ES&H Manual



6680 Appendix T1

Lead Work Requirements



Jefferson Lab has determined that working with lead carries an unmitigated Risk Code >2. At a minimum, all tasks requiring lead are discussed with the supervisor prior to beginning. An Operational Safety Procedure (OSP) is written for any work considered to be Risk Code >2 in accordance with ES&H Manual Chapter 3210 Work Planning, Control, and Authorization Process.


1.0           Purpose


This appendix provides Jefferson Lab’s minimum requirements when working with lead including: pre-work planning and actual work activities (e.g.: movement of lead bricks, machining, soldering, welding, and lead based paint abatement).


2.0           Scope


This procedure defines additional mitigation measures for activities involving lead, over and above standard protecting measures. The process steps for this procedure coordinate with ES&H Manual Chapter 6680 Lead Handling Program.


3.0           Responsibilities

Note:   Management authority may be delegated to a task-qualified TJNAF employee at the discretion of the responsible manager.


3.1            Qualified Lead Worker

·       Complete and maintain appropriate training (SAF 136 Lead Worker Training, or equivalent) and medical monitoring requirements. Lead worker training must be repeated on an annual basis when a workers lead exposure has been determined to be at or above the Action Level of 0.3 mg/m3, this is determined through Industrial Hygiene air monitoring.

·       Ensure pre-work planning is adequate. Request a hazard evaluation if lead exposure is considered to be an issue.

·       Perform work activities within the hazard controls.


3.2            Supervisor, Technical Representative (TR) and Sponsors

·       Assign only Qualified Lead Workers to lead work.


3.3            Industrial Hygiene

·       Perform lead work/area hazard evaluation and determine required mitigation.


4.0           Process Steps


Unless otherwise stated, only Qualified Lead Workers may perform the process steps outlined below.


4.1            Pre-Work Planning


When working with lead, associated hazard issues should be taken into consideration (i.e. heavy lifting) due to the weight of the material.


Step 1:          Review the associated safety data sheet (SDS), if available.


Step 2:          Ensure the work plan abides by the SDS requirements and mitigates the hazards adequately. 


Step 3:          Request a hazard evaluation from Industrial Hygiene if monitoring, respirator, or other mitigation is recommended but is not called out in the work plan. (Equivalent or superior methods may already be in-place.)


4.2            Work Activities


The following activities (or similar) are prohibited when working with:  

·       Eating or chewing

·       Drinking

·       Using tobacco products

·       Applying cosmetics or lotions

Do not take these items into areas where lead is handled or stored. 


Thoroughly wash all exposed skin surfaces (e.g.: hands, face, arms) with soap and warm water prior to partaking in any of these activities.


4.2.1       Movement of Lead Brick(s) and Sheeting


NOTE: Contact Industrial Hygiene to perform a hazard evaluation regarding appropriate / adequate options for the following situations.


1.     Movement of uncoated bricks. 


2.     When airborne exposure to lead is above the Permissible Exposure Limits[1] (PEL) (whether or not a respirator is worn) a changing area, equipped with a separate storage facilities to protect street clothes from cross-contamination, is required.


·       Less than or equal to (<) 10 Bricks

o   Don appropriate PPE – See ES&H Manual Chapter 6680 Appendix T2 Lead Handling Personal Protective Equipment (PPE) and Other Related Personal Protective Measures

o   Clean-Up – See ES&H Manual Chapter 6680 Appendix T4 Lead Clean-Up, Disposal, and Recycle Procedures


·       Greater than (>) 10 Bricks

o   Same requirements as <10 above and

o   “Lead-only” HEPA Vacuum obtained from Industrial Hygiene.

o   Respiratory Protection, in accordance with Industrial Hygiene hazard evaluation – See ES&H Manual Chapter 6630 Respiratory Protection Program.

o   Air Monitoring – Contact Industrial Hygiene for a determination.

o   Lead shielding that has been mixed with heavily oxidized unpainted shielding must be wet-wiped after HEPA vacuuming to further reduce lead being distributed into the air. Contact IH for evaluation. 


·       Less than or equal to (<) 12-inch Square Sheeting (for greater amounts see Industrial Hygiene)

o   Don appropriate PPE – See ES&H Manual Chapter 6680 Appendix T2 Lead Handling Personal Protective Equipment (PPE) and Other Related Personal Protective Measures

o   Pre-Work Wet-Wipe – In accordance with instructions provided by Industrial Hygiene.


4.2.2       Machining


Jefferson Lab has determined that machining of lead carries an unmitigated Risk Code >2 because it results in the generation of dust, and particulates. An Operational Safety Procedure (OSP), minimally reviewed by Industrial Hygiene and approved by the Supervisor, is required to ensure appropriate mitigation for this type of work. 


Step 1:          Develop an OSP per ES&H Manual Chapter 3310 Operational Safety Procedure Program and include:

·       Minimum PPE requirements.

·       Ventilation – HEPA filters required obtained from Industrial Hygiene.

·       Air monitoring.

·       Isolation of the work (minimally cordoned-off).

·       Required hazard postings.

·       Post-work decontamination procedure.


Step 2:          Abide by the requirements of the OSP when performing the work.


4.2.3       Soldering[2]


·       Don appropriate PPE – See ES&H Manual Chapter 6680 Appendix T2 Lead Handling Personal Protective Equipment (PPE) and Other Related Personal Protective Measures.

·       Work in a Well-Ventilated Area – Avoid breathing in smoke or fumes generated during work. Request a hazard evaluation from Industrial Hygiene to ensure ventilation is adequate.

·       Clean Soldering Benches and Work Surfaces (after use or weekly, whichever comes first). See ES&H Manual Chapter 6680 Appendix T4 Lead Clean-Up and Disposal Procedures.

·       Wash Hands with soap and water upon completion of work. 


4.2.4       Welding


Lead welding is not authorized at Jefferson Lab.


4.2.5       Lead-Base Paint Abatement - Lead abatement activities are only authorized to be performed on behalf of Jefferson Lab by an individual, licensed by the State of Virginia. Proof of licensing must be submitted to Industrial Hygiene prior to commencement of work.


Jefferson Lab considers lead-based paint abatement activities to be a modification to existing facility and requires a Facility Design or Modification Review. See ES&H Manual Chapter 3110 Facility Design and Modification Review. 


5.0           Revision Summary


Revision 1.6 – 10/28/2022 – changed SOTR to TR; updated 3.0 Note; updated footnote; changed review cycle to 1 year

Revision 1.5 – 06/08/2020 – Periodic Review; no significant changes made.

Revision 1.4 – 07/31/19 – Updated minor typos per CATS#STR-2018-15-01-02

Revision 1.3 – 06/09/17 – Updated Qualified Lead Worker responsibilities per TPOC

Revision 1.2 – 06/16/16 – Replaced Material Safety Data Sheets (MSDS) with Safety Data Sheets (SDS)

Revision 1.1 – 05/21/15 – Periodic Review; added bullet under 4.2.1 to address movement of lead shielding that has been mixed with heavily oxidized unpainted shielding

Revision 1.0 – 02/02/12 – Updated to reflect current laboratory operations












ES&H Division

Jennifer Williams



1 year



This document is controlled as an on-line file.  It may be printed but the print copy is not a controlled document.  It is the user’s responsibility to ensure that the document is the same revision as the current on line file.  This copy was printed on 10/28/2022.

[1] PEL <0.05mg per cubic meter of air averaged over an 8-hour period (see (see OSHA 1910.1025 - Lead)

[2] Jefferson Lab does not authorize the use of lead-bearing solder for plumbing systems.  This includes domestic water supplies or waste water systems.