PDHonline Course C354 (1 PDH)

Underground Construction
(Tunelling) - OSHA Standards

Instructor: John Poullain, PE

2012

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5272 Meadow Estates Drive
Fairfax, VA 22030-6658
Phone & Fax: 703-988-0088
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www.osha.gov

Underground Construction
(Tunneling)

OSHA 3115-06R 2003

This informational booklet provides a
general overview of a particular topic
related to OSHA standards. It does not alter
or determine compliance responsibilities in
OSHA standards or the Occupational Safety
and Health Act of 1970. Because interpreta-
tions and enforcement policy may change
over time, you should consult current OSHA
administrative interpretations and decisions
by the Occupational Safety and Health
Review Commission and the Courts for
additional guidance on OSHA compliance
requirements.

This publication is in the public domain

and may be reproduced, fully or partially,
without permission. Source credit is
requested but not required.

This information is available to sensory

impaired individuals upon request.
Voice phone: (202) 693-1999; teletypewriter
(TTY) number: (877) 889-5627.
Underground Construction
(Tunneling)
U.S. Department of Labor
Elaine L. Chao, Secretary

Occupational Safety and Health Administration

John L. Henshaw, Assistant Secretary

OSHA 3115-06R
2003
Contents

Introduction…4

Construction operations covered by

the OSHA standard...4

Employers and employees covered by

the OSHA standard...5

Requirements of the OSHA standard...6

The need for a “competent person”...6

Training requirements...6

Notification and communication requirements...7

Site control procedures...8

Check-in/check-out procedures...8
Control of access and egress...9
Ground support of portal and subsidence areas...9
Ground support of underground areas...9
Ground support of shafts...10
Fire prevention and control...10

Ventilation requirements...12

Illumination requirements...13

Special air monitoring requirements...13

Test for oxygen first...14
Testing for methane and other flammable gases...14
Hydrogen sulfide levels...15

Special conditions for drilling and

blasting underground...15

2
Special requirements for using cranes
and hoists underground...16

Potential hazards that require special precautions...18

Gassy or potentially gassy operations...18

Emergency procedures...21

Recordkeeping requirements...22

OSHA assistance...22
Safety and health management system guidelines...22
State programs...23
OSHA consultation services...23
The OSHA Voluntary Protection Program (VPP)...24
Strategic Partnership Programs...25
The OSHA Alliance Program...25
OSHA training and education...26
Information available electronically...26
OSHA publications...27
Contacting OSHA...27

OSHA Regional Offices...28

3
Introduction
The construction of underground tunnels, shafts, chambers, and
passageways are essential yet dangerous activities. Working under
reduced light conditions, difficult or limited access and egress, with
the potential for exposure to air contaminants and the hazards of
fire and explosion, underground construction workers face many
dangers. To help employers protect the safety and health of under-
ground construction workers, the Occupational Safety and Health
Administration (OSHA) has prepared a number of guidance
documents, including the underground construction regulations,
found in Part 1926, section 800 of Title 29 of the Code of Federal
Regulations (29 CFR 1926.800).
OSHA regulations relating to underground construction were
originally adopted in 1971 and revised over the years to add new
protective measures and enhance worker safety. This publication
summarizes OSHA’s regulations related to underground construc-
tion. As such, it should be used as a guide but not as a substitute
for the complete text of 29 CFR 1926.800.

Construction operations covered

by the OSHA standard
The OSHA underground construction regulation (29 CFR
1926.800) applies to the construction of underground tunnels,
shafts, chambers, and passageways. It also applies to cut-and-
cover excavations connected to ongoing underground construction
as well as those that create conditions characteristic of under-
ground construction. These hazards include reduced natural venti-
lation and light, difficult and limited access and egress, exposure to
air contaminants, fire, flooding, and explosion. The regulation does
not apply to excavation and trenching operations for above ground
structures that are not physically connected to an underground con-
struction operation or to underground electrical transmission and
distribution lines.
OSHA has developed the following definitions for construction
activities that fall within the underground construction field:

4
 A tunnel is “an excavation beneath the surface of the ground,
the longer axis of which makes an angle not greater than 20
degrees to the horizontal.”
A shaft is “(1) a passage made from the surface of the ground to
a point underground, the longer axis of which makes an angle
greater than 20 degrees to the horizontal; or (2) a pit in which there
are employees, and it is foreseeable that they may enter (or do
enter) the horizontal excavation; or (3) a pit that has typical
underground construction hazards and is connected to a
horizontal excavation.”

Employers and employees covered

by the OSHA standard
In general, OSHA authority extends to all private sector
employers with one or more employees, as well as to civilian
employees in federal agencies. As such, OSHA coverage applies to
employers and employees in the construction industry. Workers
not covered by OSHA include the self-employed; public employees
of state and local governments; employees whose working condi-
tions are regulated by other federal agencies, such as mine workers
and atomic energy workers; and immediate family members of
farming operations that do not employ outside workers.
States can administer their own occupational safety and health
programs through plans approved by the Department of Labor
under section 18(b) of the Occupational Safety and Health (OSH)
Act of 1970, but they must enforce standards that are at least as
effective as federal requirements. In 2003, 26 states operated their
own safety and health programs under approved programs. (See
OSHA’s website at www.osha.gov for a list of those states.) Of
these, 23 states cover both private and public employees while
three states cover only public sector employees.
State safety and health standards under approved plans
must either be identical to or at least as effective as federal
OSHA standards.

