Coke oven emissions scope

The standard applies to controlling employee exposure to coke oven emissions at workplaces where coke is produced, except where another federal agency has statutory authority to set occupational safety and health standards. See 1910.1029(a).

• This means employers operating coke ovens (retorts) or coke oven batteries must follow the rule unless a different federal agency explicitly governs those working conditions.

Coke oven emissions are defined as the benzene-soluble fraction of total particulate matter present during the carbonization of coal for coke production, and monitoring and controls must target this fraction. See the definition in 1910.1029(b).

• Because the standard focuses on the benzene-soluble fraction, sampling and analytical methods should capture that specific metric when determining exposures against the PEL.

The permissible exposure limit (PEL) is 150 micrograms per cubic meter of air (150 µg/m3), averaged over any 8-hour period. See 1910.1029(c).

• Employers must ensure employee exposures measured over full 8-hour work periods do not exceed 150 µg/m3.

Employers must establish regulated areas and limit access to authorized persons; specifically the coke oven battery (topside, pushside, cokeside, battery ends), the wharf, the screening station, and beehive ovens and their machinery are designated regulated areas. See 1910.1029(d)(1) and 1910.1029(d)(2)(i)-(ii).

• Keep these areas posted or otherwise controlled so only authorized persons (as defined) enter them.

An 'authorized person' is anyone specifically authorized by the employer because their duties require entry into a regulated area or an employee-designated representative observing monitoring procedures under paragraph (n). See the definition in 1910.1029(b) and the regulated area requirement in 1910.1029(d)(1).

• Employers should document who is authorized and why, and limit access accordingly.

Every employer with coke oven emissions present must monitor employees who work in regulated areas and obtain measurements that are representative of each employee's 8-hour exposure without regard to respiratory protection. See 1910.1029(e)(1)(i)-(ii).

• Measurements must be personal and reflect the full work shift so that the employer can determine compliance with the 8-hour PEL.

Employers must collect full-shift personal samples for at least one worker per shift per battery in specified job classifications, including lidman, tar chaser, larry car operator, luterman, coke side machine operator, benchmen (coke and pusher sides), heater, quenching car operator, pusher machine operator, screening station operator, wharfman, oven patcher, oven repairman, spellman, and maintenance personnel. See the list in 1910.1029(e)(1)(iii)(a)-(p).

• This ensures representative sampling across the full range of higher-risk tasks and job categories.

Employers must repeat the monitoring and measurements required by paragraph (e)(1) at least every three months. See 1910.1029(e)(1)(iv).

• If exposures are stable and below action levels, quarterly monitoring is still the statutory minimum unless other provisions (like redetermination) apply.

Employers must repeat monitoring whenever a production, process, or control change may increase exposures, or whenever they suspect exposure has increased; they must notify affected employees of monitoring results within 15 working days after receiving them, and if the PEL is exceeded the notification must state that fact and list corrective actions. See 1910.1029(e)(2) and 1910.1029(e)(3)(i)-(ii).

• Notifications may be individual written notices or posted where employees have access; include corrective measures when results exceed the PEL.

Monitoring methods must have an accuracy (95% confidence level) of ±35% or better for coke oven emissions at concentrations greater than or equal to 150 µg/m3. See 1910.1029(e)(4).

• Employers should verify the sampling and analytical method’s performance meets this accuracy before relying on results for compliance decisions.

No — measurements must determine employee exposure without regard to the use of respiratory protection, so monitoring should reflect actual airborne concentrations employees would experience unprotected. See 1910.1029(e)(1)(ii).

• This ensures the employer evaluates engineering and work-practice controls for effectiveness independent of respirator use.

For existing coke oven batteries, employers must institute the engineering and work practice controls listed in paragraphs (f)(2), (f)(3), and (f)(4) as soon as possible but no later than January 20, 1980, unless the employer can demonstrate those controls are not feasible. See 1910.1029(f)(1)(i)(a).

