hsemanual

Safety Health & Environment Manualfor

Construction Site

Larsen & Toubro LimitedE & C Division

LARSEN & TOUBRO LIMITED

E & C DIVISION

SAFETY, HEALTH AND ENVIRONMENTMANUAL FOR CONSTRUCTION SITE

E & C Division SHE Manual

Contents 1

Contents

Part I: SHE - Administration• Foreword

1. Introduction

2. SHE Policy

3. SHE organisation and Management

3.1. Management Commitment

3.1.1. Site commitment

3.2. SHE Organisation

3.2.1. Safety Control - Organisation Chart

3.2.2. Site Safety Organisation Chart

3.2.3. Duties and Responsibilities

3.2.3.1. Management

3.2.3.2. Safety Control Department

3.2.3.3. Resident Construction Manager

3.2.3.4. Site Engineer

3.2.3.5. Site Safety Officer

3.2.4. Returns

3.2.4.1. Site Opening / Closing Report

3.2.4.2. Monthly Reports

3.2.4.2.1. Monthly statistics report

3.2.5. Positive Reporting

3.2.5.1. Format

3.2.6. Daily Log – Book

3.2.6.1. Format

3.2.7. Safety Promotion and Recognition

3.2.7.1 Display Board of Safety Performance

3.2.7.2 Recognition

3.3. Statutory Requirements

3.4. Pre qualification for Selection and Performance of Contractors –

for L & T work.


Contents 2

3.4.1. Basic Requirements for Contractors

3.4.2. Rules governing contractor’s work

3.4.3. Safety in Contractor’s work

3.5. Safety Committee

3.6. Construction Safety Plan

3.7. Accident reporting and Investigation

3.8. SHE Audits

3.9. SHE Training

3.9.1. Tool Box Talks

3.9.2. Training at Site

3.10. Permit to work System

3.11. Safety of L&T Site Visitors

Part II: SHE - Implementation

4. Concept of Accident Prevention

5. Site Planning

5.1. Site layout

5.2. Construction details

5.3. In-built safety measures

5.4. Housekeeping

5.5. Safety at stores

6. Civil Work:

6.1 Blasting

6.2 Excavation

6.3 Piling

6.4 Working at heights

6.4.1 Ramps and Runs

6.4.2 Ladders

6.4.3 Scaffoldings

6.5 Demolition

6.6 Carpentry Workshop

6.7 Grinding Operation


Contents 3

7. Mechanical Works

7.1 Manual Handling

7.1.1 Winch

7.1.2 Reeving

7.1.3 Rigging Procedure and Precautions

7.1.4 Test Certificates

7.1.5 Operators & Banksman

7.1.6 Safe working load for men and women.

7.2 Crane Safety

7.3 Erection of Structures

7.4 Use, Care and Maintenance of Slings

7.4.1 Synthetic Ropes / Slings

7.4.2 Wire Ropes

7.4.3 Lifting Gears – Hooks, Shackles etc

7.5 Hoists

7.6 Other mobile machinery and their movement at the site

8. Critical Jobs:

8.1 Work over water

8.2 Confined Space

9 Welding and Gas Cutting

10 Health and Hygiene

10.1 Work Environment

10.1.1 Noise and Vibration

10.1.2 Lighting

10.1.3 Ventilation ( Heat Stress )

10.2 Personal Protective Equipment


Contents 4

11 Occupational Health Center and First Aid

12 Electrical Safety

13 Non Destructive Testing

13.1 Radiography

14 Abrasive blasting and spray painting

15 Hand tools and power tools

16. Handling of chemicals / hazardous substances

16.1. Handling and Storage of Chemicals

16.2. Material Safety Data Sheet ( MSDS )

17. Fire prevention

18. Onsite emergency preparedness plan

Part III: Commissioning of plant

Part IV: Environment protection

Environment Management (Construction)

F O R E W O R D

On behalf of Safety Control Department I am pleased to issue this(SHE) Safety, Health and Environment manual to E&C division. Thismanual will serve as a ready reference for methods and procedures tobe followed in Safety, Health & Environment by those who areengaged in construction activity.

This four-section manual contains information based on the mostcurrent knowledge and practices with the SHE (Safety Health &environment) much of this information based on practice and researchand will remain relevant during the next decade. However changes arebound to occur that will require Site managers to find innovativesolutions to SHE problems on the job.

The need for a SHE manual for those engaged in or concerned withconstruction activity was recognized during the activities of BusinessSpecific initiatives for safety Assurance by the senior management.

I appreciate the assistance given by D.Venugopal our consultant, allteam members of safety assurance team and my colleagues in thepreparation of the text of the manual.

I hope, By following safe methods and procedures in construction letus all in L & T E & C division make Safety - A way of life.

J.B.DesaiDy.General ManagerSafety Control. E & C Div.


Introduction 1

1. Introduction

1.1.1 This Safety, Health and Environment Management Manual hasbeen developed for Projects under construction in E&C Divisionto ensure compliance of the Safety, Health & Environmentrequirements during project construction.

1.1.2 This Safety, Health and Environment Management Manualincludes the procedures, responsibilities and safe practicesrequired to be followed at project site by all personnel involvedin the project, including crews and representatives ofContractors.

1.1.3 This Safety, Health and Environment Management Manual shallbe followed while carrying out activities at project site and thismanual supersedes any other document on these subjects.

LARSEN & TOUBRO LIMITEDEngineering & Construction Division

CORPORATE POLICY

1. To Engineer and Execute projects with consistent quality, cost and delivery in line withthe requirements of our customers, and to exceed or meet their expectations, whilstenhancing our shareholder value.

2. To set and review quality objectives for Continual Improvement of our products and services,

whilst implementing the globally recognised management systems for Quality, Safety,

Environment and Information Technology, and integrating these systems with our business

partners and customers.

3. To design / operate and maintain safe and environmentally friendly plants which meet allapplicable statutory and regulatory requirements.

4. To advance / ensure the use of better and cleaner technology to minimise adverseenvironmental impacts.

5. To continually reduce the risk of pollution through setting environmental objectives inour design / operation and maintenance processes, based on the feedback.

6. To deploy Information Technology for increasing the efficiencies of our businessprocesses, while ensuring its security by protecting information as valuable assets andensure availability, integrity and confidentiality of all information.

7. To comply with all applicable occupational Health & Safety legislation and continuallyimprove safe working practices through setting health and safety objectives andensure good health, safety and security of all our people, our biggest asset.

8. To encourage enthusiasm, innovation and empowerment whilst developing inspiringleaders to make working at L&T a rich experience and create new global benchmarks inwhatever we do.

9. To promote a culture of mutual trust, caring and sharing achievements, with our people,our society, our stakeholders and our customers for the growth and benefit of ourNation.

10. As an undisputed leader in the Indian context, we continue to make things that makeIndia proud, and shall strive to be amongst the globally outstanding companies, whichthe World is proud of.

__________________________Date: 3rd May, 2000 K. VENKATARAMANAN

(Member of the Board & Sr. VP)


SHE Organisation & Management 1

3. SHE organisation and Management

In order to implement the policy of the management given underchapter-2 SHE policy, a committed organisation is required. Aftercareful consideration the management has made Safetyorganisations at different levels with each person’s commitmentwell defined. These are given in this chapter.

3.1. Management Commitment

The E&C Division of L&T, is committed to continuousimprovement in creating and maintaining:- A safe and healthy Environment at all its work places and

project sites- A Zero accident record;- A risk free operation;- An improved business performance; and- A responsible image within the marketplace.

LARSEN & TOUBRO LIMITEDE & C Division

SAFETY COMMITMENT

Pursuant to the L&T Safety Policy Statement, we L&T employees at thissite shall comply with the L&T Safety Management System by thefollowing actions.

! Work with competent and adequately resourced contractors tocarry out work and ensure their co-ordination and co-operation.

! Ensure that contractors have information about risk on-sites andthey provide details of how they intend to safely carry out high riskoperations.

! Ensure that workers on site will be given adequate training andcomply with the site safety rules.

! Monitor health and safety performance.! Ensure that all workers are properly informed and consulted on

hazards and risks of their work.! Make sure that only authorised people are allowed on to the site.! Communicate by reports and safety meetings with all concerned at

the site and Powai about all safety matters.! Give priority to safety in our day-to-day work.! Follow L&T Rules and Procedures to ensure accident-free, safe

construction site.

Site Safety Officer ________________

Resident Construction Engineer ________________

11th January, 99. Resident Construction Manager ________________

SAFETY FIRST



3.2. SHE Structure

The SHE organisational structure of L&T’s E & C Division SafetyManagement’s system and personnel responsible for safetyaspects are as follows:

Sr.Vice President (Operation)and Member of the Board

Cluster Heads

BusinessGroup Leaders

Head(Safety)

LEGEND : Communication / Interaction

Site SafetyOfficers

Chief(ManagementServices)

ResidentConstruction Managers

SafetyEngineers

Head(Project Management/ER&C)



3.2.1. Safety Control Organisation Structure

3.2.2. Site SHE Organisation Structure

The Site SHE organisational structure of L&T’s E & C DivisionSafety Management system and personnel responsible forSafety aspects are as follows:

3.2.3 Duties and Responsibilities

3.2.3.1. Management

3.2.3.1.1 The management shall have ultimate responsibility for SHEmanagement system. The responsibilities include.• Providing adequate resources essential to the

implementing continual improvement of SHE organisationsystem.

• To ensure organisational freedom necessary to implementthe SHE management system.

• Adherence to statutory requirements pertaining tooccupational Safety, Health and Environment.

Site SafetyOfficers

ResidentConstruction Managers

Head(Safety)

SafetyEngineers



3.2.3.2. Safety Control Department Responsibilities

3.2.3.2.1. To set up standards for prevention and control of losses3.2.3.2.2. To participate in safety activities and give full support for the

programme.3.2.3.2.3. To review and act upon safety records.3.2.3.2.4. To insist on safety being planned into all the operations

undertaken at all times under any conditions.3.2.3.2.5. To review an OH&S management programme.3.2.3.2.6. To review the effectiveness of the provisions of the Safety,

Health and Environment Manual.3.2.3.2.7. To periodically inspect and audit the site for SHE to provide

training to the engineers and supervisors.3.2.3.2.8. To identify hazard and carry risk assessment and keep the

information up to date.3.2.3.2.9. To identify and have access to the applicable legal

requirement and keep the information up to date.3.2.3.2.10. To ensure communication to all employees and other

interested parties on the SHE requirements including legaland other requirements.

3.2.3.2.11. To set up an OH&S objectives and consider the above whilesetting up the objectives.

3.2.3.2.12. To establish and maintain OH&S management program forachieving objectives.

3.2.3.3. Resident Construction Manager

He is overall in-charge of the safety of the site, for thestatutory compliance and adherence to the guidelines given inthis manual. In addition to this his other responsibilities are:

3.2.3.3.1. To ensure & maintain safe working conditions and practicesfor all employees under his supervision.

3.2.3.3.2. Ensure that contractors follow safe working practices in linewith the company policy and will take steps to rectify.

3.2.3.3.3. To provide adequate training to all personnel working at site.3.2.3.3.4. To ensure the understanding of the job hazards and safe

procedures before putting them on to the job.3.2.3.3.5. To maintain good housekeeping at the project site.3.2.3.3.6. To ensure the provision of adequate personal protective

equipment and their maintenance and proper use.



3.2.3.3.7. To encourage safety suggestions and act upon themimmediately.

3.2.3.3.8. To conduct regular safety meetings.3.2.3.3.9. To ensure that SHE manual is made available at site and

copies/ abstracts are issued to all concerned including subcontractors.

3.2.3.3.10. To ensure that sub contractors are given proper instructionsto comply with safety standards and entries are made in thedaily logbook maintained at the site of all verbal instructionsgiven to the contractors.

3.2.3.3.11. To ensure proper feedback is given to the connected L & Tdepartments about shortfalls in design etc. from constructionsafety point of view, for future actions.

3.2.3.3.12. To ensure First aid arrangement are made and maintained atwork place.

3.2.3.4. Site Engineer

The site engineer is responsible for ensuring the complianceof the statues and the recommendations given in this manualby the contractor and sub-contractors working under them. Inaddition to this he will:

3.2.3.4.1. Inspect working area regularly.3.2.3.4.2. Report accidents and near misses immediately to RCM/SSO.3.2.3.4.3. Ensure that all persons working under him are trained on safe

and proper working procedures by giving toolbox talk.3.2.3.4.4. Assist the Site Safety Officer in conducting accident

investigation involving his workers.

3.2.3.5. Site Safety Officer

The site safety officer is responsible to ensure the over allsafety of the site. Functionally he will be reporting to thesafety control department and take guidance from them. Inaddition he will:

3.2.3.5.1. Promote & implement the SHE manual at project sites.3.2.3.5.2. Give assistance in solving safety-related problems, and making

recommendations for improving safety.

3.2.3.5.3. Suggest standards to prevent injuries/losses.3.2.3.5.4. Investigate near miss incident and accident reports and monitor the

site safety performance against L & T’s internal standards.



3.2.3.5.5. Advise RCM to stop work when the need arises.3.2.3.5.6. Advice on legal requirements affecting safety.3.2.3.5.7. Maintain liaison with other departments such as Medical and

Training, official bodies such as Factory Inspectorate andInsurance Companies and outside bodies such as the NationalSafety Council, Productivity and Standards Board, etc.

3.2.3.5.8. Propagate safety through leaflets, memos, reports, poster,notices, etc.

3.2.3.5.9. Provide assistance to all level of management to implementaccident prevention activities.

3.2.3.5.10. Arrange and participate in periodic safety inspection of workareas.

3.2.3.5.11. Prepare and keep adequate records of accidents and reportsand tendering of advice to prevent recurrences.

3.2.3.5.12. Monitor and man the access and egress to project on thework site.

3.2.3.5.13. Liase as required with the Fire Watch.3.2.3.5.14. Conduct Safety meeting at least once a month to discuss

various aspects on safety with sub contractors and clients andminuted.Initiate Tool-Box talks with workers

3.2.3.5.15. Be important member of the on-site emergency team andperform duties as mentioned in the emergency plan.



3.2.4. Returns

3.2.4.1. Reporting about Opening/ Closing of Construction Sites

3.2.4.1.1. Objective

In order to conform with norms set in the safety policy, it isessential to know in advance the opening and closing of asite.

A detailed procedure is given below for compliance.

3.2.4.1.2. Procedure

3.2.4.1.2.1 This Procedure requires that SCD at Powai should beinformed about opening and closing of a construction sitewithin seven days of its opening/ closing.

3.2.4.1.2.2 The information to be sent to SCD, Powai shall be filled inthe format annexed to this Procedure.

3.2.4.1.2.3 It should be sent by a fax message (No. 022 - 8581020) forthe attention of Head-Safety Control followed by aconfirmatory copy by post/ courier.

3.2.4.1.2.4 Project Execution Manager at Powai / Baroda shall beresponsible to provide the information. However, RCM/ RCEshall ensure that the information has been sent to SCD,upon taking charge of the site.

3.2.4.1.2.5 All construction sites of E & C Division shall be coveredunder this Procedure so long as any person/s of E & Cdivision and/ or its appointed contractors/ agents carry outactivity of any kind at the site.

3.2.4.1.3. Definitions

3.2.4.1.3.1. Opening of a Construction Site

3.2.4.1.3.1.1. An event/day when L&T personnel or L&T’s contractor/s orL&T’s vendor/ agent/s start carrying out activity of anykind at a site where construction activities will be furthercarried out.

3.2.4.1.3.1.2. For reporting to SCD, man-hours shall be countedfrom the opening of the site and all safety proceduresshall apply to the site.

3.2.4.1.3.2. Closing of Construction Site



3.2.4.1.3.2.1. An event/day after which no further activity of any kindis carried out by L&T personnel or L&T’s contractor/s orL&T’s vendor / agent/s at the site.

3.2.4.1.3.2.2. RCM/ RCE will stop sending reports to SCD from this dayonward, for the specific site, which is closed.

3.2.4.1.4. This revision:

The annexed form has been revised to request additionalinformation while opening a site.

3.2.4.1.5 RECORDForms Records

Site opening and closing Report CSC – 10 –R2



Annexure -1

Larsen & Toubro Limited Safety ControlPowai, Mumbai E & C Division

To: Head (Safety Control), E & C Division

(A) SITE OPENING REPORT : (Attach separate sheet if required)

1 Name of site/ project

2. Project job no. & Debit code no.3. Location

4. Complete address

Telephone, V-sat (hotline) & faxnos.e - mail address

5. Name of Resident ConstructionManager / Resident Engineer

6. Names of Site Engineers

7. Name of Site Safety Officer

8. Names of contractors & nature/type of their activities

9. Estimated no. of man-hours

10. Duration of construction activities11. Safety manual, procedure

manual and DACP (Safety -34 )Available at site /required at site

12. Whether commissioning is in L&T’sscope of responsibilities or whetherL&T will provide commissioningassistance only to the client ?

13. When will ownership of the plant/facility be transferred to the client?(a) After mechanical completion.(b) After commissioning & Test-run.

14. Date of opening of construction site

15. Any other relevant information

Date: __________ Signature: ________________________________

Name : ________________________________ (Project Execution Manager/ Resident Construction Manager)

Copies to :: All SBU Heads: Project Execution Manager - Powai/ Baroda: Champion of concerned SBU



Annexure 2

Larsen & Toubro Limited Safety ControlPowai, Mumbai E & C Division

To: Head (Safety Control), E & C Division

(B) SITE CLOSING REPORT :

This is to certify that there will be no further construction/ commissioningactivity of any kind on the construction site at________________________ (location), from _______________ (dateof closing of construction site).

Total no. Of man-hours worked at this site from _______________ (dateof opening of construction site) is ____________________.

I have handed over to Mr. ___________________________* / retainedwith me * all safety documents listed in point A (11) of the annexedform.

Date: __________ Signature : _____________________

Name : _____________________ (Project Execution Manager/

Resident Construction Manager)

Copies to:: All SBU Heads: Project Execution Manager - Powai/ Baroda: Champion of concerned SBU

* [Strike off whichever is not applicable.]



3.2.4.2. Monthly Reporting & Analysis of Mishap at L & TConstruction Sites


3.2.4.2.1.1. This procedure is to report and highlight monthly safetyperformance record of L&T sites to the management.

3.2.4.2.1.2. Based on these reports, the management can takenecessary steps and augment safety efforts as required atthe sites.


3.2.4.2.2.1. SSO shall write the correct Accident Data & Man – Hours asper the standard format given by Safety Control Dept. E &C Division.

3.2.4.2.2.2. SSO & RCM shall sign report. If RCM is not present, hisrepresentative will have to sign and to be forwarded toSafety Control Dept. in the first week of every month.

3.2.4.2.2.3. Monthly statistic report are processed and analysed bySafety Control Dept. and performance is evaluated forfurther action. Also it will be published in quarterly safetybulletin.

3.2.4.2.3 Administration

3.2.4.2.3.1 Site Safety Officer of E & C Division or Main Contractor shallsend the report to Safety Control Dept. by the first week ofevery month.

3.2.4.2.3.2 If Site Safety Officer is not present, RCM will be responsibleto send the report to SCD.

3.2.4.2.3.3 If there is nothing to report in a particular month then “Nothing to report’’ will be written in “ Month under report ‘‘and the same cumulative data as that of previous monthshall be written.

3.2.4.2.4 Clarification

3.2.4.2.4.1 After an accident to a contractor’s workmen, if anotherworkmen replace him, then there are two types of man -hours lost.



3.2.4.2.4.2 ACTUAL man - hours lost, which equals to stoppage of workby the injured person/s. i e. No. of injured person / s Xno. of hours not worked.

3.2.4.2.4.3 NOTIONAL man - hours lost which equals to no. of hoursnot worked ( for medical treatment , etc. ) by the injuredperson/s, even if he is replaced/ transferred to other site,after his recovery from the ailment.(Total man - hours lost due to stoppage work, as a result ofaccident /mishap, by the site work-force may also bereported as a third parameter, to record overallconsequence of the accident).

3.2.4.2.5 RECORD

Form Reference3.2.4.2.5.1 Monthly Statistic Report - CSC-02-R1

Annexure

Larsen & Toubro Limited Date of Issue : __________________ E & C Division Project Name & Job No. : __________________

Ref.: CSC-02-MR-R1MONTHLY STATISTICS REPORTFor the month of ________ Year ________

Accident Dataa Lost time Accidents No. Of

incidentsManhourslost

No. ofpeopleInvolved

No. ofContractors

involved

L & TPersonIf any

No. ofreportingto Govt.

For the month under report ( ____2000)

CumulativeFrom _______ 1999 to________ 2000

b Minor InjuriesFor the month under report ( ____2000)


c Fires No. Ofcidents

Manhours

lost

No. ofpersoninjured

No. ofequipmentdamaged

Lossin

Rs.

No. offires

reportingoutside

For the month under report(____,2000)


d Other mishaps not coveredin a, b, c.

No. ofNear-Miss

No. ofFirst aidcases

No. ofpersoninjured

No. of eqpt.Damaged

Loss inRs.

Total Nearmiss &

First aidFor the month under report ( ____2000)


Data for Man hours workedDetails L&T E & C

(A)Main Contractors

(B)Sub-contractors

(C)

No. of People

Man hours workedO.T hours

Total Man hoursGrand total of man hours worked during the month ( A + B + C ) :

Cumulative man-hours ( from _________1999 to _________2000) : ( Since the opening of site )

_____________________________ __________________ Signature of Site Safety Officer Signature of RCM Date: Date :

Note: 1. Report should be legible, properly typed. 2. Standard 48,000 man hours lost is taken for any fatal accidents as per IS No. 3786-1983.

3. Reportable accident report is to be sent within 24 hours of occurrence.

Copy distribution : 1. Site Safety Officer 2. Site in charge contractor through RCM

3. DGM, E & C Division Safety, Powai 4. DGM QAIS Process Cluster Baroda

5. BUH Powai or Baroda / Champion 6. Head Construction Baroda / Powai



3.2.5. Positive Reporting on Safety At Construction Sites

3.2.5.1. Objective

Procedure Nos. CSC-01 and CSC-02 deal with reporting ofaccidents and mishaps at E & C Division construction sites.These reports give negative information, albeit necessary,about Safety Performance & Management at the sites andenables measurement of safety in terms of reduction ininjury/harm/loss.

However, when Safety Performance is good, and injury & lossare low at a particular site, these negative measurements arenot sufficient to have adequate feedback for managing safety,because potential for injury/mishap may be high at the sitebut likelihood of risk of events may be very low. Hence,absence of accidents is not a sufficient indication of goodSafety Management and other measurements of SafetyPerformance are necessary to have assurance that theabsence of accidents is due to good Safety Management.

3.2.5.2. Procedure

The Procedure deals with formally reporting to the SafetyControl Department (SCD) of E & C Division, at Powai, inwriting, about the positive aspects of safety such as follows inconstruction activities at sites.

(a) Compliance to Safety Control Procedures (CSC) in theProcedure Manual.

(b) Provision and use of APTs to/by L&T and Contractors atsite

(c) Regular On-site training of workmen, mock fire-drills etc.(d) First Aid and Fire Fighting Training of site personnel(e) Any additional safety provision at site(f) Any aspect of safety promotion at site such as Safety

Slogans/essay/quiz competition, safety poster displayetc.

(g) Compliance with statutory requirements(h) Interaction with the client/contractor on safety matters

like joint safety inspection (weekly)(i) Achieve milestones such as accident-free 100,000 man-

hours.



Before reporting, RCM/E should ensure that the followingrequirements are met:

(I) Compliance/provision being reported must be ofpermanent/regular nature, i.e. they must continue at thesite until the site is closed.

(II) Compliance/provision must be seen as having definiteand positive effects on preventing mishaps and personalinjuries at the site.

3.2.5.3. Administration

(a) Whenever a positive action is taken at the site, RCM/Ewill send its details to SCD in the form attached to thisProcedure. Both RCM/E and SSO will sign the form.

(b) The information may be sent at any time, as and whenthe positive safety action is taken at the site.

(c) Safety Officer from SCD will check the actual provision ofthe measure/s reported by RCM/E, when he visit the site.

(d) SCD will record the action and use it for co-relation ofsuch actions with the Safety Performance of the site andalso use it for safety awards, when instituted in E & CDivision.



Annexure

Positive Safety Measure/Action

Name of Site :Ref. :Date :

To: Head Safety Control E & C Division L&T-Powai.

From :

We are pleased to report the following positive safety measure/s at oursite:

Sr.No.

Date of action/implementation

Description Whether one-time orContinuous/regular(Frequency)?

We shall ensure that this measure/practice will continue until the site isclosed.

_____________________ __________________________ Site Safety Officer Resident Construction

manager / engineer Name: Name:



3.2.6. Daily Log - Book

The Site Safety Officer is required to make the SafetyInspection of the facility and Observations of the workmethods and procedures adopted by the contractors and theirmen and record the same in the daily logbook. The entriesshould be shown to the Resident construction Manager forgetting his signature and for prompt proper action

The format of the Daily Log-Book is given in the annexure.



Annexure

Format for Daily Log - Book

DATESR.NO

OBSERVATIONS ACTION TAKEN SIGN OF SSO SIGN OF RCM



3.2.7. Safety Promotion and Recognition

3.2.7.1. Display of Safety Performance at Construction Site


One of the Codes of Conduct in the E & C Division - ‘SafetyPolicy Statement’ is to promote interest and enthusiasm insafety efforts through awareness and recognition of safetyperformance. This is possible, if all persons working at theL&T site are informed about the safety performance at thesite. Efforts to correct/improve poor safety performance andto maintain good safety performance will be put by people atthe site, if they know about the current performance, oncontinuous basis.

One of the methods of informing persons working at the siteabout safety performance of the site, is by displaying it on aboard which is placed prominently and up-dated daily.Persons working at the site, when they read the informationon the Board, will feel proud of their good safety performanceand will strive to maintain it.

The objective of this Procedure is to require allconstruction sites to display information about thesafety performance of their individual sites.


The Procedure deals with the preparation, installation andupdating of the Display-Board giving up-do-date, correct andaccurate information about safety performance of theconstruction site, where the Board is installed.



3.2.7.1.3. Suggested specifications of the board:

Dimensions - 1500 mm L x 1000 mm H(Dimensions may be reducedproportion-ately to suit siteconditions but not below 1000mm L x 800 mm H).

- Number Plates : 230 mm H x 115mm W

Material : Aluminium (preferable) or G.I.Sheet1 mm thick or plywood5 mm thick

Colour : Background : WhiteLettering : Dark GreenNumbers & L&T Logo: Black

Layout : See Annexure for a Specimen

Quantity : One or more depending on thearea of the site

3.2.7.1.4. Location of the Board shall be such that it is visible toall persons working at the site while they move aroundthe site.

One of the following locations shall be considered:

* Hung on the outside wall of L&T site office nearentrance to RCM office

* Mounted on a grouted frame at the entrance to the L&Tsite.

3.2.7.1.5. Languages of safety information on the Board:

- English or Hindi (top half of the Board)- Local language (lower half of the Board)



3.2.7.1.6. Administration

(a) Within 15 days from the effective date of this ProcedureRCM/Site In-charge will get the Display Board/s readyand have them installed at any of the suggestedlocations mentioned in 2.2 above.

(b) Nos. of days to be displayed will be from the date of thelast LTA/MI/DI. (See Definitions in 3.8).

(c) The safety performance shall coverpersons/equipment/assets of L&T-Group II (P) and of allits Contractors at the site.

(d) Responsibility of operating/updating the Board shall be ofthe Site Safety Officer (SSO). If SSO is not present atthe site, then RCM or his designated person shall beresponsible for operation/updating of the Board.

(e) Name of the person responsible for operation of theBoard and date of updating shall be clearly shown on theBoard.

(f) SSO/RCM shall update the information on the Boardevery day (except on weekly offs) at 9 A.M., afterreviewing information of the previous 24 hours.

(g) Safety Officer from SCD (Powai) shall include, in hisinspection, working of this Procedure, during his siteinspection/audit and check that the information matcheswith the one provided through Accident Reports sent toSCD by the site RCM vide Procedure of existing CSC-01.

(h) Definitions of Lost Time Accident (LTA), Minor Injury (MI)and Dangerous Incident/Occurrence (DI) are given belowfor ready reference.

Lost Time Accident (LTA):

An incident which causes death of a person or which causesbodily injury to a person due to which s/he is prevented fromworking for a period of 48 hours or more immediatelyfollowing the incident.

Minor Injury (MI) :

An incident which causes bodily injury/ies to a person, who istreated by the first-aid facility at the site or by a doctor andwho is permitted to work at the site, immediately after thefirst-aid treatment.



Dangerous Incident/Occurrence (DI) :

An incident in which (with or without personal injury) there isor could have been a damage/loss to property, equipment,materials of L&T or its Contractor and in the surrounding.Examples: Fire, gas leak, explosion, vessel/cylinder bursting,collapse or failure of structure, machine etc., subsidence offloor, roof, chimney etc. and such incidents.

Personal injury/ies during a Dangerous Incident shall also becovered separately in LTA or MI as may be the case.

500500

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3.3. Statutory Requirements:

The Government of India has enacted “THE BUILDING ANDOTHER CONSTRUCTION WORKERS (REGULATION OFEMPLOYMENT AND CONDITIONS OF SERVICE) ACT, 1996”AND “THE BUILDING AND OTHER CONSTRUCTIONWORKERS (REGULATION OF EMPLOYMENT ANDCONDITIONS OF SERVICE) CENTRAL RULES 1998” and thecopy can be procured for the site.

In order to facilitate for easy reference for important chapters,the rules governing the subject of the chapter are also given.



3.4. Prequalification for selection and performance ofContractors for L & T work

(A) Objective

This procedure is to scrutinise / evaluate L & T ConstructionContractors w.r.t their sutability to work safely on L & T sites.It is expected that by emloying the contractors who meet thequalification requirements laid in this procedure, accidents anddangerous occurences on L & T sites would be minimised. Byfollowing the procedure, L & T Manager should encouragecontractors on safety and make every effort to qualify them byadvising them corrective actions to be taken by them.

(B) PROCEDURE

The Procedure covers basically four situations / status w.r.t. thecontractors at E & C Division sites and these are shown in tablesbelow :

CONTRACTOR CONTRACTOR PROCDURE STATUS ACTIVITY NO. CSC-03/

1. New Request for prequalification; / 1 (Not qualified in no bidding safety by L & T) 2. New Bidding for a specific / 2 (Not qualified in project safety by L & T) 3. Existing Working at Group II- / 3 (Not qualified in projects site / s safety by L & T) 4. Existing Not Working at Group II - / 4 (Not qualified in projects site / s safety by L & T)

Procedure for Prequalification in Safety of a New Contractor( Not bidding for specific project )

1. Contractor desiring to register with L & T E & C Division, approachesany BU Manager / SAFETY CONTROL, for working on L & T project .

2. Contractor is given a blank of ‘ Contractor Safety CapabilityEvaluation ‘ Form (CSCE) - Sample copy attached to this procedurefor reference , excluding Section H of CSCE which he fills andsubmits to either Project / Site Manager or Head - SAFETYCONTROL.



In any case, the original must come to Head – Safety Control andothers retain copies.

3. Safety Control Engineer (SCE) from Safety Control scrutinises theinformation and visits the contractor office / sites for inspection, if hefinds more than 80 % of the requirements are met . SCE advises thecontractor about the shortfalls, if any.

4. If 80 % requirements not met, Head – Safety Control reject thecontractor’ s application to register and asks him to resubmit when isready to meet the requirements. If the contractor intends to know,Head – Safety Control will inform the contractor in writing about hisshortcomings in safety qualification.

5. If the contractor qualifies,- Head – Safety Control will inform the contractor about his

acceptance by L&T for registration.- Head Safety Control will inform all BUH’s / DGM’s / AGM’s / PM’s

/ SM’s by a memo and a copy of updated list of prequalifiedcontractors.

6. If during the site inspection of SCE , any shortfall in the qualifiedcontractor safety capability is observed , he will be instructed tocorect it within a specified time , failing which he will be disqualified.Then- Head – Safety Control will inform the contractor about his

disqualification.- Head – Safety Control will inform all BUH’s / DGM’s / AGM’s /

PM’s / SM’s by a memo and a copy of updated list of prequalifiedcontractors. Name of the disqualified conractor will be deleted inthis list.

It will be decision & responsibility of PM / SM about the continuationof services of the subject contractor at the ongoing sites. In anycase, the contractor shall not be awarded any new contract forwork/services, untill he requalifies in safety.

Procedure for Prequalification in Safety of a New Contractor( Bidding for a specific L & T project )

1. Project / Site Manager will send the CSCE form along with otherdocuments of RFQ , to all prospective contractors, who are notqualified in Safety with L & T E & C Division.

2. When PM / SM receives the filled - in CSCE , he will send original toDGM ( QA & I ), retaining a copy of the same.



3. Same as in Procedure No. CSC-03/1.4. Same as in Procedure No. CSC-03/1.5. Same as in Procedure No. CSC-03/1.6. If the contractor fails to meet the qualification standards of Safety,

DGM ( QA & I ) will inform him accordingly , in writing , with copiesto BUH’s / DGM’s / AGM’s / PM’s / SM’s, who shall not award workto the said contractor / s at Group II Project sites .

7. Same as No. 6 in Procedure No. CSC-03/1.

Procedure for Prequalification in Safety of an Existing Contractor( Working at L & T Group II projects site / s )

1. PM / SM at the site / s issues the CSCE form to the contractor andrequires him to fill in and submit it to PM / SM within 15 days.

2. PM / SM will snd the original to DGM - QA & I , retaining a copy ofthe same.

3. SCE scrutinises the information given inthe csce and visits thecontractor office site / s. If the Safety requirements are not metsatisfactorily , SCE advises , in writing , PM / SM about theshortcomings , and sends a copy of the advice to the contractor forcorrecting / reinforcing his safety capability.

4. If 80 % of the requirements are not met within 15 days after SCE’sadvice to the contractor, DGM - QA & I rejects the contractor fromqualifying in safety and informs the contractor and BUH’s / DGM’s /AGM’s / PM’s / SM’s in writing.

It will be decision & responsibility of PM / SM about the continuationof services of the subject contractor at the on-going sites . In anycase the contractor shall not be awarded any new contract forwork/services, untill he requalifies in Safety.

Procedure for Prequalification in Safety of an Existing Contractor( Not Working at any L & T Group II projects site / s )

1. All such contractors , who are desirous of working at L & T site, withinone year , are informed by PM / SM about L & T’s requirement for pre-qualification in SAFETY.

2. Same as in Procedure No. CSC-03/1.3. Same as in Procedure No. CSC-03/1.4. Same as in Procedure No. CSC-03/1.5. Same as in Procedure No. CSC-03/1.



(C) Administration

(a) Books containing 5 sets of CSCE Forms will be sent to all sitesby Safety Control Department . More forms can be obtainedfrom Safety Control Department. However, if forms areexhausted, the CSCE should be prepared in photocopy/typedcopy and submitted to Head Safety Control.

(b) SE will periodically check at all E & C Division Sites whether thecontractors working at sites are qualified in Safety by L & Tand advise Sr. V. P. / BUH’ s about the status every quarter.

(D) Definitions / Abbreviations

- BUH : Business Unit Head- Head–Safety Control : Deputy General Manager, E & C Division.- SCD : Safety Control Department- SM : Site Manager- PM : Project Manager- SCE : Safety Control Engineer from QA & I- CSC : Construction Safety Control- RFQ : Request For Quotation

( Same as ITB - Invitation to Bid )



3.4.2 Rules governing Contractor’s work

(A) Objective

Procedure No. CSC-06 stipulates that the standard Terms &Conditions (T&C) of HSE should be included in thecontract/purchase orders issued to the L&T site contractors, by therespective Project/Site Managers of E & C Division

In order to ensure that the managers, engineers, supervisors &safety officers of L&T and the contractors are constantly madeaware of these T&C, it is necessary that these T&C are availablereadily with these persons, as Rules in the form of a booklet,which are individually issued to each of these persons.

(B) Procedure

This Procedure deals with the issuing of standard Rules of SHE toall L&T-and contractors-managers, engineers, supervisors andsafety officers, who are concerned with health and safety of theiremployees working at the site.

The following actions are required to be taken by RCM/RCE ofL&T/LTCG (in case of site synergy situation).

1. RCM/RCE shall request to SCD adequate no. of copies of thebooklet well in time before any contractor is employed at hissite.(Fifty booklets are being sent with this procedure, for theon-going sites) .A sample copy of the same is enclosed in theannexure.

2. REC/RCE shall ensure that the booklet is individually issued toL&T and contractor personnel who are responsible forsupervising their workers activities at his site.

3. RCM/RCE shall fill up the necessary details and sign them,and have the person (to whom the booklet is issued) sign, inthe space provided for this purpose.

4. RCM/RCE shall ensure that the persons issued with thebooklet shall have the booklet with them at any time whilethey are working at the site, have read and understood theRules and have been provided with clarifications as needed.

5. RCM/RCE shall ensure that, additional rules, if any, includedin the contract are incorporated/attached to the bookletcopies before issuing to the contractors.



(C) Administration

1. SCD shall maintain adequate stock of the booklet in Powai.2. RCM/RCE shall request to SCD for copies of the booklet

allowing adequate time for mailing etc.3. If the stock of the booklet is exhausted temporarily at the

site, RCM/RCE shall issue photocopy of the booklet from thecontract document and immediately request SCD foradditional copies.

4. During the site visits, Safety Officers from Powai shall checkthat the booklets issued to all concerned are available withthem. Safety Officer shall also check that the Rules areunderstood by them.

5. SCD shall send 50 booklets with this procedure, toRCM's/RCE's of the on-going sites.

FOR L&T USE ONLYVENDOR CODE No.

TO BE UPDATED INJANUARY EVERY YEAR

SECTION A – BASIC DETAILSCOMPANY NAME ADDRESS FOR COMMUNICATION

MAIN CONTACT NAME / DESIGNATION TELEPHONE NUMBER FAX NUMBER

PERSONNEL RESPONSIBLE FOR SAFETY AT SITE

TYPE OF COMPANY / INDUSTRY / FIRM (TICK AS APPROPRIATE)

PUBLIC PRIVATE GOVERNMENT PARTNERSHIP PROPRIETRY CONTRACTORS OTHERS (SPECIFY)

SECTION B – EVALUATION REQUIREMENTS

SERVICE PROFILE (TICK AS APPROPRIATE)

CIVIL MECH.ERECTION PIPING ELECTRICAL INSTRUMENTATION

INSULATION PAINTING STRUCTURAL OTHERS (SPECIFY)

SCOPE OF APPROVALTHE SCOPE OF APPROVAL DETERMINES THE NATURE OF YOUR SERVICES YOU INTEND TO PROVIDE TO L&T

CONTRACTOR SAFETY CAPABILITY EVALUATIONTo enable us to assess & evaluate you capabilities in Safety please complete & return to:LARSEN & TOUBRO LIMITED TELEPHONE : 022-8581401/1411E & C Division – Safety Control Department TELEFAX : 022-8581020Saki Vihar Road, P.O.Box 8901, Powai, Mumbai 400 072, India

SECTION C – SAFETY ORGANISATION1. Do you provide safety officers at your job sites? Yes / No

Give details, no. of safety officers, their qualifications, their accountability and authrities, their nature of work. (Full-time or Part-time?)_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

2. Do you nominate trained safety observers among workmen at your job-sites? Yes / No

Give details and account of their effectiveness._______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

3. Do you have formal / written accident (personal & equipment) reporting & investigation system? Give details and attach blankforms used in your company. How does the system work?

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

4. Do you keep records of all accidents, mishaps, dangerous occurrences at all your job-sites?

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

_______________________________________________________________________________________________________

SECTION D – SAFETY RECORD / PERFORMANCE1. Give the following details (for last three years) (incl: your sub-contractors)

Incident No. No. of job-sites No. of man-hours Compensation paid /Involved worked Loss (Rs.)

a. Minor injuries _____ _____________ ________________ _________________

b. LT accidents _____ _____________ ________________ _________________

c. Fires _____ _____________ ________________ _________________

d. Explosions _____ _____________ ________________ _________________

e. Other dangerous occurrences (describe) _____ _____________ ________________ _________________

f. Fatal accidents _____ _____________ ________________ _________________

g. Frequency rate ________________ Severity rate __________________

2. Have you paid third party compensation? Give details for the last three years (incl : your sub-contractors)

Year Amount paid Rs. No. of persons Total contract valueInvolved for the year (Rs.)

______ _______________ ________________ ___________________

______ _______________ ________________ ___________________

______ _______________ ________________ ___________________

______ _______________ ________________ ___________________

______ _______________ ________________ ___________________

______ _______________ ________________ ___________________

______ _______________ ________________ ___________________

3. Was your company / company official involved in any litigation due to accident / fire etc. at your job sites in the last three years? Is there any court case pending against your company / company official? Give details.

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________

SECTION E – ADDITIONAL INFORMATION1. Give additional information (on safety), if any.

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________

SECTION F – YOUR PROPOSAL FOR THE SPECIFIC JOB-SITE FOR WHICH ARE BIDDING TO L&T1. Give details of insurance, legal arrangement etc. you will provide / have provided for in this bid.

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________

2. Will you indemnify L&T and its personnel against any legal action due to accident, fire, dangerous occurrence at L&T site & itssurroundings? Give details.

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________

_________________________________________________________________________________________________________



3.5 Safety Committee

3.5.1. Introduction:Statutorily (See section 38 of The Building and other constructionworkers (Regulation of employment and condition of service) Act1996) each site should have a safety committee having equalednumber of representatives from management and workers/contractors. A well-planned safety committee is a great motivatorfor safety. It’s primary purpose is to enable management andworkers to work together to monitor the site safety plan, so as toprevent accidents and improve working conditions on site. Itssize and membership will depend on the size and nature of thesite and upon differing legal and social conditions in the stateconcerned, but it should always be an action orientated group ofpeople in which both management and workers are represented.The safety committee carrying out a site inspection togetherraises the level of safety consciousness at the site.