5
Requirements of the OSHA standard
The underground construction standard covers many topics of
concern to those who work in the challenging environment of
underground construction. A sampling of items covered by the
standard includes requirements for safe access and egress routes,
employee training in hazard recognition, a “check-in/check-out”
procedure, and emergency procedures. This booklet summarizes
all requirements of the standard.
The standard provides some flexibility in methods to control
workplace hazards in underground construction as long as appro-
priate precautions are taken to protect workers in a variety of situa-
tions. OSHA requires that a “competent person” be responsible for
carrying out several requirements of the underground construction
regulations. Situations that require intervention by a “competent
person” are identified in the following sections.

The need for a “competent person”

The definition of a “competent person” in 29 CFR 1926.32 (f) is
as follows:
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 correctivemeasures to eliminate them.
Under Subpart S, Underground Construction, caissons, coffer-
dams, and compressed air, a competent person is responsible for
inspecting and evaluating workplace conditions, including air moni-
toring and the presence of air contaminants, ground stability, and
the drilling, hauling and hoisting of equipment, to identify and
correct any deficiencies.

Training requirements
All employees involved in underground construction must be
trained to recognize and respond to hazards associated with this
type of work. Training should be tailored to the specific require-
ments of the jobsite and include any unique issues or requirements.

6
 The following topics should be part of an underground construc-
tion employee training program:
■ Air monitoring and ventilation
■ Illumination
■ Communications
■ Flood control
■ Personal protective equipment
■ Emergency procedures, including evacuation plans
■ Check-in/check-out procedures
■ Explosives
■ Fire prevention and protection
■ Mechanical equipment

Notification and communication

requirements
Any time an employer receives a notification of a hazardous
condition, all oncoming shifts must be notified of occurrences or
conditions that either have affected or might affect their safety.
Examples of this type of situation include equipment failures, earth
or rockslides, cave-ins, flooding, fires, explosions, or release of gas.
The employer must also maintain open lines of communication
with other employers at the worksite to ensure a rapid and
complete exchange of information concerning events or situations
that may impact worker safety.
Employers must maintain lines of communication with
employees during underground construction activities. To ensure
effective communications are always available, communication
systems must be tested upon initial entry of each shift to the under-
ground and as often as necessary at a later time to ensure they are
in working order. Powered communication systems must operate
on an independent power supply and be installed so that the use of
or disruption of any single communication device or signal location
will not disrupt the operation of the system in any other location.

7
 If natural unassisted voice communication is ineffective at any
time, a power-assisted means must be used to ensure communica-
tion between the work face, the bottom of the shaft, and the
surface. In the case of an individual employee working alone
underground in a hazardous location who is out of range of natural
unassisted voice communication and not able to be observed by
other employees, the employer must provide an effective means of
obtaining assistance in the event of an emergency.
All shafts being developed or used for personnel access or
hoisting require two effective means of communication. In
addition, hoist operators must have a closed-circuit voice communi-
cation system connected to each landing station, with speaker-
microphones located so that the operator can communicate with
individual stations while the hoist is in use. (See the section on
cranes and hoists later in this booklet for more specific information.)

Site control procedures

Check-in/check-out procedures
The employer must maintain a check-in/check-out procedure to
ensure that above ground personnel maintain an accurate account-
ing of the number of persons underground and to prevent unautho-
rized persons from gaining access to the site. This is especially
important in the event of an emergency but is a common sense
requirement at all times.
The only time this procedure is not required is when an under-
ground construction project designed for human occupancy is
completed to the point that permanent environmental controls are
effective and any remaining construction activity does not have the
potential to create an environmental hazard or structural failure in
the construction area.
Any time an employee is working underground, at least one des-
ignated person must be on duty above ground. This person is
responsible for calling for immediate assistance and keeping an
accurate count of employees who remain underground in the event
of an emergency.

8
Control of access and egress
In addition to establishing a check-in/check-out procedure, the
employer must ensure safe access to and egress from all worksta-
tions at the construction site to protect employees from potential
hazards, such as being struck by excavators, haulage machines, or
other moving equipment.
To help control access, all unused openings, including chutes
and man ways, must be tightly covered, bulk headed, barricaded,
or fenced off, and posted with warning signs that read, “Keep Out”
or similar language.

Ground support of portal and subsidence areas

Portal openings and access areas must be guarded by shoring,
fencing, head walls, shotcreting or equivalent protection to ensure
that employees and equipment have a safe means to access these
areas. Subsidence areas must be similarly guarded by shoring,
filling in, or placing barricades and warning signs to prevent entry.
Adjacent areas must be scaled or secured to prevent loose soil,
rock, or fractured materials from endangering portal, subsidence,
and access areas.