• Employers must document feasibility determinations and prioritize implementing feasible controls promptly.

Employers must institute the best available engineering and work practice controls on all new or rehabilitated coke oven batteries to reduce and maintain exposures at or below the PEL, except where the employer demonstrates those controls are not feasible. See 1910.1029(f)(1)(ii)(a)-(b).

• If exposures still exceed the PEL after applying required controls, employers must implement any additional feasible controls necessary to reach compliance.

Employers must institute engineering and work practice controls on all beehive ovens at the earliest possible time to reduce and maintain exposures at or below the PEL, unless they demonstrate those controls are not feasible. See 1910.1029(f)(1)(iii)(a).

• The rule treats beehive ovens similarly to other batteries for the purpose of implementing controls and reducing exposures.

If exposures still exceed the PEL after implementing the controls in paragraphs (f)(2)-(f)(4) or after January 20, 1980, whichever is sooner, the employer must implement any other engineering and work practice controls necessary to reduce exposure to or below the PEL, unless the employer can demonstrate such controls are not feasible. See 1910.1029(f)(1)(i)(b).

• Where controls cannot reduce exposures to the PEL, employers must still use all feasible controls to lower exposure as much as possible and supplement them with respirators per paragraph (g).

Respiratory protection must supplement engineering and work practice controls when those controls cannot reduce employee exposures to or below the PEL; employers must ensure respirators comply with the requirements of paragraph (g). See 1910.1029(f) and 1910.1029(g).

• Employers must implement a respirator program consistent with paragraph (g) (selection, fit testing, maintenance, and training) when respirators are used to control exposures.

When monitoring indicates the representative employee exposure exceeds the PEL, employers must notify affected employees within 15 working days and inform them that the exposure exceeded the PEL and describe the corrective action being taken to reduce exposure. See 1910.1029(e)(3)(i)-(ii).

• The notification can be written to individuals or posted where employees have access; be clear about actions and timelines for reducing exposure.

Yes — maintenance personnel are explicitly listed as a job classification requiring at least one full-shift personal sample for each shift and each battery, so employers should collect representative full-shift samples that reflect maintenance tasks in each battery where they work. See 1910.1029(e)(1)(iii)(p).

• If maintenance workers rotate across batteries, employers should ensure sampling captures the exposures typical for the tasks and locations performed during a full shift.

A beehive oven is defined as a coke oven in which products of carbonization other than coke are not recovered but are released to the ambient air; beehive ovens are specifically included among regulated areas and control requirements. See the definition in 1910.1029(b) and the regulated area listing in 1910.1029(d)(2)(ii).

• Because beehive ovens release the carbonization products directly to air, employers operating them must follow the monitoring and control provisions applicable to regulated areas.

Employers should use sampling and analytical methods validated to provide an accuracy of ±35% (95% confidence) or better at concentrations ≥150 µg/m3 and maintain documentation that the chosen method meets that performance standard. See 1910.1029(e)(4).

• Consult method validation data from the laboratory or method developer and keep records showing the method’s accuracy and suitability for coke oven emissions.

The employer must first implement all feasible engineering and work practice controls to reduce exposures to the lowest achievable level and then supplement those controls with respiratory protection that meets paragraph (g) when exposures still exceed the PEL. See 1910.1029(f) and 1910.1029(g).

• Selection should follow a hierarchy: implement feasible engineering/work-practice changes first, and where they are insufficient, institute a written respirator program (fit testing, selection, maintenance, training) as required.

Employers must use one of the charging methods listed in 1910.1029(f)(2)(i)(a). 1910.1029(f)(2)(i)(a) requires stage charging, sequential charging, or pipeline/enclosed charging as described in the standard.

• Stage charging and sequential charging are described in 1910.1029(f)(3)(i)(b).
• Pipeline or other enclosed charging must comply with the specific enclosed-charging requirements in paragraph (f)(2)(i) except for selected subparagraphs noted in the standard.

Cite: 1910.1029(f)(2)(i)(a).

