rungs
Needs to be at least 3 feet above the ledge and maintain safe access Notes
Check air manifolds
check for whip checks and broken lines
Yellow lines Notes
Conduct visual inspection of electrical cords
Check for broken, frayed, exposed conductors in cords
Ensure ground pin is in place
ensure cords are properly sized
Ensure cords are protected from mechanical damage
Check water lines
broken lines, leakage Notes
Red lines Notes
Check oxygen lines
Green lines Notes
Conduct visual inspection of lifting devices
chains
hooks
pins with locking device
Conduct visual inspection of the work box
welds
chains
shackles
pins/locking devices
gate cable
floor condition
Check tools
hammer
Saw Block level
Wear and use fall protection
Reinforce maintenance and care of fall protection devices (lanyards, trauma kits, length of lanyards) Notes
Check walkways for tripping hazards
rocks, tools, other debris Notes
Check walkways for snow/ice accumulations
shovel or plow area Notes
use sand/cal mixture from drum to remove accumulations Notes
Check that kick boards are in place
replace if necessary Notes
Check that railings/guard rails are in place
replace if necessary Notes
Check ladder
Ensure ladder is tied off at the top and pinned in at the bottom
check for broken or missing rungs
Needs to be at least 3 feet above the ledge and maintain safe access Notes
Check air manifolds
check for whip checks and broken lines
Yellow lines Notes
Conduct visual inspection of electrical cords
Check for broken, frayed, exposed conductors in cords
Ensure ground pin is in place
ensure cords are properly sized
Ensure cords are protected from mechanical damage
Check water lines
broken lines, leakage Notes
Red lines Notes
Check tools
check hammer heads and handles
check for mushroomed heads, cracks, handle cracks, resurfaced heads Notes
check driver
add oil before/during use Notes
check plug drill bit
sharp edges Notes
mushroomed heads Notes
air fittings for wear Notes
check cross bit
sharp edges Notes
mushroomed heads Notes
check jack hammer
add oil before/during use Notes
air fittings for wear Notes
check wedges and half rounds
18" and 5" Notes
check for mushroomed heads, cracks Notes
check pipe wrenches
check for wear on the jaws Notes
check lifting pins
20-ton and 30-ton Notes
check for cracks, shim and cable wear Notes
conduct visual exam (walk-a-round)
check for movement in stone
check for slides
check for pressure cracks
3. C. Extraction
Obtain tools/supplies
obtain crayons
obtain tape measure
obtain chalk line
obtain shovel
obtain pry bar
obtain sledge hammer
replace handles and resurface as needed Notes
obtain jack hammers
minimum of 2 Notes
obtain driver
obtain plug drill
obtain wedges and shims
18" and 5" Notes
obtain grease/rock drill oil
review/discuss MSDS Notes
Subtopic
obtain plug and cross bits
1 1/2 and 2 1/4" cross bits Notes
3/4" plug bit
obtain gluts
obtain methanol
obtain yo-yo's
obtain pin rod
18" Notes
obtain drill rod
24" length Notes
obtain dust bags
obtain vacuums
two Notes
obtain sand/ salt (if needed)
obtain tool bucket
obtain air lines/manifolds
obtain whip checks
obtain 4"x6"x4' lumber for cribbing/blocking
Climb down ladder, up ladder or ride in work box
based on whether you're working off the bottom or top of saw block Notes
Maintain 3-point contact Notes
Re-evaluate bed formation
On-going evaluation throughout shift Notes
Tightness Notes
Lay out line for drill
measure according to need Notes
drill from the top
begin drilling
turn on the air
slowly start the drill (spot the hole)
turn vacuum on and place boot over the rod
drill 18 inches in depth
observe spacings as marked Notes
constantly maintain and monitor down pressure
ensures proper bit rotation Notes
maintain proper balance Notes
load the holes with wedges and half-rounds (18")
grease each wedge and place it in the hole
average 1-2 wedges per hole on the curb Notes
average 4-5 wedges per block (5' block) Notes
send back wedges that need grinding (mushroomed heads, chips) Notes
install half-rounds
place ears facing out Notes
move the hose and jack hammer
pound wedges in place
using sledge hammer
pound wedges/half-rounds until snug if using sledge hammer
ensure swing area is clear of persons
Once snug, begin splitting stone
using air driver
place collar over the head of the wedge and push lever holding firmly
discuss back injuries, proper lifting procedures, slip/trip/fall hazards Notes
repeat for each wedge
keep split going in one direction
facing the stone
turn on the air
begin drilling
slowly start the drill (spot the hole)
turn vacuum on and place boot over the rod