Ground support of underground areas

A competent person must inspect the roof, face, and walls of the
work areas at the beginning of each shift and as often as necessary
to ensure ground stability. The competent person tasked with such
inspection responsibilities must be protected from loose ground by
location, ground support, or equivalent means. The ground condi-
tions along all haulage ways and travel ways must also be
inspected as frequently as necessary to ensure safe passage and
loose ground considered to be hazardous to employees must be
scaled, supported, or taken down.
A competent person must determine how often rock bolts need
to be tested to ensure that they meet the necessary torque, taking
into consideration ground conditions, distance from vibration
sources, and the specific bolt system in use. Only torque wrenches
should be used when torsion-dependent bolts are used for ground
support.
9
 Employees involved in installing ground support systems must
be adequately protected from the hazards of loose ground. The
bottoms of any support sets installed must have sufficient
anchorage to prevent ground pressures from dislodging the
support base. Lateral bracing (including collar bracing, tie rods, or
spreaders) must be provided between immediately adjacent sets to
increase stability.
Any dislodged or damaged ground supports that create a
hazardous condition must be promptly repaired or replaced. The
new supports must be installed before removing the damaged
supports. Some type of support, such as a shield, must be used to
maintain a safe travel way for employees working in dead-end
areas ahead of any support replacement operations.

Ground support of shafts

Shafts and wells more than 5 feet in depth (1.53 m) entered by
employees must be supported by steel casing, concrete pipe,
timber, solid rock, or other suitable material. The full depth of the
shaft must be supported except where it penetrates into solid rock
that will not change as a result of exposure. Where the potential for
shear exists, where the shaft passes through earth into solid rock in
either direction, or where the shaft ends in solid rock, the casing or
bracing must extend at least 5 feet (1.53 m) into the solid rock.
The casing or bracing must also extend 42 (± 3) inches above
ground level unless a standard railing is installed, the adjacent
ground slopes away from the shaft collar, and barriers exist to
prevent mobile equipment operating near the shaft from jumping
over the bracing. If these conditions are met, the casing or bracing
may be reduced to 12 inches above ground.

Fire prevention and control

In addition to the basic fire prevention and control guidance set
forth in 29 CFR 1926 Subpart F, underground construction opera-
tions are subject to several specific requirements.
Open flames and fires are prohibited in underground construction
areas except as permitted for welding, cutting, or other hot work
operations. Smoking is prohibited unless an area is free of fire and
10
explosion hazards. Signage prohibiting smoking and open flames
should be placed throughout work areas. Fire extinguishers of at
least 4A:40B:C rating or equivalent extinguishing means must be
available at the head and tail pulleys of underground belt
conveyers.
All underground structures and those within 100 feet (30.48 m)
of an opening to the underground must be constructed of materials
with a fire resistance rating of at least one hour. Also, no
flammable or combustible material may be stored above ground
within 100 feet (30.48 m) of any access point to an underground
operation. If space limitations make this unfeasible, the material
must be positioned as far as possible from the entrance with a fire-
resistant barrier that has at least a one-hour rating between the
material and the opening. Alternative precautionary measures may
be adopted from industry practices used under similar working
conditions or measures recommended under industry consensus
standards. A site hazard analysis may be helpful to determine the
effectiveness of precautionary measures. Any spill of flammable or
combustible material must be cleaned up immediately.
Gasoline may not be underground at any time for any purpose
due to its volatile qualities. Internal combustion engines (except
diesel-powered engines on mobile equipment) are prohibited
underground. Acetylene, liquefied petroleum gas, and methyl
acetylene propadiene stabilized gas may be used underground for
welding, cutting, and other hot work if all requirements of OSHA
regulations pertaining to such activities are met. (See 29 CFR 1926
Subpart J and 29 CFR 1926.800(j)(k)(m)(n) for a complete explana-
tion of these requirements.) Only enough fuel gas and oxygen
cylinders for welding, cutting, or hot work during a 24-hour period
are allowed underground. Noncombustible barriers must be
installed below such activities if they are performed in or over a
shaft or rise.
Oil, grease, and diesel fuel stored underground must be kept in
tightly sealed containers in fire-resistant areas at least 300 feet
(91.44 m) from underground explosive magazines, and at least 100
feet (30.48 m) from shaft stations and steeply inclined passage-
ways. Storage areas must be positioned or diked to ensure that if a

11
container breaks open, any fluids will not flow out of the storage
area. Any hydraulically-actuated underground machinery must use
fire-resistant hydraulic fluids unless it is protected by a fire suppres-
sion system or multi-purpose fire extinguisher rated at least
4A:40B:C and of sufficient capacity for the type and size of
equipment involved.
Several specific requirements apply to the use of diesel fuel in
underground construction operations, as follows:
■ A surface level tank holding diesel fuel to be pumped to an
underground storage site must have a maximum capacity no
greater than the amount of fuel required to supply underground
equipment for 24 hours.
■ A surface level tank must be connected to the underground
fueling station by an acceptable pipe or hose system controlled
at the surface by a valve and at the bottom by a hose nozzle.
■ The transfer pipe must remain empty at all times except when
transferring diesel fuel.
■ All hoisting operations in the shaft must be suspended during
refueling operations if the supply piping in the shaft is not
protected from potential damage.

