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SYSTEM SAFETY CHECKLIST
SYSTEM SAFETY DESIGN CHECKLIST
for MIL-STD-1472D
12 December 1996
SYSTEM SAFETY CHECKLIST
Does Design Meet Guidelines?
MIL-STD-1472D System Safety Design, Requirement
Yes
No
N/A
5.9.11.3.1 Weight Lifting Limits
The weight limits of Table XXIII (see below), conditions A
and B, shall be used as maximum values in determining the
design weight of items requiring 1 person lifting with 2
hands.
Double the weight limits in Table XXIII shall be used as the
maximum values in determining the design weight of items
requiring two person lifting, provided the load is uniformly
distributed between the two lifters.
Where three or more persons are lifting simultaneously, not
more than 75 percent of the one-person value may be added
for each additional lifter, provided the object being lifted is
sufficiently larger that the lifters do not interfere with one
another while lifting.
Where it is not possible to define the height to which an
object will be lifted in operational use, the limit wherein the
object is lifted to shoulder height shall be used rather than the
more permissive bench height value.
Table XXIII. Design Weight Limits.
Male & Female
Handling Function
Population (lbs)
A. Lift an object from the floor and place it on a surface not
37
greater than 5 feet above the floor.
B. Lift an object from the floor and place it on a surface not
44
greater than 36 inches above the floor.
C. Carry an object 33 feet or less
42
5.13
Hazards and Safety
5.13.1
General
As a part of system equipment design, safety factors shall be
given major consideration, including as a minimum, the
effective application of human engineering criteria in other
sections of this standard, together with the representative
safety criteria herein.
5.13.2
Safety Labels and Placards
5.13.2.1 Warning Placards
Conspicuous placards shall be mounted adjacent to any
equipment which presents a hazard to personnel (e.g., from
high voltage, heat, toxic vapors, explosion, radiation).
5.13.2.2 Center-of-Gravity and Weight
Comments
Male Only
Population (lbs)
56
87
82
SYSTEM SAFETY CHECKLIST
Where applicable, the center of gravity and the weight of
equipment shall be distinctly marked.
5.13.2.3 Weight Capacity
The weight capacity shall be indicated on stands, hoists, lifts,
jacks, and similar weight-bearing equipment, so as to prevent
overloading.
5.13.2.4 Identification of Protective Items
Areas of operation or maintenance where special protective
clothing, tools, or equipment are necessary (e.g., insulated
shoes, gloves, suits, etc.) shall be specifically identified.
5.13.2.5 "NO-STEP" Markings
"NO-STEP" markings shall be provided when necessary to
prevent injury to personnel or damage to equipment.
5.13.2.6 Electrical Labels
All receptacles shall be marked with their voltage, phase, and
frequency characteristics, as appropriate. For other electrical
labeling and warning requirements, see MIL-STD-454.
5.13.2.7 Hand Grasp Areas
Hand grasp areas shall be conspicuously and unambiguously
identified on the equipment.
5.13.3
Pipe, Hose, and Tube Line Identification
Pipe, hose, and tube lines for liquids, gas, steam, etc. shall be
clearly and unambiguously labeled or coded as to contents,
pressure, heat, cold, or other specific hazardous properties in
accordance with MIL-STD-1247.
5.13.4
General Workspace Hazards
5.13.4.1 Alerting Devices
A hazard alerting device shall be provided to warn personnel
of impending danger or existing hazards (e.g., fire, the
presence of combustible or asphyxiating gas, radiation, etc.).
5.13.4.2 Emergency Doors and Exits
Emergency doors and exits shall be constructed so that they:
Are simple to access.
Are readily accessible.
Are unobstructed.
Are simple to locate and operate in the dark.
Are quick opening in three seconds or less.
Require 10-30 pounds of operating force to open.
Do not themselves, or in operation, constitute a safety
hazard.
SYSTEM SAFETY CHECKLIST
Permit one person egress in 5 seconds or less.
5.13.4.3 Stairs
Stairs, including incline, step risers, and treads, shall conform
with standard safe design practice.
Skid-proof flooring, stair, and step treads shall be provided.
Where conditions warrant special precaution, surfaces shall
conform with the non-slip coating requirements of MIL-W5044 and MIL-W-5050.
5.13.4.4 Obstructions
Workspace around areas where maintenance is performed
shall be free of obstructions which could cause injury to
personnel, either through accidental contact with the
obstruction or because the obstruction requires an awkward or
dangerous body position.
5.13.4.5 Illumination
Adequate illumination shall be provided in all areas.
Warning placards, stairways, and all hazardous areas shall be
illuminated, in accordance with the recommended levels of
Table XXI of MIL-STD-1472D.
5.13.4.6 Thermal Contact Hazards
Equipment which, in normal operation, exposes personnel to
surface temperatures greater or less than those shown below,
shall be appropriately guarded. Surface temperatures induces
by climatic environment are exempt from this requirement.
Cryogenic systems shall also be appropriately guarded.
Temperature Limits
Exposure
Metal
Momentary Contact
60 degrees C
Prolonged Contact
49 degrees C
Momentary Contact
0 degrees C
Prolonged Contact
0 degrees C
5.13.5
General Equipment Related Hazards
5.13.5.1 Interlocks and Alarms
The operation of switches or controls which initiate
hazardous operations (e.g., ignition, movement of crane, etc.)
shall require the prior operation of a related or locking
control.
Where practicable, the critical position of such a control shall
activate a visual or auditory warning device in the affected
work area.