Drafting from two or more points means removing evolved gases from the oven being charged through multiple collection points such as double collector mains or jumper pipe systems to another oven. 1910.1029(f)(2)(i)(b) requires this to effectively move gases from the oven into the collector mains during charging operations.

• This control is part of the required engineering controls for charging existing coke oven batteries and is intended to minimize fugitive emissions during charging.

Cite: 1910.1029(f)(2)(i)(b).

An aspiration system must provide enough negative pressure and flow to move gases evolved during charging into the collector mains. 1910.1029(f)(2)(i)(c) requires sufficient steam pressure and steam jets of adequate diameter as part of that system.

• Employers must inspect and maintain the aspiration system so it delivers the required pressure and volume before each charge as detailed in the work-practice provisions in 1910.1029(f)(3)(i)(a)(4).

Cite: 1910.1029(f)(2)(i)(c) and 1910.1029(f)(3)(i)(a)(4).

Mechanical volumetric controls are devices on each larry car hopper that meter the amount of coal charged through each hole to maintain the gas passage (tunnel head) needed for gas flow to collector mains. 1910.1029(f)(2)(i)(d) requires these controls to ensure proper gas movement and reduce emissions during charging.

• The work-practice charging procedure in 1910.1029(f)(3)(i)(b)(1) ties into this by requiring larry car hoppers be filled to predetermined levels consistent with these volumetric controls.

Cite: 1910.1029(f)(2)(i)(d) and 1910.1029(f)(3)(i)(b)(1).

Employers must use devices like stainless steel liners, coal vibrators, or pneumatic shells to facilitate rapid, continuous coal flow into the oven being charged. 1910.1029(f)(2)(i)(e) requires these to maintain proper gas channels and minimize emissions.

• These devices reduce obstruction and help maintain the tunnel head so aspiration systems can move gases efficiently into the collector mains.

Cite: 1910.1029(f)(2)(i)(e).

Larry car drop sleeves and slide gates must be individually operable and maintained so gases are effectively removed into the collector mains. 1910.1029(f)(2)(i)(f) requires proper design and upkeep to prevent leakage during charging.

• Regular inspection and prompt repair are part of the maintenance duties spelled out in 1910.1029(f)(3)(iv)(a).

Cite: 1910.1029(f)(2)(i)(f) and 1910.1029(f)(3)(iv)(a).

Mechanized gooseneck and standpipe cleaners are required to remove blockages and carbon deposits so gases can flow from the oven to the collector mains. 1910.1029(f)(2)(i)(g) lists mechanized cleaners as an engineering control for charging operations.

• The work-practice requirements in 1910.1029(f)(3)(i)(a)(2) reinforce cleaning goosenecks and standpipes prior to each charge.

Cite: 1910.1029(f)(2)(i)(g) and 1910.1029(f)(3)(i)(a)(2).

Air seals on pusher machine leveler bars are required to control air infiltration during charging and reduce topside emissions. 1910.1029(f)(2)(i)(h) lists air seals as an engineering control for charging operations.

• Maintaining these seals is part of the regular inspection and repair requirements in 1910.1029(f)(3)(iv)(a).

Cite: 1910.1029(f)(2)(i)(h) and 1910.1029(f)(3)(iv)(a).

Roof carbon cutters or a compressed air system (or both) are required on pusher machine rams to remove roof carbon deposits. 1910.1029(f)(2)(i)(i) specifies this as an engineering control to maintain gas channels and reduce emissions.

• Inspecting for roof carbon build-up prior to each charge and removing it as necessary is also mandated in 1910.1029(f)(3)(i)(a)(3).

Cite: 1910.1029(f)(2)(i)(i) and 1910.1029(f)(3)(i)(a)(3).

A written inspection and cleaning procedure must include prompt repair or replacement of controls, cleaning and inspection of goosenecks/standpipes, roof carbon inspections and removal, aspiration system checks, nozzle and spray cleaning, standpipe cap inspection/cleaning/luting, and inspection of charging holes and lids. 1910.1029(f)(3)(i)(a) lists these required elements.