The procedure for forming the safety committee, scope andobjectives of the committee, meeting procedures, minutespreparation and circulation and follow up action is listed inannexure.



Annexure

Formation of safety committee, membership, objectives, meetings,minutes and follow up action.

1) Formation of Safety CommitteeEach site will have one Safety Committee.Safety Committee will consist of/be represented by site – in –charge of all contractors / sub – contractors and headed by the L&Tsite Manager. This committee will have periodic meetings headedby L&T Site Manager.

2) Meeting Frequency

a. Meetings of the safety committee and shall be held at leastonce in a month, in the second week of each month.

Dates of the next meeting shall be informed to allmembers in the preceding meeting, so that the memberscan make themselves available for the next meeting.This is important so that the members find / make timeavailable to attend the meeting.

b. Special safety committee meeting shall be held as required todiscuss serious accidents, potentially accident – proneactivities and such matters.

3) Scope / objectives of the Safety Meetings

Regular and frequent meetings to discuss the safety and healthprogramme on site and to make recommendations to management.

Discussion of accident and illness reports in order to makerecommendations for prevention.

Evaluating improvements made.

Examination of suggestions made by workers, particularly by safetyrepresentatives.

Planning and taking part in educational and training programs andinformation sessions.

4) Administration

a. Agenda of safety meetings shall be prepared by the L&T safetyofficer / site Manager at the site and sent to all participants atleast one week in advance.



Agenda shall include review of MoM of the previousmonth, acceptance by all participants (to be recorded)and record of actual completion dates of action items.



Larsen & Toubro Limited. Site _______________E & C Division Date of Issue ________

Sheet ____of ____

Minutes of Safety Committee Meetingheld on _______, at the site

for the month of __________’2000

PresentSr.No.

Name Company Signature



Larsen & Toubro Limited. Site:________________E & C Division Date of Issue: _______

Sheet ____of ____

Minutes of Safety Committee Meetingheld on _____________________, at the site

Sr.No.

Particulars of the minutes(Including recommendation)

ActionBy

TargetDatefor

action

ActualComple-

TionDate ofAction

1 Review of previous MoM held on ______

The next safety committee meeting will beheld on

___________________________ ____________________Name & Signature of Site Safety Officer Name & Signature of RCM/RCEDate: Date :

Note:1. Report should be legible, properly typed.

Copy Distribution: 1. Site Notice Board2. All committee member3. SCD – Powai4. Project Manager5. Safety Champions



3.6 Construction Safety Plan

(A) Objective

(i) This procedure is to inform, familiarise, involve and getcommitment of Project-ites of E & C Division, about L&T’sconcern for and recognition of Safety, Health andEnvironment (SHE) during construction, from the verybeginning until the project is completed and handed over to aclient.

(ii) Provisions for SHE during construction of projects have to bethought about, planned, incorporated and committed by L&Tfrom the time a tender is submitted to a client, and carriedthrough in techno-commercial discussions with the client, inthe contract/order document, and in the project executionsuch that construction is possible to be carried out insafe/accident-free manner.

(iii) It is expected that by following this procedure, the Client,Project Execution and Construction Departments will beenabled to make adequate provision for safety duringconstruction.

(iv) ‘Construction Safety Plan’ is meant to be a part of `ProjectSafety Plan’ (PSP) which will cover not only constructionsafety but also safety in engineering, procurement andcommissioning, i.e. Total Safety Management (TSM) in aproject.

(v) `Project Safety Plan’ will be incorporated as separateProcedure and Document.

(B) Procedure

The procedure deals with making available General ConstructionSafety Plan (CSP-G) to Marketing, Prospective Clients (throughMarketing), Project Execution and Construction Departments of E &C Division, who have all to play important roles in itsimplementation in the steps described below.



(C) Steps for Implementing the Procedure:

StepNo.

Event Action ActionBy

1. Marketing Dept. sendsproposal/tender to aclient

(a) Attach ConstructionSafety Plan (CSP-G) tothe Proposal / Tender.

Marketing

(b) Provide for safetyrequire-ments (Sections1 to 6 of CSP-G) in theprice quoted to theclient.

Marketing

(c) Request the client to fill-up Sections (7) & (8) ofCSP-G.

Marketing

2. Client wants to inspectthe attachments to CSP

(a) Show the attachmentsviz. Safety Manual, PolicyStatement, ProcedureManual, Terms &Conditions forContractors on Safety, tothe Client. Do notsubmit them to theclient.

Marketing

(b) Provide one copy ofConstruction & ProcedureManuals to MarketingDepartment (for client’sinspection).

SCD

3. Technical discussions withthe Client

(a) Obtain sections (7) & (8)of CSP duly filled up,from the Client prior tothe technical discussions.

Marketing

(b) If necessary, inviteSafety Control Dept.,Project Execution andConstruction Depts. fordiscussions on safetymatters with the Client.

Marketing



StepNo.

Event Action ActionBy

4. Techno-Commercialdiscussions with theclient

(a) Adjust the price quoted, ifnecessary, for additionalprovisions for safetyaccording to the informat-ion provided by the clientin Sections (7)&(8) ofCSP-G

Marketing +

ProjectExecution

(b) Discuss the above withthe client, finalise and getthe client’s commitmenton the information inSections (7) & (8).

Marketing+

ProjectExecution

5. Contract/Purchase Orderwith the client

Include CSP-S, which isspecific for the client in theCO/PO attaching Sections (1),(2), (5), (6), (7) & (8) of theCSP. Sections (7) & (8) willcontain the information andcommitments from the clientin Step Nos. 3 & 4 above.

Marketing

6. Project Execution Hand over the PO/CO andspecific CSP (CSP-S) toProject Execution and SafetyControl Depts.

Marketing

7. 15 days beforeConstruction starts

(a) Hand over PO/CO with(CSP-S) to theConstruction/ResidentManager

ProjectExecution

(b) Send copies of PolicyStatement, ConstructionSafety Manual, ProcedureManual to the ResidentManager (if he does nothave these).

SCD

8. Pre-Construction Meetingat the site

(a) Invite SCD to participateto explain CSP-S to thesite personnel, contractorsand the Client.

ResidentManager



Like in case of any Company Procedure, TIMELY & SINCEREACTIONS by as also CLEAR AND COMPLETE COMMUNICATIONSamong the concerned departments viz. Marketing, ProjectExecution, Construction & Safety Control Dept. is key to thesuccess of this procedure which is essential and important toachieve accident-free construction sites of E & C Division.

(D) Administration

(i) Safety Control Dept. (SCD) will initially provide copiesof CSP-G and Procedure No. CSC-07 to the MarketingManagers of E & C Division. Besides, CSP-G and theProcedure will also be sent out to the recipients ofcontrolled copies from SCD.

(ii) Copies of the Construction Safety Manual, Procedure Manual,Policy Statement Placard, Model Terms & Conditions forContractors on safety will also be sent to the MarketingManagers, who have not received them from SCD.

(iii) Clarifications/Suggestions, if any on this Procedure should becommunicated to SCD in writing for subsequent revisions.

(iv) Marketing Department is requested to print/photo copy(without any alterations/changes) the original CSP for theirfuture requirement.

(E) Definitions

(i) `Project Safety Plan’ (PSP), of which `Construction SafetyPlan’ (CSP) will be a part will be developed and issued in thenear future.

(ii) CSP-G: `General Construction Safety Plan’ which containsblanks for a client to fill up in the Section (7) of CSP and doesnot have the client’s specific safety requirements in theSection (8) of CSP.

(iii) CSP-S: `Specific Construction Safety Plan’ which containsdetailed information and commitments in the Sections (7) &(8) from the client. The cover-page of CSP-S will bear thename of the site “For __________________Site”.

(iv) SCD: Safety Control Dept. at Powai.



3.7 Accident reporting and Investigation

(A) Objective

(i) Objective of this procedure is to ensure that Safety ControlDept., E & C Division is notified of all accident as soon aspossible.

(ii) This procedure will also provide a systematic method ofinvestigating and reporting an accident at construction siteand identify corrective action steps to prevent areoccurrence.

(iii) This procedure also outlines the method of communicatingwith Safety Control Dept., E & C Division.

(B) Definitions

Fatal : Death resulting from an accident.

LTA (Lost Time Accident):

An injury causing disablement of an injured person beyond 48hours excluding the days of accident and reporting to work back.which should also include Sundays and holidays.

(a) Immediate loss of any part of the body or any limb or partthere of.

(b) Crushed or serious injury to any part of the body due to whichloss of the same is obvious.

(c) Any injury which is likely to prove fatal.(d) Unconsciousness due to accident.(e) Severe burns or scalds due to chemicals, steam or any other

cause.

Dangerous Occurrences:

(a) Bursting of a vessel used for steam having pressure greaterthan atmospheric pressure.

(b) Collapse or failures of any lifting machine (crane, wire ropehoist, chain pulley block, etc), lifting Tackle (chain sling, wirerope sling, shackle, clamp, etc.) and lifts (passenger, goodsand service).

(c) Explosion, fire, bursting out, leakage or escape of any moltenmetal, hot liquor or gas, which results into injury or materialdamage.



(d) Explosion of a receiver or container used for storing anysubstance (gas, liquid, solid etc.) at a pressure greater thanatmospheric pressure.

(e) Collapse or subsidence of any floor, gallery, roof, bridge,tunnel, chimney, Wall, building.

Minor Injury:

An injury, which requires Medical treatment, causing anydisablement of injured person from work less than as mention inLTA. Person is resumed the site within 48 hours after receiving aninjury.

First aid injury:

An injury, which requires first-aid treatment only without causingany disablement of the injured person from work. Person isresumed site within two hours after receiving an injury.

Near - Miss Occurrence:

These are incidents / occurrences wherein a serious accident asdescribed in 1, 2, 3, 4, and 5 above has not happened but couldhave happened or could happen, if the unsafe situation / actcontinues, or it did not happen due to absence of a factor, whichcould have resulted in the serious accident.

(C) Procedure

The procedure deals with reporting of accidents involving people,machinery, buildings, structure, surroundings, environment (air,water, land), dangerous occurrence and near accident & first aidoccurrence which could have resulted in an accident and / ordangerous situation.

1. Responsibility of reporting - Residence ConstructionManager

2. Reporting - As per distribution given in the forms.

3. Method of reporting - e-mail / by fax / courier(Preceded by verbal report within 4hours in case of major mishap /fatal accident to BUH/ Sr. V P (O) /DGM (Safety).

4. Report Forms : There are four basic forms:



(i) Form (Accident Report)

- This is for reporting Fatal, Lost Time Accident,Minor Injuries, Fire & other dangerousoccurrence.

- To be filled by the supervisor / engineer of L & T/Contractor and sent to his site - in - charge withcopies for L & T Site Manager and others as shownin the form, immediately within 24 hours.

- If there is any fatalities, an oral report must bemade to DGM (Safety), within 4 hours andfollowing information must be provided

• The facility name;• The location of the incident;• The time of incident;• The no. of fatalities or hospitalized employees

and their names;• The name of contact person and his Tel. No.

and;• Brief description of the incident.

(ii) Form ( Accident Investigation )

- It is for reporting investigation of the accident /dangerous occurrence already reported in (i).

- It has to be filled in by the SSO / personinvestigating or nominated by Site Manager andcopies to be sent as shown in the form within 72hours.

- When indicated by the severity of the incident,steps to secure the incident site must be initiatedimmediately to ensure the investigating party canreconstruct the events leading to the incident.

- Individual interviews should be conducted witheach person at the time of the incident.

• The witnesses should be interviewed promptly,separately and privately.

• The interviewer should explain the purpose ofthe investigation to individual.

• The interviewer should ask the witness to givetheir account of the events that occurred.



• The interviewer should avoid questions thatgive a yes or no answer.

• After the interview, the interviewer shoulddocument any concerns identified.

• The investigation should be directed atdetermining the root cause.

• The investigation team must focus on gettingaccurate and complete information.

• The investigation will identify correctiveactions, both immediate recovery actions andlong term follow – up actions to prevent theincident from reoccurring.

(iii) Form (Near Miss)

- It is for reporting Near- miss accident.- Accident, which does not come under above

category i.e, Lost time accident, minor, first aidshould be send as shown in the form within 24hours after an accident take place.

- To be filled by the supervisor / engineer of L & T/Contractor.

(iv) Form (First Aid cases)

- It is for reporting only first aid cases (Please referits definition in Section 2.0, Sub Section 2.1,Clause 5)

- To be filled by SSO / person investigating ornominated by Site Manager, one copy to be sendto Safety Control Dept. of E & C Division andothers as shown in the form within first week ofthe month.

(D) Administration

1. Safety Control Department will send revised procedure withthe forms to all sites. The reports in photocopy or in typedform should be prepared and submitted to Safety ControlDepartment of E & C Division within stipulated time frame asmentioned in the form.

2. In case of Lost time accident, the Site Manager (or Client’sProject Manager) will have to send separate reports to the



authorities as per the Section 88 of Factory Act 1948.,besides these internal reports.

3. Employees responsibility :- Inform immediately to SSO or concern supervisor for

work related illness and injuries (i.e. on the same day).

(E) Records

Form Reference1. Accident Report CSC-01-R1-AR.2. Accident Investigation CSC-01-R1-AI.3. Near miss Accident Report CSC-01-R1-NA.4. First Aid Accident Report CSC-01-R0-FAAR.

LARSEN & TOUBRO LIMITEDACCIDENT REPORT E & C Division / SAFETY CONTROL DEPT(CSC-01-R1-AR NO.__________) To be submitted immediately after the Accident (Within 24 hours)

Project Name & Job no. Exact location of Accident / Incident Date & Time of Incident SBU

Accident that has occurred ( Tick as applicable )

! Personal Accident ! Fire / Explosion ! Mechanical

! Collapse of Structure ! Spillage of dangerous fluids ! Others ( Specify ) :

Event ( Tick as applicable )

! Injury ! Property damage ! Material loss

! Environment pollution ! Others ( Specify ) :

Name of Injured Designation & Token no. Age : ____

Sex : ____

Name of Contractor ( with whom he / sheis working ) :

Brief Description of Accident :

Specify the injury, extent of damage / loss( e.g. Fatal, loss of fingers, fracture of leg, scald etc. )

Location of Injury( e.g. right leg, left hand, left eye etc. )

Object causing injury( e.g. structural material., m/c, tools etc. )

Whether there was any unsafe condition

Yes ! No !

Whether any unsafe act by injured person

Yes ! No !

Whether the person was wearing protective equipment

Yes ! No !

If Yes, relevant PPE used :

Was he under the influence of Alcohol / Drugs

Yes ! No !

Whether medical aid was givenYes ! No !

Whether person was hospitalisedYes ! No !

Has report been given to authorities

Yes ! No !

If Yes, to whom ( Specify ) :

Probable cause of Accident & any additional information :

Name of two witnesses and signatures

1. Name : 2. Name :

Date : ( Signature ) : Date : ( Signature ) :

____________________________________Name of supervisor of L & T / Contractor

Date : ( Signature ) :

L & T site manager’s remarks

Date : ( Signature ) :Note : 1. Please attach sketches or a separate sheet if

space for any column is not adequate.2. Report should be legible, properly typed.3. The purpose of accident report is to find out

the causes, not to fix blame on somebody.

Copy distribution : 1. Site Safety Officer2. Site in charge contractor through RCM3. DGM, E & C Division Safety, Powai

4. DGM QAIS Process Cluster Baroda5. BUH Powai or Baroda / Champion

6. Head Construction Baroda / Powai

LARSEN & TOUBRO LIMITEDACCIDENT INVESTIGATION E & C Division / SAFETY CONTROL DEPT(CSC-01-R1-AI NO.__________) Investigation of the Accidents reported in CSC-01-R1-AR by

persons nominated by L&T site manager ( within 72 hours )

Name & designation of investigating person Project name & Job no. Exact location of Incident

Name of Injured Designation & Token no. Age : _____

Sex : _____

Date & Time of Accident

Accident details ( CSC-01-R1-Accident Report (AR) No. ___________)

What was Injured doing at the time of Accident :

State whether it is Personal Injury / Property damage( Specify value in Rs. )

Whether LTA or Minor or Others Name of Contractor

Whether there was Unsafe Act? Give details

Whether there was Unsafe Condition? Give details

Was he under the influence of alcohol / drug Yes ! No !

The Injured person working

Since : ________ Month, ________ Year

Date & Time the person resumedwork after accident

Specify the failure / deviation fromSafety norms :

Cause of Accident

What immediate actions have been taken to prevent suchaccidents :

What actions could be taken to prevent suchaccidents in future :

Investigating Person

_____________________________Name

Date : (Signature)

Contractor / Site in-charge

_____________________________Name

Date : (Signature)

Site Manager

___________________________Name

Date : (Signature)Note : 1. Please attach sketches or a separate sheet if

space for any column is not adequate.2. Report should be legible, properly typed.3. The purpose of investigation report is to find

out the causes, not to fix blame on somebody.




LARSEN & TOUBRO LIMITEDNEAR MISS ACCIDENT REPORT E & C Division / SAFETY CONTROL DEPT(CSC-01-R1-NA NO.__________) It is important that the reporter removes unsafe

condition or stops unsafe act before filling the formProject Name & Job no. Exact location of Incident Date & Time of Incident SBU

Probable Accident that could have occurred ( Tick as applicable )

! Personal Accident ! Fire / Explosion ! Mechanical

! Collapse of Structure ! Spillage of dangerous fluids ! Others ( Specify ) :

Name of Contractor Brief description of Unsafe Act / Condition observed

Brief description of Incident :

Whether the unsafe practice / Act / Condition was informed to the person/s involved or contractor supervisor or L&Tengineer before filling the form : ! Yes ! No

To whom reported ( Give name of persons ) :

What action was taken after reporting as mentioned above

Name of the reporter with whom he is working / SSO

________________________________________Name

Date : ( Signature )

L&T site manger’s remarks

Date : ( Signature )

Note : 1. Please attach sketches or a separate sheet ifspace for any column is not adequate.

2. Report should be legible, properly typed.3. The purpose of near accident report is to find

out the causes, not to fix blame on somebody.




FIRST AID ACCIDENT REPORT LARSEN & TOUBRO LIMITED(CSC-01-R0- FAAR) E & C Division / SAFETY CONTROL DEPT

TO BE SUBMITTED WITHIN 1ST WEEK OF EVERY MONTHProject Name & Job no. : For the Month of SBU

Sr.No. Date Time Name of Injured Age Sex Name of Contractors1.2.3.

Sr.No.

Type of Injury Location of Injury Object causing Injury Deviation in Safetynorms

1.2.3.

Brief description about accidents :1.

2.

3.

Unsafe act Unsafe Condition1. 1.

2. 2.

3. 3.

____________________________________ ____________________________________NAME OF REPORTING SUPERVISOR / SSO NAME OF RCM

___________ ___________DATE: SIGNATURE DATE: SIGNATURE

Note : 1. Please attach sketches or a separate sheet if space forany column is not adequate.

2. Report should be legible, properly typed.3. The purpose of first aid report is to find out the causes, not

to fix blame on somebody. 4. Only those name shall be included who received only

first aid injury & resume duty within 2 hours.






3.8 SHE Audit

In order to ensure that the site follows all the statutoryrequirements, codes and norms, periodic monitoring is required.The regular and periodic monitoring is also required to find out theintroduction of any makeshift repairs and changes to temporaryconstruction at work site, which if left unnoticed may lead topotentially dangerous work situations resulting in losses.

The regular and thorough inspection activities which an operationundertakes on a frequency consistent with the risk, provides a wayto reduce the potential for these losses through the identification,analysis and correction of work place hazards before incidentoccurs.

Periodic measurement or Audit is more thorough than regularmeasurement or Inspection. It takes more time and it measuresthe site’s complete SHE management System. Unlike theInspection, which is of specific nature, the Audit covers the entireSHE Management System.

The formats that are in use are given in the annexure

At the end of each chapter, wherever necessary formats are givenfor inspection / audit for ensuring the safety of the machinery usedor the method adopted.

Sheet 1 of 6

SIGNATURE OF AUDITOR : SIGNATURE OF AUDITEE :

LARSENT & TOUBRO LIMITEDSAFETY CONTROL DEPARTMENT

E & C DIVISION, POWAI, MUMBAI - 400 072.

SAFETY AUDIT CHECKLIST

SITE : AUDITOR : AUDITEE :

DATE : REFERENCE : L&T SAFETY MANUAL OF E & C DIVISION

SR.NO.

REQUIREMENT TO THE COMPLIANCE ACTIVITYCOMPLIANCE

YES / NO

NONCOMPLIANCE

NOTE NO.

REMARKS

1. Is the Company Safety Policy displayed atsite office and conference room?

2. Is full time site safety officer deputed at site?

3. Is Site Safety Officer approved by SafetyControl Department?

4. Are construction safety manual & safetyprocedure manual available at site?

5. Does the site have safety committee?

6. Are sub-contractors included in safetycommittee?

7. Is safety committee meeting held monthly?

Sheet 2 of 6


SR.NO.


YES / NO

NONCOMPLIANCE

NOTE NO.

REMARKS

10. Are unsafe acts / conditions, accident causesand recommendations discussed in meeting?

11. Are action by and target date columnsincluded in minutes of meeting?

12. Are minutes of meeting circulated amongmembers and copy sent to SCD, Powai?

13. Is accident reporting and investigationprocedure followed at site?

14. Are near miss accidents reported andinvestigated?

15. Is safety inspection logbook maintained bySSO?

16. Is safety inspection signed by RCM?

17. Is SSO conducting toolbox talks at site?

18. Are records maintained?

19. Is site-opening report sent to SCD, Powai?

20. Is safety day / week celebrated at site?

21. Are safety posters displayed at site?

22. Are adequate numbers of first aid boxesavailable at site?i) Site officeii) One box for every 300 M radius

Sheet 3 of 6


SR.NO.


YES / NO

NONCOMPLIANCE

NOTE NO.

REMARKS

23. Is ambulance available at site?

24. Is clinic available at site?

25. Is house keeping in order?

26. Are walkways clear from obstruction?

27. Is material stacked properly?

28. Are sufficient dustbins provided?

29. Is work permit system followed at site?

30. Whether all safety precautions taken, whichare mentioned in work permit?

31. Are Personal Protective Equipment (PPE)provided for employees?

32. Are employees using PPE?

33. Are safety belts used for working at heightabove 2 M?

34. Are safety belts anchored to fixed point?

35. Are ear muffs / plugs provided, where noiselevel is more than 85 dB?

36. Is safe access / platform provided forworking at height?

Sheet 4 of 6


SR.NO.


YES / NO

NONCOMPLIANCE

NOTE NO.

REMARKS

37. Are adequate scaffolding provided forworking at height?

38. Is scaffolding checked / inspected beforeuse?

39. Are sufficient fire extinguishers provided atsite?i) Near site officeii) Near storesiii) Near hot work

40. Are fire extinguishers properly serviced andvalidity date marked on it?

41. Are employees trained for operating fireextinguishers?

42. Whether all lifting equipment / tackles aremarked with their S.W.L.?

43. Are inspection / test certificates ofcompetent person (s) available at site?

44. Are adequate lifting tackles provided at site?

45. Are trained operators engaged for operatingthe equipment?

46. Are lifting equipment / tackles maintained ingood working conditions and recordmaintained?

Sheet 5 of 6


SR.NO.


YES / NO

NONCOMPLIANCE

NOTE NO.

REMARKS

47. Whether proper storage is provided for gascylinders?

48. Whether valve protection caps are providedfor gas cylinders?

49. Whether flash back arresters provided foroxy-acetylene gas cutting set?

50. Whether trolley provided for gas cutting set?

51. Whether proper clamps provided for hoseconnection?

52. Are pressure vessels tested / certified bycompetent person?

53. Are ELCB's provided for electricalinstallations?

54. Are emergency nos. displayed at site?

55. Is emergency vehicle available at site?

56. Are guards of machinery’s in position?

57. Is work place properly illuminated?

58. Are adequate ladders provided at site?

59. Is monthly accident statistics report copysent to SCD, Powai?

Sheet 6 of 6


SR.NO.


YES / NO

NONCOMPLIANCE

NOTE NO.

REMARKS

60. Are accident prevention tools & safety-related items available at site as perprocedure CSC-08?

61. Is safety performance board displayed atsite?

62. Is positive reporting on safety report sent toSCD, Powai?

63. Are excavations safe for work?

64. Are excavation barricaded?

65. Is proper slope or shoring provided forexcavation?

66. Whether hand tools are in good workingcondition?

67. Are damaged tools discarded?

68. Whether portable electrical tools are in goodworking condition?

69. Is earthing provided for portable electricaltools?

70. Are guards provided for portable grindingmachines?

71. Whether AERB rules followed forradiography?



3.9 SHE Training:

3.9.1 Safety Tool - Box Meetings/ Talk (TBT) at ConstructionSites

(A) Objective

Awareness of safety in construction, and knowledge abouthazards and their elimination/ minimisation in constructionactivities is one of the prime functions of Resident ConstructionManager/ Engineer (RCM/RCE). This awareness is essential toprevent accidents to man, machine and environment under hiscontrol & responsibility.

In order to prevent accidents, RCM/RCE has to put hisknowledge about safe practices into action, to begin withhimself, and then ensure that safe practices are followed by all,who are working at his site and particularly by workmen, whoactually carry out the construction activities.

Due to the typical nature of construction activities/sites,knowledge, culture, skills and attitudes of workmen to safetyvary from site to site and it is necessary for RCM/E to impart toworkmen the knowledge and skill about safe practices inconstruction activities, in general and specific to his site.

One of the effective methods, to inform workmen about safepractices in their work is TOOLBOX TALK/ MEETING. In thesemeetings/ talks workmen are informed about hazards involvedin the activities and safe methods of carrying out theseactivities. The information must be given regularly, well in timeand in sufficient details. Annexure gives various topics thatcould be included in such talks.

(B) Procedure

This procedure spells out the requirement of conducting TOOL-BOX TALKS (TBT) at E & C division’s sites, their timings, theirfrequency, subjects and responsible person/s. The Annexure tothe procedure gives Tool-Box Talks details for some ofconstruction activities, which are normally done at almost allconstruction sites.

Steps to be taken by RCM/RCE to implement this procedure areas follows:



1. From the effective date of the Procedure, RCM shallensure that -(i) Site Safety Officer (SSO) at his site is trained &

equipped to conduct toolbox Talks. (If SSO, for anyreason is not trained & equipped to do this, he shallbe immediately sent to SCD at Powai for thetraining).

(ii) SSO conducts at least two TBT’s every day in themorning, before activities in the areas start. SSO mayconduct additional TBT’s during the day in areaswhere construction activity is likely to start.

(iii) Each TBT shall be for a duration of about 10 minutesand shall be directly addressed to workmen in alanguage they understand.

(iv) TBT shall be on one specific activity on each occasion.2. SSO shall record in a separate log book, details about the

TBT’s he has conducted, such as date, time, subject ofTBT, language, location and no. of persons attended andsignature of RCM. SSO shall ensure that RCM is informedabout the TBT’s for the day and he takes RCM’s signaturein the log book.

3. SSO shall ensure that the concerned Supervisors orEngineer/s of workmen attending the TBT’s are presentwhen TBT’s are conducted.

4. In order to make TBT’s more effective and meaningful,SSO shall get to know and RCM shall ensure that SSOknows the nature of activities on which he plans toconduct TBT, on the previous day, so that he can tailorTBTs to suit the exact site conditions and hazards.

5. SSO shall use the information annexed to this Procedureas such or with suitable modification, for conducting TBT’son the subjects of TBT’s covered in the Annexure.

6. SSO through RCM shall report on monthly basis to SCDabout no. of TBT’s conducted at his site and theireffectiveness.

7. Safety Engineers (from SCD, Powai) shall conduct TBT’swhen they visit sites.



(C) Administration

1. Uncontrolled copies of this procedure alongwith theannexure will be sent to all SSOs.

2. Safety Engineer (SE) from SCD shall check up-to-datelogbook records of TBTs conducted by SSO at the site andcommunicate his observations in the visit report.

3. SE shall also interact with SSO, during the site visit, onadditional TBTs which need to be included in the annexureand also about revision in the contents of TBTs in theAnnexure.



3.9.2 Training at site:

Introduction

An effective accident prevention and occupational health hazardcontrol program is based on proper job performance. Whenpeople are trained to do their job properly, they will do themsafely. Also training is the only way to influence human behavior.

Training Needs

A training program is needed• For new and redesigned employees• When new equipment or processes are introduced.• When Procedures have been revised or updated.• When new information must be made available and• When Employees’ performance needs to be improved.

Here are some indications of a need for a good training program.• Proportionally more accidents and injuries• High labor turn over• Excessive waste and scrap• Company expansion of plant and requirement

Program Objectives

Training programs should be based on closely defined objectivesthat determine the scope of the training and guide the selectionand preparation of the training materials. Objective should beplanned carefully and written down. They should indicate whatthe trainee is to know or do by the end of the training period.

The general topics covered by SCD in its training program aregiven in annexure 1.

Annexure 2 contains the subjects normally covered in supervisorstraining program.

Apart from the conventional training program covered inannexure 1 and annexure 2, there are other types of trainingprogram. Some of the important programs are listed below:• On –the –job training• Conference method of watching like problem solving

Conferences.• Group training techniques

(encouraging participants to share ideas)



Example: Brain storming sessions, case study presentation,discussions regarding standardisation of procedure.

• Simulation• Quiz program on specific topic• Television / screening of films.

The annexure gives the existing program schedule and also amodel training program schedule.



Annexure 1

Safety Control Department – Training Program Content

• Safety philosophy

• Building and other construction work act

• Safety in working at height

• Material handling

• Crane safety

• Safety in welding and gas cutting

• Fire safety

• Personal Protective Equipment

• Video films and discussions

• Electrical safety (Optional)

• Safety in Chemical handling at Construction Site

Participants: Both regular and contractors employees



Annexure - 2

Model Course Contents of Supervisory Training Program

Session 1Safety and The Supervisor

Safety and efficient production go together.Accidents affect morale and public relations.

The cities of a supervisor under OSHA.

Session 2Know Your Accident Problems

Elements of an accident. Unsafe acts, unsafeconditions, accident investigations, measurements

of a safety performance. Accident costs.

Session 3Human Relations

Motivation. Basic needs of workers.The supervisor as a leader.

The alcohol and drug problem.

Session 4Maintaining Interest in Safety

Committee functions, maintaining goodemployee relations. The supervisor’s role in off-

the-job safety.

Session 5Instruction for Safety

Importance of job instruction. Making a jobSafety analysis (JSA). Job instruction training (JIT).

Session 6Industrial Hygiene

Environment health hazards. Skin diseases.Lighting, noise, ventilation, temperature effects.

Session 7Personal Protective Equipment

Eye protection, face protection, foot and legProtection, hand protection. Respiratory protectiveEquipment. Protection against ionizing radiation.



Session 8Industrial Housekeeping

Results of good housekeeping. The responsibilityof the supervisor. OSHA requirement.

Session 9Material Handling and Storage

Lifting and carrying, handling specific shapes.Hand tools for material handling. Motorized

equipment. Hazardous liquids and compressed gases.

Session 10Guarding Machines and Mechanisms

Principles of guarding. Benefits of good guarding.Types of guards. Standards and codes. OSHA regulations.

Session 11Hand and Portable Power Tools

Selection and storage. Training in the safe care



3.10 Work Permit System

Objectives :

At L&T - E & C Division construction sites, numerous activities carried outby L&T and its contractor/sub-contractor personnel need to be donesafely to prevent accidents to men, machine and surroundings. The‘Construction Safety Manual’ of E & C Division lays down the basic andminimum requirements related to safety from those involved in theseactivities.

However, it is necessary to ensure that there is commitment from theManagers / Engineers / Supervisors of persons who carry out theseconstruction activities. Such commitment can be obtained, if standardand specific safety instructions related to the activities are informed, inwriting to the Managers / Engineers/ Supervisors before commencementof the activities on each day and they accept the instructions, in writing.

The commitment to follow safety instructions, in writing, is obtainedthrough ‘Permit System’, which has to commence from the day the firstconstruction activity starts at site until the last activity. The ‘PermitSystem’ is applied to those activities wherein there are higher potentialrisks and hazards. These generally are:

- Radiography work permit for NDT (CSCR)- Cold work permit (CSCP)

For working at height, opening of flanges, manual sand removal,painting, working on lifting tools/ tackles including chain pulley block,cranes( EOT, gantry, mobile) etc.

- Hot work permit (CSCW)For welding/ gas cutting, sand blasting, grinding, running I.C. enginesetc.

- Permit for entry into confined space (CSCC) For entry into vessel, pit/opening, excavated area etc.- Permit for working on electrical lines/ equipment (CSCL)

Procedure :

This procedure lays down steps to be taken by RCM/ RCE before andduring the above mentioned activities at construction site.



There are five different ‘Permit’ forms, each dealing with one of the fiveactivities mentioned above. Each form has certain standard instructionsand space for writing special instructions by RCM/ RCE, related to theactivity and site situation. These instructions have to be clearlyunderstood by the workers, Manager/ Engineer/ Supervisor and ensuredthat they are followed by the persons actually carrying out the concernedactivity. The forms, therefore, require signatures of concerned responsiblepersons, implying their commitment to the instructions. The forms alsorequire communication regarding completion of the ‘permitted’ activities.After a form is returned stating completion of an activity, the same cannot be carried out again unless the permit is renewed. The permit can berenewed for maximum 6 days only. Thereafter a fresh permit is required.Annexure - I to this procedure lists construction activities that requireissue of permits.

Adminstration

RCM/ RCE shall ensure that this procedure is followed as outlined below:

1. RCM/RCE shall inform all contractors about the permit system andadvise them in writing (by letters and notices) that permits arerequired to carry out the above mentioned five activities.

2. Contractors shall be advised to apply for permits for the concernedactivity at least 2 hours before it starts (4 hours, in case ofradiography).

3. RCM/ RCE shall issue the requisite permit form noting down specialinstructions and if instructions, if any to the contractor’s supervisor,who will sign on the form as the ‘Initiator’.

4. After the site and persons are ready as per the instructions on theform, RCM/RCE, shall inspect the work-site and persons forcompliance of the instructions and if instructions are fully complied,the contractor’s supervisor, RCM/RCE, L&T Engineer and SSO shallsign the form to permit the form to permit the activity for the periodand date mentioned on the form.

5. During the progress of the activity/ work permitted, the contractor’sand RCM’s designated Engineer/ Supervisor shall ensure that thereare no deviations from the instructions. RCM/ RCE, SSO or anySupervisor and Engineer can stop work and cancel the permit



immediately by stating the reason and signing the permit, if they findany deviations during the progress of work. The same activity can becarried out again by obtaining a fresh permit from RCM/ RCE.

6. When the activity / work is completed or the period/ date stipulatedon the form has lapsed, RCM/ RCE shall ensure that the contractor’ ssupervisor returns the form (duly signed ) to RCM/ RCE who shall fileit chronologically for future reference.

7. Permit shall only be renewed if the work - site conditions, activityand persons involved are same.

8. Fresh permit shall be issued if the activity has to be continued aftercompletion of the period, if the work-site is different, on a new dayor if the work-site conditions change.

9. Only ‘Red Copy’ shall be issued to the contractor’s supervisor and ‘Yellow Copy’ shall always remain in the Permit Book in L&T’s siteoffice.

10. Contractors’ supervisors shall be advised by RCM/ RCE to keep the‘Red Copy’ with them as long as activity/ work is in progress and‘Red Copy’ may be demanded by any L&T person as a proof forauthorisation of the work in progress.

11. All signatures and notings of the forms shall be done on both ‘Red’and ‘Yellow’ copies of the form.

12. Samples of the forms for the said five permits are annexed to thisProcedure.

13. Safety Control Department (SCD) will print and send 100 nos. ofeach form to all new and on- going sites, before the effective date ofthis Procedure. RCM/ RCE shall promptly and well in time requestadditional forms to SCD, when required or may get them printedwithout any change in the contents of the form.

RCM/ RCE may use photo copies of the blank forms if the originalsare not available, due to unavoidable delays.

14. RCM/ RCE shall ensure that under no normal circumstances, the saidfive activities / work shall be carried out by contractors without avalid permit.



15. RCM/ RCE shall inform SCD, if there is a need for an additional ‘permit’ for activities which are not concerned in this ‘ Permit System’and which in RCM/ RCE’s opinion require a permit.

Safety Officers/ Auditors from Powai will inspect/ audit this aspectwhen they visit the site.

Annexure – 1

Table for ready reference :

Activity/ Applicable Permit

Type of work CSCR CSCP CSCW CSCC CSCL

Radiography/ N. D. T. √Working at height √Working in pit/ vessel √Sand blasting/ Shotblasting

Welding/ gas cutting √Drilling/ grinding √Running diesel engine √Working on electricaleqpt.

√

Operating pneumatictools

√

Hydraulic/ Pneumatictesting

√

Manual sand removal √Tightening/opening offlanges

√

Spray painting √Manual painting √Working on lifting tools/tackles including cranes √

Note :* Some times more than one permit is required. While doinggrinding work in confined space requires ‘hot work permit’ as wellas ‘permit for entry into confined space’.

LARSEN & TOUBRO LIMITEDE & C DIVISION

COLD WORK PERMIT (CSCP)General Information

Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________Nature of work :________________________________________________________________________________Location of work : ________________________________________________________________________________

Name of Persons involved in Excavation work1. 4.2. 5.3. 6.Name of Contractor : Name of Incharge:

The following items must be checked before issuing the permitItem Y N N/A Item Y N N/A

12

3

4

5

6

78

9

10

Equipment/work area inspectedSurrounding area checked / cleanedup;oil/rags etc., removedEquipment blinded / disconnected /closed isolated / wedged open.Equipment completely drained /depressurised.Provide adequate material with which toshore the sides of excavationsGas / Oxygen deficiency test done( Oxygen level -19.6% - 23%)Precautionary tags/boards providedConfirm the locations of the Firehydrant mains/ Electrical cable/ Servicelines/ Drainage system / water mains,etc.Provide adequate ladder for getting inand out of the excavationsUsed the method of work for putting inshoring which protects the shorer

¨¨

¨

¨

¨

¨

¨¨

¨

¨

¨¨

¨

¨

¨

¨

¨¨

¨

¨

¨¨

¨

¨

¨

¨

¨¨

¨

¨

1112

13

14

1516

17

1819

20

21

Proper ventilation and Lighting provided.Sewers, manholes,etc., and hot surfacesnearby covered /sealed/ isolatedConsidered hazards from other routine/ non-routine operations & concerned personsalerted.Made sure that there are no bldg. whosestability is affected by excavationsAll persons provided with proper PPEEquipment electrically isolated / Groundedand taggedSides of excavations are sufficiently shored/are sloped back to 450

Area cordoned offEnsured that there is no spoil or eqpt. closeto the edge of the excavations.Made arrangement necessary to preventvehicles driving into the excavations.Are workers briefed about the hazards?

¨¨

¨

¨

¨¨

¨

¨¨

¨

¨

¨¨

¨

¨

¨¨

¨

¨¨

¨

¨

¨¨

¨

¨

¨¨

¨

¨¨

¨

¨

Additional permit required and / or attached:- No ¨ Yes ¨ ( If yes specify:- )

Daily Visual InspectionTime / Period To be signed only after

completing the jobDate ofWork From To

Remarks Signature ofSite Engineer

Signature ofRCM/RE Signature of

Site EngineerSignature

of RCM/RE

Special Instructions :1. This permit must be available at the work site at all times.2. Location & description of work must be clearly indicated by the permittee.3. Terms applicable must be clearly indicated by the permittee.4. All precautions given in permit must be strictly adhered to by the permittee.5. This permit shall be renewed each day only after checking all the compliance jointly by E & C Div. & the contractor.6. Permit renewal – for not more than 7 times including the issue date.7. Permit shall be returned to issuer after completing the job.

Additional Precautions required / Remarks, If any :

TO BE SIGNED JOINTLY BY L&T AND THE CONTRACTOR AFTER CHECKING FOR THE COMPLIANCEAll the points mentioned in the above checklist have been checked & found OK

____________________________________ ___________________ ________________ ________________________

(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) (RCM / RE – L&T)

TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.Permit is hereby returned after completing the job & ensuring safe removal of men & material.