drill at least 5" in depth using 3/4" plug drill bit
observe spacings as marked Notes
constantly maintain and monitor drill pressure
ensures proper bit rotation Notes
maintain proper balance Notes
move the hose and plug drill
load the holes with wedges and half-rounds (5")
grease each wedge and place it in the hole
average 2 wedges per lineal foot for 16-18" curb (3-6' foot block - holes would be closer together) Notes
average 3-5 wedges per block (5' block) Notes
send back wedges that need grinding (mushroomed heads, chips) Notes
install half-rounds
place ears facing out Notes
pound wedges in place using sledge hammer
ensure swing area is clear of persons Notes
pound wedges/half-rounds until snug
Once snug, begin splitting stone
rift stone
ensure whip checks are in place
turn on the air slowly
begin drilling
Refer to "Working from workbox" procedures Notes
slowly start the drill (spot the hole)
turn vacuum on and place boot over the plug drill bit
drill at least 5" in depth using 3/4" plug drill bit
observe spacings as marked Notes
constantly maintain and monitor drill pressure
ensures proper bit rotation Notes
maintain proper balance Notes
move the hose and plug drill
If working from man box, may need to move hose and plug drill in and out of the box Notes
load the holes with wedges and half-rounds (5")
install half-rounds
place ears facing out Notes
grease each wedge and place it between the half-rounds
average 2 wedges per lineal foot for 16-18" curb (3-6' foot block - holes would be closer together - average 3 wedges) Notes
send back wedges that need grinding (mushroomed heads, chips) Notes
pound wedges in place using sledge hammer
ensure swing area is clear of persons Notes
pound wedges/half-rounds until snug
Once snug, begin splitting stone
Subtopic
Remove all loose wedges and half-rounds
store properly (bucket, etc.) Notes
extract stone
Remove tools/supplies from work box
Unhook work box from crane and store and hook up the lift pin
Signal man will unhook work box and install lift pin if on top Notes
Spot pin hole location
location is determined by size, weight, shape, formation Notes
Obtain tools
obtain jack hammer
obtain drill with proper bits
2 3/4 for 30-ton pin
2 1/4" bit for 20-ton pin
obtain vacuum hose
Ensure whip checks are properly hooked up
Ensure jack hammer is lubricated properly
Needs oil if it bounces too much or when lever gets hard/stiff to turn on Notes
Too much oil will result in slow rotation Notes
spot the bit with soles of boots and hold firmly in place
Hold jack hammer firmly while applying adequate down pressure
Start jackhammer with minimal amount of air (low pressure)
Drill to about 1/2"
remove jackhammer and check hole to make sure it is round
if not started round, hole will end up being star shaped Notes
Place suction boot in place
turn vacuum on
drill to a depth of aprox. 10" applying same down pressure throughout and maintain proper alignment
explain proper drilling techniques
hold jackhammer straight (up/down) - 90 degree angle to the stone Notes
Don't allow drill to wobble Notes
maintain steady down pressure Notes
drill one hole and test before pre-drilling additional holes
Remove hammer and vacuum from extraction area
Pour water (summer) or methanol (winter) in pin hole
allows shims to fetch up inside the hole Notes
Notify signalman to lower the endless chain
head room determines length of chain Notes
20-ton chain is 3/4"
30-ton chain is 1"
Place pin in the hole
You may need to pull up on the cable and guide the pin into the hole if there is too much slack Notes
after placing pin in the hole, grab hold of the shackle and give it a quick upward jerk to set pin
determine weight of stone and inform crane operator
cube it up Notes
crane operator will need weight to match with load chart Notes
remove all slack from chain to ensure pin is set correctly
visually inspect lifting, swinging and landing areas
notify signalman to begin lift
notify signalman to stop lift once stone is free
remove remaining wedges and half-rounds safely and place out of the way
relocate to safe location
Never stand under suspended load Notes
stay clear of lift and swing area Notes
notify signalman to continue lift
keep your eyes on suspended load at all times until lift is complete (stone placed on blocking/cribbing)
Signalman will place cribbing/blocking Notes
Ensure no body parts are under stone at any time Notes
Avoid swing area Notes
Discuss pinch-points and associated hazards Notes
Signalman will remove pin once stone is secured properly
obtain sledge hammer
visually inspect sledge hammer before use (mushroomed head, cracked handle, etc.)