• The standard calls for these actions prior to each charge to ensure effective gas flow and seal integrity.

Cite: 1910.1029(f)(3)(i)(a).

Charging must follow the written sequence in 1910.1029(f)(3)(i)(b)(3): turn on the aspiration system, charge through outermost hoppers first, relid or seal those charging holes, follow the specified hopper relidding steps (including the special step if four hoppers are used), level coal after opening the chuck door, relid the charging hole, and turn off aspiration only after all charging holes are closed. 1910.1029(f)(3)(i)(b)(3) lays out this sequence.

• Employers must also ensure larry car alignment and hopper filling per 1910.1029(f)(3)(i)(b)(1)-(2).

Cite: 1910.1029(f)(3)(i)(b)(3) and 1910.1029(f)(3)(i)(b)(1)-(2).

If four hoppers are used, the standard requires that the third hopper be discharged and then relidded or sealed to prevent leakage before proceeding. 1910.1029(f)(3)(i)(b)(3)(iv) specifies this step to control emissions during multi-hopper charges.

• This is part of the sequential steps designed to keep a continuous gas channel and minimize topside emissions.

Cite: 1910.1029(f)(3)(i)(b)(3)(iv).

A written coking procedure must include checking oven back pressure controls, prompt repair and replacement of doors and jambs for metal-to-metal fit, cleaning of doors each coking cycle, an inspection and corrective action program to control door emissions, and luting of doors each cycle as needed. 1910.1029(f)(3)(ii)(a)-(e) lists these elements.

• Spare doors and ready repair facilities are required as engineering supports in 1910.1029(f)(2)(ii)(b)-(c).

Cite: 1910.1029(f)(3)(ii) and 1910.1029(f)(2)(ii)(b)-(c).

Employers must quench coke and coal spillage as soon as practicable and not shovel it into heated ovens, and implement a written pushing procedure that includes dampering off ovens/removal of charging hole lids, uniform heating of the charge to prevent green pushes, prevention of green pushes to the maximum extent possible, weekly inspection/adjustment of heating flues and cleaning to prevent green pushes. 1910.1029(f)(3)(iii)(a)-(b)(1)-(5) describe these requirements.

• Preventing and responding to green pushes is emphasized with inspection and maintenance obligations.

Cite: 1910.1029(f)(3)(iii).

Employers must implement a detailed written maintenance and repair procedure that includes regular inspection of controls (goosenecks, standpipes, lids, jumper pipes, air seals), keeping the regulated area free of spillage, inspecting damper/aspiration/collector mains, inspecting heating systems, preventing miscellaneous fugitive emissions, patching brickwork, maintaining equipment in good order, repairing doors and seals, and instituting prompt temporary or permanent repairs as necessary. 1910.1029(f)(3)(iv)(a)-(i)(2) lists these elements.

• Temporary repairs (like chuck door gaskets) must be installed prior to the next coking cycle when needed per 1910.1029(f)(3)(iv)(i)(2).

Cite: 1910.1029(f)(3)(iv).

Employers must provide positive-pressure, temperature-controlled filtered air to larry car, pusher machine, door machine, and quench car cabs, and also provide standby pulpits on the battery topside, wharf, and screening station equipped with such filtered air. 1910.1029(f)(4)(i)-(ii) requires these measures to protect operators from coke oven emissions.

• These engineering controls are mandatory for existing batteries during their operations.

Cite: 1910.1029(f)(4)(i)-(ii).

After an emergency, the next coking cycle may not begin until the cause is determined and corrected unless the employer can establish that starting the next cycle is necessary to determine the cause. 1910.1029(f)(5) sets this requirement to prevent further emissions or unsafe conditions.

• Employers must document and correct the root cause before resuming normal coking operations unless immediate continuation is justified to find the cause.

Cite: 1910.1029(f)(5).