__________________ _____________ __________ ____________(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) ( RCM / RE – L&T)

Permit No.: -


CONFINED SPACE ENTRY PERMIT(CSCC)General Information


Name of Persons entering into confined space1. 4.2. 5.3. 6.Name of Contractor : Name of stand by Person:


12

3

4

567

8

Equipment/work area inspectedSurrounding area checked / cleanedup;oil/rags/grass etc., removedEquipment blinded / disconnected /closed isolated / wedged open.Equipment completely drained /depressurised.Equipment properly steam purged.Equipment water flushed.Gas / Oxygen deficiency test done( Oxygen level -19.6% - 23%)Equipment properly tagged

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¨

¨

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¨

¨¨

¨

¨

¨¨¨

¨

¨¨

¨

¨

¨¨¨

¨

9

10

11

1213

141516

Proper ventilation and 24vLighting / handlamp provided.Stand by personnel provided for vesselentry.Considered hazards from other routine/ non-routine operations & concernedpersons alerted.Proper means of exit provided.All persons provided with proper PPE& APT (i.e. life line)Proper portable ladder providedSuitable scaffolding providedMeans of exit available

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¨

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¨

¨

¨

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¨

¨

¨

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Testing RecordTime / Period Meter Reading To be signed only after completing

the jobDate ofWork From To Flammability

%O2

Content %Toxic Gases

PPM

Signature ofSite

Engineer

Signature ofRCM/RE Signature of Site

EngineerSignature

of RCM/RE




____________________________________ ___________________ ________________ ________________________

(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) (RCM / RE – L&T)


__________________________________ ___________________ ________________ ________________________

(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) ( RCM / RE – L&T)

Permit No.: -


GENERAL ELECTRICAL PERMIT(CSCL)General Information


Name of Persons working on electrical equipment1. 4.2. 5.3. 6.Name of Contractor : Name of Incharge:


1*2

3

4 5 6

7 8

9 10*11

12

Equipment locked outCaution notice provided near the place ofworkSurrounding area checked / cleanedup;oil/rags/grass etc., removedIsolator / Breaker switched offFuses removed / Breaker withdrawnAux. Supply (Diesel generator) switchedoff.Transformer isolated from both ends.Equipment earthed / earthing truckinserted / earthing rod put.All person provided with proper PPE.Adequate lighting providedBarrier established to prevent inadequateentry.Verify circuits de-energized and capacitorshorted

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¨

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¨

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¨

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¨

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¨

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¨

*13

1415

16

17

18

19

20

Workers insulated from ground byinsulating material covering anyadjacent metal / energized circuits.Person certified and trainedMetal hand tools used are electricallyinsulatedAll metal and loose clothing removedfrom person doing the work.Hydraulic / air / Gas / Steam / acidvalves closed.Appropriated fire-fighting eqpt.Provided.Temporary connection required? If so,Load________ AmpTest meter is calibrated and checkedagainst known energized sourcebefore checking circuit

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¨

¨

¨

¨

¨

¨

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¨

¨

¨

¨

¨

¨

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¨

¨

¨

¨

¨


Daily Visual InspectionTime / Period To be signed only after completing the job

Date ofWork From To

Remarks Signature ofsite engineer

Signature ofRCM/RE Signature of site

engineerSignature of

RCM/RE

Special Instructions :1. This permit must be available in three copies two for initiator and one for issuer.2. Location & description of work must be clearly indicated by the permittee.3. Terms applicable must be clearly indicated by the permittee.4. All precautions given in permit must be strictly adhered to by the permittee.5. This permit shall be renewed each day only after checking all the compliance jointly by E & C Div. & the contractor.6. Permit renewal – for not more than 7 times including the issue date.7. Permit form shall be returned to issuer after completing the job.8. (*) used only for energized equipment.9. Use proper PPE while working with energized equipment / Non energized equipment



__________________ __________ ________ ____________(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) (RCM / RE – L&T)


______________________ _________ ________ _____________(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) ( RCM / RE – L&T)

Permit No.: -


HOT WORK PERMIT(CSCW)General Information


Name of Persons involved in Hot work1. 4.2. 5.3. 6.Name of Contractor : Name of Incharge:

The following items must be checked before issuing the permit

Item Y N N/A Item Y N N/A

12

3

4

567

8

9

10

Equipment / work area inspectedSurrounding area checked /cleaned up;oil/rags/ grass etc.,removedEquipment blinded / disconnected/ closed isolated / wedged open.Equipment completely drained /depressurised.Equipment properly steam purged.Equipment water flushedGas / Oxygen deficiency test done( Oxygen level -19.6% - 23%)Precautionary tags/boardsprovidedFire water hose/ portableextinguisher/ nozzle providedShield against spark provided

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¨

¨

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¨

¨

¨

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¨

¨

¨¨¨

¨

¨

¨

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¨

¨

¨¨¨

¨

¨

¨

11

12

13

141516

171819

20

Proper ventilation and Lightingprovided.Sewers, manholes,etc., and hotsurfaces nearby covered /sealed/isolatedConsidered hazards from other routine/non-routine operations & concernedpersons alerted.Proper means of exit providedAll persons provided with proper PPEEquipment electrically isolated /Grounded and taggedSuitable scaffolding providedArea cordoned offFlash back arrester provded to gascutting setAll the drain inlets(if any) been closed

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¨

¨

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¨

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¨

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¨


Testing RecordTime / Period Meter Reading To be signed only after completing

the jobDate ofWork

From To Lower ExplosiveLimit %

Upper ExplosiveLimit %

Signature ofSite

Engineer

Signatureof

RCM/RE Signature of SiteEngineer

Signatureof RCM/RE




____________________________________ ___________________ ________________ ________________________

(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) (RCM / RE – L&T)TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.

Permit is hereby returned after completing the job & ensuring safe removal of men & material.

__________________________________ ___________________ ________________ ________________________


Permit No.: -


RADIOGRAPHY WORK PERMIT(CSCR)General Information

Valid from ________________AM/PM Date________________to_______________AM/PM Date_________________Location of work :________________________________________________________________________________Source strength: ___________________________________ Curie: ____________________________________

Name of Persons involved in Radiography work1. 4.2. 5.3. 6.Name of Contractor : Name of Incharge:Name of Radiography agency : Name of Incharge of Radiography agency:

The following items must be checked before issuing the permit

Item Y N N/A Item Y N N/A

1

2

3

4

5

All the persons at the siteinformed/ removed from the areaArea around the source ofradiation cordoned off with rope/chordsRadiation warning symbol/ boardsdisplayed around radiographywork/ on ropes & chordsRadiographer worn radiationbadges during testingRadiography camera and carryingbox having radiation symbol

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¨

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¨

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¨

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¨

¨

¨

¨

6

7

Radiographer has valid certificate fromRadiation Protection Service Division,BARCRadiation survey meter is in workingcondition

¨

¨

¨

¨

¨

¨


Daily visual InspectionTime / Period To be signed only after completing

the jobDate ofWork From To

RemarksSignature of

SiteEngineer

Signatureof

RCM/RESignature of Site

EngineerSignature

of RCM/RE

Special Instructions :1. This permit must be available at the work site at all times.2. Location & description of work must be clearly indicated by the permittee.3. Terms applicable must be clearly indicated by the permittee.4. All precautions given in permit must be strictly adhered to by the permittee.5. The permit shall be submitted 4 hours before carrying out radiography to RCM/RE, L&T for his authorisation.6. This permit shall be renewed each day only after checking all the compliance jointly by E & C Div. & the contractor.7. Permit renewal – for not more than 7 times including the issue date.8. Permit shall be returned to issuer after completing the job.



____________________________________ ___________________ ________________ ________________________

(Contractor’s Site Incharge) (L&T Engineer) (L&T-S.S.O.) (RCM / RE – L&T)TO BE SIGNED JOINTLY BY L & T AND CONTRACTOR AFTER THE WORK IS OVER.

Permit is hereby returned after completing the job & ensuring safe removal of men & material.

__________________________________ ___________________ ________________ ________________________


Permit No.: -



3.11 Safety of L&T Visitors to Construction Sites

(A) Objective

L&T - E & C Division construction sites are visited by a number ofpersons who are not normally working at the sites and who are notfamiliar with the site conditions and activities.

Safety of visitors at L&T construction sites is equally important asthat of regular persons on these sites. For this, it is necessary tomake all visitors aware of the basic/minimum safety rules, beforethey enter the site, and specific/working safety rules while theywork on / go around the site.

(B) Procedure

This Procedure sets out safety guidelines and working procedureswhich are considered as the minimum standards applying to all`visitors’ entering L&T - E & C Division construction sites.

These L&T - E & C Division guidelines are intended to supplementthe applicable laws and regulations and state some of the practicesrequired of `visitors’ on L&T E & C Division construction sites.

Term `visitors’ includes all persons who are not regularlyemployed by (registered/on the role of) L&T or its contractors/sub-contractors, i.e. `visitors’ include all persons who enter L&T sitesfor discussion and/or for carrying out work/activity on behalf ofsuppliers/vendors of L&T or its contractor/sub-contractors.`Visitors’ also include all other L&T employees.

(C) Administration

It is responsibility of RCM/RCE to ensure that the following stepsare taken whenever he permits a visitor into his construction site.

1. RCM/RCE shall permit only authorised persons of companies /vendors / suppliers to enter the L&T construction site. (Thisis to ensure that such persons have knowledge about theequipment/material they carry and have adequate insurancecoverage).

2. Visitors shall be advised by RCM/RCE to read the shortversion of “Safety Guidelines for L&T Construction SiteVisitors”, given in Annexure-I. This shall be available with



RCM/RCE. (Safety Control Department will send six laminatedprints of the short version to all construction sites).

3. RCM/RCE shall take an undertaking from visitors that theyhave read L&T’s safety guidelines/rules/procedures beforethey do any kind of work in the `construction area’.

4. If the site is within the client’s premises and the entry pass isissued by the client’s security staff, then RCM/RCE shallensure that visitors, who are not familiar with the siteconditions and safety rules/procedures, shall be met at theentrance of the L&T site (not necessarily at the client’s maingate) and escorted in and out of the site by an L&Trepresentative of RCM/RCE.

RCM/RCE shall arrange to prominently display “SafetyGuidelines for L&T Construction Site Visitors” at the client’sgate where entry passes are issued to the visitors to the L&Tsite.

5. RCM/RCE shall show clearly a `safe route’ to his office fromthe entrance of the site, by clearly and prominently displayedsignboards marked “Site Office”. While walking on the `saferoute’, visitors shall not be required to wear protectiveequipment such as helmet, etc. However, if these arerequired, then RCM/RCE shall ensure that these are issued atthe entrance of the site.

6. Visitors permitted for discussion/meeting on the site, shall berestricted to stay inside the site office.If however, they are required to go around in the`construction area’, where construction activities are goingon, they shall be issued by RCM/RCE, the necessaryprotective equipment like helmets, safety shoes, gloves etc.,depending on the nature of hazards present in the area.

They shall always be accompanied by a member of the RCM’sstaff at the site, while they are inside the construction area.

7. Visitors representing vendors/suppliers and L&T officers, whoare required to carry out work such as installation, inspection,testing, commissioning or any kind of supervision which mayalso require their independent presence in the constructionarea, shall be made aware of the site safety rules byRCM/RCE and advised to read and follow the L&T



`Construction Safety Manual’ and the relevant procedures ofthe `L&T Procedure Manual’.

These visitors shall be issued all necessary PPEs or shall beadvised to bring their own PPEs and wear them before theyenter the construction area and start working.

RCM/RCE shall also ensure that these visitors have thenecessary insurance coverage for themselves and tools etc.which they bring into the site.

These visitors shall be considered as if they are L&T-contractor’s employees for all safety matters at the site.



Annexure -1

Safety Guidelines for L&T Construction Site Visitors

The following rules are the minimum L&T standards applicable to allvisitors to this site and are supplemental to statutory laws &regulations. If any doubt, please check with L & T - E & C DivisionResident Construction Manager / Engineer (RCM/E) or his staff.

1. Visitors shall enter into and work on this site at their own risk andshall have own adequate insurance cover.

2. Visitors shall follow advice of RCM/E with respect to more detailedSafety Rules & Procedures, which visitors shall request for.

3. Smoking is strictly prohibited on this site.

4. Possession of illegal drugs and paraphernalia, intoxicatingbeverages, fire arms chemicals/ solvents and other weapons areprohibited. These may be searched by L&T and visitors havingthese shall be immediately removed from the site.

5. Horseplay can be dangerous and is prohibited.

6. Littering and spillage of any kind is forbidden for maintaininghouse-keeping.

7. Entry of chemicals / solvents, gas cylinders, photographicequipment, tools / gadgets / instruments require prior writtenpermission from RCM/E.

8. Wearing of Personal Protective Equipment (PPE) is necessarywherever required/directed by L&T.

9. Visitors shall read and follow L&T’s `Construction SafetyManual’ and `Procedure Manual’, if he is required to carry outinstallation, inspection, testing, commissioning or any kind ofsupervisory work on this site.

10. Visitors shall make available RCM/E, Material/Equipment SafetyData Sheets for Materials/Equipment permitted to be carried bythem and shall be trained to use them suitably.

11. Visitors shall immediately report to RCM/E, accidents/injuries,unsafe conditions/near-misses and use of L&T’s fire fightingequipment.


Concept of Accident Prevention 1

PART II: SHE – Implementation

4. Concept of Accident Prevention:

Any accident prevention Programme is based on Hazard ControlProgramme. The Hazard Control Programme must be carefully plannedand be logical. Programme objectives and safety policies need to beestablished. Responsibility for the hazard control Programme needs to bedetermined. Specific steps to identify and control hazards need to beperformed.

Accidents and Hazard Control

Hazards are a major cause of accidents. A workable definition ofhazard is any existing or potential condition in the work place which,by itself or by interacting with other variables, can result in deaths,injuries, property damage, and other losses. This definition carrieswith it two significant points.

! A condition does not have to exist at the moment to be classified ashazard, only when total condition is considered then hazardouscondition is to be taken in to account.

! Hazard may result not only from independent failure of work placecomponents but also from one work place component acting uponor influencing another.

Effects of Hazard on the Work Process:

In a well-balanced operation, workers, equipment, and materialinteract within the work environment to produce a product or performa service. When all these function smoothly the productivity is thehighest. But if one of the components does not function to thedesired level then there would be disruption resulting in loss ofproductivity.

Hazard Control and Productivity Improvement:

The process of identifying and eliminating or controlling hazards in thework place is one way of optimising a company’s human, financial,technological, and physical resources. Hazard Control, like productivityimprovement, is a strategic process. To be effective, it must be



integrated into the day to day activities and management systems ofthe organisation and must become institutionalised – an operatingnorm and a strategic part of the company’s culture.

Determining Accident Factors:

In order to set realistic goals for its process, the company should firstdetermine the major factors likely to cause loss of control. It shoulddetermine where these factors are, their importance and their damagecausing potentials so as to evolve control measures, which could be inthe form of process/ work innovation etc.

Hazard Control and Management:

Controlling hazard is a team effort involving all the departments. Toco ordinate the departmental activities, a Programmeme of HazardControl is necessary. Those involved in establishing hazard controlProgrammeme must take into cognisance the inter relationshipsbetween the Worker – Equipment – Environment system as shown inthe figure below:

Figure on next page illustrates, an accident can intervene between thesystem and the task to be accomplished.

EQUIPMENT ENVIRON-MENT

WORKER

PERFORMANCE

TASK



The worker performs three basic functions as Sensor, InformationProcessor and Controller.Equipment should conform to all the norms.Special consideration must be given to environment factors, such aslayout, maintenance and house keeping, proper illumination,temperature etc that might detract from the comfort, health andsafety of the worker.

Accident Causes and their Control:

Accidents are caused. Close examination of each accident situationshows that it can be attributed, directly or indirectly to one or more ofthe following:! Oversight or omissions or malfunction of the management system.! Situational work factors like tools etc.! Human Factor, worker or other person.! Environmental Factors like noise etc.

Human Factor is the unsafe act of the injured or other personresulting in the accident. The unsafe act of a person may be due toseveral factors such as physical deficiency, lack of knowledge or skill,mental deficiency like lack of concentration, aptitude to the particularjob etc.

EQUIPMENT ENVIRONMENT

WORKER

PERFORMANCE

TASK

ACCIDENT



Human error is eliminated by:! Giving correct job method and procedure! Providing proper training! Considering worker performance with his physical characteristics

and fitness! Correcting potentially dangerous situation and! Providing proper and effective supervision.

Situational factors are another major cause of accidents. These factorsare those operations, tools, equipment, facilities and materials thatcontribute to accidents situation. These may be defect in design, poorsub standard construction, improper storage of hazardous materialand inadequate planning, layout and design.

Environmental factor includes physical category like noise,temperature, radiation, etc. chemical category like toxic release etcand biological category like contact with bacteria etc.

Situational and environmental hazards enter the work place frommany sources like procuring material and employee’s negligence infollowing safety norms and rules.

4.1 Principles of Hazard Control:

Hazard control is the function directed toward• RECOGNISE• EVALUATING,• ELIMINATING,

or at least reducing, the destructive effects of hazards emanating fromhuman errors and from the situational and environmental aspects ofthe work place. Its primary function is to locate, assess, and seteffective preventive and corrective measures for those elementsdetrimental to operational efficiency and effectiveness.

The process exists on three levels, namely National (laws, regulationsetc), Organisational (management of hazard control Programmeme,safety committees etc) and component (worker – equipment –environment).



Process Of Hazard Control:

An effective hazard control Programmeme has six steps orprocesses, namely:! Hazard Identification and Evaluation (through process information

giving the hazard inherent to it, previous inspection reports, andaccident reports and hazard analysis.)

! Ranking Hazards by Risk (consequence and probability) (throughranking hazard by risk taking into consideration the consequenceand severity, the probability of its occurrence and the workerexposure and risk assessment).

! Management Decision Making ( providing management with fulland accurate information, including all possible alternatives, so itcan make intelligent, informed decisions concerning hazardcontrol like training and education, for better methods andprocedures, equipment repair or replacement, environmentalcontrols etc)

! Establishing Preventive and Corrective Measures (actualinstallation of administrative and engineering e.g.: isolation ofsource, lockout procedures, design, process or proceduralchange, monitoring and warning equipment, chemical or materialsubstitution).

! Monitoring ( to locate new hazards and assess the effectivenessof existing controls through inspection, industrial hygiene testingand medical surveillance )

! Evaluating Programme Effectiveness ( by assessing financialrequirements and the benefits to be achieved through reductionof medical expenses, damages to machinery and material andimprovement in efficiency)

Organising an Occupational Safety and Health Programme:

The purpose of an hazard control Programme organisation is to assistmanagement in developing and operating a Programme designed toprotect workers, prevent and control accidents, and increaseeffectiveness of operations. The schematic diagram given below givesthe major organisational components of a hazard and loss controlProgramme.



Detailed discussions on various Hazards control measures are given inthe following chapters.

4.2 Off the Job Safety:

Essential off the job safety involves employees, and is a term used byemployers to designate that part of their safety Programme directedto the employees when they are not at work.

The principle aim of this Programme is to get an employee to followthe same safe practices while pursuing outside activities as used onthe job.

This Programme could include employee, his family and communityinvolvement and can include contest, picnic etc. To make it effectiveit should be well designed i.e. subjects well chosen and executed.

Identification andevaluation of hazards

Monitoring Programmes

Maintenance programmes

Housekeeping

Standard compliance

Accident Investigation

Evaluation of Programmeeffectiveness

Company policy

Programme objective

Assignment ofResponsibility and Authority

Adequate Physical andEconomic Resources

Safety committees

Employee orientation andinvolvement training andeducation

Supervision

Programme Enforcement

HAZARD

CONTROL

PROGRAMME


Site planning and layout 1

5. SITE PLANNING AND LAYOUT

5.1 Site layout

A badly planned and untidy site is the underlying cause of manyaccidents resulting from falls of material and collisions betweenworkers and plant or equipment. Space constraints, particularly inurban work sites, are nearly always the biggest limiting factor and alayout, which caters best for the safety and heath of workers mayappear to be difficult to reconcile with productivity. Proper planningby management is an essential part of preparation and budgetingfor the safe and efficient running of a construction operation.

Before work even begins on site, thought needs to be given to:• The sequence or order in which work will be done and to any

especially hazardous operations or processes.• Access for workers on and around the site: Routes should be

free from obstruction and from exposure to hazards such asfalling materials, materials-handling equipment and vehicles.Suitable warning notices should be posted. Edge protection willbe required at the edge of floor openings and stairs, andwhenever there is a drop of 2m or more.

• Routes for vehicular traffic: These should be “one way” as faras practicable. Traffic congestion prejudices the safety ofworkers from unsafe drivers.

• Storage areas for materials and equipment: materials need tobe stored as close as possible to the appropriate workstation,e.g. sand and gravel close to the cement-batching plant, andtimber close to the joinery shop. If this is not practicable, it isimportant to schedule the arrival of materials;

• The location of construction machinery: This is usuallydependent on operational requirements so that tower cranesare subject to constraints such as their radius of operation, andpick-up and unloading points. The objective should be to avoidthe need to slew the load over workers.

• The location of trade workshops: These are not usually movedafter they are built.

• The location of medical and welfare facilities. On large sitessanitary facilities for both sexes should be provided at severallocations



• Artificial lighting: At places where work continuos or workerspass after dark.

• Site security: The site should be fenced in to keep outunauthorized persons, children in particular, and to protect thepublic from site hazards. The type of fencing will depend on thelocation of the site, but in populated areas it should be at least2m high and without gaps or holes. Overhead protection will benecessary if tower crane loads pass over public thoroughfares.

• Arrangements to keep the site tidy and for the collection andremoval of waste.

• The need for low-voltage electric power supplies for temporarylighting, portable tools and equipment

• Training needs of both workers and supervisors.

5.2 CONSTRUCTION DETAILS:

After preparing the layout of the site, it is essential to programconstruction activities, detailing

• Sequential order of construction• Plans about layout of temporary construction site buildings, etc.• Action taken toward planning and co – ordination activities between

different operations and crafts.• Access to work areas.

These will enable the proper utilisation of the space, unnecessary wastageof material due to prolong storage, maintenance of better housekeepingand hiring of costly equipment and skilled personnel for a minimumperiod.

5.3 IN – BUILT SAFETY MEASURES:

At the planning stage itself safety should be integrated in all the plannedactivities. The material for construction, the machinery to be used andthe method of construction should all be evaluated with reference to thesite, the type of people to be engaged, the infrastructure available andthe environmental conditions and adequate in built safety measures andwork methods should be evolved.

Other measures like Safety Indoctrination and Safety Education,delegation of safety responsibilities down the line, integration of safetyinto operating methods and procedures will improve the quality of workand help in preventing accidents and dangerous occurrences at the site.



5.4 HOUSE KEEPING:

Many accidents occur at the site due to tripping, slipping or falling overmaterials and equipment which have been left lying around, and steppingon nails which have been left projecting from timber. Good housekeeping is an important element of accident prevention. It should beplanned at the beginning of the job and carefully supervised until the finalclean-up while handing over the site to the client.

It is recommended to have a regular clean up in all job sites. However,house keeping should be the concern of all supervisors and engineers intheir respective area of working and not left for the clean up crew. Inany case, house keeping should be a part of daily routine with clean upbeing a continuous procedure.

In general rubbish and scrap should not be left at the work site.Gangways, working platforms and stairways should be clear of equipmentand materials, not in immediate use.

Simple rules for good house keeping are as follows:

1. Storage areas : All materials should be maintained in neatstockpiles with well laid aisles and walkways for ease of access.There shall not be any projections in the walkways.

2. Work areas: loose materials, scrap, tools, etc shall not be allowedto be lying in the working areas especially in the vicinity of ladders,ramps stairs, etc. This is more important at heights where the loosematerials are liable to fall down.Spills of oil and grease should be removed immediately.An effective means like provision of receptacles should be providedto store waste and scrap pieces.

3. Protruding Nails : Protruding nails in wooden pieces is a chronicproblem in civil sites. It is worthwhile to have one or two helperscontinuously for retrieving protruding nails.

4. Scrap yard : Wooden scrap yard should be well away from anygas cutting or welding operations and 'No smoking' shall be strictly.ensured. All other combustible wastes like cotton wooden boxes,empty paint tins shall be disposed off safely within a reasonabletime.



5. Lighting : Adequate lighting should be provided in and around allwork areas, passage ways, stairs, ladders & other areas used bypersonnel.

6. Openings in floors : All openings in floors where our workmen.are liable to work or even pass through shall be either closed orbarricaded. If they are closed, a visible warning sign shall be keptto indicate the open . sing below the cover.

7. The approach road from and to the work site shall never beblocked by parking vehicles or stacking materials, etc. thusblocking the movement in case of emergencies.



5.5 SAFETY AT STORES:

The handling, storage and transportation of hazardous materials are dealtat the appropriate chapters.

In general the following should be adhered to:

• In case of storage of flammable or toxic substances, adequateventilation should be provided.

• Illumination should be proper and should confirm to the relevant rulesand standards.

• Adequate draining facility should be provided to avoid flooding.• There should be sufficient passage provided for easy movement of

material and lifting machinery.

In addition to above requirements, the provisions under Rule 51 of theBuilding and Other Construction Workers ( Regulation of Employment andconditions of Service ) Central Rules, 1998 should be complied with.Since it covers the stacking of all construction material, this rule is givenbelow:

Stacking of materials- The employer shall ensure, at a construction siteof a building or other construction work that-

(a) All building materials are stored or stacked in a safe and orderlymanner to avoid obstruction of any passageway or place of work;

(b) Material piles are stored or stacked in such a manner as to ensurestability;

(c) Material or equipment is not stored upon any floor or platform insuch quantity as to exceed its safe carrying capacity;

(d) Material or equipment is not stored or placed so close to any edge ofa floor or platform as to endanger the safety of persons below orworking in the vicinity.


Civil Work 1

6. Civil work

6.1 Blasting

The transportation, storage, handling & use of explosives are governedby Explosives Act and The Building and Other Construction Workers(Regulation of Employment and Conditions of Service) Central Rules 1998(Rules 212 and 213). Strict- compliance of the same should be ensured.Following three unsafe acts are strictly forbidden while handlingexplosives:

1. The use or possession of intoxicants on or around the- job2. Horse play or practical jokes3. Smoking or use of open lights

6.1.2 Blasting records

Following two records have to be maintained in 'all quarries whilehandling explosives :

A A blasting record for each blast indicating- date & time of blast- number of holes- type of explosive used- amount of charge per hole &- firing pattern & sequence

B An inventory of all explosives received, placed in, removed from &returned to storage magazines maintained current at all times.Only licensed blasters shall be allowed to handle explosives.

6.1.3 Transportation:

• Explosives should not be carried in the same vehicle with detonatorsunless the detonators are carried in a separate approved container.

• The vehicle should be equipped with a non-sparking metal or woodenfloor; the sides should be high enough to prevent the explosives fromfalling off or it should be equipped with a closed body. If it is an open


Civil Work 2

body truck, a fire & waterproof tarpaulin shall be used to cover theexplosives.

• Two fire extinguishers must be provided in the vehicle.

• Congested traffic should be avoided while transporting explosives.Unnecessary parkings at hotels, garages, filling stations etc, should beavoided.

• Unauthorised persons or ' flammable & corrosive substances ’ shall notbe allowed in the truck carrying explosives.

• Smoking is not allowed in & around the vehicle carrying explosives.

6.1.4 Storage

• Explosives should be stored only in approved storage magazineshowever small the quantity it shall be.

• While taking explosives for actual usage, it shall not be placed near sources of heat or water.

• Smoking or possessing matches, etc. near the magazine is prohibited.

• Manufacturer should be consulted, if nitro glycerine from deterioratedexplosives has leaked onto the floor of the magazine. The floor shouldbe de-sensitized with an agent approved for that purpose by themanufacturer.

• Leaves, grass, bush or debris shall not be allowed to accumulatewithin 25 feet of an explosive magazine.

• Detonators should NEVER be stored in the same magazine with anyother explosives.

• Barrication of the storage area.

6.1.5 Using explosives:

• Explosive cases should not be opened using metallic tools.


Civil Work 3

• Replace the cover of the case after the required quantity of explosiveis taken out.

• Smoking or other sources of fire are prohibited within a radius of 100feet from the place where explosives are being handled or stored.

• Only fuse and nothing else shall be inserted in the open end of theblasting cap.

• Explosive caps or fuses 'shall not be carried in the pockets of clothing,etc.

• Children or unauthorised persons are totally prohibited in the blastingarea.

• Deteriorated or damaged explosive caps and other accessories shallnot be used and these shall be returned to the manufacturer.

• Quantity of the charge to be used must be well calculated and be safeenough to prevent any damage to nearby structures due to shock &vibration resulting from the explosion. The charge can be coveredwith blasting mats, used conveyor belts or sand bags to preventsplinters flying off especially in running plants.

6.1.6 Drilling & loading

• Before drilling is started, possible presence of unfired explosivesshould be carefully checked. Never drill in the butts of old holes.

• Before loading, the condition of the holes should be checked eitherwith wooden tamping pole or measuring tape and not with hot brokendrill bit, etc.

• No. holes should be loaded except those that are to be fired in thenext round of blasting. Holes loaded during one shift should be firedon the same shift.

• To avoid misfires, the detonator should be completely inserted lengthwise in the cartridge, fastened in such a manner that it cannot bepulled out accidentally.


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• Cap crimpers of proper design should be used for crimping blastingcaps onto fuse - not with ones teeth or a knife.

• The diameter of hole drilled should be at least 3 mm more than theDiameter of the cartridge.

• Blasting should be carried out only during lean hours - say duringlunch time, night hours, etc.

6.1.7 Tamping

• Dynamite should not be normally removed from the cartridge, but ifthis is done, loose dynamite should not be tamped.

• Only wooden tamping tool should be used; if metallic parts are used,they should be of non-sparking type. Primer should never be tamped.

• Care should be exercised to avoid injuring fuse, detonating fuss. orcap wires during tamping.

6.1.7 Warning signal

A standard warning signal and an all clear signal should be used before &after firing and inspection. All personnel working in the area and nearbyarea should be made aware of this established warning procedures.

At the same time competent persons equipped with red flags should beposted at all possible approaches to the blasting area to stop traffic andby passers from entering the danger zone.

6.1.8 Firing

In electrical firing following safe practices are recommended to avoid anytrouble.

• All electrical connections should be good & rigid.


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• The blasting machine should be in good order and of sufficientcapacity to fire all the electric blasting caps connected in the circuit. Itmay be tested with a rheostat.

• Generator type blasting machine shall be operated few. times beforemaking the connections to prepare it for the maximum generation ofcurrent. This type of blasting machine should be operated withmaximum force.

• Electric detonators or delay electric detonators of differentmanufacturers should not be used in the same blast.

• The resistance of the circuit should be measured with a BlastingGalvanometer before attempting to fire.

• Radio, television and radar transmitters create fields of electrical enery which can detonate electric caps. Hence following minimum distance must be maintained between the transmitters & electric blasting caps.

Transmitter power (watts) Min.distance(feet)

5 - 25 10025 - 50 15050 - 100 220100 - 250 350250 - 500 450500 - 1000 6501000 - 2500 10002500 - 5000 15005000 - 10000 220010000 - 25000 350025000 - 50000 500050000 - 100000 7000

For FM Mobile Transmitters

1 - 10 510 - 30 1030 - 60 1560 - 250 30


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6.1.9 Misfires:

There is no absolute safe method for handling misfires. But misfires canbe prevented,

i by proper use of high-grade blasting supplies.ii by testing each electric cap with a blasting galvanometer before

loading oriii by testing the complete circuit before firing the blast.

However, if a misfire does occur, it should be handled very carefully, onlyby experienced persons.

The safest way to dispose of a misfire is to re shoot it, if throw of rockcan be tolerated. When the trouble is caused by faulty connections and ifthe leg wires are accessible, test the blasting cap with the galvanometerand try to blast it in the usual manner after giving connections properly.If the shot fails again, or if the wires are in-accessible, or if caps andfuses are being used, try to Shoot the hole with a fresh primer. If thisalso fails, the stemming should be removed carefully, a new primerinserted and then fired.

Unused, spilled or deteriorated explosives should not be abandoned. Itshould be preserved and disposed only by competent and experiencedpersons. Wood, paper or fibre used in packing explosives should beburned only in an isolated outdoor location. After the burning hasstarted, no person shall be allowed within 100 feet of the place ofburning.

Construction Blasting Inspection

Company Name: ______________________ JobsiteAddress:________________

Site Engineer: _______________________ Date/Time: ________ _________

SSO: _________________________

Yes No NA

1. Contractor qualifications and credentials

checked?

2. Explosive inventory completed and accounted

for at all times?

3. Stray electrical currents checked?

4. Blasting mats used when required?

5. All signs, warning signals, and protective

equipment in-place?

6. Non-essentials removed from area?

7. Radio transmissions limited?

8. Procedures for handling misfires in-place?

9. Explosives properly stored?

10. Is black powder prohibited?

11. Experienced and trained personnel handling

explosives?

12. Detonators tested before each shot?

13. Area inspection after each shot?

14. Proper disposal of wrappings, waste, and scrap?

15. Operations suspended during electrical storms

or when lightning is within 10 miles?

16. Explosives and related materials properly

stored?

17. All blasting operations conducted between sun-

up and sundown?


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6.2 Excavation:

To prevent injury and property damage during excavation work,make adequate` protective measures part of the job. Study pre-excavation condition, such as superimposed loads, soil structure,and hydrostatic pressure. From such a study, it is possible toevaluate changes that might occur, to prepare for situations thatmight develop, and to plan the job ahead. Excavation permitsshould be used to ensure that all the necessary precautions aretaken to protect employees.

Underground Utilities

A major hazard in urban or built-up areas is the presence ofunderground facilities, such as utility lines (water, electric, gas, ortelephone), tanks, process piping, and sewers. If this equipment isdug into, undercut or damaged in any way, there may be injury ordeath to workers, interruption of service, contamination of water,disruption of processes and expensive delays. Many states have a“one-call” system for locating buried lines. In one call all utilitiescan be identified and all underground utilities will be marked.

Before starting operations, consult the company or plant engineer,the utility companies, engineers, and the city’s or town’s engineers.The location of various facilities and their approximate depth belowground must be determined and marked by stake in the ground orby marking on the floor.

Electronic locators can be especially helpful where an excavationwould cross numerous buried obstacles. If the facilities are to beleft in place, they must be protected against damage andsometimes also against freezing.

Indicate the contents of buried tanks and piping on the locationmarkings. If the contents are flammable or toxic, have properprotective equipment readily available in case of rupture. Alsoindicate the bottom depth of tank.

Do the allow any shovel, dragline or other digging machine to


Civil Work 8

excavate close to underground facilities that must be left in place.Establish a depth limit for digging machines, and complete theexcavation by hand digging. If personnel are working in a trenchdeeper than 5-ft (1.5 m), provide adequate bracing and shoring orhave the trench slope. When hand excavation is being done, warnworkers about driving picks, paving breakers, or other poweredtools through buried facilities.

Barricades at Excavation Sites

Place excavated material at least 24-in. (0.6 m) from the edge ofthe excavation unless toeboards or other effective barricades havebeen installed to prevent fallback. Tarpaulins, sheeted barricades,or low built-up board barricades can be used to confine theexcavated material to the immediate are under construction. Do notpermit excavated material to accumulate in work areas or aisles;have them trucked or otherwise removed from the building.

Barricade excavations to prevent employees and others from fallinginto them. When an excavation must remain open for the durationof the construction work, barricades, fences, horses, and warningsigns are necessary. In some cases watchers and flaggers may beneeded. Guard the work area at night with flares, lanterns orflashing lights. (See NSC Industrial Data Sheet 482, GeneralExcavation).

Guard the sides of all excavations in which employees are exposedto danger from moving ground with a shoring system, sloping ofthe ground, or other equivalent means. The minimum slope in anysoil, with the exception of solid rock, should be no less than three-fourths horizontal to one vertical.

Base shoring, sloping and supporting systems (bracing, shoring,cribbing etc.) on careful evaluation of factors such as (1) depth ofcut; (2) possible variation in water content of the material while theexcavation is open; (3) anticipated changes in materials fromexposure to air, sun, water or freezing (4) loading imposed bystructures, equipment, overlaying material, or stored material; (5)and vibration from equipment, blasting, or traffic.


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Have a competent person approve the excavation safeguards andinspect shoring, sloping, and supporting systems daily and afterevery rainstorm or other hazard increasing occurrence. Increaseprotection against slides and cave-ins, if necessary. If evidence ofpossible cave-ins or slides is apparent, all work in the excavationshould cease until the necessary precautions have been taken tosafeguard the employees

Except in hard rock, excavations below the level of the base offooting of any foundation or retaining wall should not be permittedunless the wall is underpinned and all other precautions taken toensure the stability of the adjacent walls. If the stability ofadjoining buildings or walls is endangered by excavations, provideshoring bracing, or underpinning designed by a qualified person.Have such shoring, bracing or underpinning inspected daily or moreoften, as conditions warrant. Where it is necessary to undercut theside of an excavation, safely support overhanging material.

Groundwater should be controlled. Freezing pumping, drainage andsimilar control measures should be planned and directed by acompetent engineer. Consider the existing moisture balances insurrounding soils and the effects on foundations and structures if itis disturbed. When continuous operation of groundwater-controlequipment is necessary, provide an emergency power source. Usediversion ditches, dikes, or other means (1) to prevent surfacewater from entering an excavation and (2) to provide gooddrainage of the area adjacent to an excavation.

Store and retain excavated material at least 2-ft. (61 m) from theedge of the excavation to prevent excessive loading on the face ofthe excavation. Remove boulders. Stumps or other materials thatmay slide or roll into the excavation.

Provide walkways or bridges with guardrails where people orequipment are required or permitted to cross over excavations.Where personnel are required to enter excavations or ramps over4-ft (1.2 m) in depth, provide sufficient stair, ladders or ramps.Locate them so as not to require more than 25-ft (7.6 m) of lateraltravel. When access to excavations more than 20-ft (6.1 m) indepth is required, provide ramps, stairs, or mechanical personnel


Civil Work 10

hoists. Ladders used as accessways should extend from the bottomof the trench to not less than 3-ft (91 cm) above the surface.Provide at least two means of exit for personnel working inexcavations. Where the width of the excavation exceeds 100-ft (30m), provide two or more means of exit on each side of theexcavation.

When mobile equipment is used or allowed next to excavations,install substantial stop logs or barricades. Operators of excavatingor hoisting equipment should not be allowed to raise, lower, orswing loads over personnel in the excavation unless thosepersonnel have substantial overhead protection.

In locations where oxygen deficiency or gaseous conditions areknown or suspected, test the air in the excavation prior to the startof each shift, or more often if directed by the designated authority.A log of all test results should be maintained at the work site. If airis not within specification, ventilation may have to be provided toimprove the condition. Test until air is safe. A confined space entryprocedure should be mandatory in excavations with oxygendeficiencies or gase0ous conditions. Where such conditions aresuspected or are likely to develop in an excavation, have readilyavailable emergency rescue equipment such as breathingapparatus, safety harness and line and emergency medicalsupplies.

Trench Excavation

Trenches more than 5-ft (1.5 m ) deep should be shore, laid backto a stable slope, or provided with other equivalent protectionwhere employees may be exposed to moving ground or cave-insas per OSHA regulations. Trenches less that 5-ft (1.5 m) deep alsoshould be protected when studies show hazardous groundmovement may be expected. Bracing or shoring of trenches shouldprogress with the excavation.

Portable trench boxes, sliding trench boxes, or shields should bedesigned, constructed, and maintained to provide protection equalto or greater than the sheathing and shoring be in true horizontalposition, secured to prevent sliding falling or kick-outs.


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Back filling and removal of trench supports should progresstogether from the bottom of the trench. Release jacks or bracesslowly. In unstable soil, use ropes to pull out the jacks or bracesfrom above, after personnel have cleared the trench.

In hand-excavated trenches, spike or bolt wooden clears to join theends of braces to stringers. This will prevent the braces from beingknocked out of place.ln a long machine excavated trench a sliding trench shield may beused instead of shoring. Sliding trench shields generally arecustom made to size for a specific job. They must be designed andfabricated strong enough to withstand the pressures that will beencountered. Metal, portable hydraulic shoring systems are alsoavailable.


Civil Work 12

6.3 Piling :

Piling work is an integral part of any construction activity. If thisactivity is not carefully prepared and executed, it can result indelay as well as causing serious accidents. The Building and OtherConstruction Workers ( Regulation of Employment and Conditionsof Service ) Rules, 1998 ( Rules 214 to 222 ) give detailedstatutory requirements to be complied with while doing the pilingwork. It is advisable to adhere to certain basic safety measureswhich are given below:

6.3.1 General precautions:

There are certain hazards, which are common to all types of piling,and the following precautions are necessary.

1. Piling machine operators should be over 18 years of age andproperly trained;

2. Prior to piling, all underground services should be located andmade safe. A check should be made to ensure there are nobasements, underground water courses or ground conditionswhich might cause hazards;

3. There should be a firm level base for the crane, or crane matsprovided;

4. When working on piling operations the worker should wear asafety helmet and ear and eye protection where necessary.

5. All cranes, lifting appliances and lifting gear must haveappropriate certificates of testing and thorough examination,and should be large enough for the job;

6. Particular attention should be paid to the risk of damage tolifting gear from sharp edges;

7. Cranes used for raising or lowering workers must be fittedwith a dead man's handle and lowering should be done under


Civil Work 13

power; the worker should be carried in properly constructedcages which cannot spin or tip;

8. Piling contractors should be asked to provide a writtenmethod statement setting out the precautions relevant to thetype of piling they are to employ;

9. Induction training and information for the supervisor oroperative should be given and specifically related to themethod statement.

10. Workers should be encouraged to use Protective equipmentat all times when engaged in piling work,

6.3.2 Bored Piles:

Workers may need to enter a bore hole for inspection or forclearing out in undercuts, and there are certain precautions, whichmust be taken prior to such entry:

1. The bore hole should be at least 75 cm in diameter

2. The bore hole should be treated as a confined space and theprecautions which are advised elsewhere to ensure asatisfactory atmosphere must be closely followed

3. Waste material from the bore hole should be kept clear ofthe bore hole

4. Descent into a bore hole should be in properly designedskips, chains or cages fitted with an anti-spin device. Thepower source of the lifting-appliance should be keptrunning throughout the time someone is underground

5. While the workers are working down a bore hole they mustwear a safety harness

6. All workers concerned must be trained and competent inrescue from deep bore holes, and emergency rescue drillsshould be carried out at regular intervals


Civil Work 14

7. A banks’man who can see you in the bore hole should bepresent at all times

8. There must be adequate lighting at safe reduced voltageand a means of communication from the bore hole.

9. Wherever possible, the need for workers to enter pile boreholes should be avoided by the use of television camerasand other techniques for remote inspection.


Civil Work 15

6. 4. Safety in working at Height

Several factors and serious accidents are caused yearly topersons engaged in working at height such as buildingconstruction where men have to go at heights & unless adequatesafety precautions are taken serious accidents can happen.Investigations reveal that these accidents are caused byimprovised & make shit arrangements instead of providing propermeans of access.

6.4.1. Ramps & Runs

At the beginning of construction excavations are made to provideproper foundations. As the depth increases the means of accessto the bottom will be through ramps & runs and to cross thecuttings, gangways are to be provided.The Ramps and Runways should be constructed and maintainedin such a way to comply with the provisions under rules 82 to 85of The Building and other Construction Workers (Regulation ofEmployment and Condition of Service) Central Rules, 1998.