Ventilation requirements
Fresh air must be supplied to all underground work areas in suf-
ficient amounts to prevent any dangerous or harmful accumulation
of dusts, fumes, mists, vapors, or gases. If natural ventilation does
not provide the necessary air quality through sufficient air volume
and air flow, the employer must provide mechanical ventilation to
ensure that each employee working underground has at least 200
cubic feet (5.7m3) of fresh air per minute.
When performing work that is likely to produce dust, fumes,
mists, vapors, or gases (such as blasting or rock drilling), the linear
velocity of air flow in the tunnel bore, shafts, and all other under-
ground work areas must be at least 30 feet (9.15 m) per minute.
When such operations are complete, the ventilation systems must
exhaust smoke and fumes to the outside atmosphere before

12
resuming work in all affected areas. When drilling rock or concrete,
dust control measures such as wet drilling, vacuum collectors, and
water mix spray systems must be used to maintain dust levels
within limits set in 29 CFR 1926.55, which includes gases, vapors,
fumes, dusts, and mists.
The direction of mechanical airflow must be reversible but venti-
lation doors must be designed and installed to remain closed when
in use, regardless of the direction of the airflow. If the ventilation
system has been shut down and all employees are removed from
the underground area, only competent persons authorized to test
for air contaminants may be allowed underground until the ventila-
tion system has been restored and all affected areas have tested at
acceptable limits for air contaminants.

Illumination requirements
As in all construction operations, OSHA requires that proper illu-
mination be provided during tunneling operations (see 29 CFR
1926.56 for details). When explosives are handled, only acceptable
portable lighting equipment may be used within 50 feet of any
underground heading.
For general tunneling operations, a minimum illumination
intensity of 5 foot-candles must be maintained, although 10 foot-
candles must be provided for shaft heading during drilling,
mucking, and scaling.

Special air monitoring requirements

The employer must assign a “competent person” to perform air
monitoring. If this individual determines that air contaminants may
present a danger to life at any time, the employer must immediate-
ly take all necessary precautions and post a notice at all entrances
to the underground site about the hazardous condition.
In performing air monitoring duties, the competent person must
take into consideration the location of the jobsite (its proximity to
fuel tanks, sewers, gas lines, etc.); the geology of the site, including
soil type and permeability; the history of the site and the construc-

13
tion operation (changes in levels of substances monitored over
time); and work practices at the jobsite (use of diesel engines,
explosives, and fuel gas; hot work, welding, and cutting; and the
physical reactions of employees to working underground.

Test for oxygen first

The competent person charged with air monitoring must test for
oxygen content before testing for air contaminants. All under-
ground work areas must be tested as often as necessary to verify
that the atmosphere at normal atmospheric pressure remains
within the acceptable parameters of 19.5 and 22 percent oxygen.
After verifying oxygen levels, the competent person must test all
underground work areas for carbon monoxide, nitrogen dioxide,
hydrogen sulfide, and other toxic gases, dusts, vapors, mists, and
fumes as often as necessary to ensure that levels remain within
permissible exposure limits (see 29 CFR 1926.55 for detailed
information on these limits).

Testing for methane and other flammable gases

The competent person must also test all underground work
areas for methane and other flammable gases to determine
whether the operation must be classified as potentially gassy or
gassy. If the atmosphere meets the criteria for these designations,
the precautions listed in the section discussing gassy or potentially
gassy operations later in this booklet must be followed. Other
precautions to take when testing for methane or other flammable
gases include:
■ If 20 percent or more of the lower explosive limit for methane or
other flammable gases is detected in any underground work
area or in the air return, all employees must be evacuated to a
safe location above ground (except those employees required to
eliminate the hazard). Electrical power (except for acceptable
pumping and ventilation equipment) must be cut off to the area
until concentrations reach less than 20 percent of the lower
explosive limit.
■ If 10 percent or more of the lower explosive limit for methane
gas or other flammable gases is detected near any welding,
14
 cutting, or other hot work, the work must be suspended until the
concentration is reduced to below 10 percent of the lower
explosive limit.
■ When 5 percent or more of the lower explosive limit for
methane or other flammable gases is detected in an under-
ground work area or in the air return, steps should be taken to
increase ventilation air volume or otherwise control the gas
concentration (unless all requirements of operating under
potentially gassy or gassy operations are met).

Hydrogen sulfide levels

When air monitoring reveals the presence of 5 ppm or more of
hydrogen sulfide, the affected underground areas must be tested at
the beginning and midpoint of each shift until the concentration is
measured at less than 5 ppm for three consecutive days.
Employees must be notified if hydrogen sulfide is detected in
amounts exceeding 10 ppm and a continuous sampling and indicat-
ing monitor must be used to keep track of levels. If the concentra-
tion of hydrogen sulfide reaches 20 ppm, the monitor must be
designed to provide both visual and audible alarms to warn that
additional measures (respirator use, increased ventilation, evacua-
tion) may be appropriate.