Each employer must establish and implement a written program to reduce exposures using only the engineering and work-practice controls required in paragraph (f). 1910.1029(f)(6)(i) requires employers to document how they will meet the standard's control requirements.

• That program must describe how controls will be implemented battery by battery and include the items listed in 1910.1029(f)(6)(ii).

Cite: 1910.1029(f)(6)(i) and 1910.1029(f)(6)(ii).

The written program must include a description of each coke oven operation by battery (workforce, coking time, procedures, maintenance), engineering plans/studies used to select controls, a report of technologies considered to meet the PEL, monitoring data obtained under paragraph (e), a detailed implementation schedule for controls, and other relevant information. 1910.1029(f)(6)(ii)(a)-(f) lists these minimum elements.

• Monitoring data referenced must follow the air monitoring requirements in 1910.1029(e).

Cite: 1910.1029(f)(6)(ii) and 1910.1029(e).

Employers must implement all required engineering and work-practice controls, and if exposures still exceed the PEL or controls cannot reduce exposures to the PEL, they must use respiratory protection to supplement those controls. 1910.1029(f)(1)(iii)(b) states respirators are required when feasible controls cannot lower exposures to the permissible limit.

• Even when respirators are used, employers must still reduce exposures to the lowest achievable level through available controls.

Cite: 1910.1029(f)(1)(iii)(b).

The employer must develop a detailed written program and schedule for additional engineering controls and work practices, and make the written plan available and update it at least annually. See 1910.1029(f)(6)(iii) and 1910.1029(f)(6)(iv).

• The plan must describe the additional engineering controls and work-practice changes necessary to reduce exposure to or below the permissible exposure limit (PEL).
• The written plans must be submitted to the Secretary and the Director upon request and kept at the worksite for examination and copying.
• The plans must be revised and updated at least annually to reflect the current status of the program. 1910.1029(f)(6)(iv).

Respirators must be used whenever engineering and work-practice controls are not feasible, are not yet sufficient to reduce exposures to the PEL, during installation of controls, for certain maintenance/repair tasks, and for emergencies; and the employer must implement a respiratory protection program meeting 1910.134 requirements. See 1910.1029(g)(1) and 1910.1029(g)(2).

• Specific situations requiring respirators include periods necessary to install controls, maintenance/repair where engineering controls aren’t feasible, operations where controls don’t yet bring exposure below the PEL, and emergencies. 1910.1029(g)(1).
• The employer must implement a written respiratory protection program in accordance with 1910.134(b)–(d) and (f)–(m) as required by 1910.1029(g)(2).
• Respirator selection must match the exposures and be consistent with the selection rules in [1910.134]. 1910.1029(g)(2).

A filtering facepiece respirator may be used only when it functions as a filter respirator for coke oven emissions particulates and when the selection and program requirements of 1910.134 are met. See 1910.1029(g)(3) and 1910.134.

• Employers must select respirators appropriate to the hazard and follow the medical evaluation, fit testing, training, and program provisions in 1910.134(b)–(d) and (f)–(m).
• Filtering facepieces are allowed only for particulates from coke oven emissions and only if they provide adequate protection in the employer’s hazard assessment and respiratory protection program. 1910.1029(g)(3).

The employer must provide specified protective clothing and equipment (flame‑resistant jacket and pants, flame‑resistant gloves, face shields or vented goggles, insulated footwear, safety shoes, protective helmets) and must supply, clean/replace, repair and store that clothing as required. See 1910.1029(h)(1) and 1910.1029(h)(2).

• Required items include a flame‑resistant jacket and pants, flame‑resistant gloves, face shields or vented goggles meeting 1910.133(a)(2), insulated footwear from hot surfaces, safety shoes meeting 1910.136, and protective helmets meeting 1910.135. 1910.1029(h)(1).
• Employers must provide flame‑resistant jacket and pants and gloves in a clean, dry condition at least weekly and must clean, launder or dispose of them as necessary; repair or replace to maintain effectiveness. 1910.1029(h)(2)(i)–(iii).
• Contaminated clothing must be removed only in the required change rooms and placed in a closable container for cleaning or disposal. 1910.1029(h)(2)(iv)–(v).
• For helmet specifics and employer hazard assessment responsibilities, see OSHA’s Letter of Interpretation on head protection: https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2.