The slope to the ramps & runs should be as far as possible,max.15° to horizontal i.e. one in four and the total rise of acontinuous ramp does not exceed 3.7 meters, unless broken byhorizontal landing of at least 1.2 meters in length or as providedin relevant standards / codes.

Cleats not more than 40 cm apart should be provided on rampswith steep slopes. The width should be adequate for traffic. Toeboards should be provided where ramps extend over a workplaceor passage. The open sides should be protected by railings asrequired.

When the construction is started at some stage or other thegangways or any other means or access should have to beprovided to reach higher levels.

At the top level where the work is to be undertaken, there arecertain precautions to be taken.


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• Unprotected floors situated at a height and openings, pitsetc. in platforms should be protected by railings and toeboards or otherwise guarded suitably.

• Toe board should not be less than 15 cm.• There should also be an intermediate rail between floor and

top rail.

6. 4. 2. Ladders

Ladders should conform to the provisions given under Rules 172to 174 of The Building and other Construction Workers(Regulation of Employment and Condition of Service ) CentralRules, 1998.

Ladders may be classified under two broad categories – Portableand Fixed.

• Since the portable ladder is a hazardous piece of equipmentevery effort should be made to replace it with fixed laddersand scaffolds. It not only prevents the accident but alsosaves time for carrying ladder from one place to other.However we may have to resort to portable ladders for workto be carried out at height for short period.

Single Ladders

These are as single unit and intended to be used as such. The rungs aregenerally round or horizontal in cross section.

Some ladders are provided with flat plates in which case they are calledstepladders. B.I.S.4435: 1967 specifies that the treads should behorizontal, when the ladder is inclined at an angle 650 – 750 to horizontal.Where ladders can not be placed directly then retaining hooks or devicesshould be provided on top of the ladder.Some of the dos and don’ts while using single ladder are given inannexure-1.


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Working on Roof :

Some accidents happened due to fall of persons working on roof. Fallthrough fragile roof sheeting, loss of balance due to steep slope of theroof and insufficient care while working at the edge of the roof constitutethe principle causes for these accidents which could be prevented by thesafety measure given below.

Roofs covered with asbestos sheets, roof light covering glass or perspexcan break under the weight of the person and working along perlins cannot be relied upon.

Best way to prevent fall is to use specially designed roof ladders.

They should be atleast 38cm wide should have cross battens of at least3.2cm thick and with a gap between them not more than 38cm.

The ladder should be of sufficient to withstand the weight of the personand the material he carries, when spanning across the points of supporton the roof.It is not safe to fix the headboard or anchor board to the ladder by nailsalone. Designs of wooden and metal ladders are given in annexure-2.

A common mistake in securing the roof ladder is to allow the anchorboard or other anchorage to bare on the ridge capping. The capping maybreak off if it is off brittle material or the anchorage may slip away. Theright method is to have the anchorage to bear on the opposite slope or tobe secured by other means such as rope.

For curved roofs, special ladders to suit the shape of the roof will have tobe designed.

To ensure safe working at least two roof ladders are to be provided.

Safety belts should also be used as additional precaution.

The permit to work system given in the annexure (under the control ofrespective person) can help to ensure that persons are not allowed towork on roof without adhering to the above safety precautions. (a modelwork permit is given in annexure-3).


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Warning notices must be displayed at all approaches to the fragile roof.

Falls from the side of the roof can be prevented by providing a strongbarrier at the edges of the roof.

6. 4. 3. Scaffoldings :

Whenever construction or maintenance work above floor levelcan not be safely carried out from the ground, from any part ofthe building or permanent structure from a ladder or any othermeans of support, suitable scaffold should be provided. Thescaffold serves 2 purposes.

One is to provide convenient platform to perform work atheights.

The other is to provide safe means of access to all places whereany person is required to work at any time.

Accidents at scaffolds are generally caused either due to directcollapse of the scaffold or as a result of person or material fallingof the scaffold.

Great care is therefore necessary in erection, use anddismantling of scaffolds. These should conform to the provisionsof the Rules 188 to 205 of “The Building and otherConstruction Workers ( Regulation of Employment andCondition of Service ) Central Rules, 1998”.

General requirements are:

1. All scaffolds should be of suitable design, sound construction withmaterial of sufficient strength. The erections, alterations anddismantling of scaffold should be done under the supervision ofcompetent person.

2. Scaffold should be designed to carry at least 4 times the anticipatedload. They should be securely supported or suspended and should


Civil Work 19

wherever necessary, be sufficiently and properly strutted or braced toensure stability.

3. Safe means of access should be provided t all scaffold platforms.Failure to provide such access has caused many serious accidents. Thesafe means of access may be by ladders (portable or fixed), ramps,runways, gangways or stairways.

It is recommended that portable ladders should not be used as ameans of access if height of the platform of scaffold exceeds 3.75 m.Stairways are the fastest and the most efficient. Ramps and runwaysare also safer than ladders, but can not be used where there isappreciable difference of the levels to be connected. The use of crossbraces or framework of the scaffolds as means of access should not beencouraged.

4. Overhead protection: In case work is in progress at higher level thanthat of scaffold, then suitable protection should be provided so as toprevent falling tools etc. from the higher level informing the workersworking on the scaffold.

5. Protection under scaffold: When persons are required to work or passunder scaffold, it is necessary to provide a screen or canopy over thearea. Such protection should extend at least 30 cm outside thescaffold proper in order to catch any material falling from the edges ofscaffold. Screening with 13 mm wire mesh of 18-gauge wire issatisfactory for ordinary purpose. Instead of wire mesh planking with15-mm planks or steel corrugated sheeting can also be used.

6. Width of working platform:Following minimum widths are recommended as a general rule as perBIS 4014 (part II) – 1967.

! If a platform is used as a footing only .......... 700 mm! If a platform is used for the deposit of material .......... 900 mm! If a platform is used for support of any platform .........1100 mm! If a platform is used for dressing stone or bricks .........1300 mm! If a platform is used for purposes stated in (3) & (4) above

..........1500 mm! Extended at least 60 mm beyond the end of the support.


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6. 4. 3. 1. Railings and Toe boards

The railings should consist of a top rail at a height not less than 90 cm(max. 120 cm) above the platform and an intermediate rail halfwaybetween the top rail and the platform. The railings should be strongenough to withstand a load of 90 kg applied in any direction on the top ofthe rail.

It is also essential to provide toe boards at the edges of the platform.Height 150cms.

Steel components of tubular scaffolds should conform to therequirements laid down in BSI 2750-1964.

The scaffolds should be periodically inspected.

Other General Safety Practices

1. Competent person should inspect scaffolds after erection and beforeuse.

2. A common cause of failure in a scaffold is the removal of structuralparts while in use. This should be strictly prohibited.

3. Periodic treatment against deterioration due to weather conditionsshould be carried out.

4. There should be sufficient gap between hoisting equipment andscaffold to prevent material from hoist getting entangled with scaffold.

5. People should not be allowed to work in bad weather condition such asstorm.

6. Some of the scaffold sketches are given in annexure-4.

6. 4. 4 Safety Belts

There are many situations where it may not be practicable to provide allthe normal measures to protect persons falling from heights. In suchcases, the persons should wear safety belts secured suitably through aline to a proper anchorage.


Civil Work 21

There are four common types of safety belts namely, Pole safety belt,General purpose safety belt, General purpose safety belt with remoteanchorage and Harness (Man hoisting) type safety belt.

The material of the safety belt which should be chosen (leather andwebbing of natural and man-made fibers) according to the jobrequirements.

Lifelines should be secured to permit as little slack as possible.

In case of obstruction for free fall, shock absorbers should be providedfor the lifeline.

PP or nylon rope of 12 mm diameter are suitable for use as lifeline.

Steel cables are not suitable for use as lifeline in case where a free fall ispossible, unless shock absorber is provided. The belts should bemaintained properly with periodic inspections.

Annexure-5 gives important standards, convention pertaining to thischapter.


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Annexure 1 (Ladders)

a) While carrying ladder, the leading end should be at least 2 metersabove ground. Long ladders should be carried by 2 persons.

b) Ladder should be placed on firm base and on a level ground.

c) Ladder should be placed against a firm support for the stiles to rest onit securely. One ladder should be fixed firmly either through lashing orhooks at the top.

d) The slope of the ladder to wall / support should not be more than 75°to the floor (i.e. 1 foot gap at the base to wall and 4 feet from the topresting place to the ground.

e) Non slipping devices should be put to the bottom ends of ladder whensued on slippery flooring.

f) Persons ascending / descending the ladder should always face theladder.

g) Ladder should not be misused and should be maintained properly.

Larson & Toubro LimitedE & C Division

Safety at Working at Height Check-ListName of Job site: - SI.No.

Description Observation Yes/No

Remarks

1. All the workers have been explained safework method?

2. An established communication system havebeen established and explained to theworkers.

3 Adequate illumination has been ensured4 Work area inspected prior to start the work5. Area below the work place

barricaded,especially below hot work6. Workers provided with bags/box to carry

bolts, nuts and hand tools.7. Arrangement for fastening hand tools made.8. All work platforms ensured to be of

adequate strength and ergonomicallysuitable

9. Fabricated makeshift arrangements arechecked for quality and type of materialwelding, anchoring etc.

10. Work at more than one elevation at thesame segment is restricted.

ACCESS / EGRESS1. Walkways provided with handrail, mid-rail &

toe guard?2. All checkered plates, gratings properly

welded / bolted?3. Are ladders inspected and whether they are

maintained in good condition?4. Are ladder spliced?5. Are ladders properly secured to prevent

slipping, sliding or falling?6. Do side-rails extend 36” above top landing?7. Are built up ladders constructed of sound

materials?8. Are rungs and cleats not over 12” on

center?9. Metal ladders not used around electrical

hazards.10. Proper maintenance and storage11. Ladders placed at right slop12. Ladders, staircases welded / bolted

properly.13. Any obstruction in the stairs14. Are landing provided with handrails, knee

rails, toe boards etc.15. Whether ramp is provided with proper slope16. Proper hand rail/ guards provided in ramps.

House – Keeping1. Walk ways,aisles & all overhead

workplaces cleared of loose material2. Flammable material,if any, are cleared3. All deshuttering material are removed

after deshuttering is done4. Platforms and walkways free from

oil/grease or other slippery material5. Collected scrap are brought down or

lowered down and not dropped fromheight

PPE and Safety Devices1 Use of safety helmets,safety belts

ensured for all workers2. Anchoring points provided at all places

of work3. Common life line provided where ever

linear movement at height is required4. Safety nets are in use wherever

required5. Proper fall arrest system is deployed

at critical work places6. Crawler boards/Safety system for

work on fragile roof are used


Civil Work 23

6.5 Demolition of Structures

Plant personnel should do only minor demolition. Employ specialistsin the field if structures to be removed look as though they willpresent a problem. Wrecking specialists are familiar with theprocedures and precautions necessary to do the wo0rk safely.They know how to protect the public and adjacent property, andthey know the applicable federal, state or provincial, and municipalcodes and regulations.

Following are minor demolition work:

• Make provision to keep the public and unauthorized plant employeesat least 15-ft (5 M) away from the structure.

• Have a competent person make an engineering survey of thestructure. Determine the condition of the framing, floor, and walls, andcheck for any unanticipated conditions. Check for hazardouschemicals, gases, explosives, flammable materials, asbestos,hazardous waste, electrical circuits that may be engaged, etc.

• Disconnect utility services (gas, steam, and electricity) outside thebuilding. Notify the utility companies in advance. Maintain water linesas long as possible. Maintain or install a temporary water source forfire protection and for wetting down the site to reduce dust.

• Remove all glass doors and windows through out the structure.• Strip off lath and plaster to eliminate excessive dust during succeeding

work.• Remove chimneys and extensions of walls above the roof, down to

roof level, while working from the roof.• Remove the roof.• Remove walls by picking them apart, using either machine or hand

tools. Work from scaffolds supported independently outside the walls.• Remove all debris promptly, through chutes or internal holes. To

minimize production of dust assign persons to wet down the debris.Post signs that warn of falling materials.

• Avoid subjecting walls to lateral pressure from stored materials or tolateral impact from falling material.

• Barricade any area where material is being dumped, and placebarricades where necessary to protect workers from flying pieces.

• Prohibit employees from working below others.


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• Remove asbestos in an approved manner.• Require safety hats, goggles, foot protection, respirators, and gloves

as needed for all workers. (See Chapter 14, Personal ProtectionEquipment.)

• Develop necessary safety procedures for handling hazardous materialsand provide training for employees.

• Avoid exceeding the allowable floor loads for the storage of waste anddebris.

• Make continuing inspections to detect hazards resulting from thedemolition operation.

Sometimes the conventional methods for altering or removing concreteinstallations are unfeasible or undesirable. In such cases, use (1) “powdercutting,” a process that substitute penetration by intense heat forconcussion breakage, or (2) explosive.

6.6 Carpentry Workshop

6.6.1 Plant Layout :

The following general principles should be followed while sitingthe machinery:

• Provide a minimum of 1m backspace for the machineoperator.

• Ensure that the timber used does not interfere withoperations on adjacent machines.

• Provide clear passage around the machine.• Keep the materials properly stacked and away from

machines.

6.6.2 Housekeeping :

• The space around every wood working machine shall be freefrom obstruction.

• The floor of the workshop shall be cemented and maintainedin good condition. It shall not be allowed to become slipperyand as far as possible shall be kept free from chips or otherloose material.


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• A cordoned area shall be demarcated to dump the woodshavings, dust and pieces.

6.6.3 Machinery :

• Dangerous parts of the machinery shall be adequatelyguarded.

• Push stick should be used and should be kept near themachine.

• Stopping and starting devices shall be located within thereach of the operator.

6.6.4 Operator :

The Carpentry in-charge should nominate the required number ofoperators who will be authorised to work on the wood-workingmachines. Their names must be displayed on a board near themachine with a statement saying no other is authorised to workon the machine.

The designated operator shall be employed after he has beensufficiently trained to work on the wood working machinery andhe should be adequately instructed as to the inherent dangersinvolved in the operation.

6.6.5 Personnel Protective Equipment (PPE) :

Suitable personal protective equipment should be used by theoperator while working on the machinery. After use theseequipment should be stored near the machine.

6.6.6 Lighting :

• Lighting must be adequate and suitable for the work beingcarried out.

• Lighting should be provided in such a way to prevent glareand direct lighting on the work.

The illustrations given in the annexes provide proper method ofguarding and working on wood working machines.


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ANNEXURE 1

SUMMARY OF SAFETY RULES FOR VARIOUS WOODWORKINGTOOLS

Every operator should be trained in the safety rules covered in thischapter. As a summary, safety rules that demand close attention arelisted below. Be sure the operator checks the manufacturer's manual,understands the requirements, and follows the recommended procedures.

TABLE SAW

• Feed with the body to side of stock• Blade height• Splitter and anti kickback fingers forripping

• Stock firm to fence• Remove rip fence for crosscuts• Blade guards

CIRCULAR SAW

• Blade guards• Binding• Blade-correct type• Blade-tight on the arbor• Firm support for work• No obstructions• Begin cut with motor at manufacturer's

recommended speed for materials beingcut

• Hand and finger position

RADIAL ARM SAW

• Rip sawing-direction of feed (cut) and antikickback fingers

• Blade guards• Pull for cross cuts• End plates on track-arm tight• Clamp handles tight• Material tight to fence

Return cutter to rear of trackHand and finger position

BAND SAW

• Feed with body to side of stock• Guard height 1/8-in. clearance of material• Tension and type of blade• Release cuts before long curves• Stop machine to remove scrap or pull out

incomplete cut• Flat stock• Push stick for small parts

JOINTER/PLANER

• Depth of cut• Length of stock• Sharp cutters• No hands over cutters• Push stick for small stock• Guard

WOOD SHAPER

• Clamping work piece• Use correct guard• Feed into knives-don't back off• No feeding between fence and cutters• Collar and starting pin work for irregular work-stock

of sufficient weight• Fence opening only enough to clear cutters

Use stock as guard by shaping theunderside of stockSpindle nut tightShape only pieces 10 in. or longerProper types of cutters

SANDER

• Keep hand from abrasive surface• Ventilation• Belt or disk condition• Sand on downward side of disk

LATHE

• Stock without defects, glued joints dry• Power off when changing speeds on belt

lathes• Tool rest close to stock• Hold tools firmly in both hands• Remove tool rest when sanding or polishing


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When the width of the rip is 6 in. or wider,uses your right hand to feed the workpieceuntil it is clear of the table. Only use the lefthand to guide the workpiece-do not feed theworkpiece with the left hand.

When the width of the rip is less than 2 in., thepush stick cannot be used because the guardwill interfere. Use the auxiliary fence-worksupport and push block. Use two C clamps toattach the auxiliary fence-work support to therip fence.

When the width of rip is 2 in. to 6 in., use thepush stick to feed

the work.

Feed the workpiece by hand along theauxiliary fence until the end is about 1 in.beyond the front edge of the table. Continueto feed using the push block. Hold theworkpiece in position and install the pushblock by sliding it on top of the auxiliaryfence-work support (this might raise theguard).

Narrow strips thicker than the auxiliary fence-work support may enter the guard and strike thebaffle.Carefully raise the guard only enough to clear the workpiece. Use the push block to complete the cut.

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A clear plastic shield has been formed into a guard for this band saw.

Note the difference between a hold down (left) and a push block (right). The push block has a piece of woodacting as a Positive stop against the end of the workpiece; the hold down is flat on the bottom, Both are used tokeep the operator's thumbs and fingers away from the cutter head.


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Close – up of a properly functioning splitter (Driving knife) and antikickback deviceduring a ripping operation.


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6.7 Grinding Operation:

Introduction

The commonly used grinding m/c s in construction are theportable grinding m/cs. The speed of the wheels ranges from7000 rpm to 14000rpm or sometimes more than that. Even aminor mishandling would lead to a serious mishap. Hencegrinding operation ought to be done by a trained operatorfollowing the safety norms.Grinding is a hazardous operation. The grinding wheel rotates ata speed of more than 7000 rpm that cause a very serious injuryGrinding machines shape material by bringing it into contact witha rotating abrasive wheel or disk. Grinding includes surface,internal, external cylindrical and centerless operations, as well aspolishing, buffing, honing, and wire brushing. Portable machinesthat use small, high-speed grinding wheels have been dealtunder Hand and Power Tools.

6.7.1 Grinding Machine Hazards

Hazards associated with grinding machines include the following:

• Failure to use eye protection in addition to the eye shieldmounted on the grinder.

• Incorrectly holding the work.• Incorrectly adjusting or not using the work rest.• Using the wrong type, a poorly maintained or in- balanced

wheeler disk.• Ringing on the side of a wheel not designed for side grinding.• Taking too heavy a cut.• Applying work too quickly to a cold wheel or disk.• Grinding too high above the wheel's centre.• Failure to use wheel washers (blotters).• Vibration and excessive speed that lead to bursting a wheel or

disk.• Using bearing boxes with insufficient bearing surface.• Using a spindle with incorrect diameter or with the threads

cut so the nut loosens as the spindle revolves.


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• Installing flanges of the wrong size, with unequal diameters,or with unrelleved censers.

• Incorrect wheel dressing.• Contacting unguarded moving parts.• Using controls that are out of the operator's normal reach.• Using an abrasive blade instead of a grinder disk.• Failure to run a wet wheel dry, without coolant, for a period of

time before turning off the machine.• Using an untested, broken, or cracked grinding wheel.• Reaching across or near the rotating grinding wheel to load,

unload, or adjust the machine during set-up.

6.7.3 Abrasive Disks and Wheels

An abrasive disk is made of bonded abrasive, with inserted nutsor washers, projecting studs, or tapped plate holes on one side ofthe disk. This side is mounted on the faceplate of a grindingmachine. Only the exposed flat side of an abrasive disk isdesigned for grinding.

An abrasive wheel is made of bonded abrasive and is designed tobe mounted, either directly or with adapters, on the spindle orarbor of a grinding machine. Only the periphery orcircumferences of many abrasive wheels are designed forgrinding.

6.7.3 Inspecting abrasive wheels:

Ring test :When unpacking abrasive disks and wheels, inspect them fordamage from shipment and perform the "ring' test. This test canbe used for both light and heavy disks or wheels that are dry andfree of foreign material. To conduct the ring test, suspend a lightwheel from its hole on a small pin or the finger, and place aheavy one vertically on a hard floor. Then gently tap the wheelor disk with a light tool, such as a wooden screwdriver's handle.A mallet may be used for heavy wheels or disks. Make the tap ata point 45 degrees from the vertical center line and about 1 or 2in. (2.5 or 5 cm) from the periphery. A wheel or disk in goodcondition will give a clear, metallic ring when tapped. Wheels


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and disks of various grades and sizes have different pitches. (ringtest to be done on receipt by the user.)Visual Inspection on breakage, expiry dates designed rpm & wear& tear of the wheel etc.Daily inspection of grinding machines should include the pointsshown in Figure.Thoroughly investigate grinding wheel and disk failures,preferably with the manufacturer's representative. This type ofinvestigation, along with immediate corrective action, greatlyreduces the possibility of recurrent failures.

6.7.4 Handling abrasive disks and wheels:

! Abrasive disks and wheels require careful handling.! Do not drop or bump.! Do not roll large disks and wheels on the floor.! Transport disks and wheels too large or heavy to be carried

by hand! By truck or other means that provide the correct support.

6.7.5 Storing abrasive disks and wheels: fifo method

Store abrasive disks and wheels in a dry area not subject toextreme temperature changes, especially below-freezingtemperatures. Wet wheel might break or crack if stored below32 F (0 C). Breakage of a wheel or disk can occur if it is takenfrom a cold room and work is applied to it before it has warmedup.

Store abrasive disks and wheels in racks in a central storage areaunder the control of a specially trained person.

The length of time abrasive disks and wheels may be stored andstill be safe to use should be in accordance with manufacturers'recommendations. Give the ring test to disks and wheels takenout of long storage. Follow this by a check for recommendedspeed, and a speed test on the machine on which it will bemounted. Check the speed of all grinding wheels against thespindle speed of the machine-some are designed only for low-


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speed use. The grinding wheel must be rated at the same RPMas the machine or more than the machine rpm. If it is not, thewheel may explode and throw particles into the work areacausing serious at times fatal injuries.

Mounting wheels :

Mount all abrasive wheels between flanges. Exceptions to thisrule include mounted wheels, threaded wheels (plugs and cones),plate-mounted wheels, and cylinder, cup, or segmental wheelsmounted in chucks.

Flanges should have a diameter not less than one-third of thewheel's diameter. Flanges for the same wheel should be of thesame diameter and thickness, accurately turned to correctdimensions, and in balance. The requirement for balance doesnot apply to flanges made out of balance to counteract anunbalanced wheel.

Key, screw, shrink, or press the inner or driving flange onto thespindle. The bearing surface of the flange should run true withthe spindle. The outer flange's bore should easily slide onto thespindle. (hand tightening , blotter paper)

Schedule flange inspections frequently. Remove from the spindlea flange found to be sprung, not bearing evenly on the wheel, ordefective in any other way. Replace it with a flange that is ingood condition.

An incorrectly mounted abrasive wheel is the cause of muchwheel breakage. Since rotational forces and grinding heat causehigh stresses around the wheel's central hole, follow safetyregulations concerning size and design of the wheel.


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GRINDER CHECKLISTTYPE _____________ RPM ________

SIZE ______________ PERIPHERAL SPEED________

Item OK NOT OK

• WHEEL GUARD: securely fastenedProperly aligned

• GLASS SHIELD: clean- unscored- in place

• WORK REST: within 1/8 in. (3.2 mm) of wheel securely clamped• FRAME: securely mounted no vibration• WHEEL FACE: well-lighted dressed evenly• FLANGES: equal size correct diameter (1/2 wheel diam.)• SPEED: correct for wheel mounted• GUARD FOR POWER BELT OR DRIVE: in place

DATE _______ DEPARTMENT ________

INSPECTED BY _____________


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6.7.7. Operating a Grinding Machine:

When starting a grinding machine, stand to one side away fromthe grinding wheel. Allow at least one minute of warm-up timebefore grinding with the wheel. Always use coolant when truingthe wheel or during normal grinding. Never allow coolant to flowon a stationary grinding wheel; coolant might collect on oneportion of the wheel, causing an unbalanced condition. Thisunbalanced condition can cause the wheel to disintegrate uponrestarting. ( the underlined portion stands good for fixed grindingm/c not for portable one.)

While the machine is running, never remove a guard fastener orguard. The guards are on the machine for the operator's safety;if they are removed, serious injuries to the operator or others canresult.Do not touch any moving part of the machine or the rotatinggrinding wheel to determine its smoothness or condition.Do not attempt to physically operate a machine that is in itsautomatic mode.Never alter or try to alter the machine, its wheel speed, or any ofits safety equipment at any time.

6.7.8 Safe Speeds :

Do not operate abrasive wheels and disks at speeds exceedingthose recommended by the manufacturer. In particular,unmarked wheels of unusual shape, such as deep cups with thinwalls or backs with long drums, should be operated according tothe manufacturer's recommendations.

As the wheel wears down, the spindle's speed (rpm) sometimesincreased to maintain the surface speed (sfpm). When the wheelis nearly worn down, the spindle is running at the highest rpm.When the worn wheel is replaced, adjust the spindle's speed. It isnot possible and there is no need of adjustment of the spindle. Ifthe spindle's speed is not adjusted, the new wheel might breakbecause the surface speed exceeds manufacturer'srecommendations.


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Grinding equipment for high-speed operation should be speciallydesigned. Give special attention to spindle strength, guards, andflanges to eliminate mounting stresses. Such things as side-grinding pressure and the wheel's shape, mat also be considered.Proper maintenance and protective devices are also important forsafe high-speed operations. Obtain the manufacturer's approval(instructions) for all high speed wheel and disc operations.


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6.7.9 Work Rests :

Because work has become wedged between the work rest andthe wheel, many bench and floor-stand grinder wheels havebroken, thus causing serious injury. The work rest should besubstantially constructed and securely clamped not more than1/8 in. (3.2 mm) from the wheel. Check the work rest'sposition frequently. The work rest's height must be on thehorizontal centreline of the machine's spindle.

Never adjust the work rest while the wheel is in motion. Thework rest might slip and strike and break the wheel, or theoperator might catch a finger between the wheel and the workrest. To prevent work from adding twisting and bending stressto the wheel, operators should use guides to hold the work inposition when slot grinding or performing similar operations.

DRESSING ABRASIVE WHEELS

Abrasive wheels that are not true or not in balance will producepoor work. They can damage the machine and injure theoperator. Keeping the wheels in good condition eliminatesthese possibilities, decreases wheel wastage, and lengthens thewheel's life.

To recondition a rutted or excessively rough wheel, often it isnecessary to dress it by removing a large area of the face.Equip wheel-dressing tools with hood guards over the tops ofthe cutters. They will protect the operator from particles flyingfrom the wheel or pieces of broken cutters. The operator of awheel dresser should use a rigid work rest set close to thewheel. The operator should move the wheel dresser back andforth across the wheel's face, while firmly holding the heel orLug-on the underside of the dresser's head-against the edge,and not on top of the work rest.Occasionally test wheels for balance, and rebalance them ifnecessary. Wheels that are too worn, or too out of balance, tobe balanced by truing or dressing should be taken out ofservice.


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6.7.10 Surface Grinders and Internal Grinders:

Operating requirements for surface grinders and internal grindersdiffer from those for other types of wheels. Insecurely clampedwork pieces and unenergised magnetic chucks are commonsources of injury to operators of surface grinders.

Under these conditions, work pieces can be thrown withconsiderable forceIf the operator takes too deep a Cut or too quickly traverses thetable or wheel, the wheel can overheat at the rim and crack.Therefore, train operators, and supervise them to clamp worktightly. They must always properly adjust and turn on amagnetic chuck before applying the wheel. They must alsocontrol the work's speed and depth.Baffle plates on each end of a surface grinder are usuallystandard equipment. They should also include some provision forexhausting the grinding dust.Internal grinders can often be guarded with an automaticpositioning hood. This kind of hood covers the grinding wheelwhen it is in the retracted or idling position.

6.7.11 Grindstones:

When using grindstones, follow the manufacturer's suggestedrunning speeds and operating procedures. Never run stones ofunknown composition or manufacture at more than 2,500 sfpm(12.5 m/s), and ordinarily not more than 2,000 sfpm (10 nets).The size and weight of grindstones require a stand that is rigidlyconstructed, heavy enough to hold the stone securely, andmounted on a solid foundation to withstand vibration.

Since grindstones are run wet, take all possible precautions toprevent slipping accidents near the stones. Use rough concreteor other slip-resistant floor material in grindstone operatingareas.

Carefully inspect grindstones for cracks and other defects, assoon as they arrive from the manufacturer. Store those not to


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be used immediately in a dry, uniformly heated room, where theywill not be damaged.

Many grindstone failures result from faulty handling and incorrectmounting. Do not leave grindstones partially submerged inwater. This practice causes an unbalanced stone that can breakwhen rotated. Do not use wooden wedges on power-drivenstones. Often, these wedges are too tightly driven or canbecome wet and swell. In either case, cracks start in the cornersof a square center hole, radiate outward, and weaken the stonecausing ruptures to occur when operated at normal speeds.

After the stone has been centred, fill the central space about thearbor with lead or cement. Use double thickness of leather orrubber gaskets, rather than wood washers, wherever possible. Ifwood washers are used between the flanges and the stone, thewashers should be '/2 to 1 in. (1.3 to 2.5 cm) thick and theflanges should be clamped in place by heavy nuts.

To remove dust and wet spray or mist when dressing oroperating power-driven grindstones (either wet or dry), providean adequate exhaust system. Work rests should comply with thesame requirements as those for grinding wheels.

6.7.12 Polishing Wheels and Buffing Wheels :

Polishing wheels are either wood faced with leather or made ofstitched-together disks of canvas or similar material. A coat ofemery or other abrasive is glued to the periphery of the wheels.

Buffing wheels are made of disks of felt, linen, or canvas. Theperiphery is given a coat of rouge, Tripoli, or other mild abrasive.

The softness of the wheel, built up of linen, canvas, felt, orleather, is determined by the size of the flanges used-the largerthe flange, the harder the surface. When large flanges are used,it often is necessary to soften the working surface of the built-upwheels to conform to the contour of the object being polished. Asafe procedure for softening the working surface is to place thewheel on the floor or other flat surface and pound the edges of


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the wheel with a hammer or mallet. Do not place the wheel onthe spindle with a file or other object held against it. The filecould catch in the wheel and be thrown with such force that theoperator or nearby workers are injured.

6.7.13 Mounting :

Mount polishing wheels and buffing wheels on rigid andsubstantially constructed stands that are heavy enough for thewheels used. Mounting procedures for polishing wheels andbuffing wheels are the same as those for grinding wheels.

6.7.14 Safeguards :

Hood guards should be designed to prevent the operator's handsor clothing from catching on protruding nuts or the ends ofspindles. If working conditions require a hood that does not givethe needed protection, then use a spanner wrench to installsmooth nuts over the spindle's ends. Never substitute a prickpunch and hammer for a spanner wrench. Exhaust hoods shouldbe designed to catch particles thrown off by the wheels whenworking in a workshop.

Operators of polishing wheels and buffing wheels should not weargloves. A glove can catch and drag the operator’s hand againstthe wheel. Operators should not attempt to hold a small pieceagainst the wheel with the bare hands. Small pieces beingpolished or buffed can frequently be bed in a simple jig or fixture.Some operators use a piece of an old linen or canvas wheel forholding small pieces.

When applying rouge or tripoli to a revolving wheel, hold the sideof the cake lightly against the wheel's periphery. If a stick isused, apply the side of the stick to the off side so, if thrown, itwill fly away from the wheel.

6.7.15 Wire Brush Wheels:

Wire brush wheels or, more commonly, scratch wheels are usedto remove burrs, scale, sand, and other materials. These wheels


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are made of various kinds of protruding wires, with differentthickness.

The same machine set up and conditions that apply to polishingand buffing wheels apply to wire brush wheels. Use flanges ornuts to hold scratch wheels rigidly in place. Do not exceed thespeed recommended by the manufacturer. The hood on scratchwheels should enclose the wheel as completely as the nature ofthe work allows. The hood should also be adjustable soprotection will not lessen as the diameter of the wheel decreases.The hood should also cover the exposed arbor ends. If not,install a smooth nut on them. Adjust the work rest to about 1/8in. (3 mm) from the wheel.

Personal protective equipment is especially important whenoperating scratch wheels because the wires tend to break off.Make it mandatory for operators to wear aprons made of leather,heavy canvas, or other heavy material; leather gloves; faceshields; and goggles.


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Grinding Wheel

Undercutnecessaryfor firm fit

Grinding Wheel

Wheel Blotter

Flange Recessed

Wheel SpindleWheelSpindle

Inner flange keyed screwed,shrunk or pressed

Wheel easyfit on flangeshoulders

Blotter

Correct methods of mounting abrasive wheels with largeholes (left) and wheels with small holes (right)


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Top: with a properly adjusted work rest, theoperator can keep the hands away from thewheel and still firmly hold the work in place.

Bottom: there should be a safe space of nomore than 1/8 in. (3.2 mm) between the toolrest and the wheel.

A badly rutted or out – of – balancegrinding wheel should be taken out ofservice and dressed


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6.8 Formwork & Falsework

The planning and design of formwork and falsework should be inaccord with provisions of the American Concrete InstitutePublication ACI 347-78, Recommended Practice for Concreteformwork and ANSI A10.9 Safety Requirements for ConcreteConstruction and Masonry Work.

All formwork, falsework, structural shoring and bracing should bedesigned, erected, braced and maintained to safety support allvertical and lateral loads that might be applied until such loads canbe supported by the structure. Drawings and plans shall beavailable at the job site.

All shoring equipment shall be inspected prior to erection todetermine that it is as specified in the shoring layout. Anyequipment found to be damaged should not be used for shoring.Erected shoring equipment shall be inspected immediately prior to,during and immediately after the placement of concrete.Immediately reinforce or reshore any shoring equipment found tobe damaged, displaced or weakened.

The sills for shoring should be sound, rigid and capable of carryingthe maximum intended load. All baseplates, shore heads,extension devices, or adjustment screws should be in firm contactwith the footing sill and the form. Prohibit eccentric loads on shoreheads and similar parts, unless these parts have been specificallydesigned for such loading.

When single post shores are used one on top of another (tiered),

1. The design of the shoring shall be prepared by a qualifieddesigner and the erected shoring inspected by an engineerqualified in structural design.

2. The shores shall be vertically aligned.3. The shores shall be spliced to prevent misalignment.4. The shores shall be adequately braced in two mutually

perpendicular directions at the splice level.5. Each tier shall also be diagonally braced in the same two

directions


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6. Adjustment of single post shores to raise formwork shall not bemade after placement of concrete.

Remove and stockpile stripped forms and shoring promptly afterstripping. Protruding nails, wire ties and other form accessories notneeded for later work should be pulled, cut, or by other means taken out.

Supply employees with eye and or face protection when nailing intoconcrete. Require employees to wear this personal protective equipment.Provide reshoring to safety support slabs and beams after stripping. Alsoprovide reshoring when slabs and beams are subjected to superimposedloads due to construction. When temporary storage of reinforcing rods,material, or equipment on top of formwork is needed, strengthen theseareas to meet the intended loads.

Adequately reinforce steel for walls, piers, columns, and similar verticalstructures to prevent overturning or collapse. Do not load metal tubularframes used for shoring beyond the safe working load recommended bythe manufacturer. Keep all locking devices on metal tubular frames andbraces in good working order. Coupling pins should align the frame orpanel legs. Pivoted cross braces should have their center pivot in place.All components should be in a condition similar to when originallymanufactured.

Fasten devices for attaching the outside lateral bracing to the legs of themetal tubular shoring frames. When using tube and coupler shoring, usecoupler (clamps) made of drop-forged steel, malleable iron, or structuralgrade aluminum. Do not use gray cast iron. Do not use couplers(clamps) if they are deformed, or broken or have defective or missingthreads on bolts, or other defects.

When checking the erected shoring frames with the shoring layout, thespacing between towels and cross brace spacing should not exceed thatshown on the layout. On metal tubular frame shoring, all locking devicesshould be closed. On tube and coupler shoring, check all interlocking oftubular members and tightness of coupling.

Floor & Wall Openings

Guard all floor and roof holes, skylights, and openings into which persons


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can walk with an enclosure guard. Or cover them completely withmaterial and bracing strong enough to support any load. Securecoverings for floor and roof openings to prevent accidental removal ordisplacement.

Guard every stairway and ladderway floor opening on all exposed sidesexcept the entrance opening. Install a securely anchored standard railingwith intermediate rail and toe-board.

Offset temporary stairway and ladderway entrances, or provide themwith a gate to prevent anyone from walking into the opening. Guardevery hatchway and chute floor opening with a hinged floor-openingcover. Equip the cover with railings attached so as to leave only oneexposed side. Provide the exposed side either with a swinging gate, oroffset it so that persons cannot walk into the opening.

Guard wall openings from which there is a drop of more than 4-ft (1.2 m)and the bottom of the opening is less than 3-ft (0.91 m) above theworking surface, with a top rail, top rail and intermediate rail, or standardguardrail. Provide a toeboard where the bottom of the wall opening,regardless of width, is less than 4-in. (10 cm) above the working surface.

An extension platform outside a wall opening onto which materials can behoisted for handling should have a standard railing. However, one side ofa extension platform may have removable railings to enable handling ofmaterials.


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7. Mechanical works:

At any construction site, the main activity will be handling ofmaterial either manually or with mechanical means. About 80% ofthe accidents occur while doing this activity. This chapterexclusively deals with problems encountered while undertaking theabove task.

7.1. Manual handling:

Due to the occurrence of large number of accidents, workers andmanagers must know the correct procedures for material handlingand storage to protect their health and safety. The safetyprofessional must evaluate employee fitness and job tasks todetermine the specific material-handling engineering andadministrative controls and personal protective equipment required.

To reduce the number of injuries caused by material handling, theproject managers should try to minimise the manual handling ofmaterial as much as possible. They can combine or eliminateoperations, introduce ergonomic principles to job design, and movematerial mechanically whenever possible. For hazards or jobs thatcannot be mechanised, workers must learn safety techniques toreduce their risk of injury.

Although physical differences make it impractical to establish safelifting limits for all workers, some general principles can be applied.In manual lifting, worker should make sure the route they musttravel with the object is clear. Next, they should inspect the objectand determine how best to grasp it to avoid sharp edges slipperysurfaces, and other injury-producing factors. 1f mechanical aids arerequired (slings, block and tackle etc.) they should be securedbefore any lifting is done.

Guidelines for lifting must satisfy four criteria:- Epidemiological,- Bio –mechanical,- Physiological and- Psycho-physical

Some safe-lifting techniques include two-hand squat lift and teamlifting and carrying.


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Squat lifting emphasises correct placement of feet, straight back andbent knees, load held close to the body, correct grip, chin in, anduse of body weight to move the object.Team lifting and carrying emphasises two or more people working inunison to avoid injuries.

Accessories for manual lifting include hand tools (hooks, crowbars,rollers), jacks, and hand trucks. Jacks must be inspected regularlyfor signs of wear o defects. They should be placed on a clean, levelsurface and used with shims and blocks to prevent accidents.

Hand trucks include two-wheeled and four-wheeled carts and trucks.Workers should be aware of the main hazards(1) running wheels off bridge plates or platforms,(2) colliding with other trucks or obstructions, and(3) jamming their hands between trucks an other objects.

Temporary and permanent storage of materials should be neat andorderly to eliminate hazards and to conserve space. Materialsstorage must be carefully planned to allow adequate ceilingclearance under sprinklers; to keep aisle and exits clear; to installadequate bins, racks, and shelving; to secure mechanical liftingaids; to establish warning signs and signals; and to develop disasterand emergency planning procedures.

Rigid containers such as metal and box pallets, fibreboard/cardboard boxes, barrels and kegs, rolled paper and reels,and compressed gas cylinders must be stored to conserve space andto provide easy access when the material is needed. Uncratedstock, such as lumber, bagged materials, pipes, and sheet metal,presents special storage problems. Supervisors must ensure thatthese material are secured and will not fall or come loose and injureworkers when being removed from storage.

Hazardous liquid and combustible materials stored containersrequire special handling and storage methods to ensure worker’ssafety and health. These containers must be protected fromextremes of temperature or humidity, fire hazards, electricalhazards, and jarring or excessive movement. Storage areas mustbe well ventilated and preferably isolated from other work areas.Workers must exercise extreme caution when cleaning, removing,


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using, or filling these containers. They must be taught to followproper safety procedures and wear protective clothing.

Handling and storage of cryogenic liquids:

The storage and handling of cryogenic liquids (oxygen, nitrogen,argon, helium, and hydrogen) require careful planning and workertraining. These liquids can cause frostbite on contact with skin and(except for oxygen) displace breathable air in an enclosedworkspace. To reduce the risks in handling these materials, workersmust know the nature and properties of each cryogen, know how tooperate the equipment, use only approved and compatiblematerials, use protective clothing and equipment, know emergencymedical techniques, and be prepared to deal with emergencysituations.

Cryogenic liquids should be stored only in the containers designedfor the particular gas. Containers should be transferred slowly into awarmer environment to prevent thermal shock to the containers andequipment. Workers must avoid dropping warm solids or liquids intocryogenic liquids, never breathe vapours from cryogenic sources,always check containers for leaks or loss of insulating vacuum, anduse only approved transfer lines to move the liquid from onecontainer or point to another.

Supervisors of shipping and receiving areas must be aware ofappropriate regulations and labels. Floors must be level, able tobear the weight load required, and kept clean and slip resistant.Ramps must have slip-resistant surfaces, be equipped withhandrails, and be clearly marked. Aisles should be wide enough toallow employees to move about while handling materials and toallow passage of loaded equipment. Warning signs, mirrors, anddirectional markings can ensure that workers avoid collisions andblind corners.