Special conditions for drilling

and blasting underground
Before initiating any drilling operation underground, a
“competent person” must inspect all drilling and associated
equipment as well as the drilling area and correct any hazards.
Employees are not allowed on a drill mast when a drill bit is in
operation or a drill machine is being moved. Also, when moving a
drill machine, all associated equipment and tools must be secured
and the mast placed in a safe position.
Working on or around jumbo decks involves special safety
precautions, including the following:
■ Locate all receptacles or racks to store drill steel on jumbos.

15
■ Warn employees working below jumbo decks when drilling is
about to begin.
■ The top deck of a jumbo must have a mechanical way to lift
unwieldy or heavy items.
■ Only employees assisting the operator may ride on the jumbo
unless it is equipped with seating for each passenger and
protection from crushing or catching hazards.
■ Jumbo decks more than 10 feet high must be equipped with
guardrails on all open sides unless an adjacent surface provides
fall protection. Jumbo decks and stair treads must be slip-
resistant, secured, and maintained to prevent slip, trip, and
fall hazards.
■ Jumbos must be chocked so they will not move when
employees are working on them.
Whenever an underground blasting operation in a shaft is
complete, a “competent person” must check the air quality and
make sure that no walls, ladders, timbers, blocking, and wedges
have been loosened as a result of the activity. If repairs are
required, only employees involved in repair activity may be in or
below affected areas until repairs are complete.
All blasting wires must be kept clear of electrical lines, pipes,
rails and other conductive material (except earth), to prevent explo-
sions or exposure of employees to electric current.

Special requirements for using

cranes and hoists underground
The OSHA standard has provisions for the use of cranes or
hoists that are unique to underground construction. In addition to
provisions that apply to all construction activities using cranes or
hoists (29 CFR 1926.550 and 29 CFR 1926.552), cranes used in
underground construction must be equipped with a limit switch to
prevent overtravel at the top and bottom of the hoist way. The limit
switch should only be used when operational controls malfunction.
Hoist controls must be arranged so the operator can reach all

16
controls and the emergency power cutoff without reaching beyond
his/her normal operating position.
Underground hoists must be designed to allow powering of the
hoist drum in both directions and so that brakes are automatically
applied upon power release or failure. The hoist operator must
have a closed-circuit voice communication system with speaker
microphones to communicate with individual landing stations.
Also, hoists must be equipped with landing level indicators
(marking the hoist rope is not adequate) and fire extinguishers
(rated at least 2A:10B:C) in each hoist house.
Before using a hoist that has been out of operation for a
complete shift or after repair or service, the operator must test run
the equipment and correct any unsafe conditions before use.
Inspections and load testing to 100 percent of capacity must be
performed at least annually and after any repairs or alterations
affecting the structural integrity of the hoist.
For material hoists, wire rope used in load lines must support at
least five times the maximum intended load or the factor recom-
mended by the rope manufacturer, whichever is greater. Personnel
hoists must have at least two means to stop the load, each able to
stop and hold 150 percent of the hoists’ rated line pull. For
personnel hoisting, a broken-rope safety, safety catch, or arrest-
ment device are not adequate means of stopping.
Other aspects of hoist safety that apply to underground con-
struction include:
■ Employees may not ride on top of any cage, skip, or bucket
unless inspecting or maintaining the system and wearing a
safety belt or harness.
■ Personnel and materials must be hoisted separately (except
small tools and supplies secured in a nonhazardous manner).
■ When sinking shafts 75 feet (22.86 m) or less, cages, skips, and
buckets that may swing, bump, or snag against shaft sides must
be guided by fenders, rails, ropes, or a combination. If the shaft
is more than 75 feet, hoisted objects must be rope- or rail-
guided for the full length of travel.

17
 Additional safety requirements for personnel hoists in under-
ground operations include:
■ The operator must be able to see and hear signals at the
operator’s station.
■ All cages must be equipped with a steel-plate protective canopy
that slopes to the outside and can be pushed up for emergency
egress and have a locking door that opens only inward.
■ The sides of personnel cages must be enclosed by 1/2 inch wire
mesh to a height of at least 6 feet (1.83 m). If the cage is being
used as a work platform and is not in motion, the sides may be
reduced to 42 inches (1.07 m).
■ During sinking operations in shafts where guides and safeties
are not used, the personnel platform may not exceed 200 feet
(60.96 m) per minute and governors must be used during
personnel hoisting. The speed may increase to 600 feet
(182.88 m) per minute when guides and safeties are used and
greater speeds when shafts are complete.

Potential hazards that require

special precautions
Gassy or potentially gassy operations
Gassy or potentially gassy operations present specific hazards to
underground construction workers. It is essential that employers
understand the terms “gassy” and “potentially gassy” and to know
what precautions to take when dealing with such environments.
Operations that meet the criteria for this hazardous classification
must be equipped with ventilation systems constructed with fire-
resistant materials; have acceptable electrical systems, including
fan motors; and have above ground controls to reverse the air flow.
When using a mine-type ventilation system with an offset main fan
on the surface, the system must be equipped with explosion doors
or a weak-wall with an area at least equivalent to the cross-
sectional area of the airway.

