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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 adjust based on weather conditions 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 safety glasses w/side shields steel-toed safety shoes/boots harness hearing protection gloves respirator (if needed) Travel to work shack company work truck personal vehicle w/prior permission walk Obtain job assignments from foreman Check/Start forklift Follow checklist for conducting pre-op on forklift Walk to saw block B. Workplace Examination Crane Level Check walkways for tripping hazards rocks, tools, other debris Check walkways for snow/ice accumulations shovel or plow area use sand/cal mixture from drum to remove accumulations Check that kick boards are in place replace if necessary Check that railings/guard rails are in place replace if necessary 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 Check air manifolds check for whip checks and broken lines Yellow lines 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 Red lines Check oxygen lines Green lines 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) Check walkways for tripping hazards rocks, tools, other debris Check walkways for snow/ice accumulations shovel or plow area use sand/cal mixture from drum to remove accumulations Check that kick boards are in place replace if necessary Check that railings/guard rails are in place replace if necessary 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 Check air manifolds check for whip checks and broken lines Yellow lines 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 Red lines Check tools check hammer heads and handles check for mushroomed heads, cracks, handle cracks, resurfaced heads check driver add oil before/during use check plug drill bit sharp edges mushroomed heads air fittings for wear check cross bit sharp edges mushroomed heads check jack hammer add oil before/during use air fittings for wear check wedges and half rounds 18" and 5" check for mushroomed heads, cracks check pipe wrenches check for wear on the jaws check lifting pins 20-ton and 30-ton check for cracks, shim and cable wear conduct visual exam (walk-a-round) check for movement in stone check for slides check for pressure cracks 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 obtain jack hammers minimum of 2 obtain driver obtain plug drill obtain wedges and shims 18" and 5" obtain grease/rock drill oil review/discuss MSDS Subtopic obtain plug and cross bits 1 1/2 and 2 1/4" cross bits 3/4" plug bit obtain gluts obtain methanol obtain yo-yo's obtain pin rod 18" obtain drill rod 24" length obtain dust bags obtain vacuums two 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 Maintain 3-point contact Re-evaluate bed formation On-going evaluation throughout shift Tightness Lay out line for drill measure according to need 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 constantly maintain and monitor down pressure ensures proper bit rotation maintain proper balance 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 average 4-5 wedges per block (5' block) send back wedges that need grinding (mushroomed heads, chips) install half-rounds place ears facing out 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 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 constantly maintain and monitor drill pressure ensures proper bit rotation maintain proper balance 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) average 3-5 wedges per block (5' block) send back wedges that need grinding (mushroomed heads, chips) install half-rounds place ears facing out pound wedges in place using sledge hammer ensure swing area is clear of persons 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 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 constantly maintain and monitor drill pressure ensures proper bit rotation maintain proper balance 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 load the holes with wedges and half-rounds (5") install half-rounds place ears facing out 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) send back wedges that need grinding (mushroomed heads, chips) pound wedges in place using sledge hammer ensure swing area is clear of persons pound wedges/half-rounds until snug Once snug, begin splitting stone Subtopic Remove all loose wedges and half-rounds store properly (bucket, etc.) 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 Spot pin hole location location is determined by size, weight, shape, formation 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 Too much oil will result in slow rotation 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 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 Don't allow drill to wobble maintain steady down pressure 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 Notify signalman to lower the endless chain head room determines length of chain 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 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 crane operator will need weight to match with load chart 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 stay clear of lift and swing area 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 Ensure no body parts are under stone at any time Avoid swing area Discuss pinch-points and associated hazards 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 obtain ladder to remove pin if you lifted a block pull cable until pin comes out of hole avoid pinch points 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.) 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 Conduct visual inspection of the work box welds chains shackles pins/locking devices gate cable floor condition Enter work box and hook up lanyard Discuss fall protection latch gate cable across front of box Stand at back of box and hold onto the rails avoid pinch points position the box tight against the face to prevent swing-out Subtopic 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 Discuss pinch-point hazards 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) Limit load to 50 ton per railcar 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 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 plug in mobile equipment primarily the equipment operator's responsibility properly store PPE (fall protection, etc.) in work shack shut off the compressor travel back to quarry office clock out F. Unusual conditions/Emergency Situations Lightening If lightening is observed, shut down operations Foreman will make determination Refer to company policy High Wind Restrict lifting Restrict working near the edge Could result in shutdown of operations Refer it company policy Snow/Ice Caution on slip/trip/fall hazards Ramp could be shut down Could result in shutdown of operations Refer to company policy Heavy Rain Caution on slip/trip/fall hazards Ramp could be shut down Refer to company policy Heat Refer to company policy Mechanical Crane Rope failure maintain a safe distance from load Brake failure Reinforce safe distance rule hydraulic system failure maintain a safe distance from equipment Medical emergencies First responders Refer to Emergency Medical Procedures Fire Firefighting, evacuation, and rescue procedures