Workers in shipping and receiving must be trained in the proper useand handling of such common items as dock-boards, machines andtools, steel and plastic strapping, burlap and sacking, glass andnails, pitch and glue, barrels, kegs, drums, and boxes and cartons.They must also be taught how to load and unload railcars, safelyusing mechanical aids and protective clothing.


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Common personal protective equipment used in material handlingincludes safety shoes, gloves, goggles, aprons, and leggings toprotect against the most common injuries to hands, feet,extremities, and eyes. Where workers handle toxic or irritatingmaterials, they should take showers or wash hands and facethoroughly at the end of their shifts. The management / contractorshould provide a change of clothing or laundry facilities at the site.

Treating Cold-Contact Burns

Workers will rarely come in contact with a cryogenic liquid if properhandling procedures are used. However, in the event of contactwith a liquid or cold gas, a cold-contact ‘ Burn ’ may occur. Actually,the skin or tissue freezes.

Medical assistance should be obtained as soon as possible. In theinterim, the following emergency measures are recommended:

• Remove any clothing that may restrict circulation to the frozenarea. Do not rub frozen parts, as tissue damage may result.


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• As soon as is practical, immerse the affected part in warmwater (not less than 105 F or more than 115 F, 0 C to 46 C ).Never use dry heat. The victim should in a warm room, ifpossible.

• If the exposure has been massive and the general bodytemperature is depressed, the patient should be totallyimmersed in a warm-water bath. Supportive treatment forshock should be provided.

• Frozen tissues are painless and appear waxy and yellow. Theywill become swollen and painful and prone to infection whenthawed. Do not re-warm rapidly. Thawing may require 15 to60 minutes. For white people, thawing should continue untilthe pale blue tint of the skin turns pink or red. For blackpeople, assess frostbite by the swelling and blistering of theskin. Reduction of swelling indicates alleviation of frostbite.Morphine or tranquillisers may be required to control painduring thawing and should be administered under professionalmedical supervision.

• If the frozen part of the body thaws before the doctor arrives,cover the area with dry, sterile dressings and a large, bulkyprotective covering.

• Alcoholic beverages and smoking decrease blood flow to thefrozen tissues and should be prohibited. Warm drinks andfood may be administered.

• As with any injury or illness, monitor vital signs.


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7.1.1 Winch :

Crabs and Winches may be either hand operated or electricallydriven. Some form of braking or safety lowering device should beinstalled, and portable units should be installed securely againstthe pull of the hoisting rope or chain.

Under Rule 59, The Building and Other Construction Workers(Regulation of Employment and Conditions of Service) CentralRules, 1998 provides the statutory requirements to be compliedwith while using the winch. A schematic diagram of the winch isgiven below

The opera

•

•

• •

The operator of this car puller winch stands behind theshield, which protects the employee if the rope breaks.

orks 6

following are some of the guidelines given for the safetion of the winches:

The Safe Working Load of the winch should be marked andthis should never be exceeded.Barricade guard should be installed to protect the operatoragainst flying strand of wire and the recoil of broken ropes.The operator should also be protected against extremeweather condition.It should be placed on a firm base and properly anchored.The brake, ratchet arrangement, gear and pinion includingthe meshing, wire rope and its clamping arrangements anddirection of receiving rope drum, tie rods should be checkedbefore using the winch.


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• Ratchet arrangement should be kept in position while hoistinga load.

• Tie rod should be adjusted not to allow drum movementcausing clutch arrangement to slip.

• The locking pawl on the ratchet of a winch frequentlypresents a serious hazard to fingers of the operatorparticularly when he attempts to disengage the pawl. Toreduce this hazard, a small lever may be welded to the pawlso that it can be safely grasped.

• Hand operated equipment that has a crank handle instead ofa hand wheel poses a major danger if operator loses controlwhile lowering the load (struck by the revolving handle).Provide a dog to lock the gears. A pin through the end of acrank will keep it in the socket during hoisting operation.

• Providing strap brake will be useful when load is to loweredrapidly.


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7.1.2 Reeving :

If more than one tackle block is used in material handling, theprocess of connecting them is termed as REEVING;

Block and Tackle :

A safety factor of 10 is recommended for determining the safeworking load of Manila rope (falls) in a block-and tackle assembly.This large safety factor allows for(1) error in estimating the weight of the load,(2) vibration or shock in handling the load on the tackle,(3) loss of strength at knots and bends, and(4) deterioration of the rope due to wear or other causes.

The governing factor usually is the safe working load of the blocks,rather than of the falls (rope).

By multiplying the number of sheaves and rope parts, the weight ofthe load that can be handled by the rope multiplies but does notcorrespondingly increase the strength of the blocks. Calculationsshow that, in most instances, using a safety factor of 10 for therope automatically makes the load on the blocks correspond to therope size within safe work load limits. (Mark blocks with their safeworking load. as specified by their manufacturers.) The total weighton the tackle should never exceed this safe load limit. The safework loads for rope used in block-and-tackle assemblies conversely1 / 10th of the block's breaking strength, based on a safety factorof 10.

To find the required breaking strength for new rope, proceed asfollows:

1. For each sheave of 3 in. (7.6 cm) in diameter or larger, add10% to the weight of the load to compensate for friction loss.

2. Divide this figure by the number of ropes or parts runningfrom the movable block.

3. Multiply the resultant figure by a safety factor of 10.

An example for working out the procedure given above follows:

1. A load to be lifted weighs 2,000 lb (900 kg), and the tackleconsists of two double blocks-four sheaves, four rope parts atthe movable block.


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2. Friction loss (10% for each sheave) = 40% or 800 lb (363 kg).2,000 + 800 = 2,800 lb (1,270 kg), which divided by 4 (thenumber of parts at the movable block) = 700 lb (3 1 8 kg).

3. Applying the safety factor of 10 (10 x 700) gives 7,000 lb(3,200 kg), the required breaking strength of the rope.

4. New Manila rope of 7/8 in. (22 cm) has a breaking strength of7,700 lb (3,500 kg) and, therefore, is the proper size for theload. Synthetic fibres would have greater tensile strength.

The safe work load limit for two double blocks made for rope Of7/8- in. (22-cm) diameter is 2,000 lb (900 kg)-the equivalent ofthe total load in the example.

Attach the rope to the block with a thimble and a proper eye splice.A mousing of yarn or small rope should be placed on the upperhook of a set of falls as a precaution against its accidentaldetachment.

Inspect blocks thoroughly and frequently, paying particularattention to parts that are subject to wear.

Figure below shows how tackle blocks should be reeved.

If the sheave holes in blocks are too small to permit sufficientclearance, excessive surface wear of the rope will occur.

Likewise, excessive internal friction on the fibres will occur if thediameter of the sheave is too small for the rope.

When using block and tackle in confined spaces, provide guards onthe pulley block so that a person's hands cannot be caughtbetween the pulley and the rope.

When blocks and falls are used to lift heavy materials or to keepheavy loads in suspension, as on heavy-duty scaffolds, wire rope ismore serviceable than fibre rope.


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7.1.3 Rigging:

In lifting the various materials and supplies, a number of standardchokers, slings, bridle hitches, and basket hitches can be used.Because loads vary in physical dimensions, shape, and weight arigger needs to know what method of attachment can be safelyused. It is estimated that at least about 15 to 50% of the craneaccidents are due to improper rigging.

The contractor needs to train those employees who are responsiblefor rigging loads about the :-1. Knowledge of the load2. Judgement of distance3. Selection of tackle and lifting gear4. Proper operational directions to be given.

The most important rigging precautions are to determine theweight and the size of the load before attempting to lift it. This willdetermine the type of equipment and gear to be used and themethod of slinging.

There are various methods of hitching the load to the hook throughchoker hitch, basket hitch etc. Some of the types of hitching /slinging are given below: -

Watch forbroken wires in

This socket mustbe replaced


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The fiber, wire ropes and chain slings attachments are dealt underappropriate headings.

A wire rope which has beenkinked. A kink is caused bypulling down a loop in a slackline during improper handling,installation, or operation. Notethe distortion of the strandsand individual wires. Early ropefailure will undoubtedly occurat this point.

A “ bird cage” caused bysudden release of tension andresultant rebound of rope fromoverloaded condition. Thesestrands and wires will notreturn to their originalpositions.

A wire rope which has beensubjected to repeated bendingover sheaves under normalloads. This results in “fatigue”breaks in individual wires-thesebreaks are square and usually inthe crown of strands

A wire rope which has jumped asheave. The itself is deformedinto a “curl” as if bent around around shaft. Close examination ofthe wires show two types ofbreaks – normal tensile “cup andcone” breaks and shear breakswhich give the appearance ifhaving been cut on an angle witha cold chisel.

An example of “fatigue” failureof a wire rope which has beensubjected to heavy loads oversmall sheaves. The usualcrown breaks are accompaniedby breaks in the valleys of thestrands – these breaks arecaused by “strands nicking”resulting from the heavy loads.

A fatigue break in a cable tooldrill line caused by a tight kinkdeveloped in the rope duringoperation


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Method of Attachment:

All hooks and rings used as sling connections should develop the full ratedcapacity of the sling.

Sockets and compression fittings, when properly attached with wire ropesling should develop 100% of the rated strength of the wire rope. Swagedsleeve sling endings should develop 92 to 95% of the wire rope’s strength.Compression fittings and swaged sleeve fittings are available from thewire rope manufacturers.

Hand tucked splices develop about 90% of the rope’s strength in ropeshaving diameter less than ½” and 80% for larger diameters.

The recommended load rating for a sling assembly is usually based on 1/5the calculated strength of the assembly.

As a general rule, hooks and rings, oblong links, pear shaped links,coupling links and other attachments should be made of the same, orequivalent, heat treatable alloy steel as the chain itself. In most cases theattachments are provided by the manufacturers themselves.

When rigging irregular shaped loads or heavy loads proper rigging shouldbe made. Some of the special rigging methods are shown below: -

The three most common hitches for all types ofslings are the Regular, Choker, Basket Hitch. Typical Double-chain sling

Identificationtag

Safety lock


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Safe Slinging Practices:

2 – Leg Bridle Hitches1 - Single VerticalHitch

NOTE: Load may besupported on only 2legs while 3rd legbalances it.

3-Leg Bridle Hitch

Leg length canbe adjusted withturnbuckles.


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Single DoubleWrap Basket Hitch

This hitchcompresses theload and preventsit from slippingout of the slings.

Pair of DoubleWrap Basket

Double Wrap Basket Hitch

Single Choker Hitches

Not recommendedRecommended

Chokers do not provide full support for loose loads –Material can fall out.

Wrong

Right

“Double” chokerUse to turn loads


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Types of Slinging and SWL of this Mode:

Sling with Choke HitchSWL= 0.8 x SWL of rope

Load held onone part of rope

Load held onTwo part ofrope

Packers topreventchafe

Simple sling with two legsSWL= 0.8 x SWL of rope

Sling with two separate legsSWL= 1.25 x SWL of rope

Load held on twoparts of rope

Endless Sling with Two legsand Choke HitchSWL= 1.60 x SWL of rope

Load held on fourparts of rope

Packers toprevent chafe

Packers topreventchafe

Endless Sling with Four LegsSWL= 1.60 x SWL of rope

Sling with Four Separate LegsSWL= 2.00 x SWL of rope


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Sling Calculation: -

When this angle is greater than 450 SWL = SWL (of single vertical hitch) x 3/4

When this angle is less than 450 SWL = SWL (of single vertical hitch) x A/B

Determining capacity of single choker hitch

When this angle is greater than 450 SWL = SWL (of single verticalhitch) x ¾ x H/L x 2

When the choker angle is less than 450 SWL = SWL (of single vertical hitch) x ¾ x H/L x 2

Determining capacity of double choker hitch


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Special Rigging / Heavy Rigging: -

Double, Triple, quad chainsling to handle loads ofvirtually any size or shape.

Out - of - balance load by a double sling withchain leg adjusted (Two short chains withgrab hooks attached to the master links.)

Extreme wear at load bearing surfaces.

WearSurfa

Web sling protects roller polished surface


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7.1.4. Test Certificates:

THE BUILDING AND OTHER CONSTRUCTION WORKERS(REGULATION OF EMPLOYMENT AND CONDITIONS OFSERVICE) CENTRAL RULES, 1996 vide rule 56 require theemployer to ensure that all lifting machinery including all parts andgears thereof are tested periodically by the competent person beforetaking them into use for the first time or after repairs and also after5 years of their use. Apart from this,these machinery and gearshould be annually examined by a competent person and a record ofthe same should be maintained.

The formats in which these are to be maintained are given inannexes 1, 2, 3 and 4.

The format for keeping the record of annealing of loose gear is givenin annexe 5.

The format of annual through examination of loose gear exemptedfrom annealing is given in annexe 6.

A record of these tests should maintained in the form of a register asgiven in annexe 7.

The pressure vessels should be periodically tested and examined asper the procedure laid under rule 207 ( as given in annexe 8) and asuitable record of the same should also be maintained. The formatcan be the same as given under Factories Act & Rules.


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7.1.5. Operators and Banksman:

Crane Driver and Slinger:

Normally crane operator tries to do several operationssimultaneously resulting in flying start, jumpy and jerky operation,quick reversal and sudden stops. In order to avoid these andprovide smooth and safe operations, the following rules aresuggested.

1. Crane controls should be moved smoothly and gradually toavoid abrupt, jerky movements of the load. Slack must beremoved from the sling and hoisting ropes before the load islifted.

2. Centre the crane over the load before starting the hoist to avoidswinging the load as the 1ift is started. Loads should not beswung by the crane to reach areas not under the crane ( Figurebelow )

3. Crane hoisting ropes should be kept vertical. Cranes shall notbe used for side pulls.

4. Never lower the block below the point where less than two fullwraps of rope remain on the hoisting drum. Should all the ropebe unwound from the drum, be sure it is rewound in the correctdirection and seated properly in the drum grooves, otherwisethe rope will be damaged and the hoist limit switch will notoperate to stop the hoist in the high position.

5. Be sure everyone in the immediate area is clear of the load andaware that a load is being moved. Activate the warning device


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(if provided) when raising, lowering, or moving loads whereverpeople are working to make them aware that a load is beingmoved.

6. Do not make lifts beyond the rated load capacity of the crane,sling chains, rope slings, etc.

7. Do not operate the crane if limit switches are out of order or ifropes show defects or wear.

8. Make certain that before moving the load, load slings, loadchains, or other load lifting devices are fully seated in thesaddle of the hook.

9. When a duplex hook (double saddle hook) is used, a doublesling or choker should be used to assure that the load is equallydivided over both saddles of the hook.

10. On all capacity or near capacity loads, the hoist brakes shouldbe tested by returning the master switch or push button to theOFF position after raising the load a few inches off the floor. Ifthe hoist brakes do not hold, set the load on the floor and donot operate the crane. Report the defect immediately to thesupervisor.

11. Check to be sure that the load is lifted high enough to clear allobstructions and personnel when moving bridge or trolley.

12. At no time should a load be left suspended from the craneunless the operator is at the master switches or push buttonwith the power on, and under this condition keep the load as


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close as possible to the floor to minimise the possibility of aninjury if the load should drop. When the crane is holding a load,the crane operator should remain at the master switch or pushbutton.

13. When a hitcher is used, it is the joint responsibility of the craneoperator and the hitcher to see that hitches are secure and thatall loose material has been removed from the load beforestarting a lift.

14. Do not lift loads with any sling hooks hanging loose. (If all slinghooks are not needed, they should be properly stored or adifferent sling should be used.)

15. All slings or cables should be removed from the crane hookswhen not in use. (Dangling cables or hooks hung in sling ringscan inadvertently snag other objects when the crane is moving.)

16. Crane operators should not use limit switches to stop the, hoistunder normal operating conditions. (These are emergencydevices and are not to be used as operating controls)

17. Do not block, adjust or disconnect limit switches in order to gohigher than the switch will allow.

18. Upper limit switches (and lower limit switches, when provided)should be tested in stopping the hoist at the beginning of eachshift, or as frequently as otherwise directed.

19. No loads should be moved or suspended over people regardlessof the attachment, mechanical, magnetic, friction, or vacuum.

20. Molten metal shall never be carried overhead where it couldsplash onto personnel.

21. If the electric power goes off, place your controllers in the OFFposition and keep them there until power is again available.

22. Before closing main or emergency switches, be sure that allcontrollers are in the OFF position so that the crane will notstart unexpectedly.

23. If plugging protection is not provided, always stop thecontrollers momentarily in the OFF position before reversing--except to avoid accidents. (The slight pause is necessary to givethe braking mechanism time to operate.)


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24. Whenever the operator leaves the crane, the followingprocedure should be followed:(a) Raise all hooks to an intermediate position.(b) Spot the crane at an approved designated location.(c) Place all controls in the OFF Position.(d) Open the main switch to the OFF Position.(e) Make a visual check before leaving the crane.

NOTE: On yard cranes (cranes on outside runways), operatorsshould set the brake and anchor it securely so the cranewill not be moved by the wind.

25. When two or more cranes are used in making one lift, it is veryimportant that the crane operators take signals from only onedesignated person.

26. Never attempt to close a switch that has an OUT OF ORDER orDo NOT OPERATE card on it, regardless of whether it is lockedout or not. Even when a crane operator has placed the card, itis necessary to make a careful check to determine that no oneelse is working on the crane, before removing the card.

27. In case of emergency or during inspection, repairing, cleaning,or lubricating, a warning sign or signal should be displayed andthe main switch should be locked in the OFF position. Thisshould be done whether the work is being done by the craneoperator or by others. On cab-operated cranes when others aredoing the work, the crane operator should remain in the cranecab unless otherwise instructed by the supervisor.

28. Never move or bump-another crane that has a warning sign orsignal displayed. Contacts with runway stops or other cranesshall be made with extreme caution. The operator shall do sowith particular care for the safety of persons on or below thecrane, and only after making certain that any persons on theother cranes are aware of what is being done.

29. Do not change fuse sizes. Do not attempt to repair electricalapparatus or to make other major repairs on the crane unlessqualified and specific authorisation has been received.

30. Never bypass any electrical limit switches or warning devices.


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31. Load limit or overload devices shall not be used to measureloads being lifted. This is an emergency device and is not to beused as a production operating control.


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7.1.6. Lifting and carrying of excessive weight-

As per Rule 38 of THE BUILDING AND OTHER CONSTRUCTIONWORKERS (REGULATION OF EMPLOYMENT AND CONDITIONSOF SERVICE) CENTRAL RULES, 1996

“An employer shall ensure at a construction site of a building orother construction work that

(a) No building worker lifts by hand or carries over-head or overhis back or shoulders any material, article, tool or appliancesexceeding in weight the maximum limits set out in thefollowing table:

Person Maximum Weight LoadAdult-man 55 kg

Adult-woman 30 kgAdolescent-male 30 kg

Adolescent-female 20 kg

Unless aided by any other building worker or a mechanicaldevice. ”

(b) No building worker aided by other building workers, lift byhand or carry overhead or over their back or shoulders, anymaterial, article, tool or appliance exceeding in weight the sumtotal of maximum limits set out for each building workerseparately under clause (a), unless aided by a mechanicaldevice.


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7.2. Crane Safety

Derricks and Cranes:

Derricks:

The derricks are normally rigged/fabricated at the site to do aspecific repeated type of job like piling operation, within a smallradius of swing. Rules 67 & 68 of THE BUILDING AND OTHERCONSTRUCTION WORKERS (REGULATION OF EMPLOYMENT ANDCONDITION OF SERVICE) CENTRAL RULES, 1998 give statutoryguidance regarding the construction of the derrick. The followingdiagrams show some of the common type of derricks used atconstruction site.

Stiff Leg Derrick


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Frame Derrick

Guy Derrick


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The following guidelines may be followed:

♦ A competent person should ascertain the lifting capacity of the derrickand it should not be overloaded.

♦ The mast, guy ropes, wire ropes, swivel hook, rope clamps etc., of thederrick should be thoroughly checked before erecting the derrick.

♦ Depending on the type of derrick, the mast should be firmly fixed by guyropes / structure.

♦ All precautions should be taken so that base of the derrick does not shiftor sink.

♦ Guys of the derrick should be anchored tightly with strong structures /hold fasts/ anchorage blocks

♦ The load being hoisted should not run against the derrick♦ All welded parts of derricks especially in bracing and stiffeners should be

periodically checked for any crack, or defects in metal itself♦ If bolted joints are used, check for proper bolts and their tightness

CRANES:

Some of the common types of crane in use at the site are given below:


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JIB CRANE PILLER CRANE


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According to the site requirement, the crane is chosen.

The Do’s and Don’ts of operation have been given under Ropes and Rigging.

Some of the important requirements as given under THE BUILDING ANDOTHER CONSTRUCTION WORKERS ( REGULATION OF EMPLOYMENTAND CONDITION OF SERVICE ) CENTRAL RULES, 1998 are givenbelow:

1. The capacity of the crane should be ascertained before using. Brakesshould be checked while lifting critical load and adjusted if needed.

2. Crane should never be overloaded.

3. Mobile cranes should be parked on hard soil or strong base. Theyshould not be placed near the edge of the pit or excavation.

4. Safe working load of any mobile crane depends on

• Operator’s skill• condition of the ground• Boom length• Radius of rotation while lifting the load inclination of boom to the

vertical• out rigger blocked/free

The Safe working load is generally tabulated in the Load chart of thecrane. Sometimes cranes are derated due to the defects in welding,bend in angle, Bracing etc; and Condition of clutch brake, etc.The load is the total load, hung from the rope sheaves of the boomincluding weight of hook block, ropes/slings, etc.

5. Standard signalling code properly understood by the Operator andtrained signal man should be used. The Crane operator shall respondto signals only from the appointed signaller but shall obey stop signalat any time no matter who gives it.

6. Tag lines should be used while hoisting heavy and bulky materials.


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7. The brakes, boom, hook, wire ropes and pulleys, rope anchoringshould be checked periodically by Maintenance personnel to ensurethe crane's safe operation.

8. The load being lifted should not touch the boom.

9. The boom or any part of the crane should not come near any liveelectric line/service line.

10. Swinging of load should be done smoothly.

11. Proper quality of packing should be used and the outrigger shouldrest tightly on the packing.

12. Nobody should stand below the boom or load.

13. The operator should be able to see the hook and load throughout thehoisting period.

14. During storm, the hook block should be anchored firmly and swinglock be released.

15. When an extended boom is used on the crane, the operator must useextreme care in lowering load to the ground. An extended boomnever should be lowered to one side of the chassis for the stability ofthe crane is usually reduced in that position and the crane will getover turned.

16. The crane has to be travelled on a heavy timber mat whenever thereis instability of soil.

17. The use of any make shift methods to increase the capacity of cranesuch as timbers, with blocking, or adding counter-weight, should notbe permitted.

18. Before leaving the crane at the end of the workday, the craneoperator should remove the load from the hook and raise the hookblock to maximum height.

19. The crane operator should keep the deck clean of any oil, mud and -


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grease.

20. Operator should always keep the windshield clear, in order to preventaccident due to this.

21. Ensure atleast two full turns of rope be always on the rope drum.After a boom extension, the hooks shall be lowered to the requiredlowest point to ensure that atleast two turns of rope remain on thedrum and to the highest point to check that the drum capacity will notbe exceeded.


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Mobile Cranes:

Following precautions have to be taken while using, tyre mounted mobilecranes in addition to the precautions given above.

1. The capacity of the crane should be ascertained before use. Brakesshould be checked while lifting critical load and adjusted if needed.

2. Crane should never be overloaded.

3. Mobile cranes should be parked on hard soil or strong base. Theyshould not be placed near the edge of the pit or excavation.

4. Safe working load of any mobile crane depends on Operator's skill,condition of the ground, Boom length, Radius of rotation while liftingthe load, inclination of boom to the vertical out rigger blocked/free.

5. The Safe working load is generally tabulated in the Load chart of thecrane.Sometimes cranes are derated due to the defects in welding,bend in angle, Bracing etc; and Condition of clutch brake, etc.

6. The load is the total load. hung from the rope sheaves of the boomincluding weight of hook block, ropes/slings, etc.

7. Standard signalling code properly understood by the Operator andtrained signal man should be used.

8. The Crane Operator shall respond to signals only from the appointedsignaller but shall obey stop signal at any time no matter who givesit.

9. Tag lines should be used while hoisting heavy and bulky materials.

10. The brakes, boom, hook, wire ropes and pulleys, rope anchoringshould be checked periodically by a Maintenance person to ensure thecrane's safe operation.

11. The load being lifted should not touch the boom.


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12. The boom or any part of the crane should not come near any liveelectric service line.

13. Swinging of load should he done smoothly.

14. Proper quality of packing should be used and the outrigger shouldrest tightly on the packing.

15. Nobody should stand below the boom or load.

16. When travelling up a gradient, the load shall be kept in front of thecrane and when travelling down a gradient, the crane should travel inthe reverse and on reaching level ground it should travel in thenormal way otherwise, constant watch on the radius should bemaintained while travelling on uneven surfaces.

17. The mobile crane shall be fitted with suitable horn, Headlights, SideLamps, rear and stop lights and flashing direction indicator.

18. Cranes with cantilever type jib, when travelling without load, the jibshould be lowered to a horizontal position.

19. The pneumatic tyres shall be maintained at the correct pressure at alltimes.


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Crane Operation Daily Checklist

Crane Operation Daily Checklist For The Month _________ 2001

Name of Site:___________________Operator's Name:______________Lincence No.__________Crane No.___________________ Model#__________________ Type: _______________________Date of Inspection: __________________________Date of expiry: _________________by competent person

Description Date Item NumberThe following applicable items shall be checked daily, other

items may apply.1 2 3 4 5 6 7 8 Operators

RemarkSign

123456789

101112131415161718192021222324252627282930

1.) Test run unit, observe operation for malfunctions

-Safety, Emergency stop -Pendant, Joystick -Correct direction of motions -Brakes of all motions

2.) Check for deterioration or leakage in lines, tanks, valves drain pumps and other parts of air or hydraulic systems

3.) Examine load hooks for wear, Cracks, or Damage

-Saddle wear (10%) Max -Twist (10%) Max -Throat opening (15%) Max4.) Check Hoist Rope, or Chain

-End connections Chain-excessive wear, Twist distorted links, stretch Rope- crushing, kninking, broken wires -Latch

5.) Check load attachments

-Capacity ratings, End connections Chain- excessive wear, Twist, Distorted links, Stretch Slings- crushing, Kninking, Broken wires tears

6.) Check for excessive wear, Cracks or components

-Hok block, Sheaves, Hook

7.) Check all running ropes and chains for correct reeving

- Proper spooling

8.) Check upper limit with no load 31Code: A= Acceptable D=Defective, Report at Once

Signature of P & M Incharge :

Signature of Site Safety Officer :

Signature of RCM :


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7.3 Erection of Structures:

1. Load should be properly ascertained to identify Centre ofGravity and load transfer at slinging point, before handling anyequipment.

2. A visual check must be done regarding fitness of all lifting &,haulage tackles. ropes, slings etc. before every use.

3. The common tendency of checking gear meshing lubrication,coupling matching, hole matching, etc by feeling with a fingermust be strictly curbed.

4. Selection of Tommy bars, rollers, skids, etc. should madedepending, on the type of equipment to be handled.

5. Eye bolts provided at correct slinging points for heavyMachinery parts such as motors, generators, turbine, etc.should be utilised for handling.

6. No sling should be overloaded.

7. Proper quality of pulley block should be used. In no case, pulleyblock suitable for fibre rope should be used for steel wire ropes,while being used as diversion pulleys.

8. No person shall walk, stand or work beneath suspended load.

9. During erection, only one signaller shall give proper signals.However, a ‘STOP' signal should be obeyed whoever gives it.

Structural Erection:

1. The structural members should be kept in orderly manner onthe ground so that they do not roll down or slide while beinghandled.

2. The structural members should be able to be taken out as persequence of erection without disturbing the stack. At the sametime, light structures should not be stacked below heavystructural members where they are likely to be damaged.


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3. Clear passages should be left for easy handling andtransportation of structures.

4. All persons shall stand clear when a crane is sorting or shiftingsteel girders or other structural materials.

5. While using spanners, revetting hammers, etc. at heights, theyshould be tied with a rope fixed to nearby structure so that theywill not drop on the ground in case of any slip.

6. Only those persons who are skilled in working at height shouldbe engaged for jobs to be done at height. Persons sufferingfrom diseases, (epilepsy, blood pressure, etc. or addicted todrug/alcohol, etc. should not be allowed to work at height.

7. Care should be taken while lifting loads. Proper tag line mustbe used for guiding while lifting loads.

8. While positioning a beam or fabricated structure, etc., it shall beso held that the employee's hand does not get jammed againstother objects.

9. Loose bolt, nuts and tools must be kept in boxes and not onstructures. Boxes must have proper anchorage.

10. Care should be taken to fasten the erected members properlyand to secure by guys, etc. whenever necessary.

11. Providing padding over sharp edges should protect ropes andslings.

12. Slinging should be carefully done so as to prevent the load fromslipping.

13. Proper sequence of erection should be followed.

14. All electrically operated equipment like grinding machine,Drilling machine, Welding machine, etc. must have properearthing.

15. All safety appliances like safety helmet, gloves, safety beltsmust be used in erection site. All persons working at height andstanding on structural members must wear safety beltsequipped with suitable lifeline. Lifeline must be tied to anyindependent strong members.

16. In the process of ascending or descending a column and whileplacing a truss in position, it may not be possible to use safety


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belts or provide platforms, in such cases, riggers with expertisein such jobs should be engaged. Use of nets is recommendedwhile job is done in elevated places, where suitable platformcannot be provided. If semi -permanent cat-ladders cannot beprovided, rope ladders must be used. Rope ladder should beplaced in position and its top should be tied with individualstrong members.

17. When a column is erected, it should be kept in vertical positionusing a minimum of 4' guy ropes unless secured otherwise.Only after bracing system is fixed the ropes in that axis can beremoved and the other two can be removed only after rooftrusses are fixed.

18. A lot of precautions are to be taken for erecting roof girders androof trusses as they are usually slender, very long and unstableby themselves. The trusses, which have a bracing system,should be erected first and held by separate cranes and onlyafter bracing are fixed, the crane should be released. For allother spans, only purling and horizontal runners need to befixed before release of cranes. Roof truss should never beerected along with monitor roof truss. Monitor roof should beerected separately.

19. C.G.1 sheets should be lifted manually by proper system. Theman on the roof should use safety belt. C.G.I sheet fallingfrom a height can cause heavy casua;ty.

20. C.G.1 sheet should be kept tied on the top. The requirednumber of CGI sheets only should be lifted and unbolted.


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7.4. Use, Care and Maintenance of Slings :

In any construction site the main activity will be handling andstorage of material.

This chapter deals with different types of slings, their use, care andmaintenance.

7.4.1 Synthetic Fibres:

Nylon, Polyester, and polyolefin ropes are the major types ofsynthetic fibre ropes used.Synthetic fibre ropes are used more often than natural fibre ropesfor the following reasons.

• More is known about the properties of various synthetics.Successful use of synthetic fibre rope depends largely onselecting the synthetic with physical properties andcharacteristics that most closely match the requirements of thejob.

• Splices can be made readily in synthetic fibre rope and candevelop nearly the full strength of the rope. Tapered splices arehighly recommended for rope sizes with a 1-in. (2.5-cm), orlarger, diameter.

Nylon rope:

• Nylon rope has over two and a half times the breaking strengthof Manila rope and about four times its working elasticity. It is,therefore, well suited to shock loading, such as is required forrestraint lines.

• Its resistance to abrasion is remarkably high in comparison toother ropes.

• While nylon rope is wet or frozen, its breaking strength isreduced by 10% to 15%.

• Nylon rope also is highly resistant to organisms that causemildew and rotting and to attack by marine borers in sea water.


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• Exposure to air produces little loss of strength over long periodsof time.

• Since there is no swelling, wet nylon rope runs through blocksas easily as dry nylon rope.

• Although resistant to petroleum oils and most common solventsand chemicals, nylon's strength is affected by drying oils, suchas linseed oil or the phenols. Nylon rope is also vulnerable tostrong mineral acids, phenolic compounds, and heat.

• Nylon loses some of its strength at 300 F (150 C) and all of it at482 F (250 C)-its normal melting point. Short of melting, mostof nylon's strength is regained upon cooling to normaltemperature. Nylon of a higher melting point is available.

• Nylon, more than any other rope material, will absorb and storeenergy in the same manner as a spring. When nylon ropebreaks, this energy makes the rope's moving ends as dangerousas a projectile. Exercise caution, therefore, when working nylonlines around corners, capstans, timber heads, and the like.

Polyester rope:

• The best general-purpose rope available, especially for criticaluses, is made of polyester.

• Polyesters stretch about half as much as nylon, so energyabsorption is also about half as much.

• It is not weakened by rot, mildew, or prolonged exposure toseawater. Polyester, also, retains its full strength when wetbecause it does not absorb moisture.

• It shows little deterioration from long exposure to sunlight andhas good resistance to abrasive wear. Polyester is somewhatvulnerable to alkalis, but its resistance to ultraviolet light.

• It burns at about 480 F (250 C), and loses strength attemperatures over 390 F (200 C).

Polyolefin rope:

• In general, polyolefin rope is strong and inexpensive.• It floats and is unaffected by water. Polyolefin, like polyester,

does not absorb moisture; therefore, it does not shrink or swellwith water. It is unaffected by rot, mildew, and fungus.


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• Polyolefin rope is also highly resistant to a wide variety of acids(except nitric acid) and alkalis, as well as to alcohol-typesolvents and bleaching solutions. However, it swells andsoftens with hydrocarbons, particularly at temperatures above150 F (66 C).

• The movement of crossed ropes, as well as other types ofabrasion, must be avoided because even modest loads willcause a sawing motion that leads to a built up of friction.Descriptions of two types of polyolefin ropes are given below:

• Polypropylene rope, with a specific gravity of 0.91 and asoftening point of 300 F (150 C), is made in several differentsize filaments and from film with or without longitudinalfracturing.

• Polypropylene rope is about 50% stronger than Manila rope,size for size.

• Pure polypropylene rope has relatively poor renderingproperties. It burns at 330 F (166 C) and loses some strength at150 E E Polyethylene rope, with a specific gravity of 0.95 and asoftening point of 250 F (120 C), is characteristically slipperyand has very little springiness.

• It is strong and has little stretch.• Polyethylene rope also has a comparatively low softening point

and low coefficient of friction.

Composite rope :

• Rope made by combining several types of synthetic fibres or bycombining synthetic and natural fibres is also available.

• Composite rope results from attempts to give the surface of therope or strand more wear resistance, greater internal tensilestrength, or more structural strength to retain its shape.Composite rope can be made to match the requirements ofspecific jobs.

Working Load :

• Because the safety factor is not the same for all ropes and isbased upon static loading, caution has to be exercised whileusing thumb rule. Also caution has exercised when using theworking load figures supplied by the manufacturer.


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• To provide guidelines, working loads are tabulated for rope(1) in good condition,(2) with appropriate splices in non critical applications,(3) under normal service conditions, and(4) with very modest dynamic loads included.

• It is advisable to Select a higher working load only with expertknowledge of conditions and a professional estimate of the risksinvolved. Factors to consider include:

(1) whether the rope has been subject to dynamic loading orother excessive use,

(2) whether it has been inspected and found to be in goodcondition,

(3) whether it is to be used in the recommended manner, and(4) whether the application involves high temperatures,

extended periods under load, or obvious dynamic loading,such as sudden drops, snubs, or pickups.

• For all such applications and for applications involving moresevere conditions of exposure, or for recommendations onspecial applications, consult the manufacturer.

• Many uses of rope involve serious risk of injury to personnel orof damage to valuable property. This risk is often obvious; forexample, a heavy load supported above one or more workers.An equally dangerous situation occurs if personnel are in linewith a rope that is under excessive tension. Should the ropefail, it may recoil with considerable force-especially if the rope ismade of nylon. Workers should be warned against standing inline with the rope. In all cases where such risks are present, orif there is any question about the loads involved or theconditions of use, the SWL should be greatly reduced and therope should be properly inspected and the manufacturer shouldbe consulted for recommendations on working loads.

• Dynamic loading automatically voids the working load. Workingload figures do not apply when rope is subject to significantdynamic loading. Whenever a load is picked up, stopped,moved, or swung, there is an increased force due to dynamic


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loading. The more rapidly or suddenly such actions occur, thegreater this increase will be. In extreme cases, the force put onthe rope may be two, three, or even more times the normalload involved, such as when picking up a tow on a slack line orusing a rope to stop a falling object.

• Dynamic effects are greater on a rope with little stretch such asManila than on a rope with higher stretch such as nylon.Dynamic effects are also greater on a shorter rope than on alonger one. The working load listed contains provision for verymodest dynamic loads. This means, however, that when aworking load has been used to select a rope, the load must behandled slowly and smoothly to minimise dynamic effects andto avoid exceeding the provision for them.

• Before placing new rope in service, thoroughly inspect its entirelength to determine that no part of it is damaged or defective.Any irregularity in the uniformity of appearance is evidence ofpossible weakness. There is no agreement on what determineswhen a rope should be removed from service. Synthetic ropedamage is not always visible.

• Every 30 days, under ordinary conditions, the rope should beinspected before taken in to use. The rope should be inspectedmuch oftener if it is used in critical applications, such as tosupport scaffolding on which employees work.

• Inspection consists of examining the entire length of the rope,inch by inch, for wear, abrasions, powdered fibre betweenstrands, broken or cut fibres, displacement of yarns or strands,variation in size or roundness of strands, discoloration, androtting.

• To inspect the inner fibres, untwist the rope in several places tosee whether the inner yarns are bright, clear, and unspotted. Ifexposed to acids, natural fibre ropes, such as Manila, should bescrapped or retired from critical operations, as visual inspectiondoes not always reveal acid damage. Likewise, damage tosynthetic rope is not always visible. If there is a visible core orcore damage, replace or splice out the rope.


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• Natural fibre rope loaded to over 50% of its breaking strengthwill be permanently damaged; synthetics loaded to over 65%may be damaged. Damage from overloading may be detectedby examining the inside fibres. These will be broken into shortlengths in proportion to the degree of overload. To make agood estimate of the strength of fibres, scratch the fibres with afingernail-fibres of poor strength will readily part. This"fingernail test" is a quick test for chemical damage.

• If the diameter of a rope is worn more than 5 % the ropeshould be replaced. In small ropes (up to 1/4in., 19 mm, indiameter), surface wear that has progressed to the centre ofthe twisted element (yarn) may account for more than an 80%loss of the rope's strength.

• In ropes with a 3/4-1n. (19-mm), or more, diameter, surfacewear may destroy the strength of the cover yarns, yet not affectthe original strength of the core yarns. The remaining strengthof the rope will be in the proportion that the core yarns are tothe original total of yarns. If fibre samples can be secured fromthe rope, an estimate of the rope's strength can be made.Manually break the fibre samples, and estimate the distributionof fibres in a cross section, quartered to allow for twistconfiguration.

• Due to slippage on a supporting surface when under hightension, synthetic ropes sometime melt on the surface and forma skin. This skin is the evidence of wear. Rope, using multi-filament synthetic fibre on the surface, will often "fuzz." This isdue to minute fibre breakage. If a rope is very fuzzy, replace itand look for the source of abrasion.

Care of Rope Being Used :

• Safe use of different types of rope results from factors such aschaffing, cutting, elasticity, diameter-strength ratio, and generalanticipated mishandling. To keep rope in good condition, thefollowing precautions should be observed:


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• If possible, do not drag rope since this wears away the outerfibres. If a rope picks up dirt and sand, abrasion within thestrands of the rope will rapidly wear it out.

• Handle twisted rope so it retains the amount of twist (calledbalance) that the rope seeks when free and relaxed. If rotatingloads and improper coiling and uncoiling change the balance,restore it by properly twisting the rope at either end. Severeunbalance can cause permanent damage; localised over twistingcauses kinking or hocking. Kinking strains the rope and mayover stress the fibres. It may be difficult to detect a weak spotmade by a kink.

• To prevent a new rope from kinking while it is being un -coiled,lay the rope coil on the floor with the bottom end down. Pullthe bottom end up through the coil, and unwind the ropecounter clockwise. If it uncoils in the other direction, turn thecoil of rope over, and pull the end out on the other side.

• Avoid sharp bends over an unyielding surface since this causesextreme tension on the fibres. To make a rope fast, select anobject with a smooth round surface of sufficient diameter.

• If the object does have sharp corners, pad the corners.

To avoid excessive bending, use sheaves or surface curvatures ofsuitable size for the rope's diameter.

• Splice lengths of rope that must be joined. Do not knot them.A well-made splice will retain up to 100% of the strength of therope, but a knot retains only 50%.

• Thoroughly dry out rope that has become wet; otherwise, it willquickly deteriorate. Do not allow wet rope to freeze. Hang up awet rope, or lay it in a loose coil in a dry place until thoroughlydry. Rope deteriorates more rapidly if it is alternately wet anddry than if it remains wet.

• Do not use wet rope, or rope reinforced with metallic strands,near power lines or other electrical equipment. Use of suchrope could cause injury by electric shock to workers.


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7.4.2 Wire rope :

• Wire rope is more widely used than fibre rope. Wire rope has greaterstrength and durability under severe working conditions than does fibrerope. The physical characteristics of wire rope do not change whenused in varying environments. Wire rope has controlled andpredictable stretch characteristics.

Construction

• Wire rope is composed of steel wires, strands, and core. The individualwires are cold drawn to predetermined size and breaking loads accordingto required grades. Grades include iron, tractor, mild plow steel, plowsteel, improved plow steel, and extra-improved plow steel. The wiresare then laid together in various geometrical arrangements according toconstruction requirements for strands and classifications of wire rope (6x 19, 6 x 37, etc.).