18
 Gassy operations occur under the following conditions:
■ When air monitoring discloses 10 percent or more of the lower
explosive limit for methane or other flammable gases measured
at 12 inches (304.8 mm) ± 0.25 inch (6.35 mm) from the roof,
face, floor, or walls in any underground work area for three
consecutive days; or
■ There has been an ignition of methane or other flammable
gases emanating from the strata that indicates the presence of
such gases; or
■ The underground construction operation is connected to an
underground work area classified as gassy and subject to a
continuous course of air that contains the flammable gas
concentration.
The underground construction standard requires that gassy
operations meet several special requirements, including both
personnel and equipment safety concerns. These requirements
include:
■ Entrances to a gassy operation must be marked with
prominently posted signage that identifies the area as gassy.
■ Maintain a fire watch when performing hot work (welding,
cutting, heating) in a gassy area and for a sufficient period after
completing the work to ensure no possibility of fire remains.
(See 29 CFR 1926.352(e))
■ Use only acceptable equipment in well-maintained condition.
Any mobile diesel-powered equipment must either be approved
by MSHA and meet the requirements of 30 CFR part 36
(formerly Schedule 31) or the employer must demonstrate that
the equipment is fully equivalent to MSHA-approved equipment
and operated according to these regulations.
■ Smoking is prohibited in all gassy operations; the employer
must collect all possible sources of ignition (matches, lighters,
etc.) from any person entering a gassy operation area.
■ All operations in the affected area must stop when an operation
is classified as gassy until full compliance with gassy operation
requirements is confirmed or the operation is downgraded to a
potentially gassy operation (see the following section). The only
19
 exceptions are operations to control the gas concentration,
installation of above ground equipment to reverse the airflow,
or actions to comply with gassy operation requirements.
Gassy operations can be downgraded to potentially gassy when
air monitoring results remain below 10 percent of the lower
explosive limit for methane or other flammable gases for three con-
secutive days.
Potentially gassy operations, such as an unexpected pocket of
gas, occur when the following conditions exist:
■ Air monitoring shows 10 percent or more of the lower explosive
limit for methane or other flammable gases measured at 12
inches (304.8 mm) ± 0.25 inch (6.35 mm) from the roof, face,
floor or walls in any underground work area for more than a 24-
hour period.
■ The history of the geographical area, geological formation, or
past experience indicates that 10 percent or more of the lower
explosive limit for methane or other flammable gases is likely to
be encountered in such underground operations.
Both gassy and potentially gassy operations require special air
monitoring actions under the guidance of a “competent person,”
including testing for oxygen and flammable gas content in the
affected underground work areas and adjacent work areas at the
beginning and midpoint of each work shift. A manual flammable
gas monitor should be used for gas testing and a manual electrical
shut down control must be provided near the heading for the gas
monitor.
The use of rapid excavation machines requires continuous
automatic flammable gas monitoring to monitor the air at the
heading, on the rib, and in the return air duct. If 20 percent or more
of the lower explosive limit for methane or other flammable gases
is encountered, the continuous monitor alert should signal the
heading and shut down electrical power in the affected under-
ground work area (except for required pumping and ventilation
equipment).
Local gas tests must be conducted before and throughout
welding, cutting or other hot work. In underground operations

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driven by drill-and-blast methods, the air in the affected area
must be continuously tested for flammable gas when employees
are working in the area as well as before reentering after
blasting operations.

Emergency procedures
Whenever an employee is working underground at least one
designated person must be on duty above ground, responsible for
maintaining an accurate count of the number of employees under-
ground and summoning emergency aid if needed. Every employee
working underground must have a portable hand lamp or cap lamp
for emergency use unless natural light or an emergency lighting
system provides adequate illumination for escape. Employers must
provide self-rescuers approved by the National Institute for
Occupational Safety and Health (NIOSH) in all underground work
areas where employees might be trapped by smoke or gas. (See
CFR 1926.103 for more information.)
If 25 or more employees work underground at one time, the
employer must provide at least two 5-person rescue teams, one at
the jobsite or within 30 minutes travel time from the entry point to
the site and the other team within two hours travel time. If less
than 25 employees work underground, the employer must have
one 5-person rescue team at the jobsite or within 30 minutes travel
time. In both situations, advance arrangements can be made for
local rescue services to meet this requirement. Rescue team
members must be trained in rescue procedures, the use and limita-
tions of breathing apparatus, and the use of firefighting equipment
with qualifications reviewed annually. When flammable or noxious
gases are anticipated at a jobsite, rescue teams must practice using
self-contained breathing apparatus once a month. The rescue
teams must be available through the duration of a construction
project.
If a shaft is used as the means of egress, the employer must
arrange for a readily available power-assisted hoisting capability in
case of emergency, unless the regular hoisting means will function
in the event of a power failure.