replace if needed
hit the pin until wedge releases
listen for release Notes
obtain ladder to remove pin if you lifted a block Notes
pull cable until pin comes out of hole
avoid pinch points Notes
signal crane operator once pin is free
Process inventory/quality control paperwork
Signalman Duties (curb)
measure length, width and rise of each stone
record the data
submits recorded data to foreman at end of shift/beginning of next shift
foreman will submit to main office
Foreman Duties (block)
measure length, width and rise of each stone
record the data
submits recorded data to main office at end of shift/beginning of next shift
Working out of a Work Box
Discuss company policy on safety concerns of working from box (safety, weather conditions, etc.) Notes
Ensure work box is properly rigged before lifting
check chains, d-rings, shackles for elongation and cracks
ensure safety latch is working and pinned on crane hook
ensure signal man is in place and understands signals to be used
Review and discuss signals Notes
Conduct visual inspection of the work box
welds Notes
chains Notes
shackles Notes
pins/locking devices Notes
gate cable Notes
floor condition Notes
Enter work box and hook up lanyard
Discuss fall protection Notes
latch gate cable across front of box
Stand at back of box and hold onto the rails
avoid pinch points Notes
position the box tight against the face to prevent swing-out
Subtopic
4. D. Shipping
Ensure pre-op has been conducted on forklift prior to use
Tram forklift to stone to be transported
Determine need for additional help
good idea to have someone on rail cars to help position and set stone on cribbing Notes
Discuss pinch-point hazards Notes
position forks for lift
begin lift
tram forklift to the railcar
maintain visual contact with spotter
align stone with timbers
place stone on cribbing for transport
follow spotter's signals (if a spotter is available) Notes
Limit load to 50 ton per railcar Notes
back forklift up
clean up the landing
continue to prepare blocking
lift and load stone until railcars are full or all stone is loaded
park forklift
lower forks
engage park brake
notify locomotive operator when cars are fully loaded
5. E. End-of-shift activities
pick up and store all of the tools
wedges/half-rounds
hammers
drills
hoses
shovels
drivers
bits
cover tools with tarp during adverse weather conditions
turn off air manifolds
leave water lines on (if available)
exit work area
walk, ladder, workbox Notes
plug in mobile equipment
primarily the equipment operator's responsibility Notes
properly store PPE (fall protection, etc.) in work shack
shut off the compressor
travel back to quarry office
clock out
6. F. Unusual conditions/Emergency Situations
Lightening
If lightening is observed, shut down operations
Foreman will make determination Notes
Refer to company policy Notes
High Wind
Restrict lifting
Restrict working near the edge
Could result in shutdown of operations
Refer it company policy Notes
Snow/Ice
Caution on slip/trip/fall hazards
Ramp could be shut down
Could result in shutdown of operations
Refer to company policy Notes
Heavy Rain
Caution on slip/trip/fall hazards
Ramp could be shut down
Refer to company policy Notes
Heat
Refer to company policy
Mechanical
Crane
Rope failure
maintain a safe distance from load Notes
Brake failure
Reinforce safe distance rule Notes
hydraulic system failure
maintain a safe distance from equipment Notes
Medical emergencies
First responders Notes
Refer to Emergency Medical Procedures Notes
Fire
Firefighting, evacuation, and rescue procedures Notes