• To make a strand, carefully selected lengths of pitch or lay are used.These lengths have a definite ratio to the length of lay or pitch used informing the finished wire rope. After the individual strands are made,the required number are coiled around the core, which supports theload-carrying strands. The core can be made of sisal or synthetic fibre;or it can be a metallic strand core or independent wire rope core (IWRC).

• The service for which the rope is to be used determines the size, thenumber and arrangement of wires, the number of strands, the lay, andthe type of core In a wire rope.

Classifications:

• The most popular and most generally used constructions of wire rope aresix-strand ropes of these two classifications-the 6 x 19 and 6 x 37. The6 x 19 classification contains a variety of constructions for wire rope,ranging in number of wires per strand from 15 to 26. Typicalconstructions are 6 x 19 Seale, 6 x 25 filler wire, and 6 x 19 Warrington.

• The 6 x 37 classification also covers a large number of designs andconstructions for wire rope with the number of wires per strand ranging


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from 27 to 49. Typical constructions of this classification are 6 x 41 fillerwire, 6 x 37, 6 x 36 Warrington Seale, and 6 x 49 filler wire. Generallyspeaking, the greater the number of wires per strand, the more flexiblethe wire rope. However, the fewer number of wires per strand, the moreabrasion resistant and crush resistant is the rope.

• In ropes with large diameters, 2 in. (6.4 cm) and larger, practically allwire rope is produced in the 6 x 37 or 6 x 61 class. Therefore, becauseof the large number of possible rope constructions that are available,exercise care to make the proper selection

Service Requirements:

• Depending upon service requirements and conditions, six-strand ropesmay have a fibre core (FC), a wire strand core (WSC), or an RVRC.Wires in the strands may be laid in the opposite direction (regular lay)from that of the strands in the rope, or they may be laid in the samedirection (lang. lay) as those of the strands in the rope.

• Where maximum flexibility is required, eight-strand hoisting ropes arealso used. They are usually of the 8 X 19 classification with regular layand a FC or IWRC. Flexibility is not a requirement for guy wires,highway guards, and similar services. Therefore, wire rope of 6 x 7construction (six strands with seven wires per strand) is suitable. Whenselecting wire rope for a particular job, consult engineers from reliablewire rope manufacturers.

• Some conditions require rope with special qualities. Fibre cores areaffected by temperatures above 250 F (120 C). Under such conditions, ametallic core provides greater efficiency and safety. A zinc-coated orstainless-steel wire rope effectively resists some types of corrosion.

• Since preformed wire rope does not unravel, it has advantages forcertain services, such as for slings to hoist heavy constructionequipment. Preformed wire rope is less likely, to set or kink; thus,broken wires are less likely to protrude and create a hazard to workers.


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Design Factor for Rope Used in Hoisting:

• The operating or design factors for rope used in hoisting are calculatedby dividing the nominal catalogue strength of the rope by the sum of themaximum loads to be hoisted. It is normal practice to base this on staticloads. It is recommended that hoisting rope have at least the strengthof improved plow steel. For some applications, use extra-improved plowsteel, which is the greatest in strength, to provide an adequate designfactor and better service.

• The minimum design factors for rope used in hoisting depend upon thetype of service required and the state codes covering the particularhoisting operation. Many of these codes describe exactly how the designand operating factors should be figured. Therefore, it is prudent tocheck what codes are in force before making a final determination orselection of wire ropes to be used in hoisting. Also obtain the advice of areliable wire rope manufacturer.

Causes of Deterioration:

• Deterioration of wire ropes is caused by a number of factors, which varyconsiderably in importance depending on the conditions of service. Forexample, corrosion often is the principal cause of deterioration of wirerope used for hoisting in wet conditions. Moisture and the presence ofacid in the water lead to corrosion. Corrosion, particularly of the interiorwires, is indicated by pitting. Corrosion accelerates wear. This highlydangerous condition is difficult to detect. Among other factors causingdeterioration are the following:

• Wear, particularly on the crown or outside wires, from contact withsheaves and drums.

• Kinks, acquired from improper Installation of a new rope or from hoistingwith slack in the rope. A kink cannot be removed without creating aweak place.

• Fatigue, indicated by a square type of fracture at the end of the wire,can be caused by bending stresses from sheaves and drums with smallradii; by stresses from whipping, vibration, and pounding; or bytorsional stresses.

• Drying out of lubrication, often hastened by heat and operating pressure.


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• Overloading, including dynamic overloading, if acceleration anddeceleration are factors of importance. Damage to wire rope may occurbut not become known until some time after the overload.

• Over winding, when rope length is greater than the drum canaccommodate in a single layer. This can cause heavy abrasion andexcessive wear at crossover points. However, successful over windingcan be achieved by using specially engineered drum grooving.

• Mechanical abuse, such as running over rope with equipment andpermitting obstructions to remain in the rope's path of travel. It is morecommon for wire rope to be thrown away because of abuse than fromuse.

Lubrication:

When possible, clean a wire rope before lubricating it.1. Regular application of a suitable lubricant to wire rope used for hoisting

prevents corrosion, wear from friction, and drying out of the core.2. Good lubricants are free from acids and alkali and have adhesive

strength. They also have the ability to penetrate the strands.3. The lubricant should be insoluble under the prevailing conditions.4. Ropes should be dry when lubricant is applied so that moisture will not

be entrapped by the lubricant.5. Thin lubricants can be applied by hand. However, providing some

means of dripping thin lubricants on the rope, or using a spray device toapply the proper quantity automatically, is a better way to apply them.

6. Clean wire rope monthly, such as is done in mine shafts. to remove dirt,abrasive particles, and corrosion-producing moisture.

7. Do not use cleaning fluids on wire rope-they harm the core's lubricant.Light oils are sometimes used to loosen the coating of lubricant andharmful materials. Compressed air or steam jet, or other mechanicalmethod, cleans a rope effectively and thoroughly.

Chain Slings:

• The safety of a chain sling assembly depends on the material used, itsstrength for the load handled, method of attaching chain to fittings, andproper inspection and maintenance. Alloy steel is the standard materialfor chain slings because of its resistance to corrosion and wear and hightensile strength. Hooks and attachments are generally made of thesame material,


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• Chains should be inspected daily by workers, with a six monthsinspection conducted by a trained professional. The most commoncauses of chain wear include overloading, faulty rigging, or other unsafepractices. Workers must be trained in proper procedures for using andinspecting chain sling assemblies.

• Synthetic web slings and metal mesh slings are also widely used inindustry. Synthetic web slings are useful for lifting loads that need theirsurfaces protected; however, these slings are easily cut and have littleresistance to abrasion. As a result, these web slings require an initialinspection, frequent on-the-job evaluation, and periodic formalinspection by trained personnel.

• Metal mesh slings are classified as either heavy-duty. medium-duty, orlight-duty. They are used to handle sharp edged material, concrete, andhigh-temperature loads. Safe use of metal mesh slings is determined byuse of the right sling for the right load and by the construction of thesling. All metal mesh slings should be labelled to show their safeworking load limit. These slings rnust be inspected regularly, with aformal inspection conducted once a year. Workers should never shortenmetal mesh slings, twist or kink the legs, or use the sling when thespirals are locked.

Remove metal mesh slings from service if a broken weld or brazed joint isdiscovered along the sling edge. Also watch for the following signs of wear.Any one of these conditions or a combination of them, if ignored, couldeventually result in sling breakdown:

• broken wires in any part of the mesh• a loss of 25% in wire diameter due to abrasion• a lack of sling flexibility• cracked end fitting• visible distortion.

A link-by-link inspection should be made to detect the following:

• bent links• cracks in weld areas, in shoulders, or in any other section of link• kinks and gouges


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• transverse nicks and gouges.• corrosion pits• stretching caused by overloading.

When inspecting the hook, measure between the shank and the narrowestpoint of the hook opening. Whenever the throat opening exceeds 15% ofthe normal opening, replace the hook. Pay special attention to slings towhich hooks have been added; make sure the hooks are secure.

Safe Practices

Follow these recognised safe practices to prevent chain failures:

• Purchase chain slings complete from the manufacturer. Wheneverrepairs are required, send them back to the manufacturer.

• Never anneal or normalise alloy steel chains and hooks. Theseprocesses reduce their hardness and, therefore, greatly reduce theirstrength.

• Never splice a chain by inserting a bolt between two links. Never put astrain on a kinked chain. Train workers to take up the slack slowly sothey can see that every link in the chain seats properly.

• Do not use a hammer to force a hook over a chain link.• Never remove the permanent identification tags that have been attached

to chain slings by the manufacturer.• Remember that decreasing the angle between the legs of a chain sling

and the horizontal increases the load of the legs.• Use chain attachments (rings, Shackles, couplings, and end links)

designed for the chain to which they are fastened.• See that the load is always properly set in the bowl of the hook.• Loading on or toward the point (except in the case of grab hooks or

others especially designed for the purpose) overloads the hook andleads to spreading and possible failure.

• Store chains not in use in a suitable rack. Do not let them lie on theground or floor where they can be damaged by lift trucks or othervehicles.

• Secure "out-of-balance" loads properly.

Operating Practices for all type of Slings:

The following safe practices for all slings are given as guidance:


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• Slings having suitable characteristics for the type of load, hitch, andenvironment shall be selected in accordance with appropriatespecifications.

• The weight of a load shall be within the rated load capacity) of the sling.• Slings shall not be shortened or lengthened by knotting or other

methods not approved by the sling manufacturers.• Slings that appeared to be damaged shall not be used unless inspected

and accepted as usable.• Sling shall be hitched in a manner providing control of the load.• Sharp corners in contact with the sling should be padded with material of

sufficient strength to minimise damage to the sling.• No portions of the human body should be kept from be the sling and the

load, and from between the sling a crane hook or hoist hook.• Personnel should stand clear of the suspended load.• Personnel shall not ride the sling.• Shock loading should be avoided.• Slings should not be pulled from under a load when load is resting on the

sling.• Slings should be stored in a cool, dry, and dark place to prevent

environmental damage.• Twisting and kinking the legs (branches) shall be avoided.• A load applied to the hook should be centred in the base (bowl) of the

hook to prevent point loading on the on the hook.• During lifting, with or without a load, personnel shall be alert for possible

snagging.• In a basket hitch, the load should be balanced to prevent slippage.

When using a basket hitch, the sling's legs (branches) should contain orsupport the load from the sides above the centre of gravity.

• Slings should be long enough so that the rated load (rated capacity) isadequate when the angle of the legs (branches) is taken intoconsideration.

• Slings should not be dragged on the floor or over an abrasive surface.• In a choker hitch, slings shall be long enough so the choker fitting

chokes on the webbing and never on the other fitting.• Nylon and polyester slings shall not be used at temperatures in excess of

194 F (90 C).• When extensive exposure to sunlight or ultraviolet light is experienced

by nylon or polyester web slings, the sling manufacturer should be


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consulted for recommended inspection procedure because of loss instrength due to such exposure.

7.4.3 Lifting gears:

Sheaves and Drums:

• Fatigue of wire rope resulting from bend' g stresses depends upondrums' and sheaves' diameters-the larger the diameter of the drums andsheaves, the more favourable will be the rope's life. However,sometimes a sacrifice must be made because of designs andconsiderations for other equipment. Many types of equipmentsuccessfully operate with smaller drum-and-sheaves rope ratios, whileothers use much larger ratios.

• The safety and the service life of installations for hoisting rope can begreatly increased by using sheaves and drums of suitable size anddesign and by properly lubricating them.

• Maintenance of the rope and of the hoisting equipment is also required.• It is essential that heads, idlers, knuckles, curved sheaves, and grooved

drums have grooves that support the rope properly. Before installing anew rope, inspect the grooves, and, where necessary, machine them toproper contour and groove diameter.


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Sheaves:

• The condition and contour of sheave grooves Is important for the servicelife of wire rope. Periodically check sheave grooves (Figure 10-4), anddo not let them wear to a smaller diameter than those shown for usedgrooves in Table 10-G. If they become worn more than this, expect areduction in the rope's service life. Reconditioned sheave groovesshould conform to the tolerance, shown in Table 10-G, for new (or remachined) grooves.

• On all new sheaves, the grooves should be made for the size of ropespecified. The bottom of the groove should have a 150-degree arc ofsupport, and the sides of the groove should be tangent to the ends ofthe bottom arc. The depth of the groove should be one times thenominal diameter of the rope. The radius of the arc should be one-halfthe nominal rope diameter plus one-half the value.

• Check sheaves for proper alignment when they are installed. Duringrope changes, check the sheaves for worn bearings, broken flanges,proper groove size, smoothness, and contour. Recondition or replaceheavily worn or damaged sheaves.

• Sheave groove bearing pressures can become very hot depending uponoperating conditions and rope loading. High pressures can causeexcessive sheave wear and shorten the life of wire rope. It is necessary,therefore, to consider this factor and to select proper sheave materialsand liners at the time of installation. Information on this subject may befound in most wire rope manufacturers' handbooks.


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Recommended Tread Diameters of Sheaves and Drums for Wire Rope

AverageRope Recommended

Classification (times rope diameter) Minimum

6x7 72 42

6x19 45 30

6x37 27 18

8X19 31 21

Drums:

• Avoid multiple-layer winding of rope on drunk if possible. Multiplelayering causes the rope to wear thus shortening the rope's life,particularly at the point where the rope rises to the next layer. Wherepractical, use drums wide enough diameter and length that they cantake all the rope in a single layer.

• Minimise crushing and excessive wear of wire rope using spirally grooveddrums with capacity for one layer rope. In any case, limit the number oflayers to three. Rope lifters at the flanges are recommended when twoor more layers are wound on drums. To distribute wear uniformlycrossover points, cut off one-and-a-quarter wraps every 6 months orthree or four times during the life of the rope. In no case should there befewer than two full wraps on a drum; three is preferred.

• In general, avoid reverse bending of wire rope (bending first in onedirection and then in the opposite) over sheaves or drums. This wearsout the rope faster.

• Correct fleet angle is important for even, efficient winding of wire rope.The fleet angle is the included angle between the rope winding on thedrum and a line perpendicular to the drum shaft and running throughthe head or lead sheave.

• To reduce any tendency for the rope to open-wind, do not let the fleetangle exceed 1o30'. To assure the rope's starting back on the next


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layer, use a minimum angle of 0030’ for smooth drums and 2o forgrooved drums. Adhering to these 'fications helps achieve uniformwinding on smooth-faced drums and also increases the windingefficiency of grooved drums. For smooth-faced drums, proper directionof lay of rope for specified winding conditions further helps achieveuniform winding.

• Installing a wire rope on a plain- or smooth-faced drum requires a greatdeal of care. The starting position should be at the drum end so thateach turn of the rope winds tightly against the preceding turn. Maintainclose supervision during the entire installation process to make surethat:1. the rope is properly attached to the drum2. appropriate tension on the rope is maintained as it is wound on the

drum3. each turn is guided as close to the preceding turn as possible so that

there are no gaps between turns4. there are at least two dead turns on the drum when the rope is, fully

unwound during normal operating cycles. Loose and uneven windingon a plain- or smooth-faced drum, can, and usually does, createexcessive wear, crushing, and distortion of the rope. The results ofsuch abuse are lower operating performance and a loss in the rope'seffective strength. Also, on jobs that require moving and spotting aload, the operator will encounter control difficulties because the ropewill pile up, pull into the pile, and fall from the pile to the drumsurface. The ensuing shock can break or otherwise damage therope.

Pulleys:

• Proper pulleys should be used, according to the requirement of work• In no case pulley meant for Manila/ Nylon rope should be used with steel

rope.• Sheaves, Shaft, Hook pin, Locking pins should be checked before use

and lubrication done on necessary parts.• Grooves of the sheaves should be uniform and smooth. The wire rope or

fibre rope should run free without touching against the block orsuspension parts.

• Sheaves should rotate freely on the shaft.• The shaft should be free from crack and should not be worn out.• Anchorage should be strong and firm.


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• Anti twister should be used to prevent rubbing of ropes against oneanother.

Groove Diameter in Relation to Wire Rope DiameterAmount that Groove DiameterShould Be Larger than Nominal

Rope Diameter (inches)

Rope Size (inches) Used New

1/4 and 5/16 1/128 1/64

3/8 to 3/4 incl. 1/64 1/32

13/16 to 11/9 incl. 3/128 3/64

1- 3/16 to 1- 1/2 incl. 1/32 1/1 6

1- 3/16 to 2- 1/4 incl. 3/64 3/32

2- 5/16 and larger 1/16 1/8

Chain Block / Pulley Lift :• Chain blocks of proper lifting capacity supported by test certificate

should be used for lifting known loads.• Chain block must be checked, and tested periodically as specified by the

statue. It should be lubricated before every use.• No cannibalising should be done on the chain block.• Chain block should be tested for slip by suspending safe load.• It should operate freely and the chain should not come out of the pulley.• The anchorage should be strong and rigid.• They should be checked for cracks, excessive wear and tear, elongation,

etc. Hooks which are opened out should not be used.• No chain block or pulley which has been tampered, be used unless it is

thoroughly checked and tested by competent person as laid down underthe relevant statute.

• Chain block / pulley must be checked if stored for a long time, bysubjecting to shock load, to observe slipping of load, jamming of linksetc.


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BendLink tend toclose – upandelongate

WearTwistedLink

Bend

StretchedLink

CutsRemaining Material


HOOKS:

Inspect and discard if:• Throat opening exceeds 15% of original opening• Twist exceeds 10o along the vertical axis• Deep nicks and gauges are observed• If loss of metal due to filing is more than 1/64th for 1” depth of the hook• Wear in the hook exceeds 8% of the depth

Throat openingmore than 15% -Hook should berejected

Normal Defective –Throat Open

Defective – Hook bent
Defective –Hook worn out
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s

BentWorn outhook


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SHACKLES:

Inspect and discard if

• Wear exceeds 8% of the diameter• Body is distorted• Damage to thread on pin or body is observed

Rope Fittings:

There are several ways to attach wire rope to fittings:pressed fittings, mechanical sleeve splices, hand-tucked splices, clips andclamps, sockets, and knots.

Fittings are important for safety because they develop from 75% to 100%of the breaking strength of the rope. Manufacturers also specify fittings ofsuitable size and design for ropes of different sizes.

The strength of an attachment is attained only when the connection ismade exactly according to the manufacturer's instructions.

Some types of attachments, such as pressed fittings or mechanical sleevesplices that are used in making slings, must be made at either a wire ropemanufacturer's plant or at a properly equipped commercial sling shop.

Efficiencies of properly made hand-tucked splices vary according to thesplicer's ability and the rope's diameter but can be as high as 90%.

The efficiency of mechanical sleeve splices varies from 90% to 95% whenIWRC-type wire rope is used.

Rope often is connected to the fittings of conveyances by means of clipsand clamps. They are rated to develop 75% to 80% of the rope's breakingstrength. It is important to retighten the nuts on all clips after the rope'sfirst load-carrying use, as well as at all subsequent regular inspectionperiods.


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Socketing with zinc and a thermostate plastic resin will develop 100% ofthe rope's breaking strength.

Since there is no ready way to detect flaws in the finished job, follow therecommended procedure exactly.

In high-speed hoisting, fatigue is especially likely to develop with this typeof attachment. For this reason, cut off and discard, at frequent intervals,the section adjacent to the conveyance.

Square knots and other types of knots have low and unpredictableefficiencies-40% or less. Using them is likely to result in the failure of arope assembly and under certai conditions to result in serious accident.

Inspection and Replacement:

The frequency of inspections and replacement of rope depends on serviceconditions. Some plants and mines, for instance, make a daily inspectionfor readily observable defects, such as kinking and loose wires, and athorough inspection weekly.

For the latter inspection, the rope speed is generally less than 60 feet perminute (fpm).

The supervisor checks specifically for wear of the crown wires, kinking, highstrands, corrosion, loose wires, nicking, and lubrication. Rope callipers andmicrometers are used to determine changes in the cross section of rope atvarious locations.

In most cases, sudden change in rope length and/or diameter is a warningthat the wire rope is nearing the end of its useful life and that it should beremoved from service. The reason for this change is general deteriorationof the structure of the interior rope, such as corrosion of uninspectablewires and general deterioration of the core of wire rope. A decrease in therope's diameter, which may also occur, is difficult to determine in manycases.

The number of broken wires per lay is one of the principal bases for judgingthe condition of a rope. If most of the broken wires in a lay areconcentrated in several strands, that section of the rope is weaker than it


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would be if the broken wires were uniformly distributed throughout allstrands and along the length of the rope. If, however, the number ofbroken wires along the length of a rope increases rapidly betweeninspections, the rope is becoming fatigued and nearing the end of its usefullife.

Inspection codes are given in the statutes.Usually inspections are based on numbers of broken wires per strand in onerope lay or number of broken wires per rope lay in all strands. Electronicinspection devices are available for determining loss of strength due tocorrosion, loss of metallic area, and broken wires.Experience and judgement of all these factors, combined with the length oftime the rope has been in service and the tonnage hoisted, or other workdone by the rope, determine when it should be discarded and replaced. Atintervals throughout the life of the rope, a short section should be off at thesocket end. This practice has two purposes:1 remove wires damaged by vibration dampened at the socket and2 to change the positions of critical wear poi throughout the system.


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7.5 Hoists

Material hoists and personnel hoists are made of tubular steel. Besure to consult with tubular steel manufacturers or suppliers forcurrent technical data. The plant supervisor or the contractor mustcomply with the manufacturer’s specifications and limitations.

Hoists may be erected in hoistways inside the building or in outsidetowers. Personnel hoists are used just for the transport of people.Never permit personnel to ride on a material hoist. Do not permitwork in or on the hoistway while the hoist is in operation.

Post the rated load capacities, recommended operating speeds andspecial hazard warnings or instructions on cars and platforms.

Inside Material Hoistways

If the material hoist is installed inside the building, enclose thehoistway. Solid enclosure is preferred. However, heavy wirescreening, ½-in. (1.25 cm) mesh, No 18 US gage wire, is oftensubstituted. Partition adjacent hoistways.

Protect entrances by solid or slatted wood gate at least 5-ft (1.7m)high and within 4-in. (10 cm) of the hoistway. Counter-weightgates and use latching or locking mechanisms.

Provide protective covering of heavy planking below the cathead ofall hoists. This will prevent objects from falling down the hoistway.

Outside Material Hoistways

Hoisting towers are usually made of tubular steel and are used onconstruction sites. Base the design on a safety factor of at leastfive. Erect the tower on a level and solid foundation, and have itwell guyed or fastened to the building.

Enclose the tower with heavy wire screening and equip it with afixed ladder extending the full height of the tower. Install standardrailings and toe-boards on runways connecting the tower to thebuilding.


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Material Hoist Platforms

Build material hoist platforms with a safety factor of at least five.Use timer not less than 2-in. (5 cm) for flooring. Enclose sides notused for loading with heavy wire screening, and provide 6-in (15cm) toeboards. Install an overhead plank covering at thecrosshead. The covering can be built in hinged sections to permithandling of long material. Where wheelbarrows are handled, attachstop cleats to the floor. Equip the car with a broken-rope-type ofsafety device. If a car’s cable breaks, the car safety clamps ordogs are then thrown into position on the guide rails to stop thecar.

Signal Systems

A good signal system is necessary to safety operating hoists.Electrically operated lights or bells, bells operated by pull cords, acombination of bells and lights, or telephone system can be used.Adopt standard signals and post them at each entrance and at theengine.

Personnel Hoists

Any hoist used for carrying passengers should conform to the safetyrequirement of BSI. Rack and pinion hoists can be used to carrypersonnel or material but never both, according to strictmanufacturing specifications and safety rules. Include all safetydevices, including an over-speed governor, normal limit and finallimit switches and thoroughly inspect and maintain the hoistregularly.

Temporary use of permanent elevators. Permanent passengeror freight elevators in buildings under construction modification ordemolition may be used for carrying workers or material or both.However, they must be approved for such use and a temporarypermit must be issued for the class of service.

Tower, masts and hoistway enclosures. Design and install thetower or mast construction that forms the supports for the


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machinery and guide members to support the load and forcesspecified. For hoists located outside of a structure, the enclosures(expect the one at the lowest landing) may be omitted on the sidewhere there is no floor building’s side of the hoistway should be fullheight or a minimum of 10-ft (3 m) at each floor’s landing.Enclosure at the pit should be not less than 8-ft (2 m ) on all sides.

For hoists located inside a structure, enclose the hoistwaythroughout its height. Construct hoistway enclosures so that whenthey are under a horizontal pressure of 100 lb. (445 N)

• they cannot deflect more than 1-in (2.5 cm)• The running clearance between the car and the hoistway

enclosure is not reduced below ¾-in (2 cm) except on the sidesused for loading and unloading.

If the open-work, provide hoistway enclosures with an unperformedkick plate on all sides within the building or structure. The kick plateshould extend not less than 12-in. (30 cm) above the level of eachfloor above the lowest.

Foundations of hoists should distribute the transmitted load, as notto exceed the safe load-bearing capacity of the ground upon which itis set. Anchor hoist structures to the building (or other structure)at vertical intervals not exceeding 25-ft (8 m). If tie-ins cannot bemade, guy the hoist structure to adequate anchorage for stability.When wire rope is used for guys, it should be at least ½ -in (2 cm)in diameter. Tie-ins should conform to, or be equal to, themanufacturer’s specifications and should remain in place until thetower or mast is dismantled.

Where multiple hoistways are used and one or more of the cars aredesigned solely as a material car in accord with ANSI 10.5 personnelcars are prohibited. Each personnel hoist should be independentlypowered and operated. Never use Chicago booms on a hoiststructure.

Doors or gates for hoistways should not be less than 6 ½ -ft. (2 m)high. If a solid door is used, it should have a vision panel, not widerthan 6-in. (1.5 cm) and not larger than 80-in (0.05 m2), covered


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with expanded metal. Protect all hoistway entrances withsubstantial gates or bars.

Landing doors should lock mechanically so they cannot be operatedfrom the landing side. At landings other than the lowest one, uselocks that can be released only by a person in the car. Some doorsat the lowest terminal landing automatically lock when closed withthe car at the landing. In such cases, provide a means to unlock thecar from the landing side to permit access to the car. Never use ahook and eye as a door-locking device.

Car platforms. Each car should have a platform or protectivecovering that extends over the entire area of the car’s enclosure.The covering should be non-perforated, fire retardant and supportedby the car’s frame. Design the frame and the floor to handle theanticipated loads.

Car enclosures. Enclosures and linings of cars should be made ofmetal or fire retardant wood. Permanently enclose personnel hoistcars on the top and all sides, except the entrance and exit. Securelyfasten this enclosure to the car’s platform. Support the enclosure sothat it cannot become loosened or displaced when the car’s safety orbuffer is engaged. Make the enclosure’s walls strong enough so thattheir running clearance is reduced by no more than ¾ in. (2 cm)when a force of 100 lb (445 N) is applied horizontally to the walls ofthe enclosure.

Provide an emergency exit with an outward opening cover in the topof all cars. The opening should be not less than 400-in.2 (10.16 m)in area, with a minimum dimension of 16-in. (0.41 m). It shouldprovide a clear passageway unobstructed by fixed hoist equipmenton or in the car. Use wire glass, or the equivalent, for vision panels.Use plain glass only for car’s operating appliances.

Do not locate a working platform on top of the hoist car, unlessspecifically provided in ANSI A10.4, Safety Requirements forPersonnel Hoists Do not place equipment that is not required for theoperation of the hoist or its appliances, on the top of the hoist car.Require that the hoist be locked out per lockout / tagout procedureprior to performing repairs.


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Wire Ropes & Sheaves

Use hoisting ropes not less than ½-in. (1.25 cm ) in diameter excepton such equipment as small winches, like those on gin poles. In anycase, they should provide a safety factor conforming to therequirements of applicable elevator codes. Inspect ropes frequentlyand keep them lubricated. Replace ropes when inspection disclosesthat wear, breakage, or corrosion has reduced their strength belowthe permitted safety limit.

Where clip fastenings are used, there shall be at least three clips,with the U-side on the dead end of the rope. Ropes shall beguarded at points where persons may come in contact with themand where objects may strike or rub against them. Keep sheavesaligned and bearings lubricated. In general, sheaves diametershould be at least 20 times the rope’s diameter.

Hoisting Engines

Do not locate hoisting engines in public streets. If they must belocated there, enclose them with barricades to protect the public. Inany case, install a roof to protect the equipment and operator fromthe elements.

Engines should have brakes that can stop and hold 150% of therated safe load. In addition, engines should have a pawl for holdingsuspended loads.

Enclose exposed gears, shafting and couplings. Cover exposedsteam pipes and place exhaust pipes where steam cannot strikenearby persons.

Where electric hoists are used, install enclosed safety-type switches.Enclose or guard all current carrying parts to prevent personalcontact and ground installation.


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7.6 Other Mobile Machinery & their Movement at the Site:

At the construction site number of mobile machinery are used apartfrom cranes. They cause a large number of accidents. Hence it isimperative to use them safely. This chapter deals with some of themost commonly used mobile machinery at the site.

Trucks and other mobile equipment:

Contractors working at the site should take great care to preventtheir trucks and other mobile equipment from colliding withpipelines, power lines, and other equipment. In this way, they willavoid interrupting the operations at the site.

Before mobile equipment is moved, contractors should survey thearea in which it is located to check for overhead wires, pipelinesexcavations, invisible ground conditions, and similar hazards.

Timber mats may have to be provided for providing firm footing.

Equipment with high clearances, such as cranes, should not bemoved into or out of, or operated in, any area containing electricpower lines until the approval of the superintendent has beenobtained. No part, including the load, may reach within 10-ft (3 m)of electric lines carrying up to 50 kV and an additional 4-in. for every10 kV above 50 kV, unless power in the lines is shut off. Detailshave been given under chapters captioned“Cranes ”and “Electrical hazards”.

Powered Trucks:

One method of handling construction deliveries by trucks is to havea signaller serve as the eyes for the truck driver. If there is nosignaller, install reverse alarms on all heavy mobile equipment andtrucks. Also be sure barricades, guard-rails, and warning signs arein place to assure maximum safety.

When trucks, bulldozers, powered wheelbarrows, and othermechanised construction equipment are to be operated within a


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plant, the contractor and the plant's management should agree uponthe traffic flow. In that way, the areas in which the constructionequipment is to be operated will be known and isolated wherepossible. The contractor’s key personnel and the plant's designatedpersonnel should receive drawings of these areas.

To avoid extra handling and vehicle movement, contractors shouldbe notified by the site officials about the exact location to makedeliveries.

Sometimes it may be necessary to transport employees in trucksfrom one location to another within the work area. Unless this iscontrolled, this operation can become a major source of seriousinjuries.In tractors and trailers, the coupling mechanism must be carefullysafeguarded and loads secured to the trailer. Motorised hand trucksmust be safeguarded

(1) to prevent the operator from being pinned between the truckand a fixed object and

(2) to prevent the truck running up on the operator's heels.

Automated guided vehicles must have some means of stoppingshould someone step in front of them. Such trucks should beequipped with flexible bumpers that shut off power on contact.

Operators of industrial trucks can prevent accidents by using thesame safe driving techniques they employ on the highways. Theyneed to observe speed limits, exercise care in backing up, stop atblind corners and doorways, keep trucks a safe distance apart, avoiddriving trucks into elevators unless authorised, and exercise cautionat railroad crossings.

Loading and unloading trailers require careful procedures to avoidaccidents. Operators should make sure the brakes are on, wheelsare blocked, loads are neatly stacked and stable, and the load isfastened to the trailer securely.

Industrial trucks should not be used for any purpose other than theone for which they were designed.


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Operators are responsible for the care of trucks and should neverleave a truck unattended, park in an aisle or doorway, idle enginesfor too long, or ignore mechanical problems.When driving, they should keep arms and legs inside the truck'sguard or operating station, keep passengers off the truck, and watchout for pedestrians.

Industrial powered trucks should be inspected and overhauledregularly.

Operators should inspect their trucks before and after each shift.Repairs, replacements, or other work should be performed only bytrained mechanics wearing proper protective equipment, particularlywhen handling electrically powered trucks. Repairs or re-fuelling ofgasoline and liquefied petroleum trucks should be done as pernorms/instructions to avoid health hazards and burns andexplosions. Only authorised fuel and fuel tank equipment should beused on these trucks.

Operators must have a valid driver's license, good driving record,and few, if any traffic violations. Contractors must carefully selecttrainees to meet certain physical and mental qualifications requiredby safety standards. Training programs should centre on companypolicies, operating conditions, and types of trucks used.Management should maintain records of each employee's drivingperformance.

Secure all equipment being towed not only with a regular hitch ordrawbar but also with a safety chain attached to the pulling unit. Adrawbar failure can result in a serious accident.

When towing a scraper from one job to another, the operator shoulduse a scraper bowl safety latch, or place a safety bolt in the beam togive maximum clearance for road projections such as at crossings.This precaution prevents the bowl from striking the ground orpavement and injuring persons or damaging equipment.


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Clearing work:

Work requiring exposure to low limbs of trees or to high brushinvolves serious hazards. Suitable protective measures and safepractices can readily eliminate these risks

When using a bulldozer, equip it with a heavy, well-supported,arched steel-mesh canopy to protect the operator. The operator alsoshould wear goggles to shield the eyes from whipping branches.

Head protection guards against injuries from falling branches. Whena bulldozer shoves hard against the butt of a large dead tree, thetree may crack in the middle or limbs may fall onto the machine.Dead branches or tops also can drop from live trees. A safeprocedure to eliminate the danger is to cut the roots on three sidesand then apply the power to the fourth side. Use a long rope to pullover large trees, but make sure in advance that the tractor andoperator will be in the clear when the tree falls. Operators shouldensure that all workers in the area are out of harm's way beforepushing over any trees, bulldozing rock, and rolling logs.

Special hazards:

Fatalities can occur easily when equipment is used on dumps andfills, near excavations, and on steep slopes. The operator shouldkeep the bulldozer blade close to the ground for balance when themachine is travelling up a steep slope.

When a worker is driving a tractor-dozer down a slope, the personshould doze three or four loads of dirt to the edge of the slope,keeping the loads in front of the blade. If the dirt is lost on the waydown, the operator should not lower the blade to regain the loadbecause of the danger of overturning. Never use the blade as abrake on a steep slope except in cases of extreme emergency.

Ground’s conditions will determine how close to an excavation or thecrest of a dump and operator safely work a machine. Wet weathermeans the operator must work at a greater distance from the edgeor crest. When the ground is treacherous, assign someone to signalthe driver.


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Sometimes employees, the public, livestock, and property areendangered when material is pushed over the edge in side hill work.In such cases, make sure there is sufficient clearance below beforethe work begins.

Some Useful tips for Safe Operation:

Don't allow anyone to stand on the running board or bed of a truck,or sit at the side or end of a flatbed truck.

Provide seats for each person if required to ride on vehicledequipment.

Supply safety belts for all passengers who ride in the cabin with thedriver.

Do not permit workers to ride on a loaded truck or other machinesnot equipped for the purpose.

When people are boarding or descending from a truck, the truckshould be standing still.

Prohibit workers from getting off or on moving equipment. Provide aboarding ladder. If necessary, provide a bus to transport employeestothe work site.

Vehicles that will be moving slower than normal traffic at nightshould have a yellow flashing light or four-way flashers visible fromall directions.

Equipment left unattended at night, adjacent to a highway in normaluse, or adjacent to construction areas where work is in progressshould have lights or reflectors, or barricades equipped with lights orreflectors to identify the location of the equipment.

Whenever equipment is parked, operators should set the parkingbrake. Equipment parked on inclines should have the wheelschocked, or track mechanism blocked, and the parking brake set.


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Bulldozer blades and scraper blades, end loader buckets, dumpbodies, and similar equipment should be either fully lowered orblocked when being repaired or when not in use.

Personnel should not work or pass under the buckets or booms ofloaders in operation.

No modifications or additions that affect the capacity or safeoperation of equipment should be made without the manufacturer'swritten approval.

Tools should not be left suspended from cranes, hoists, etc.

Guarding, safety devices, platforms, and means of access:

Provide guarding for belts, pulleys, sheaves, gears, chains, shafts,clutches, drums, flywheels, and other reciprocating or rotating partsof equipment.

Do not remove or make ineffective any guard, safety appliance, ordevice unless immediate repairs or adjustments are required, andthen only after the power has been shut off. Replace guards anddevices as soon as repairs and adjustments have been completed.

Properly insulate or guard current-carrying parts of electricallyoperated equipment. Properly ground all non-current-carrying metalparts.

Cover high-temperature lines and equipment, located where theyendanger employees or create a fire hazard, with suitable insulatingmaterials.

Properly release exhausts from all equipment powered by steam orinternal combustion engines (carbon monoxide hazard) and also,locate them so that they do not endanger workers or obstruct theview of the operator.


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Install platforms, footwalks, steps, ladders, handholds, guardrails,and toeboards on all equipment where they are needed to providesafe access.

Provide suitable floors or platforms, surfaced with slip-resistantmaterial, for all equipment operators.

Operators of equipment should be protected against the elements,falling objects, swinging loads, and similar hazards. Be sure thatwindows in cabs or enclosures on equipment are made of safetyglass and kept in good repair at all times.

Provide safety devices to prevent unauthorised persons from startingequipment. This could simply be a key ignition system or simplyblocking and locking the starter. At the end of a work shift,operators should set and lock equipment. This prevents it frombeing released, dropped, or activated in any way. Themanufacturer's procedure for shut down should be followed.

Do not permit debris, oil, grease, oily rags, and waste to accumulateon equipment.

Post safe load capacities and operating speeds on all equipment.

Be sure each piece of equipment is placed on an adequatefoundation and properly secured.

Flammable liquid:

Prohibit refuelling of gasoline-operated equipment while the motor isrunning. Allow continuously operating equipment to be fuelled onlyfrom properly protected tanks located outside the work area. Tanksshould be adequately grounded and bonded to equipment to preventstatic electricity build-up.

Do not locate fuel-tank filler openings in such a position that spills oroverflows can run down on a hot motor, exhaust pipes, or battery.

Prohibit smoking or the use of open flames on, or in the immediatevicinity of, gasoline-operated equipment while it is being refuelled.


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Workers should not use solvents with flash points below 100 F (37.8C) for cleaning equipment or parts.

When gasoline and other highly flammable fluids are used, transferthem by approved pumps or store them in approved safety cans. Donot store gasoline, fuel oil, and other flammable or combustibleliquids on equipment except in fuel tanks or approved safety cans.

Locate suitable fire extinguishers on, or close to, each industrialtruck.

Repairs:

Shut down all hazardous equipment for repairs.

Post suitable signs, and do not remove them until repairs have beencompleted.

Move mobile equipment, if possible, to a safe location whereoperations will not interfere with the repair work.

Block or crib equipment suspended in slings or supported by hoistsor jacks for repairs before anyone is permitted to work underneathit.

For repairs on equipment made away from the source of power, suchas conveyors and cable ways, use chains, blocking, or similardevices. Such precautions will prevent injury in case the equipmentis accidentally started.

Before repairs on electrically powered equipment are begun, lock themain switch in the open (OFF) position. The person doing therepairs should retain the key to the switch lock. If there is morethan one repairperson, each should lock the main switch with apersonal lock and retain the key.


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Fork lift trucks:

Powered trucks require safeguards for the operator's protection andfor the safety of other workers. Site Management must establishguidelines for the operation, maintenance, and inspection of thisequipment.

Common types of industrial trucks include lift trucks, straddle trucks,crane trucks, tractors and trailers, motorised hand trucks, andautomated guided vehicles.

Power source, operator position, or means of engaging the loadclassifies powered industrial trucks.

Rider controlled trucks, such as the lift truck, are designed to becontrolled by a driver who rides on the truck.

Motorised hand trucks and electronically controlled or automatedguided vehicles can be controlled from the outside.

Factors to consider in purchasing/hiring trucks include work siteconditions, operator comfort, backup systems, and safety featuressuch as seat belts and wraparound seats.

Safeguards common to all trucks include guarded lifts and tires,horns or other warning devices, reinforced platforms, and nameplatewith rated capacity.

Standards specify certain hazardous locations, Classes 1 through Ill,in which various types of trucks should not be used unless theycomply with requirements or are officially approved.

All trucks should carry fire extinguishers regardless of their locationclassification.

Lift trucks should have overhead guards designed to prevent injury.

Operators should realise that lift trucks are generally steered by therear wheels, handle more easily when loaded, are used in reverse asoften as forward, and are often steered with only one hand. Driversmust be shown how to handle various types of loads, to drive ondifferent gradients, to load and unload the truck properly, and tostack pallets safely.


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Straddle trucks present a special problem because the operator sitso high off the ground they cannot see directly in front or behindthem.

Horns, red flags, or other warning devices should be used to protectpedestrians.

Crane trucks should be driven at the lowest possible speed whencarrying a load to maintain its balance.

Some useful tips for drivers for safe operation of the fork lifttruck:

• When you back out of an aisle, remember to allow enough roomfor forks to clear the sides before starting the turn.

• If you leave your forklift unattended for any reason. alwayslower the mast completely, turn off the engine and set thebrake

• Some policies may state that if you are closer than 25 feet ormaintain

• Visual contact with the forklift, you may leave the enginerunning.

• Practice and concentration on your work are the keys tobecoming a successful operator. Keep in mind that you putyourself and your

• Co-workers in danger when you do not follow safe operatingprocedures.

• A professional forklift driver will make sure that equipment is ingood condition and will practice safe operating techniques.

Points to remember about inspecting and operating a forkliftinclude:

Pre-Use Inspections:

- Always inspect the forklift before you start work. ( mast forbroken weld, proper lubrication of roller tracks and chain, forksproperly placed/not cracked, hydraulic fluid level and leakage)

- Inspecting the Power Source:

- Finding The Rated Capacity;


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Safety Tips:

• Never lift load while moving• Stop before you raise mast.• Be sure that load sits squarely on stack, or it could tip over.

Driving With A Load:

Always travel with load tilted slightly back, keep load at properheight. Drive slow. If you can't see, drive in reverse.