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Recordkeeping requirements
Records of all air quality tests must be maintained above ground
at the worksite and be available on request to the Secretary of
Labor or his or her representative. The record must include the
location, date, time, substance and amount monitored. Records of
exposures to toxic substances must be kept for 30 years. (See 29
CFR 1910.1020 for more detailed information on access to
employee exposure and medical records.) All other air quality test
records must be retained until the project is complete.
Inspection certification records for all hoist equipment indicating
the date of the most recent inspection and load-test, the signature
of the person performing the inspection and test, and a serial
number or other identifier for the hoist must be maintained on file
until the project is complete.

OSHA assistance
OSHA can provide extensive help through a variety of
programs, including technical assistance about effective safety and
health programs, state plans, workplace consultations, voluntary
protection programs, strategic partnerships, and training and
education, and more. An overall commitment to workplace safety
and health can add value to your business, to your workplace, and
to your life.

Safety and health management

system guidelines
Effective management of worker safety and health protection is
a decisive factor in reducing the extent and severity of work-related
injuries and illnesses and their related costs. To assist employers
and employees in developing effective safety and health programs,
OSHA published recommended Safety and Health Program
Management Guidelines (Federal Register 54 (16): 3904-3916,
January 26, 1989). These voluntary guidelines can be applied to all
places of employment covered by OSHA.

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 The guidelines identify four general elements critical to the
development of a successful safety and health management
system:
■ Management leadership and employee involvement.
■ Worksite analysis.
■ Hazard prevention and control.
■ Safety and health training.
The guidelines recommend specific actions, under each of these
general elements, to achieve an effective safety and health
program. The Federal Register notice is available online at
www.osha.gov.

State programs
The Occupational Safety and Health Act of 1970 (OSH Act)
encourages states to develop and operate their own job safety and
health plans. OSHA approves and monitors these plans. There are
currently 26 state plans: 23 cover both private and public (state and
local government) employment; 3 states, Connecticut, New Jersey,
and New York, cover the public sector only. States and territories
with their own OSHA-approved occupational safety and health
plans must adopt standards identical to, or at least as effective as,
the federal standards.

OSHA consultation services

Consultation assistance is available on request to employers
who want help in establishing and maintaining a safe and healthful
workplace. Largely funded by OSHA, the service is provided at no
cost to the employer. Primarily developed for smaller employers
with more hazardous operations, the consultation service is
delivered by state governments employing professional safety and
health consultants. Comprehensive assistance includes an appraisal
of all-mechanical systems, work practices, and occupational safety
and health hazards of the workplace and all aspects of the
employer’s present job safety and health program. In addition, the
service offers assistance to employers in developing and imple-

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menting an effective safety and health program. No penalties are
proposed or citations issued for hazards identified by the consult-
ant. OSHA provides consultation assistance to the employer with
the assurance that his or her name and firm and any information
about the workplace will not be routinely reported to OSHA
enforcement staff.
Under the consultation program, certain exemplary employers
may request participation in OSHA’s Safety and Health
Achievement Recognition Program (SHARP). Eligibility for participa-
tion in SHARP includes receiving a comprehensive consultation
visit, demonstrating exemplary achievements in workplace safety
and health by abating all identified hazards, and developing an
excellent safety and health program.
Employers accepted into SHARP may receive an exemption from
programmed inspections (not complaint or accident investigation
inspections) for one year. For more information concerning consul-
tation assistance, call 800-321-OSHA or visit www.osha.gov.

The OSHA Voluntary Protection Program (VPP)

Voluntary Protection Programs and onsite consultation
services, when coupled with an effective enforcement program,
expand worker protection to help meet the goals of the OSH Act.
The three levels of VPP, Star, Merit, and Demonstration, are
designed to recognize outstanding achievements by companies
that have successfully incorporated comprehensive safety and
health programs into their total management system. The VPP
motivates others to achieve excellent safety and health results and
establish a cooperative relationship between employers,
employees, and OSHA.
For additional information on VPP and how to apply, contact the
OSHA regional offices listed at the end of this publication or call
800-321-OSHA or visit www.osha.gov.

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Strategic Partnership Programs
OSHA’s Strategic Partnership Program, the newest member of
OSHA’s cooperative programs, helps encourage, assist, and
recognize the efforts of partners to eliminate serious workplace
hazards and achieve a high level of worker safety and health.
Whereas OSHA’s Consultation Program and VPP entail one-on-one
relationships between OSHA and individual work sites, most
strategic partnerships seek to have a broader impact by building
cooperative relationships with groups of employers and employees.
These partnerships are voluntary, cooperative relationships
between OSHA, employers, employee representatives, and others
(e.g., trade unions, trade and professional associations, universities,
and other government agencies).
For more information on this and other cooperative programs,
contact your nearest OSHA office, call 800-321-OSHA, or visit
www.osha.gov.