5.13.5.2 Access
Glass
68 degrees C
59 degrees C
0 degrees C
0 degrees C
Plastic or Wood
85 degrees C
69 degrees C
0 degrees C
0 degrees C
SYSTEM SAFETY CHECKLIST
Units shall be so located and mounted that access to them can
be achieved without danger to personnel from electrical
charge, heat, moving parts, chemical contamination,
radiation, or other hazards.
5.13.5.3 Hazardous Access
Where access areas must be located over dangerous
mechanical or electrical components, the access door or cover
shall be designed to actuate an internal light when opened,
and a highly visible warning label shall be provided on the
outside of the door or cover.
5.13.5.4 Edge Rounding
Where applicable, all exposed edges and corners shall be
rounded to a minimum of 0.03 inches.
Sharp edges and corners that present a personal safety hazard
or potential damage to equipment during usage shall be
suitably protected or rounded to a minimum of 0.5 inches.
5.13.5.5 Safety Pins and Streamers
Safety pins and streamers shall be clearly visible and
accessible during ground maintenance.
5.13.6
Platforms
5.13.6.1 Locks
Self-locking or other fail-safe devices shall be incorporated
on elevating stands, work platforms, and "draw bridges" to
prevent accidental or inadvertent collapsing or falling.
5.13.6.2 Handrails, Safety Bars, and Chains
Handrails, safety bars, and chains shall be installed around
platforms and across stair or step openings in platforms,
ledges, catwalks, etc.
Such guards shall be placed 42 inches above the standing
surface.
An intermediate guard rail shall be provided.
Chains shall only be used where it is not feasible to install
handrails or safety bars.
Kickboards, 6 inches high, shall be installed.
5.13.6.3 Safety Mesh
Screen or safety mesh shall be installed on the underside of
open gratings, platforms, or flooring surfaces where there is a
possibility that small tools, parts, or debris may fall through
the grating on workers or equipment beneath the platform.
SYSTEM SAFETY CHECKLIST
5.13.7
Electrical, Mechanical, Fluid, Toxic, and Radiation Hazards
5.13.7.1 Electrical Hazards
5.13.7.1.1 Insulation of Tools
Tools and test leads to be used near high voltages shall be
adequately insulated.
5.13.7.1.2 Plugs and Receptacles
Plugs and receptacles shall be designed so that a plug of one
voltage rating cannot be inserted into a receptacle of another
rating.
5.13.7.1.3 Voltage Exposure
Equipment shall be designed so that all hot contacts will be
socket contacts.
5.13.7.1.4 Dangerous Voltage or Current
Guards, grounding, interlocks, and warning placards shall be
provided to minimize the possibility of exposing personnel to
dangerous voltages or currents.
5.13.7.1.5 Ground Potential
Equipment shall be designed so that all external parts, with
the exception of antenna and transmission line terminals, will
be at ground potential in accordance with Requirement 1 of
MIL-STD-454.
5.13.7.1.6 Electrically-Operated Hand Tools
Electrically operated hand-held power tools shall be designed
with three-wire power cords with one wire at ground
potential.
All exposed surfaces shall be either non-conducting or
electrically connected to the ground wire. Exposed surfaces
includes cases, grips, handles, switches, triggers, chucks, and
other surfaces which are capable of being contacted during
operation.
Portable tools, protected by an approved system of double
insulation or its equivalent, may be used without a ground
wire when approved by the procuring activity.
5.13.7.1.7 Electronic Equipment
Electronic equipment safety provisions shall be in accordance
with Requirement 1 of MIL-STD-454.
5.13.7.1.8 Vehicle Batteries
Batteries which have a rating greater than 25 amp hours shall
have terminal guarding to prevent inadvertent short-circuit.
SYSTEM SAFETY CHECKLIST
Such guarding shall also prevent short-circuiting of the
battery in spite of clearly improper but possible acts by
personnel, such as placing tools across terminals, resting a
heavy object on the battery cover, or standing on a battery
cover.
5.13.7.2 Mechanical Hazards
5.13.7.2.1 Guards
A guard shall be provided on all moving parts of machinery
and transmission equipment, including pulleys, belts, gears,
blades, etc., on which personnel may become injured or
entangled.
5.13.7.2.2 Telescoping Ladders
Adequate finger clearance shall be provided between rungs of
telescoping ladders.
5.13.7.3 Fluid Hazards
5.13.7.3.1 Connectors
Each connector utilized in handling or control of hazardous
fluids, including propellants, solvents, toxics, hypergolics,
asphyxiants, etc., shall be incompatible with other connectors
within the access area of that connector.
5.13.7.3.2 Fluid and Fuel Servicing Equipment
Automatic shut-off devices shall be provided on fluid and fuel
service equipment to prevent overflow and spillage.
5.13.7.4 Toxic Hazards
5.13.7.4.1 General
Personnel shall not be exposed to the concentrations of toxic
substances in excess of the limits specified in either the DOD
Occupational Safety and Health (OSH) standards or
specialized standards applicable to military unique
equipment, systems, or operations.
5.13.7.4.2 Carbon Monoxide
Carbon monoxide in personnel areas shall be reduced to the
lowest level feasible.
Personnel shall not be exposed to concentrations of carbon
monoxide (CO) in excess of values which will result in
carboxyhemoglobin (COHb) levels in their blood greater than
the following percentages (Note: see MIL-STD-1472D for
methods in estimating COHb blood levels):
5% COHb (all system design objectives and aviation
system performance limits).
10% COHb (all other system performance limits).
SYSTEM SAFETY CHECKLIST
5.13.7.5 Radiation
Ionizing radiation exposure rates produced by any device
shall not exceed 0.5 milliroentgens/hour at a distance of 2
inches from any point on the external surface.
Microwave, radio frequency, X, and laser radiation limits
shall conform to those specified in Requirement 1, MIL-STD454