Safe Steering: Drive slowly, slow for turns; stay wide when turninginto aisles.

There are many floor surfaces a forklift must operate on.These Suggestions will help to ensure safe operation:

Slippery floors - Slow speed, brake carefully, and avoid tight turns.

Overhead clearance - Be aware of clearance, mast and overheadguard height.

Tight spaces - Move empty forks to one side, steer to maximiseturning angles.

Heavy traffic areas - Set loads carefully, maintain safe speed, anduse horn to alert others.

Loading docks - Check for bridge security, avoid acceleration.


Critical Jobs 1

8.1 Work over water:

Falling into water and being drowned or carried away by currents isan ever-present danger when working over or adjacent to water.

Rules 86 & 87 of “ THE BUILDING AND OTHER CONSTRUCTIONWORKERS (REGULATION OF EMPLOYMENT AND CONDITIONS OFSERVICE) CENTRAL RULES, 1998 ” give the requirements whenworkers are allowed to work on or adjacent to water.

Even though the worker may be a good swimmer, the followingprecautions should always be followed:

! Make sure that the working platform is secure and has no trippinghazards such as tools, wire, timber or bricks. Surfaces soon becomeslippery and should be treated immediately by cleaning, gritting orapplying industrial salt or sand.

! Check that access ladders guard-rails and toe boards are firmly fixed inposition.

! Wear a safety helmet at all times - if you are struck on the head andfall into water you are at special risk.

! Wear a life jacket, and ensure that it is properly fastened.

! Use any safety nets or safety harness provided.

! Check that lifebuoys fitted with lifelines are ready to hand forimmediate use.

! Make sure that there is a safety boat and that it is manned while youare working above water - if over tidal water or a fast-flowing river, itmust have a motor with a self-starting device Ensure that you know theroutine for raising the alarm and for rescue drill.

! Needs of both workers and supervisors.


Critical Jobs 2

8.2. Confined Spaces:

If you are one of the workers who work in confined spaces each year, youknow your job is dangerous.Serious injury or death in a confined space can be result of:

" Asphyxiation" Engulfment" Electric shock" Fall & heat stress

NOISH defines a confined space as

A space that by design has limited openings for entryand exit;Unfavorable natural ventilation which could contain or produce dangerousair contaminants,

&Which is not intended for continuous human occupancy.

Class A spaces are those that present situation which are immediatelydangerous to lift or health. These include spaces that are either deficient inoxygen or certain explosive, flammable or toxic atmospheres.Class B spaces do not present an immediate threat to life or health:however, they have the potential for causing injury or illness if protectivemeasures are not used.Class C spaces are those where any hazards posed are so insignificantthat no special work practices or procedures are required.

Some examples of Confined Spaces

TANK SILO PIPELINE


Critical Jobs 3

Typical reasons for confined space entry:# Inspection of physical integrity and process equipment.# Maintenance such as abrasive blasting and application of surface

coatings.# Tappings, coating, wrapping and testing of underground sewage,

petroleum, steam and water piping system.# Installing, inspecting, repairing and replacing valves, piping, pumps,

motors, etc. in below ground pits and vaults.# Cleaning to remove sludge and other waste materials.# Repair, including welding and adjustments to mechanical equipment.# Adjusting and aligning mechanical devices and components.# Checking and reading meters, gauges, dials, charts and other

indicators.# Installing, splicing, repairing and inspecting electric and telephone

cables.# Rescue of workers who are injured or overcome inside the space.

Permit - required Confined SpacePermit required confined space has one or more of the followingcharacteristics:

# Contains or has potential to contain a hazardous atmosphere.# Contains a material that has the potential for engulfing an entrant.# Has an internal configuration such that the entrant could be trapped or

asphyxiated by inwardly converging walls or by a floor which slopesdownward and tapers to a smaller cross-section.

# Contains any other recognized serious safety or health hazard.

Confined Space Hazards

1. Oxygen deficient atmospheres are atmospheres which containless than 19.5% v/v oxygen.

2. Toxic vapors and gases which exceed their PEL(Permissible Exposure Limit) should be considered Immediately Dangerous to Life or Health. Conditions may result in acute or immediately severe health effects.

3. Flammable or Combustible Atmospheres are hose in which flammable or combustible vapors/gases are equal to or greater than 10% LEL (Lower Explosive Limit).


Critical Jobs 4

Confined Space hazards:

A. Atmospheric Hazards# Oxygen deficiency atmospheres.# Oxygen enriched atmospheres.# Flammable atmospheres# “Toxic” or irritating atmospheres.

B. Physical Hazards:# Unexpected movement of machinery.# Electrocution by electrically energized conductors.# Fluids: liquids, powders and gases.# Heat stress, Thermal condition: hot or cold.# Engulfment by finely divided material or liquid.# Ionizing and non-ionizing radiation.# Contact with corrosive substances.

The PERMIT Space Programme

Steps to control the hazards of permit spaces:# Identify all permit spaces in your workplace.# Reduce employee risk around permit spaces with signs or

training.# Prevent unauthorised employee entry in permit space

Program.# Develop & implement a written permit space program.# Document procedures establishing a non-permit space.# Re-evaluate spaces when conditions change.# Make special arrangements with contractors who may enter

permit spaces.# Supply safety and personal protective equipment.

Elements of Confined Space Entry Programme:

# Procedures for identifying hazards associated with entry.# Procedures, method and practices used to control confined space

hazards.# A written permit system.


Critical Jobs 5

# Specialized equipment, such as air sampling struments,ventilation equipment, rescue gear, Personal ProtectiveEquipment, etc. required for entry.

# Designation of employees who have an active role in the entry,e.g., authorised entrants, attendants, and entry supervisor.

# Provision for testing and evaluating the space to ensure thatconditions are suitable for entry.

# Coordination of contractor activities.# Emergency response procedures, including provision forrescue

equipment and an attendant.# Employee training and information.# Annual program review to assure continued effectiveness.


Critical Jobs 6

THE WORK BEING DONE CAN CAUSE CONDITIONS IN ACONFINED SPACE TO BECOME MORE HAZARDOUS:

# Hotwork uses up oxygen and can release hazardous materials.# Sanding, scraping and loosening residue can stir up hazardous materials.# Workers bring hazardous materials, such as solvents, paints into the permit space.# Work outside a permit space can produce harmful vapors that collect inside.

Preparation of the Permit Space:

# All departments likely to be affected by service interruption must be noticed.# Post signs and put up barriers to protect entrants from vehicle traffic and pedestrians from falling into the space.# Blind or disconnect and cap all input lines, that no hazardous materials can enter the space.# When ventilation is needed, begin long enough in advance so that the air will be safe before anyone enters. Verify breathing safety by air testing.# Empty the space of any materials that may be hazardous. If necessary, clean, purge or inert hazardous residue in the space.# Make sure no hazardous energy can be released. Follow your company’s lockout / tagout rules.# Assignment and training of entry supervisor, attendant and entrants is required to comply with the employer’s Permit space Plan.# Attach completed Hotwork permit, if required, to Confined Space# Entry Permit.# Add emergency contact telephone numbers.


Critical Jobs 7

Equipment required for entry and work:# Appropriate personal protective equipment, such as hard hats, face

shields and encapsulated suits must be made available at the site.# Decide whether respirators and portable air monitors are required and

which types match the hazard.# Choose and list devices for communication. Test it before entry.# List any special light sources, spark-proof tools and other electrical

equipment that must be on hand before entry begins.# Make sure this equipment is intrinsically safe and in good condition.# List any measures needed to guard against shock, such as ground-fault

circuit interrupters.# List any measures needed to guard against shock, such as ground-fault

circuit interrupters.# List devices such as ladders, boatswain’s chairs and work platforms.

Test this equipment before entry begins.

Permit Authorisation:# The entry supervisor fills up the confine space entry work permit.# After verifying that acceptable entry conditions exist, the entry

supervisor signs and dates the permit.# ONLY THEN workers are allowed to enter the permit space.

General Entry Work Practices in Confined Spaces:

! The air in the vessel must be tested for oxygen and for flammable andtoxic gases before entry

! Lifelines and safety harness must be used by all the persons entering inthe confined spaces.

! A person must also be stationed outside the vessel in a position tohandle the lifeline and to summon assistance in case of an emergency.

! Self-contained breathing apparatus must be kept ready for emergency.! All the inlet of the vessel that could injure the entrant if operated

unexpectedly must be blinded or locked in the“Safe” position.

Welding & Gas cutting in confined Spaces:

# Minimum general ventilation rate of 2000 cubic feet per minute perwelder be maintained in confined spaces.


Critical Jobs 8

# If local exhaust is used, the capture velocity at the point of work mustbe at least 100 feet per minute.

# Local exhaust or air-supplied respirators must be provided if welding,cutting or heating is performed on beryllium -, lead -, cadmium - ormercury -coated base metals.

# Welding machines and compressed gas cylinders must be kept outsidethe confined spaces.

# When work stops for a prolonged period of time, electrodes must beremoved from their holders and gas flow to torches must be shut offfrom outside the space.

Excavations, Trenching and Shoring:

# Special precautions must be taken when employees enter trenchesdeeper then four feet that are dug in locations where atmospherichazards may be present.

# These locations include places such as landfills, hazardous waste sites,chemical plants, refineries and underground storage tank removalprojects.


Critical Jobs 9

Physiological effects of Oxygen at different levels.

Oxygen enriched atmosphere.

Normal air oxygen level.

Minimum safe entry level.Disturbed respiration, emotional sets,abnormal fatigue on exertion, flamesare extinguished.

Increased respiration, heart coordination may be disturbed, some euphoria, possible headache.

Nausea and vomiting, inability to move freely, possible unconsciousness, possible collapse while remaining conscious but helpless.

Gasping respiration, Respiration stops, followed by cardiac arrest, death in minutes.

Causes of Oxygen Deficiency

In confined spaces ambient oxygen being,# Consumed by industrial processes like welding, torch cutting and

blazing, fuel fired space heaters.# Consumed by chemical reactions like oxidation (Rusting and naturally

occurring fermentation)# Displaced by inert gases like argon, carbon dioxide and nitrogen# Adsorbed by porous surfaces like activated charcoal.


Critical Jobs 10

OR

If make-up air is inadequate, Carbon monoxide produced by inefficientcombustion, which combines with hemoglobin about 200 times moreeasily than oxygen.

Oxygen Enriched Atmosphere

# Permit flammable gases and vapors to ignite over a much wider rangeof concentrations than is possible in ordinary air.

# Alters the burning characteristics of many materials, making themboth easier to ignite and faster burning once ignited.

Sources

1. Oxygen used to ventilate tank during repair.2. Compressed oxygen used to dislodge welding slag.3. Leaking welding oxygen lines in barge wing tank.


Welding and Gas Cutting 1

9. Welding and Gas Cutting:

Introduction:

The purpose of welding is to join metal parts. All welding process requiresheat and sometimes other substances to produce the weld. Because highheat is used to make the weld, a number of by-products results from theprocess, including fumes and gases that can be a serious health hazard toworkers. Safety hazards are also associated with welding, such as thepotential for fire or explosion and injuries form arc radiation, electricalshock, or material handling.Definitions used in this chapter are those of the American WeldingSociety. “Welder” and “Welder Operator” refer to the individual only. Themachine performing the welding operation is referred to as the “Weldingmachine”. Equipment supplying current for electric welding is called eithera “Welding generator” or a “Welding transformer”.

Hazards:

1. Health Hazards:

The most significant health hazard in the welding process is thegeneration of fumes and gases. The amount and type of fumesand gases involved will depend on the welding process; the basematerial, the filler material, and the shielding gas, if any. Thetoxicity of the contaminants depends primarily upon theirconcentrations, and upon the physiological responses of thehuman body. Sampling by an industrial hygienist or otherqualified person may be necessary to fully identify the fumes andgases actually being given off in a specific operation.

(a) Toxic Gases:Exposure to various toxic gases generated during welding mayproduce one or more of the following effects:• Inflammation of the lugs (chemical pneumonitis)• Pulmonary edema (swelling and accumulation of fluids)• Emphysema (loss of elasticity of the lungs; very small

percentage of emphysema caused by occupationalexposure)

• Chronic bronchitis



• AsphyxiationThe major toxic gases associated with welding are classified asprimary pulmonary and nonpulmonary.

(b) Cleaning Compounds usedBecause of their chemical properties, cleaning compounds cancreate health hazards if improperly mixed. They often requirespecial ventilation precautions. Follow the manufacturer'sinstructions.

(c) Chlorinated HydrocarbonsDegreasing operations often employ chlorinated solvents that candecompose to toxic phosgene gas in the presence of theultraviolet radiation emitted by the welding arc.

(d) AsbestosIf welding or cutting involves asbestos, the regulations of theagency having authority must be consulted before beginning thejob. Asbestos can produce fibrosis and lung and other cancers.

2. Safety Hazards

(a) Fire Protection

Because portable welding and cutting equipment creates specialfire hazards, it should be used in a permanent welding andcutting location that can be designed to provide maximum safetyand fire protection. Otherwise, the welding and cutting siteshould be inspected to determine what fire protection equipmentis necessary.

It is advisable, particularly in hazardous locations, to require "Hotwork" permits issued by the welding supervisor, a member of theplant fire department, or some other qualified person beforewelding or cutting operations are started. Specifications for hotwork permits are outlined in the annexe.

(b) Floors and Combustible MaterialsWhere welding or cutting must be done near combustiblematerials, special precautions are necessary to prevent sparks or



hot slag from reaching such material and starting fires. If thework itself cannot be moved, the exposed combustible materialshould, if possible, be moved a safe distance away. Otherwise, itshould be covered with sheet metal. Spray booths and ductsshould be cleaned to remove combustible deposits. Beforewelding or cutting is started, wood floors should be swept cleanand, preferably, covered with metal or other non-combustiblematerial where sparks or hot metal may fall. In some cases, it isadvisable to wet down the floor, though the wet floor increasesthe shock hazard to electric (arc and resistance) welders andnecessitates special protection for them.

If gas welding or oxygen cutting is done inside a booth providedfor arc welding, the gas cylinders should be placed in an uprightand secured position away from sparks to prevent contact withthe flame or heat.

Hot metal or slag should not be allowed to fall through cracks inthe floor or other openings, nor into machine tool pits. Cracks orholes in walls open doorways, and open or broken windowsshould be covered with sheet metal guards. Because hot slagmay roll along the floor, it is important that no openings existbetween the curtain and the floor. Similar protection should beinstalled for wall openings through which hot metal or slag mayenter when welding or cutting operations are conducted on theoutside of the building.

If it is necessary to weld or cut close to wood construction, ornear combustible material that cannot be removed or protected,a fire hose, water pump tank extinguisher, or fire pails should beconveniently located. Portable extinguishers for specificprotection against Class B and C fires should also be provided.Pails of limestone dust or sand may be useful. It is good practiceto provide a fire extinguisher, either dry chemical, multipurposechemical, or carbon dioxide, for each welder.

A fire watcher equipped with a suitable fire extinguisher shouldbe stationed at or near welding or cutting operations conducted inhazardous locations to see that sparks do not lodge in floorcracks or pass through floor or wall openings. The fire watch



should be continued for at least 30 minutes after the job iscompleted to make sure that smoldering fires have not beenstarted.

Hazardous Locations

Welding and cutting operations should not be permitted in or near roomscontaining flammable or combustible vapours, liquids, or dusts. Norshould they be permitted on or inside closed tanks or other containersthat have held such materials until all fire and explosion hazards havebeen eliminated. All of the surrounding premises should be thoroughlyventilated, and frequent gas testing provided. Sufficient draft should bemaintained to prevent accumulation of explosive concentrations. Localexhaust equipment should be provided for removal of hazardous gases,vapours, and fumes (present in the surroundings or generated by thewelding or cutting operations) that ventilation falls to dispel.

1. Drums, Tanks, and Closed Containers

Closed containers that have held flammable liquids or other combustiblesshould be thoroughly cleaned before welding or cutting. If the containerscannot be removed for standard cleaning procedures, two other practicesare sometimes followed: (1) the containers are purged with an inert gas(Figure 19-1), or (2) they are filled with water to within an inch or two ofthe place where the work is to be done and a vent is left open. Either ofthese measures may also be used

The accepted method for preparing tanks and drums for welding is:

1. Remove all sources of ignition (open flames, unguarded electric lights,etc.) from the vicinity of the drum to be cleaned.

2. Remove the bung w' h a special long-handled wrench.3. Examine the inside for rags, waste, or other debris that might interfere

with free draining. Use a portable electric hand lamp that is listed forhazardous location, or an electric extension lamp protected by a guardof spark resistant material.

4. Place the drums on a steam rack with the bungholes at the lowestpossible point, and let the drums drain for some minutes.

5. Steam the drums for at least 10 minutes. Drums that have containedshellac, turpentine, or similar materials require longer steaming.



6. Remove the drums from the steaming rack, and fill drum part waywith caustic soda or soda ash solution. The drums for at least 5minutes. Light hammering with a wood mallet will help to loosenscale.

7. Thoroughly flush the drums for at least 5 minutes boiling water. Awater spray nozzle placed 6 to 8 in to 20 cm) inside the drum can beused. Drums should placed so that water can drain out the

8. Wash down the outside of the drum with a hose stream of hot water.9. Dry the drum thoroughly by circulating warm air throughout the

inside.10.Thoroughly inspect the interior of the drum, using a light that islisted for hazardous locations, and a small mirror. If it is not clean,repeat the cleaning process.

11. Test the container for the presence of flammable vapours with acombustible gas indicator. Test for toxic contaminants and for oxygensufficiency or enrichment if personnel are to enter.

12. Make similar tests just before welding repair operations areperformed. If operations extend over an appreciable period of time,make repeated tests.

Precautions for employee protection during container cleaning operationsinclude the following suggestions:

• Wear head and eye protection, rubber gloves, boots, and apronswhen handling steam, hot water, and caustic solutions. Whenhandling dry caustic soda or soda ash, wear approved respiratoryprotective equipment, long sleeves, and gloves.

• To handle hot drums, wear suitable hand pads or gloves. Steamirons or other hot surfaces that may be touched should be insulatedor otherwise guarded.

• Dispose of residue in a safe manner. In each instance, the methodof disposal should be checked for hazards.

• If a vessel must be entered, wear respiratory protective equipmentapproved for the exposure and a safety harness with attachedlifeline tended by a helper who is similarly equipped and stationedoutside the vessel. Rescue procedures should be tested foradequacy before beginning.

Refer to Material Safety Data Sheets provided by the manufacturer toidentify any of the materials listed above that may be contained in theconsumable. Whenever these materials are encountered as



designated constituents in welding, brazing, or cutting operations,ventilation precautions must be taken to assure the level ofcontaminants in the atmosphere is below the limits allowed for humanexposure. Unless atmospheric tests under the most adverseconditions have established that exposure is within acceptableconcentrations, the following precautions need to be observed.

Ventilation

Natural. Natural ventilation is acceptable for welding, cutting, andrelated processes where the necessary precautions are taken to keepthe welder's breathing zone away from the plume and where sampling ofthe atmosphere shows that concentrations of contaminants are belowthe levels given above. Taking air samples at the breathing zones of thepersonnel involved is the only way to assure that airborne contaminantlevels are within the allowable limits.

Natural ventilation often meets the standards if the necessaryprecautions are taken to keep the welder's breathing zone away fromthe plume and all of the following specifications are met:

• Space of more than 10,000 ft3 (284 m-3) per welder is provided• Ceiling height is more than 16 ft (5 m)• Welding is not done in a confined space• Welding space refers to a building or an enclosed room in a building,

not a welding booth or screened area that is used to provideprotection from welding radiation; nor does the welding spacecontain partitions, balconies, or other structural barriers thatobstruct cross-ventilation m materials covered above are notpresent as deliberate constituents.

Mechanical : Mechanical ventilation includes local exhaust, local forced,and general area mechanical air movement. Local exhaustventilation is preferred. It means fixed or movable exhaust hoodsplaced as near as practical to the work and able to maintain a capturevelocity sufficient to keep airborne contaminants below the limits.

Local forced ventilation means a local air-moving system (such as afan) placed so that it moves the air at right angles (90 degrees) to thewelder (across the welder's face). It should produce an approximate



velocity of 100 ft per min (30 m per min), and be maintained for adistance 'Of approximately 2'ft (0.6 m) directly above the work area.Precautions must be taken to ensure that contaminants are notdispersed to other work areas.

General area mechanical ventilation includes roof exhaust fans, wallexhaust fans, and similar large area air movers. General mechanicalventilation is not usually satisfactory. It is often helpful, however, whenused in addition to local ventilation. General mechanical ventilation maybe necessary ventilation to maintain the general background level ofairborne contaminants below the levels referred to or to prevent theaccumulation of explosive gas mixtures.



Handling and storage of cylinders:

Precautions in handling of gas cylinders :

1. Do not remove or change numbers or marks stamped on cylinders.

2. Because of their shape, smooth surface and weight, cylinders are difficult to carry by hand, carry it with some Mechanical Aid.3. Protect cylinders from cuts or abrasions.

4. Do not lift compressed gas cylinders with an electro-magnet. Wherecylinders must be handled by a crane or derrick, as on constructionjobs, carry them in a cradle or similar device and take extreme carethat they are not dropped. Do not use slings.

5. Do not drop cylinders or let them strike each other violently.

6. Do not use cylinders for rollers, supports, or any purpose other than tocontain gas.

7. Do not tamper with safety devices in valves on cylinders.

8. When in doubt about the proper handling of compressed gas cylindersor its contents, consult the supplier of the gas.

9. When empty cylinders are to be returned to the vendor, mark themEMPTY with chalk. Close the valves and replace the valve protectioncaps.

10. Load cylinders to be transported to allow as little movement aspossible. Secure them to prevent violent contact or up setting.

11. Always consider cylinders as full and handle them with correspondingcare. Accidents have resulted when containers under partial pressurewere thought to be empty.

12. The fusible safety plugs on acetylene cylinders melt at about theboiling point of water. If an outlet valve becomes clogged with ice orfrozen, it should be thawed with warm (not boiling) water, appliedonly to the valve. A flame should never be used.



13. Cylinders together with their valves and other fittings and otherfittings and the identification colours under these rules shall alwaysbe maintained in good condition.

14. No oil similar lubricant shall be used on any valves or other fittings ofany cylinder.

15. Every cylinder containing compressed gas shall have valve securelyclosed so as to prevent leakage.

16. If a leak in the valve can not be rectified by lightening the gland nutor the spindle, the cylinder shall be removed to an open space whereit is least dangerous to life and properly and the filler shall beinformed.

17. As per rule 9 (2) of gas cylinder rules,1981.

Rule 9(2) of gas cylinder rules, 1981 prescribes 4 warning in the followingterms are attached to every cylinder containing permanent or liquefiablegas, namely:

“WARNING”Gas Cylinder Rules, 1981

(i) The colour of the cylinder should not be changed.(ii) The cylinder should not be filled with any gas other than the one it contains.(iii) No flammable material should be stored in the immediate vicinity of the cylinder or in the same room in which it is kept.(iv) No oil or similar lubricant should be used on the valves or other fittings of this cylinder.(v) The cylinders should be periodically tested and inspected and the record of the same should be maintained.

COLOUR CODING:

The cylinders should be painted as per the Indian Standards for easyidentification. To prevent inter change of fittings, the valve out lines arescrewed left and right respectively.



Precaution in Storage of Cylinders

1. Store cylinders in a safe, dry, well - ventilated place prepared and reserved for the purpose.

2. Flammable substances, such as oil and volatile liquids, should not bestored in the same area.

3. Never store cylinders near elevators, gangways, stairwells or otherplaces where they can be knocked down or damaged.

4. Never store oxygen cylinder close to cylinders containing flammablegases.

5. Store acetylene and liquefied fuel gas cylinders with the valve end up.

6. Acetylene storage rooms and buildings must be well ventilated, andopen flames must be prohibited.

7. Cylinders should be stored on a level floor.

8. To prevent rusting, cylinders stored in the open should be protectedfrom contact with the ground and against extremes of weather -accumulations of ice and snow in winter and continuous direct rays ofthe sun in summer.

9. Cylinder storage should be planned so those cylinders will be used in the order in which they are received.

10. Cylinders are not designed for temperatures in excess of 130 F.Accordingly, they should not be stored near sources of heat, such asradiators or furnaces, or near highly flammable substances likegasoline.

11. Cylinder storage should be planned so those cylinders will be used inthe order in which they are received from the supplier.

12. Never permit cylinder to have contact with direct flame or electricarc.



13. For storage of gas cylinders flammable storage rooms for cylinderscontaining flammable gases should be well ventilated to prevent theaccumulation of explosive concentrations of gas.

14. Never allow cylinders to come into contact with electrical apparatusor live wires, since arcing may be set up which will heat or damagethe cylinders.

15. Never strike an arc or tap an electrode on a gas cylinder whether fullor empty.

16. Oil or grease must under no circumstances be allowed to come incontact with one another.

17. Never transport cylinders with the regulators and hose attachedunless a proper trolley or carrier is used. When transporting by atrolley the cylinder valve must be shut before the cylinder is movedfrom place to place.

18. If an acetylene cylinder becomes hot or fires internally due toexternal fire or uses of faulty equipment, close the valve, disconnectthe regulator (if possible) remove the cylinder into the open, theopen the valve fully to allow the gas to escape freely. Meantime,apply water to cylinder body from a hose or immerse the cylinder ina tank of water and inform the supplier immediately.

Care in the Use of Gas Cutting Set

1. Before attaching a regulator to the cylinder it is necessary to ‘Shift’the valve in order to remove foreign particles or moisture from thevalve seat. Care should be taken to see that the regulator chosen bethe correct one to use for the gas contained in the cylinder.

2. Before fixing a regulator on to a full cylinder, always release theadjusting screw for regulating the pressure output, otherwise there isa risk of damage to the regulator.

3. Make sure that the threads on regulators and other auxiliaryequipment are the same as those on the cylinder valve outlets.



4. Leaks of gas are dangerous. Check all connections regularly faulty orleaky equipment should be changed without delay.

5. There are two types of blowpipes in common use i.e. low pressure andhigh pressure. Remember, a low pressure blow pipe may be used on ahigh pressure system, but under no circumstance, can a high pressureblow pipe be used on a low pressure system.

6. Inspect rubber hose periodically to see that it is free from cuts, cracks,burns and worn places and arranges it so that it can not be cut bycontact with sharp edges or corners, falling metal, sparks or the blowpipe flame.

7. Use red hoses for acetylene and to other fuel gases and black foroxygen and be careful to see that they are never inter changed.

8. Use hoses of equal length and do not coil any surplus hose aroundregulators or cylinders.

9. Nozzle tips should be kept clean as otherwise distortion of flames andback-fire may result. Never poke a nozzle orifice with a steel wire.

10. Cylinders should not be used to support the work, nor should theblow pipe flame be allowed to come in contact with the cylinders. Theblow pipe when alight should not be hung on the cylinder or on theregulator.

11. To blow out dust or dirt that otherwise might enter the regulator,“crack” the discharge valve on the cylinder by opening it slightly foran instant and the close it. On a fuel gas cylinder, first see that noopen flame or other source of ignition is near; otherwise, the gasmay ignite at the valve.

12. Connect the regulator to the outlet valve on the cylinder. Be sure theregulator inlet threads match the cylinder valve outlet threads. Neverconnect an oxygen regulator to a cylinder containing fuel gas, or viceversa. Don’t force connections which do not fit. Be sure that theconnections between the regulars and cylinder valves are gas-light.



13. Release the pressure adjusting screw on the regulator to its limit –turn it counter - clockwise until it is loose.

14. Open the cylinder valve slightly to let the hand on the high pressuregauges move up slowly. On an oxygen cylinder gradually open thecylinder valve to its full limit, but

Care in the Use Arc Welding Transformer / Generator

1. Provide switch fuse adjacent to the equipment in order that it may beisolated from supply main, if necessary.

2. Both portable and stationary equipment must be double earth with 8SWGI wire. In addition, the work must, of course, be earthed.

3. On the output (i.e. Secondary) side of transformer, cables of thecorrect type and capacity tied with the appropriate connectors / lugs.

4. In service, the welding operator should check all external connectionsdaily and report any weakness, defects etc.

5. Ensure that all connections are clean and tight, that they are correctlymade, that the correct types and sizes of cables, earthing clamps,electrode holders, cable connectors are being used.

6. Periodically clean and tight the jaws of electrode holder to preventoverheating.

7. Much of the heat generated in a holder is the result of poor electricalcontact at the jaws holding the electrode, and a spring or other gripsensures a uniform pressure. Use good quality insulated electrodeholder.



Personal Protection for Welders

(A) Protective clothing for the body

Wear leather apron to protect his body and clothing from the heat ofthe work, to prevent burns which can be caused by small globules ofmetal falling on his thigh and legs, and in gas shielded ultra-violetradiation and ozone on clothing.

1. Flame - resistant gauntlet gloves, except on very light work.

2. Aprons of leather, asbestos or other flame - resistant material towithstand radiated heat and sparks.

3. For heavy work, fire-resistant leggings, high boots or similarprotection.

4. Safety shoes, wherever heavy objects are handled, Low - cutshoes with unprotected tops should not be used because of thespark hazard.

5. For overhead work, capes or shoulder covers of leather or othersuitable

(B) Gloves

To protect the hands against heat, spatter and radiation, gloves mustbe worn, and these should be of the leather gauntlet type withcanvas or leather cuffs, as specified in IS :

(C) Head protection

* When molten metal or hot particles are emitted during welding, thewelder should wear a leather apron to protect his clothing.

In the case of cutting operation it is advisable to wear asbestos -cloth or leather spats so as to prevent hot particles from falling intothe boots or shoes.



General Safety Protections

1. Sparks from welding and particularly from gas cutting can travel aconsiderable distance.

2. Fire extinguishers and sand should be readily accessible and watershould be used to flood the floor where no other protection is possible.

3. Do not weld out tanks or vessels which may have contained petrol,oils, spirits or any other inflammable or explosive material withoutmake it safe. They should be washed out thoroughly with caustic sodaor carbon tetrachloride and then with water. If possible pass steamalso.

4. When cutting or welding inside boilers or other confined spaces, gascylinders should always keep gas cylinder outside and take special careto make sure that the hose is in good condition. Have a pail of waterand fire extinguisher at hand and have an assistant outside to controlthe gas supply and to give any necessary help.

5. Wear an approved respirator when paint burning, cutting, welding orflame cleaning on painted galvanized plate for an extended time or ina badly ventilated place

6. Never do welding or cutting on a concrete floor, because when heated,a portion of the concrete may spell and fly with possible injury to theoperator.

7. If welding or cutting is performed in a confined space and an operatormust enter through a manhole or other small opening some meansshould be provided for quickly removing him in ease of an emergency.

8. Use a spark lighter and not a match-stick to light up a flame.

9. Suitable fire-extinguishing apparatus should always be ready to handand, if the working condition are such that a fire risk is present, aresponsible person should keep the site under observation for at leasthalf an hour after completion of the work, in order to watch for and



deal with any outbreak of fire. It is not un - common for a fire tosmolder for many hours before breaking out.

10. It is the operator’s duty to adequately protect his own clothing andperson from sparks, flying particles of incandescent metal or slag.Never wear oily or greasy clothing of any kind.

11. For work at more than 5 ft. above the floor or ground, use aplatform with railings, or a safety belt and lifeline.

12. Wear respiratory protection as needed and a safety harness withattached lifeline for work in confined spaces, such as tanks andpressure vessels. The lifeline should be tended by a similar equippedhelper whose duty is to observe the welder or cutter and effectrescue in emergency.

13. Take special precautions if welding or cutting in a confined space isstopped for some time Disconnect the power on arc welding orcutting unit and remove the electrode from the holder. Turn off thetorch valves on gas welding or cutting units, shut off the gas supplyat a point outside the confined area, if possible, remove the torchand hose from the area.

14. After welding, or cutting is completed, mark hot metal or post awarning sign to keep workers away from heated surfaces.

15. Follow safe house keeping principles, Do n’t throw electrode or rodstubs on the floor - discard them in the proper waste container. Keeptools and other tripping hazards off the floor - put them in a safestorage area.

16. Obtain a written permit before using portable cutting or weldingequipment any where.

17. Before starting, sweep floors clean, wet down wooden floors, or coverthem with sheet metal or equivalent. In outside work, don’t letsparks enter doors or windows.



18. Move combustible material 13 meters away; cover what can’t bemoved with asbestos curtains or sheet metal, carefully andcompletely.

19. Station extra men with hose, extinguishers, or fire pails to watchsparks and see that they do not start fire.

20. After completion, watch scene of work half-an-hour for smolderingfires, and inspect adjoining rooms and floors above and below.

21. Don’t use the equipment near flammable liquids, or on closed tankswhich have held flammable liquids or other combustibles. Removeinside deposits before working on ducts.

22. Keep cutting and welding equipment in good condition. Carefullyfollow manufacturer’s instructions for use and maintenance.

23. See that the fire service should be called at the first sign of fire.

24. Cutting and welding operators, and every other person concerned,shall be instructed to watch for and be ready immediately toextinguish any fire that may occur and know how to transmit a call tothe nearest fire station.

25. Ample supply of dry sand in suitable containers shall be provided.

26. Suitable extinguishers conforming to IS : 1648 - 1961 shall beavailable for immediate use.

27. Hoses connected to an effective water supply, or where such supplyis not available an ample supply of water in suitable containers shallbe available.



ANNEXURE

GAS CUTTING & WELDING

CHECK LIST

Sr. Description Observation Action /No. Yes / No Comments

1. Is the welding cables routed properly abovethe ground?

2. Is welding equipment installed in anelevated position & operating?

3. Is there any system of maintaining themachines--- with records?

4. Is the welding cables inspected periodically?

5. Is there any shed / cover for the weldingmachine?

6. Are operators / welders qualified?

7. Whether proper safety appliances are givenand used.

8. Are the flammable materials removed /covered?

9. Are clamps clips on hoses conforms to BIS& physical condition is O.K.?

10. Are hose conform to BIS Specification?

11. Is physical condition of hose O.K?

12. Are hoses stored after us in oil & greasefree place?



13. Are clamps and clips are used only for tyingup of welding hoses?

14. Is welding torch conforms to BISspecification & nozzle is free from scale?

15. Is tip of welding torch nozzle is free fromscales?

16. Are colour code marking for flammable gascylinder and oxygen cylinder is done?

17. Are pressure gauges are provided & are inworking condition?

18. Are electrode holder used, conforms to BISspecification?

19. Is current carrying capacity of electrodeholder is adequate?

20. Is physical condition of connecting lead isO.K.?

21. Is crimping of lugs on welding lead O.K.?

22. Are gas cylinder kept vertically at safeplaces?

23. Are hazardous (combustible)materials keptbeside / below gas cutting operation?

24. Are fire extinguishers / fire bucketsavailable near work place?

25. Are empty & filled cylinders storedseparately away from heat / sun light?



26. Are protective caps provided to allcylinders?

27. Is tightness of connection of leads O.K?

28. Is distinctive double earthing of weldinggenerator / transformer done?

29. Is insulation resistance of weldingequipment checked?

30. Is separate cable for earthing taken forwelding return?

31. Is welder’s safety helmet provided towelder?

32. Is fire blanket used to arrest weldingsparks?

33. Is hot used to arrest welding sparks?


Health and Hygiene 1

10 HEALTH & HYGIENE

10.1 Work Environment:

The work environment at any construction site can cause discomfort tothe personnel working at the site due to any of the following reasons.While elaborating these factors in the following chapters care has beentaken to give proper guidance either to completely eliminate them, if not,to minimise their effect.

10.1.1 Noise and vibration:

Construction sites are noisy places. Excessive exposure to loud noisecan cause permanent damage to hearing of the workers. Noise at workcan cause stress, making it difficult to sleep. Very high levels of noisecaused, for example, by using cartridge tools can cause instantaneoushearing damage.

The levels of noise produced in operations such as piling, tunnelling andcleaning operations may be such that unprotected persons will exceedtheir maximum recommended daily dose in a matter of seconds. Even afew minutes' exposure every day to very noisy machines can be enoughto start permanent hearing damage. Loud noise can cause a temporarypartial loss of hearing, with recovery time varying from 15 minutes toseveral days depending on the noise level. There may also be a"ringing" in the ears which should be regarded as a warning - temporaryloss may become permanent with repeated exposure. Deafnessdevelops very gradually but cannot be cured once the damage has beendone.

Noise also makes it difficult to hear sounds that you need to hear such aswork signals and warning shouts.

THE BUILDING AND OTHER CONSTRUCTION WORKERS ( REGULATIONOF EMPLOYMENT AND CONDITIONS OF SERVICE ) CENTRAL RULES,1998 under Rule 34 indicate the requirement at the site for suppressionof excessive noise and vibration and also give under Schedule VI themaximum permissible limit of exposure. This is given in Annexe 1.



10.1.1.2 Noise control

There are several steps that can be taken on site to reduce noise:

• Check that exhaust outlets are fitted with silencers or mufflers, and donot keep machinery running unnecessarily.

• Keep compressor motor covers closed when they are running.• Check that concrete breaker mufflers and similar devices are securely

fitted.• Check that machinery panels are secured and do not rattle.• Ensure that sound-insulating screens are provided to reduce noise

from stationary plant, and that where practicable noisy machinery issited behind earth mounds or brick stacks to isolate or screen it as faras possible.

10.1.1.2 Hearing protection:

If the workers are expected to work at or near a noisy machine, then

• The noise levels have to be measured, and those measurements are tobe recorded.

• If the level of the noise is high then appropriate earmuffs or ear plugsshould be provided for persons working near the source of such noiseand the worker should wear the ear plug until he completes his job.The hearing protection should be kept clean and stored in a safe placewhen not in use. The ear plug should be periodically examined andshould be replaced when found damaged.

10.1.1.3 Vibration:

Many noisy machines or hand-operated tools also transmit vibrations tothe body - pneumatic rock dribs or concrete breakers are commonexamples. In this way they can injure muscles and joints, and affectblood circulation causing what is known as "white finger disease". Whenusing these tools the worker should wear gloves, which help to cushionthe vibrations.



10.1.2 Illumination:

THE BUILDING AND OTHER CONSTRUCTION WORKERS ( REGULATION OFEMPLOYMENT AND CONDITIONS OF SERVICE ) CENTRAL RULES, 1998under Rules 50 & 124 provides statutory illumination requirements forpassages and for excavation sites. The general requirements are givenbelow.

All parts of the site need to be properly lit by natural or artificial meanswhenever work is going on. Site lighting is always necessary in thoseareas short of natural light such as shafts and enclosed stairways.Artificial lighting should be placed to avoid deep shadows - these mayconceal hazards which would be obvious in good light. Mounting of lightsshould be as high as practicable to avoid glare, and lights should beplaced so that workers do not have to work in their own shadow.

Only robustly installed fittings which are well out of reach, such asfloodlighting, should be used and operated at full mains voltage.Temporary electric lighting should be installed by trained electriciansusing low-voltage equipment.Ensure that the following are followed by workers:

• Do not interfere with the installation.

• Report any damaged insulation, on broken bulbs, lamp holders orfittings.

• Make sure that cables are fastened well off the ground and do not letcables or connections trail in wet conditions.

• Do not change bulbs.

10.1.3 Ventilation:

THE BUILDING AND OTHER CONSTRUCTION WORKERS ( REGULATION OFEMPLOYMENT AND CONDITIONS OF SERVICE ) CENTRAL RULES, 1998under Rules 153, 154, 155, 156, 157, and 158 gives broad statutoryrequirements for adequate and proper ventilation while undertakingexcavation and tunnelling works.

10.1.3.1 Hot weather



Workers on construction sites are often exposed to all weathers.In tropical countries radiation from the sun, with high air temperaturesand humidity, increases fatigue from heavy work and causes heat stresswhich may lead to heat exhaustion and heat stroke, the latter a medicalemergency, and to ill health. The effects of heat combined with physicalworkload tend to accumulate.

Good welfare facilities are essential to health in hot climates, and thesuitable arrangement of working time is important. There should be:

• sufficient work breaks .. for moderately heavy or heavy work 50 percent or more rest time is essential;

• Rest areas should be away from workstations to cool off.,

• Adequate supply of clean, cool drinking-water should be provided andthe workers should be encouraged to drink as often as possible and insmall quantities .

• Washing facilities should be provided to allow the workers to bathe andkeep their work clothes clean.

10.1.3.2 Tips for Keeping the Body Cool:

- Keep out of direct sunlight as much as possible.- Avoid unnecessary quick movements.- Ensure that there is air circulation in operators' cabins.- Avoid wearing tight clothes or those which prevent evaporation of

perspiration such as some plastic materials.- Wear head protection.- Take cool drinks regularly to replace moisture lost through

perspiration.- Add salt to food or eat food that contains natural salt.- Find a shady place for rest pauses.

10.1.3.3 Cold weather:



Cold is not just uncomfortable - it may affect health and judgement.Although not a serious problem in tropical climates, it may neverthelessbe experienced at high altitudes and in the early morning at sites whichare well inland.Some of the hazards of cold weather are as follows:

- There are more likely to be accidents if the temperature of the handsfalls below 150 Celsius, there is loss of concentration and co-ordination.

- Workers repeatedly using vibratory tools such as rock drills may suffer"white finger" syndrome involving sensory loss as a consequence ofcold.

- Prolonged exposure to temperatures around freezing may causefrostbite or hypothermia.

- Wind can affect temperature. When the air temperature is 100 Celsiusand the wind speed is 32 km per hour, the temperature, so far as thebody is concerned, falls to freezing. This is called the chill factor.

Even where the temperature is above freezing point, a condition called "immersion foot" can occur in wet conditions if the feet are not kept dry.

10.1.3.4 How to keep warm

The following points should be considered when working in cold conditions

- Choose clothing which allows moisture to escape but does not allowwind and rain to penetrate: waterproof clothing tends to preventevaporation of moisture.

- Avoid bulky clothes, as they hamper movement - a number of layersof clothing are preferred.