The employer must inform the laundry or cleaner of the potentially harmful effects of exposure to coke oven emissions and include coke oven emissions in the employer’s Hazard Communication program. See 1910.1029(h)(2)(vi) and 1910.1029(l)(1).

• Notify the laundry in writing (or other effective communication) about hazards and any special handling, storage, or containment needed so workers who handle the clothing are protected. 1910.1029(h)(2)(vi).
• Include coke oven emissions in your Hazard Communication program and make applicable safety data and labeling available to the laundry per 1910.1200 and 1910.1029(l)(1).

In the regulated area employees may not have or consume food, apply cosmetics, or use smoking products, but drinking water is allowed; employers must provide lunchrooms with temperature‑controlled, positive‑pressure, filtered air and make them readily accessible. See 1910.1029(i)(5) and 1910.1029(i)(3).

• Food, beverages, smoking products, and cosmetics are prohibited in the regulated area; these activities may occur only in the designated lunchrooms, change rooms, or showers. 1910.1029(i)(5)(i).
• Drinking water may be consumed in the regulated area. 1910.1029(i)(5)(ii).
• Lunchrooms must have a temperature‑controlled, positive‑pressure, filtered air supply and be readily accessible to employees working in the regulated area. 1910.1029(i)(3).

Employers must provide medical surveillance at no cost for any employee who works in a regulated area at least 30 days per year, including initial exams with specific elements and periodic exams at least annually (with expanded annual requirements for employees 45 or older or with ≥5 years in the regulated area). See 1910.1029(j)(1), 1910.1029(j)(2), and 1910.1029(j)(3).

• Covered employees: anyone employed in a regulated area at least 30 days per year. 1910.1029(j)(1)(i).
• Initial exam elements include work/medical history (including smoking), chest X‑ray, pulmonary function tests (FVC and FEV1.0), weight, skin exam, urinalysis, and urinary cytology. 1910.1029(j)(2)(i)–(vii).
• Periodic exams: at least annually provide specified elements (medical history, pulmonary function tests, skin exam, urinalysis, etc.); employees ≥45 years old or with ≥5 years in a regulated area require expanded annual exams including urinary cytology. 1910.1029(j)(3)(i)–(iii).
• All exams must be by or under the supervision of a licensed physician and provided without cost to the employee. 1910.1029(j)(1)(iv).

The employer must train each employee who works in a regulated area at least annually on the hazards, medical surveillance, respirator use, written procedures/schedules, and the substance information sheet; the employer must also make the standard and appendices readily available. See 1910.1029(k)(1)(iv) and 1910.1029(k)(2).

• Required training topics include the information in the substance information sheet (Appendix A), the purpose/proper use/limitations of respirators required under 1910.1029(g), the purpose and description of the medical surveillance program, a review of all written procedures and schedules required under 1910.1029(f), and a review of the standard. 1910.1029(k)(1)(iv)(a)–(e).
• Training must be provided at least annually for employees in the regulated area, and the employer must make a copy of the standard and its appendices readily available to those employees. 1910.1029(k)(1)(i) and 1910.1029(k)(2)(i).

Yes; employees working in the regulated area must shower at the end of the work shift and the employer must provide shower facilities in accordance with [1910.141(d)(3)]. See 1910.1029(i)(2)(i) and 1910.1029(i)(2)(ii).

• Employers must assure that regulated‑area employees shower at the end of the shift. 1910.1029(i)(2)(i).
• Shower facilities must comply with the sanitary standards in 1910.141(d)(3) to ensure adequate hygiene and prevent off‑site contamination.