The OSHA Alliance Program

Alliances enable organizations committed to workplace safety and
health to collaborate with OSHA to prevent injuries and illnesses in
the workplace. OSHA and its allies work together to reach out to,
educate, and lead the nation’s employers and their employees in
improving and advancing workplace safety and health.
Alliances are open to all, including trade or professional organiza-
tions, businesses, labor organizations, educational institutions, and
government agencies. In some cases, organizations may be
building on existing relationships with OSHA through other cooper-
ative programs.
There are few formal program requirements for alliances, which
are less structured than other cooperative agreements, and the
agreements do not include an enforcement component. However,
OSHA and the participating organizations must define, implement,
and meet a set of short- and long-term goals that fall into three cat-
egories: training and education; outreach and communication; and
promotion of the national dialogue on workplace safety and health.

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OSHA training and education
OSHA area offices offer a variety of information services, such as
compliance assistance, technical advice, publications, audiovisual
aids and speakers for special engagements. OSHA’s Training
Institute in Des Plaines, IL, provides basic and advanced courses in
safety and health for federal and state compliance officers, state
consultants, federal agency personnel, and private sector
employers, employees, and their representatives.
The OSHA Training Institute also has established OSHA Training
Institute Education Centers to address the increased demand for its
courses from the private sector and from other federal agencies.
These centers are nonprofit colleges, universities, and other organi-
zations that have been selected after a competition for participation
in the program.
OSHA also provides funds to nonprofit organizations, through
grants, to conduct workplace training and education in subjects
where OSHA believes there is a lack of workplace training. Grants
are awarded annually. Grant recipients are expected to contribute
20 percent of the total grant cost.
For more information on grants, training, and education, contact
the OSHA Training Institute, Office of Training and Education, 1555
Times Drive, Des Plaines, IL 60018, (847) 297-4810. For further infor-
mation on any OSHA program, contact your nearest OSHA office.

Information available electronically

OSHA has a variety of materials and tools available on its
website at www.osha.gov. These include e-Tools such as Expert
Advisors, Electronic Compliance Assistance Tools (e-cats), Technical
Links; regulations, directives, publications; videos, and other infor-
mation for employers and employees. OSHA’s software programs
and compliance assistance tools walk you through challenging
safety and health issues and common problems to find the best
solutions for your workplace.

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OSHA publications
OSHA has an extensive publications program. For a listing of
free or sales items, visit OSHA’s website at www.osha.gov or
contact the OSHA Publications Office, U.S. Department of Labor,
200 Constitution Avenue NW, N-3101, Washington, DC 20210.
Telephone (202) 693-1888 or fax to (202) 693-2498.

Contacting OSHA
To report an emergency, file a complaint, or seek OSHA advice,
assistance, or products, call (800) 321-OSHA or contact the nearest
OSHA regional or area office listed at the end of this publication.
The teletypewriter (TTY) number is (877) 889-5627.
You can also file a complaint online and obtain more information
on OSHA federal and state programs by visiting OSHA’s website at
www.osha.gov.
For more information on grants, training, and education, contact
the OSHA Training Institute, Office of Training and Education, 1555
Times Drive, Des Plaines, IL 60018, (847) 297-4810, or see Outreach
on OSHA’s website at www.osha.gov.

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OSHA Regional Offices
Region I Region VI
(CT,* ME, MA, NH, RI, VT*) (AR, LA, NM,* OK, TX)
Boston, MA 02203 525 Griffin Street, Room 602
(617) 565-9860 Dallas, TX 75202
(214) 767-4731 or 4736 x224
Region II
(NJ,* NY,* PR,* VI*) Region VII
201 Varick Street, Room 670 (IA,* KS, MO, NE)
New York, NY 10014 City Center Square
(212) 337-2378 1100 Main Street, Suite 800
Kansas City, MO 64105
Region III
(816) 426-5861
(DE, DC, MD,* PA,* VA,* WV)
The Curtis Center Region VIII
170 S. Independence Mall West (CO, MT, ND, SD, UT,* WY*)
Suite 740 West 1999 Broadway, Suite 1690
Philadelphia, PA 19106-3309 PO Box 46550
(215) 861-4900 Denver, CO 80202-5716
(303) 844-1600
Region IV
(AL, FL, GA, KY,* MS, NC,* SC,* Region IX
TN*) (American Samoa, AZ,* CA,* HI,
Atlanta Federal Center NV,* Northern Mariana Islands)
61 Forsyth Street SW, Room 6T50 71 Stevenson Street, Room 420
Atlanta, GA 30303 San Francisco, CA 94105
(404) 562-2300 (415) 975-4310

Region V Region X
(IL, IN,* MI,* MN,* OH, WI) (AK,* ID, OR,* WA*)
230 South Dearborn Street, 1111 Third Avenue, Suite 715
Room 3244 Seattle, WA 98101-3212
Chicago, IL 60604 (206) 553-5930
(312) 353-2220

*These states and territories operate their own OSHA-approved job safety and
health programs (Connecticut, New Jersey, and New York plans cover public
employees only). States with approved programs must have a standard that is
identical to, or at least as effective as, the federal standard.

Note: To get contact information for OSHA Area Offices, OSHA-approved state plans,
and OSHA Consultation Projects, please visit us online at www.osha.gov or call us at
(800) 321-OSHA.

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