- Hands and feet are particularly susceptible to cold.

- Use facilities for preparing hot meals and drinks, and for storing and drying clothing.



Annexure -1

SCHEDULE-VIPERMISSIBLE EXPOSURE IN CASES OF CONTINUOUS NOISE

(See rule 34)

Total time of exposure (continuous or anumber of short term exposoures) perday (in hours)

Sound level (in dBA) Pressure

(1) (2)8 906 924 953 972 100

1 ½ 1021 105¾ 107½ 110¼ 115

Notes:- 1. No exposure in excess of 115 dBA is to be permitted.2. For any period of exposure falling in between any figure and

the next higher or lower figure as indicated in column (1), thepermissible sound pressure level is to be determined byextrapolation on a proportionate basis.



10.2 Personal Protective Equipment

Introduction:

Methods of controlling hazards in the workplace fall into three categories:engineering controls, administrative controls, and personal protectiveequipment (PPE). When engineering and administrative controls cannoteliminate work hazards, PPE must be used to ensure worker health andsafaty. Generally speaking, however, it is the least desirable method ofcontrolling hazards because the hazard still is present in the workplace.

Once a company decides on the use of PPE, it should develop a companypolicy on PPE usage for employees and visitors, select the properequipment for the existing hazards, implement a training program, andenforce the use of PPE.

In selecting the proper equipment, the most important criterion Is thedegree of protection that a particular piece of equipment can provideunder various conditions. The Safety Equipment Institute helps to ensureobjective, fair testing and certification of PPE devices.

Workers should be encouraged to use PPE and should receive some typeof sanctions if they fail to wear the equipment. Companies can increasecompliance by enlisting the aid of line supervisors and managers, lettingemployees have some choice in the type of equipment purchased, andestablishing a sound training program with consistent enforcement of allrules and regulations.

General guidelines on the type of Personal Protective Equipmentto be used.

All workers exposed to head injury hazards must wear protectiveheadware to shield them from falling objects, blows, and electric shockand burns. These devices include helmets (classified as A, B, or C); bumpcaps; and hair protection. Before each use, helmets should be inspectedfor any defects or signs of wear that can reduce their protectiveeffectiveness. Every 30 days or sooner, headware should be thoroughlycleaned and disinfected.



Protection of eyes and face from injury is vital in any occupationalhealth and safety program. Protective devices include safetyglasses, goggles and face shields. Face shields alone generally donot provide adequate protection against eye injuries and must becombined with basic eye protective glasses or goggles.

Safety glasses and goggles should be large enough to shield the entireeye socket area and should contain lens materials matched to the hazardworker’s face, particularly for laser and welding operations. Hoods canprovide protection against chemical splashes. Both eye protectiondevices and face shields must be kept scrupulously clean to avoidcontaminating the surface of the eyes or face.

Management must evaluate the workplace for hearing hazardsand determine the need for hearing protection devices. Daily work insteady noise of more than 85 decibels for eight-hour shifts is consideredhazardous noise exposure. Hearing protection devices are given a noisereduction rating that indicates their protective effectiveness, although realworld values may be considerably less.

Hearing protector’s fall into four categories: enclosure (helmets), aural(ear insert formable, custom molded, molded). Each hearing protectorshould be fitted to each worker, and employees must be taught properinsertion techniques and maintenance procedures.

Fall protection is defined as a means of preventing workers fromexperiencing accidental falls from elevations. Fall protection systems areeither passive (nets) or active (lifelines, harnesses etc.). In selecting theright fall protection system, management should conduct a thorough jobsurvey analysis and establish a fall protection program.

Passive fall protection systems include personal and debris nets placedbeneath work areas to catch workers or falling debris. These nets can becombined to serve as both personnel and debris nets for the same job.Active fall protection systems include secure anchorage points and theuse of lanyards, safety belts, fall arresters and shock absorbers,harshness retracting lifeline devices, horizontal and vertical lifelines, andhardware connectors.



Companies must also develop rescue procedures for retrieving a fallenworker from above ground, below-ground or confined spaces operations.Fall protection equipment must be inspected, cleaned, and repaired orreplaced on a routine basis.

To protect workers from airborne health hazards, management mustprovide respiratory protection equipment against gaseous, particulate andcombination contaminants and oxygen deficient environments. Properselection of equipment depends on the toxic substance encountered,conditions of exposure, individual worker capabilities, and equipment fit.Respiratory protection is evaluated according to a “protection factor” thatdescribes the overall effectiveness of the equipment.

Respirators are classified as air supplying or air purifying devices. Airsupplying respirators provide a breathing gas to the worker and include(1) self contained breathing apparatus (SCBA); (2) supplied air devices;and (3) combined supplied air SCBA respirators.

Air purifying respirators are classified as either gas/vapor devices (alsoknown as chemical cartridge respirators) or particulate devices. Theserespirators are available in three configurations; quarter-face, half-face,and full-face models. Each type provides increased protection againsthigher concentrations of toxic materials.

Air purifying respirators must be properly fitted and tested usingqualitative, quantitative, negative pressure, and positive pressure tests.All respirators must be routinely inspected, cleaned, and properly storedto ensure their protective effectiveness. The company must establish acomplete training and medical surveillance program to make sure thatemployees know how to use and maintain their equipment and that onlyphysically qualified personnel use respirators.

Safety footwear includes steel, reinforced plastic, and hard rubbermodels, depending on the shoe design protective level required. Somejobs require conductive, nonconductive, foundry, or chemical splashes.Footwear must be kept clean and in good repair.

Special protective clothing is used to shield workers form such workplacehazards as heat, hot metal, chemical splashes, weather extremes, andelectrical shock or burns. Such clothing includes leather garments, wool



and asbestos substitutes, aluminized clothing, flame resistant or flame-retardant materials, aprons kneepads, gloves and gauntlets, handleathers and arm protectors, imperious materials, heat-stress and coldweather clothing, and conductive or nonconductive clothing.

Specification for safety equipment is given in annexure – 1. In eachtechnical chapter of part II, whoever required specific personal protectiveequipment requirements is dealt with.



Annexure – 1

SPECIFICATION FOR SAFETY EQUIPMENT

A SAFETY HELMET

Fibre glass HDP etc should weigh 400 to 450 gms and bemoisture shock and fire resistant. It should withstand 20 degand plus 50 deg. C. If a plumb bob of 500 gms weight withconical steel point is dropped from a height of 3M there shouldbe no piercing or denting.

B SAFETY BELT

General purpose harness safety belt consists of one body beltand two shoulder straps made from strong closely wovenapproximately 50 mm wide 6 ply cotton webbing with 3 mmlong 12 mm dia tested quality polypropylene rope. All ironfittings be galvanised and jointless cut from solid. A special D-ring to be provided at the back of safety belt and life line isdirectly spliced (minimum 9”) from back of D-ring.

C GOGGLES

(a) For chippers / grinders / hammer men clear glass 50 mm diawith shatterproof toughened glass preferable panoramic view.Face shield with headband may also be used.

(b) For welders / gas cutters heat proof unbreakable zero powersmoke colour glass of suitable shade according to the type ofhob with protective clear glass. The fibre frame should haveprovision for side ventilation padded cup edge, leathercovered nosepiece, fitted with elastic headbands andconformable to use.

(c) Over head grinding panorama goggles moulded PVC frame,unbreakable flame proof with wide flexible and replaceableplastic highly transparent full view ‘O’ optically correct visor



deep frame to fit over power spectacle indirect ventilationfitted with elastic headband.

D GLOVES

(a) All leather made of chrome / calf leather 450 mm long withfive fingers double stitching for joints. The fit of glovesshould be such that the fingers have ample room and thebridge connecting the thumb to the gloves should besufficiently deep so that the thumb will not cause strain onthe palm of the gloves. Stitching should be done with goodquality thread.

(b) For Electricians gloves made of rubber 380 mm / 450 mmlong tested to 15000 volts.

(c) For material handling leather cum canvas 304 mm longdouble leather for palm single leather for five finger type,double stitching with stitches spaced 1 mm from each otherwith good quality thread. The cloth should be of thick cottoncanvas. The gloves should be comfortable to use so thatfingers have ample room and the bridge connecting thethumb to the gloves should be sufficiently deep so that thethumb will nto cause strain on the palm of the gloves.Stitching done should not be too near the edge.

E DUST MASK

Cloth dust mask flannel type made from netting cloth outside andfine canvas cloth inside sandwiched with 3 mm foam padding,enclosing the mouth and the nose, with elastic head strap ensuringsafe breathing in dusty atmosphere.

F SAFETY NET

6 mm dia with twin rope inside for 50 mm x 50 mm meshing withprovision for intermediate rope of 12 mm dia every 1M and 20 mmdia rope on all four sides, with provision for tying the net at everyone meter. All ropes should be made of tested qualitypolypropylene rope. There should not be any joint in the mesh.



The safety net should withstand a load of 500 kg on 2.5 m span.The safety net should pass through a drop test which specifies thatthe deflection should not be more than 2 M or half the length ofshortest side when a sand bag of 140 kg mass is droppedsuccessively three times on to the centre of the net from a height of50 feet.

G WELDING FACE SHIELD (HELMET TYPE)

Shield made of vulcanised fibre swivel type with adjustable spongepadded head gear. Centre metal frame aperture to accommodateglass of 107 x 82 x 3 mm size dark green colour of shade 11 DINsandwiched with a pair of clear protective glass of same size.

H EAR MASK

When noise level exceeds 85 to 90 decibels, ear muffs / earplugsare to be used.


Occupational Health Center and First Aid 1

11. Occupational Health Center and First Aid at Construction Site

Serious or minor injuries are often occur at construction site. Thereforefirst aid becomes essential to control the condition of injured to avoidfurther deterioration. In order to give first aid immediately at accidentspot, some trained first-aid personnel should be available at theOccupational Health Center which also monitors the health of thepersonnel working at the site.

This procedure gives information about the following:

1. Duration of training.2. Frequency to training.3. Responsibility and arrangement of first aid training.4. Maintenance of records.5. Placement of first aid boxes.6. Contents of first-aid box.7. Minimum No. of trained first aiders.

• Duration of training: The duration of training shall be of one full dayto first aider and / or nominated persons at the site.

• Frequency of training: The frequency of training shall be six monthsfrom the date of commencement of project or six months from thedate of issue of this procedure.

• Responsibility and arrangement of first-aid training program:The responsibility to train the persons in first aid leis with RCM/RCE.RCM/RCE shall arrange training program by engaging services ofagencies such as St. John Ambulance or other local agencies likeHospitals, Govt. bodies etc.

• Maintenance of records: The record of each first aid treatment caseshall be recorded in a register, titled as "First Aid Register" (Annexure3). This record should be maintained and be made available for theaudit team. In addition to first aid treatment cases, record of traininggiven to personnel should also be kept in a separate register, titled as"Training Register". (Annexure 4)



• Placement of first aid boxes: Over every 50 workers a first-aid boxshall be provided at work site or at distance of 500 meters. One morebox for every additional 100 persons shall also be provided.

• Contents of First-Aid box: As attached in annexure I,& II.

• Minimum No. of trained first aiders: At any time of work at least 5trained first-aiders shall be available at site.

RCM/RCE shall ensure the enforcement of this procedure:

1. Information about first aid shall be displayed at all prominentlocations at site.

2. RCM/RCE shall check and sign all registers pertains to first aid oncein every fifteen days.

3. All records maintained shall be checked by Safety Engineers fromSCD whenever they come for inspection/audit at site. If anydeviation found, that will be highlighted in inspection/audit report.



Annexure - I

Contents of First Aid Box

The first aid shall be distinctively marked with a red cross on a whilebackground and contain following:

1. Band aids (200 Nos.).For local application2. Ointment Thrombhob (10 Nos.) For local application 2/3 times a day3. Ointment Sofraycin (10 Nos.) Local application4. Ointment Multigesic (10 Nos.) Local application5. First aid sprays (2 Nos.) For burn / cuts / bruise etc.6. Savlon lotion (5 Bottles) For cleaning of wounds7. Tincture Benzoine (5 Bottles) For local application8. Bandages all types 1/2/3" (20 Nos. each) For bandage9. Cotton wool (10 Rolls.) For cleaning / use for dressing10. Large size burn dressings (10 Nos.).11. One pair of scissors.12. One pair of adhesive plaster (2.5 cms X 1 Mtr.).13. Jonhnson & Jonhnson Eye pads - 15 to 20 Nos.14. Dettole Ointment Silversuphidezine For burns (One Nos.)15. Eye Wash Bottle (One Nos.).16. One copy of first aid leaflet.

Medicines

17. Caps. Amoxyciline 250 mg. (300 Nos.) 1Cap.Three times a day.18. Tabs. Althrocine 250 mg. (100 Nos.) 1 Tab four times. a day19. Tabs. Ibugesic plus. (500 Nos.) 1 Tab 3 times a day.20. Tabs. Polycrol forte (PFT) (500 Nos.) 1/2 Tab at a time to be

chewed 2/3 times a day.21. Tabs Metrogyl Compound (500 Nos.)/ 1 Tab. 3 times a day X 5

days.22. Tabs Neobarb/Entro-quinol 1 Tab 3/4 times a day.23. Tabs Domid (200 Nos.) 1 Tab 2 times a day.24. Tabs Polaramine (200 Nos.) 1 Tab 2 times a day.25. Tabs Avomin (100 Nos.) 1 Tab 2/3 times a day.26. Tabs Vikoryl (300 Nos.) 1 Tab 3/4 times a day.27. Tabs Crocin (500 mg) (500 Nos.)/ 1 Tab 3/4 times a day.



28. Tabs Placidox (2 mg ) 1 Tab SOS29. Tabs Colinol P/ Spasmoproxyvon 1 Tab 3 times a day (200

Nos.)30. Tabs Rantidine (200 Nos.) 1 Tab 2 times a day31. Gentycin Eye / Ear drops (10 Bottles) 2/3 drops, 2/3 times a

day32. Tabs Theo-asthaline (100 Nos.) 1Tab 2/3 times a day33. Electral Powder - Small Pack (100 Nos.) For gassing

Note: All medicines to be taken after meals. Please ensure 'Medicineallergy' to any of the above medicines, before consumption.



Annexure - II

INSTRUCTIONS

FOR FEVER / COLD CAPS. AMOXICILINE +TABS. NEOFARBRIN ORTABS. CROCIN.

FOR EAR PAIN CAPS. AMOXICILINE +TABS. IBUGESIC

FOR HEADACH/ SLIGHT FEVER TABS. CROCIN

FOR SORETHROAT TABS.ALTHROCIN+CROCIN

FOR BRONCHITIS CAPS. AMOXYCILINE + ANYCOUGH SYRUP

FOR DYSENTRY TABS METROGYL COMPOUD

FOR SYMACH PAIN TABS. COLINOL P

FOR ACIDITY / GASTRICS TABS. PTF / TABS. RANTIDINE

FOR BONY PAIN/ BACKACHE/ TABS. IBUGESICCONTUSION INJURY/ RHEMATICPAIN

FOR SKIN ALLERGY/ REACTIION POLARAMINEOR MILD COLD

FOR VOMITING/ GIDDINESS TABS. DOMID / TABS.AVOMIN

FOR SLEEP DISTRUBANCE TABS PALCIDOX 2

FOR ASTHAMATIC PROBLEMS TABS THEO-ASTHALINE

FOR LOCAL APPLICATION FOR MULTIGESIC CREAMPAIN OR RHEUMATIC PAIN



FOR LOCAL APPLICATION NOT OINTMENT THROMBOPHOBTO BE RUBBED - APPLYSUPERFICIALLY - FORCONTUSIION INJUTY/ BLUNTINJURY

FOR SMALL CUTS ETC. BAND AIDS/TINC. BENZOINE FOR CUTS / BRUISES, BURNS SOFRAMYCIN CREAM



Annexure - III

The format for first-aid treatment register shall be as follows:

Sr.No.

Name of patient Date Sex &Age

Type ofInjury

Part ofbody

injured

Type ofTreatment

given


__________________________________________________________Electrical safety 1

12. Electrical Safety

General :

Electrical Injuries:Current flow and time are the factors that cause injuries in electricalshock. The severity of electrical shock is determined 1) by the amount ofcurrent that flows though the victim (Table 1), 2) by the length of timethat the body receives the current and 3) the part of body involved.

But current flow depends on voltage and resistance, these factors arealso important and if it is alternating current frequency. Heat is asecondary effect on the body. Such current flow can easily be received oncontact with low voltage sources of the secondary lighting or powercircuit.

A person’s main resistance to current flow is the skin’s surface. Dry skinhas a fairly high resistance. A sharp decease in resistance takes placewhen the skin is moist (Table 2). Once the skin’s resistance is brokendown, the current flows readily through the blood and the body’s tissues.The resistance decreases rapidly with increase in voltage. Low voltage isdangerous as it prevents the victim from breaking the contact with thecircuit.

Internal Injuries:Death or injuries from electrical shock may result from the followingeffects of current on the body:1. Contraction of the chest muscles, which may interfere with

breathing to such an extent that death will result from asphyxiationwhen the contact is prolonged.

2. Temporary paralysis of the nerve center, which may result in failureto breath, a condition that often continues long after the victim isfreed from the circuit.

3. Interface with the normal rhythm of the heart, causing ventricularfibrillation. In this condition, the fibers of the heart muscle, insteadof contracting in a coordinated manner contract separately and atdifferent times. Blood circulation ceases and unless properresuscitation efforts are made, death occurs. The heart cannot



spontaneously recover from this condition. It has been estimatedthat 50 ma is sufficient to cause ventricular fibrillation.

4. On contact with heavy current, the muscular contractions of theheart stop. The heart may resume its normal rhythm when thevictim is freed from the circuit.

5. Hemorrhages and destruction of tissues, nerves and muscles fromheat due to heavy current along the electrical circuit’s path throughthe body.

6. Severe burns may result from contact with low-voltage systems incars, trucks and lift trucks when metal, wenches or jewelry makecontact with current carrying conductors. Injuries from electricalshock are less severe when the current does not pass through ornear centers and vital organs. When current flows from the handsto the feet involving both the heart and the lungs the results arevery serious.

Skin and Eye Injuries :Another type of injury is burns from electrical flashes. Such burns areusually deep and slow to heal and may involve large areas of the body.Persons at a reasonable distance from the arc may receive eye burns.Where high voltages are involved, flashes of explosive violence mayresult. This intense arcing is caused by

1) short circuits between bus bar or cables carrying heavy current2) failure of knife switches3) operating knife switches while they are carrying a heavy load4) pulling fuses in energised circuits

Injuries from FallsOther injuries from electrical shock include falls from one level toanother. When worker receives a shock from defective or malfunctioningequipment causes muscles to contract so worker loses his balance andfall.

Cardiopulmonary Resuscitation ( CPR)Because electrical shock can stop the heart and lungs the worker involvedin hazardous energy levels know cardiopulmonary resuscitation (CPR)and rescue procedure. Immediately apply CPR to a victim of electricalshock and continue until they revive.



The Risk Due to Use of Electricity at The Site:

• Construction sites present one of the most challenging workenvironment for the safe use of electricity. Much of the work is carriedout outdoors in all weather conditions thereby increasing the risk andthe severity of the electrical shock. As the work progresses, the sitekeeps on shifting inducing the contractors to adopt / improvise supplysystems. Excavations, demolitions and routine work may all result indamage to both the temporary site distribution system and / or thepermanent installations.

• The cables and equipment are likely to be damaged by the movementof heavy plant and materials. Congestion at the sites and also thedifficulty in identifying the energised and dead installations may alsoincrease the risk.

• Different contractors with varying methods and different tools furtheraggravate the risk due to the usage of the same facility.

Planning the work:

• Planning helps in removing most of the inherent risks at the initialstages itself. The Building code and the statue the necessaryrequirements to provide a risk free work environment. As a first step,a suitable person should be appointed to plan the work. He shouldmake the line diagram.

• As a next step, the possibility of eliminating the risks should beexplored such as the provision of pneumatic tools instead of electricalones in wet conditions. In such cases low voltage system (max. 50 V)or reduced voltage system (110 V system which provides only 55 Vbetween phase and earth in single phase system) or system providedwith residual current device can also be considered.

• Try to tackle the risk if it cannot be completely eliminated and givepriorities to the control of risks that could directly result in injuring theworkers.



• At the design and planning stage, and as the project develops, issueswhich need to be considered or reviewed will include the following:

! Giving intimation to the state authorities for providing powersupply for commencing the work.

! Location of overhead lines and buried cables.! Environmental conditions such as weather.! The supply voltage required.! The need for providing alternate power for augmenting the

supply requirements.! Earthing requirement / system to be used.! The installation and commissioning of the temporary site

distribution system, in particular the siting and protection ofmetering equipment and switchgear, distribution boards andsupply cables.

! The way in which the system will be modified /extended as thework progresses.

! Operation of temporary system and the use of plant andequipment connected to the distribution system.

! Provision of lockable switches and means of isolation.! Use of existing permanent systems as a supply for plant and

equipment.! If refurbishment works are to be carried out, identification of

parts of the system which are alive.! Commissioning and handover arrangement for completed

buildings or installations.

Most of these issues are covered in the following chapters.

Selection of equipment for the temporary site distribution system:

• While selecting equipment particular attention should be paid to anyrestriction on use specified by the manufacturer.

• Site distribution units should be designed and manufactured to asuitable standard and should have features like repeated usability,easy transportability, sturdiness and lockable switches and means ofisolation.



Staff Appointments:

• Before starting work the principal or main contractor/s should appointkey personnel responsible for electrical installation. Their competencyis based on their training and experience, knowledge of the risksinvolved in their job and the ability to complete them safely.

Electrical Equipment Locations1. The entrances to enclosures containing exposed high voltage

energised parts, such as transformer switch yards, generatorline and neutral cabinets or rear entry motor control centers,shell be kept locked. Access doors or gates to rooms, vaults orfenced enclosures containing electrical equipment shell bereadily opened from the inside without the use of a key.

2. Permanent and conspicuous warning signs shell be posted on alldoors or gates that provide access to enclosures containingexposed energised parts and conductors forbidding unqualifiedpersons to enter. Such signs shall be legible at 12 feet, ofsufficient durability to withstand the environment involved, andshall read substantially as follows:

“WARNING – HIGH VOLTAGE – KEEP OUT “

Some typical site situations along with the precautions to betaken are given below:

Generators:A supply from electrical board is not always available. In these instancesthe electricity supply for the site can be provided by an ac generating set.Care is needed to ensure that the generator is installed safely and expertadvice may be needed particularly on earthing.

For small-scale work, or in locations remote from the site supply, portablegenerator (with outputs of up to 10kVA) are often used. For short timework (e.g. less than one day), these generators need not be earthedprovided that they are only used with ClassII (double insulated or all –insulated) tools or equipment.



The smaller, single phase generators used for 110V supplies, (i.e. thosewith ratings up to about 5kVA) need not be earthed, if all the equipmentin use is double insulated, or if it is supplies only one item of “earthed”equipment. However, the equipment should be bonded with the frame ofthe generator. (Bonding involves connecting items of metalwork togetherin a way that is electrically continuous.)

In all other circumstances, a suitable earth should be provided.

When larger generators are used (output in excess of 10kVA), thegenerating set may be either single or 3 phase. Particular care is neededto ensure that the system is installed safely and this may requirespecialist advice. Matter to consider include the following:

" Generator needed to be earthed, by bonding the neutral to theframe and connecting the frame to earth;

" The impedance of the bonding needs to be low enough to ensurecorrect operation of protective devices (fuses, circuit breakersetc.)

" Sensitive earth fault protection may be necessary if earthingconditions are difficult.

Further guidance on earthing and bonding of generator system are givenunder appropriate headings.

Generator should be connected and operated so that they are separatefrom the public supply system unless agreement has already beenobtained in writing from the electricity authorities.

Earthing:Electrical safety often depends upon the existence of effective earthing.The responsibility for ensuring that the electrical earthing is effectiverests with the person in charge of the site, not with the electricitysupplier.

" Many electricity suppliers systems use protective multiple earthing(PME). (In these systems neutral and earth are combined.) Where aPME system is used all metalwork, including structural metalwork,must be bonded together (connected together in a way that iselectrically continuous). This is generally difficult to achieve on a



construction site for a variety of reasons, particularly wheresteelwork is being added in the course of the work, where steelworkhas been treated against corrosion or where individual metal framedportable buildings or cabins are used. Therefore most electricitysuppliers will not connect the site electrical system unless there isan adequate alternate earth. The use of an earth from a PME systemis not allowed for the electrical supply to site caravans.

" There are several alternative methods of providing a secure andeffective earth. On a construction site a system that uses earthelectrodes is most commonly used and will ensure that fuses etc willoperate if there is a fault. Where necessary, specialist advice shouldbe sought to ensure that there is adequate electrical protection.Guidance can be taken from relevant BIS.

" If the work involves extending an existing site or structure, theexisting electrical installation may be supplied from a PME system.In these circumstances it is strongly recommended that temporarysite distribution system which, for their effective earthing, dependon the provision of their own earthing electrodes, are kept separatefrom the PME system.

" Fixed cable armouring and metal conduit can be used as a protective(earthing) conductor. Flexible metallic conduit should not be used asthe only earthing conductor; it needs to be bonded (metalworkconnected together in a way that is electrically continuous) and aseparate protective (earth) conductor will be necessary.

" The effective operation of any electrical protection depends on a lowresistance earth path in the event of a fault. Joints in the earth pathare particularly vulnerable to damage so there should be goodelectrical connection between the various componets, e.g. betweenconduit, cable glands, and the equipment. Additional electricalconnections between the various metal parts may be necessary toprovide this low resistance path, ensuring reliable operation of fusesetc.

" Guidance on earth impedance values is contained in BSIRequirements for electrical installations. Specialist advice onappropriate values may be necessary. Earthing should always betested after an item of equipment has been installed, payingparticular attention to the continuity of protective (earthing)



conductors, as well as to the polarity and to insulation resistance.See BIS for the above.

Earthing equipment connected to the supply:

" Equipment that is either double insulated, (constructed with twolayers of insulation to provide electrical protection in case of damageto the outer insulation) or all insulated, (constructed with reinforcedinsulation) does not need, and will not be fitted with a means ofconnected to earth. Double insulated equipment is marked with thissymbol:

and will therefore be supplied with a two core cable only.Equipment, which is not double, insulated or all insulated must beearthed. A three-core cable will be needed.

" If extension leads are used, it is strongly recommended that these arealways of three core construction having a separate protective(earth) conductor. This will ensure that the supply to tools, whichare not double insulated, always includes an earth.

The temporary site distribution system:

" This is the cabling system and equipment installed to distribute andsupply electricity to points of use at the various locations on the siteduring the construction phase. The temporary site distributionsystem is always removed when site work is completed, as it is thenno longer required. Removal may begin on completion andcommissioning of all or part of the permanent, fixed installation.

" Although the site distribution system may be only temporary, the harshconditions on site require that it is to a high standard. Equipmentmust be adequately protected against damage and contaminationdue to dust etc.



" Switchgear and metering equipment should be provided with secureaccommodation, and protected from adverse environmentconditions. It should preferably be located at a place where it is lesslikely to be damaged. Make sure that switchgear, and in particularthe means of turning off the supply, is accessible at all times in caseof emergency.

Uses and other Protective devices:

" The use of correctly rated fuses and / or circuit breakers is essential forall the supplies on site.

" Makeshift arrangements, such as unprotected wiring, taped and twistedcable joints, are often dangerous and should not be permitted. Allwiring on site should be installed to appropriate standards.

" Distribution cables should be located where they are not likely to bedamaged by site activities. They should be kept clear ofpassageways, ladders and other services. If they need to cross asite roadway or walkway they can be put into ducts with a marker ateach end of the duct. If the roadway is used by vehicles, the ductshould be at least 0.5m below the surface. A record of the locationany underground cables, using maps or plans showing the line anddepth of such cables will be invaluable in avoiding damage as workprogresses. Alternatively, cables properly protected can be carriedat a suitable height above the roadway or footway. A goalpost typesystem may be required.

" All fixed distribution cables which carry 400V or 230V on a constructionsite are recommended to be of a type which has metal sheath and /or armour which is continuous and earthed. The metal sheath and /or armour should be protected against corrosion.

" Site offices and fixed floodlighting will generally require 230V supplies.Installation within site offices and the other buildings should be to asuitable standard. The equipment should be suitable to thesurrounding enviroment.

" It is strongly recommended that, on larger sites, any existing or newpermanent fixed supply contractors’ equipment during theconstruction work. This will minimise unauthorised interference withthe permanent fixed installation.

Moveable Plant:



" Plant such as lifts and hoists, which may be relocated occasionallyduring the work, is recommended to be supplied by armour cable.If, in the course of the construction operations, the plant is to berelocated, a safe method of work must be adopted. This will includeturning off the supply and disconnecting the cable before the plantand cables are moved. Plant which is moved frequently (e.g. acement mixer) should be connected to the supply by a flexible cablewith protective braid and abrasion-resistant sheath. Cables will needto be suitably located and adequately protected so that they will notbe damaged.

" If equipment has a high current requirement (current ratings greaterthan 16 amps), arcing can occur if the plug and socket areseparated under load, causing burn or other injuries. Ways ofisolating the supply should be provided to ensure that the supply isswitched off before the plug and socket are separated.

Portable Equipment:

" Portable equipment and its leads face harsh conditions and rough use.Equipment is likely to be damaged and may become dangerous.Modern double insulate tools are well protected, but their leads andplugs are still vulnerable to damage and should be regularlychecked. It is essential that the type of equipment selected issuitable for use on a construction site, and that any restrictions onuse given by the manufacturer are followed.

" The site supply voltage will often influence the choice if equipment.Where the supply is 230V or above, contractors can themselveseliminate or reduce the risks by selecting cordless tools or tools,which operate, from a reduced low voltage supply, (e.g. 110Vsystems which are center tapped to earth). For lighting, lowervoltages can be used and are even safer.

" There have been fatal accidents where 110V equipment fitted with plugsdesigned for a 230V system or damaged.110V plugs have beenplugged into 230V supplies. To avoid danger, plugs and socketsused on the reduced low voltage system should not beinterchangeable with 230V (mains) plugs and sockets. Theseindustrial plugs and sockets are more robust than domestic typeequipment, which is not designed for use on construction sites.



" Cables with solid conductors (non-stranded) are designed for use infixed installations. The conductors inside are brittle and liable tobreak if bent, so they should not be used as either extension leadsor replacement cables for portable equipment.

Use of main voltage equipment:

" When main voltage equipment is used on construction sites, the risk ofinjury or death arising from the use of damaged or faultyequipment, leads or plugs is unacceptably high unless specialprecautions are taken. The precautions must reduce the risk to anacceptable level taking into account the constraints regarding RCDsmentioned in following paragraphs. Reasonably practicableprecautions include:

(a) Protecting people who may receive an electric shock by fittingnon-adjustable residual current devices (RCDs) with a ratedtripping current of 30mA. RCDs should be installed either atthe distribution board, which feeds the mains supply sockets,or at the fixed mains supply socket. In either of these positionsthey will provide protection for both the cable and tool. RCDsfitted close to the tool only protect the tool. RCDs should be:" Installed in a dustproof and weatherproof enclosure (see

the manufacture’s instructions) or designed for use industy and outdoor environments;

" Protected against mechanical damage and vibration;" Checked daily by operating the test button;" Inspected weekly together with the equipment it is

supplying during the formal visual inspection;" Tested every threee months by an electrician using

appropriate electrical test equipment.NOTE: The tests should not be carried out on RCDs at a timewhen loss of power may adversely affect other work activities.

(b) Reducing the risk of flexible supply leads being damaged by:

" Positioning them where they are less likely to bedamaged, (e.g. run them at ceiling height inside abuilding); and / or



" Protecting them inside impact resistant conduit whereappropriate; or

" Using special abrasion resistant or armoured flexiblesupply leads where appropriate.

(c) Selecting tools that are designed for trade and work use.Double insulated equipment is strongly recommended where itis necessary to use a main voltage supply, because the toolsthemselves are less likely to give rise to danger. (Danger canstill arise, however, if the cables, plugs or equipment casingare damaged). Any restrictions on use out in themanufacturer’s instructions should be observed.

(d) Regular maintenance checks which should be made of allelectrical equipment. These should include:

" Checks by the user each time the tool is used;" Formal visual checks by a trained person on a regular

basis." Combined inspection and testing by a trained person at

suitable intervals depending on the risk of damage andthe potential for injury.



Residual Current Devices (RCDs)" Due to the delicate nature of an RCD, it is not ideal for use in

the rough environment of a construction site. It may not bepossible to ensure that the housing for the RCD is maintained tothe quality required in these locations, and control over thenumber of times the test button is operated may be difficult. Themanufacturers of RCDs do not generally recommend them to befitted on portable apparatus that may receive mechanical shockor on equipment that might vibrate. In case if it is decided touse RCD in the system then it’s limitation should be taken intoaccount.

" If an RCD fails to operate, or is faulty, this will not be indicatedand the worker may remain unaware of the danger. They onlyprotect against earth faults and will not operate when there is noconnection to earth, ie if current is passing from live to neutral.So it is possible to suffer an electric shock and injury eventhough the RCD is operating correctly.

" RCDs for protecting people have a rated tripping current of notmore than 30mA and operating time of 200 milliseconds(ms) or150mA for 40 ms.

Maintaining portable electrical installationOn construction sites, the risks from damaged or faulty portable electricalequipment are high and need to be managed and controlled byappropriate maintenance system.

" Formal daily visual inspections on a regular basis because thiscan detect about 95% of faults or damage.

" Checks by the user." Combined inspection and electrical testing where necessary." Check daily RCDs." Bare wires are not visible" The cable covering is not damaged and is free from cuts and

abrasion." The plug is in good condition, the casing is not cracked, the pins

are not bent or the socket is not blocked with loose material." There are no taped or other non-standard joints in the cable." The outer sheath of the cable is gripped where it enters the plug

or equipment.



" The outer cover of the equipment is not damaged or loose andall screws are in place.

" There are no overheating or burns marks on the plug, cable orthe equipment.

" It is serviced regularly in line with the manufacturer’sinstruction.



Annexure – I

General Precaution" Implement lockout / tagout procedures prior to performing any electrical

work." Make dielectric tests on rubber gloves and blankets at regular intervals.

They should be air tested daily before use and kept powered." Notify all personnel concerned before starting any electrical equipment." Always assume a circuit is energised until you have checked it." Do not energise a tagged starter or switch without first properly

removing the ‘lock-out/tag-out’." Always remove the load from a circuit before de-energising it." Ventilate the working area well and keep fires and sparks away from

charging batteries since the acid fumes explode as hydrogen gas isgenerated while charging a battery.

" Never use water on an electrical fire." Never look directly at open switches or breakers when energising or de-

energising to avoid retinal burns." Only trained authorised personnel should perform maintenance and

repair work on electrical equipment." When repair work on energized circuits must be made, the following

precautions must be taken:

(a) Work must be performed only by trained and experiencepersonnel.

(b) There should be ample light.(c) The worker should stand on non-conducting material such as

layers of dry canvas, dry wood or rubber.

" Never pull any fuse that is carrying current. Never break a circuit underload, severe arcing may occur.

" Use approved tools and “hot” circuit handling equipment when workingon energized equipment. Be thoroughly familiar with the circuit tobe worked on.

" Personnel should be stationed near the main switch or circuit breaker sothat the equipment can be de-energized immediately in anemergency.



" Metal ladders and scaffolds are electric conductors, they should never beused around electric circuits or in place where they can come incontact with electrical circuits.

" Extension cords should not be tied to electric outlets. These cords mustbe free so they can be unplugged in an emergency.

" Use hand line when raising or lowering tools. Never lower electrical toolsby the cord.

" Cable trays are not designed to support loads, to be walked on, or usedto secure safety belt lanyards.

" Always de-energize circuits before attempting to reset them." Follow the following safe work practices:

Table1 - Safe work Practices

Voltage RemoveJewelry(Y/N)

Insulatedtools(Y/N)

RubberGloves(Y/N)

EyeProtection

(Y/N)

RubberMatting(Y/N)

SafetySigns(Y/N)

SafeDistance(Table2/3)

0-150 Y Y N N N YLine (a)Table 2

151-300 Y Y N N N YLine (b)Table 2

301-600 Y Y Y Y Y YLine (b)Table 2

>600 (*) Y Y Y Y Y Y Table 3

(*) In no situation are SSOI employees authorized to work on or nearenergized circuit parts or equipment when the voltage level exceeds 600volts, nominal due to the extreme dangers associated with and the lackof frequent experience working on high voltage systems. In thesesituations, a licensed electrical contractor must be used.



Annexure - II

Working Clearance (Safe Distance):

The dimension of the working space in the direction of live partsoperating at 600 volts or less and likely to require examination,adjustment, servicing, or maintenance while energized shall not be lessthan indicated in Table 2 and less than indicated in Table 3 for live partsoperating at greater than 600 volts. Distances shall be measured fromthe live parts if such are exposed, or from the enclosure front opening ifsuch are enclosed.

Table 2 working Clearances (less than 600 volts)

Nominal Voltage toGround

Minimum Clear(I)

Distance for(II)

Condition(III)

(ft) (ft) (ft)0-150 3 3 3

151-600 3 3.5 4

Table 3 Working Clearance (greater than 600 volts)

Nominal Voltageto ground

Minimum clear(I)

Distance for(II)

Condition(III)

(ft) (ft) (ft)601-2,500 3 4 5

2,501-9,000 4 5 69,001-25,000 5 6 925,000-75kV 6 8 10Above 75kV 8 10 12

Where for both Tables 2 and 3 conditions (I), (II), and (III) are asfollows:

(I) Exposed live parts on one side and no live or grounded parts on theother side of the working space, or exposed live parts on both sideseffectively guarded by suitable wood or other insulating materials.Insulated wire or insulated busbars operating at not over 300 voltsshall be considered live parts.

(II) Exposed live parts on one side and grounded parts on the other side.(For Table II; concrete, brick, or tile walls will be consideredgrounded surface).



(III) Exposed live parts on both sides of the workspace (not guarded asprovided in condition (I)) with the operator between.

NOTE : Distances shall be measured from the liveparts if such are exposed or dorm the enclosurefronts or opening if such are enclosed.

HEADROOM: In both cases (600 volts or less and greater than600 volts), the minimum headroom of workingspaces about service equipment, switchboards,panelboards, or motor control centers shall be 6 ft3 in.



Annexure - III

Overhead Lines:

When work is performed in locations containing energized overhead lineswhich are not guarded, isolated, or insulated, precautions shall be takento prevent employees form contacting such lines directly (through thebody) or indirectly (through conductive tools or equipment, i.e. ladders).When work near overhead lines is required, minimum distance shall bemaintained to those lines in accordance with following table.

Nominal Voltage to Ground Minimum Distance

50KV or below 10 ft.

50KV or above 10ft. + **

** Add 4 in. for each 10 KV above 50 KV



Annexure – IV

Personal Protective Equipment:

" Protective clothing and equipment:-Employees shall be safeguarded from injury by utilizing appropriateprotective equipment while working in situation in which there arepotential electric hazards. All personal protective equipment shall be ofsafe design and construction for the specific part of the body to beprotected and for the work to be performed. All protective equipmentshall be inspected prior to each use, shall be tested annually, and shallbe maintained and stored in a safe, reliable condition.

" Eye and Face Protection:-Suitable eye or face protection shall be worn for voltages in excess of300 volts, nominal and when performing work on exposed energizedparts of equipment where there is a danger of injury to the eyes orface from electrical arcs or flashes.

" Electrical Safety Gloves:-Suitable insulated gloves shall be worn for voltage in excess of 300volts, nominal sees table 2 for glove classes and according voltagerating. Whenever rubber gloves are used, they shall be protected byouter leather or canvas gloves. In addition, rubber gloves shall be airtested prior to each use, and leak tested every six (6) months.

Table 2

Class ofInsulating Item

Nominal Maximum Use Voltage, Phase a-c, rms.

0 1,0001 7,5002 17,0003 26,0004 36,000

Note: The a-c voltage (rms) classification of the protective equipmentdesignates the maximum nominal design voltage.


Non Destructive Testing 1

13. Non-Destructive Testing

Visual observation, even with magnification, cannot locate all small,below-the-surface defects in cast and forged metals, or in weldments,such as found in pressure vessels, boilers, and nuclear components.Proper nondestructive testing, however, reveals all such defects withoutdamaging the parts being tested. Nondestructive testing methods locatethe following defects:• defects that are inherent in the metal, such as nonmetallic

inclusions, shrinkage and porosity.• defects that result from processing such as high residual stressed

cracks and checks caused by handling, shruing, or grinding ofcasting and forging.

• in-service defects, such as corrosion, erosion, and sharp changes insection.

The types of testing most commonly used for forged and cast metalsare the following:1. Magnetic Particle Inspection2. Penetrant Inspection3. Ultrasonic Methods4. Triboelectric Method5. Electro-magnetic Tests6. Radiography

These methods, as well as others that apply to nonmetallic substances,are fully discussed in National Safety Council Industrial Data Sheet12304-0662, Ultrasonic Non-destructive Testing for Metals.Recommendations for installation, inspection and maintenance of theelectrical equipment used in many of these testing procedures are givenin Chapter 15, Electrical Equipment, in this volume.

13.1 Radiography

Radiography uses x-ray and gamma rays. X-rays are unidirectional andtheir wavelengths can be varied, within certain limits, to suit the



condition. Gamma radiography differs from x-ray radiography in thatthe gamma rays are multidirectional and their wavelengths beingcharacteristic of the source, cannot be regulated. Gamma rays forradiography usually are obtained from isotopes of cobalt-60 or iridium-192.

In some instances, gamma-ray exposures are inferior to x-rayexposures in sensitivity and contrast. Gamma radiography, however,has several advantages. Because of the nature of isotopes, a numberof tests can be made at tha same time, provided that specimens can besuitably located. Moreover, isotopes are independent of electricalpower, their sources are portable, and the small size of the sourcesmakes it possible to obtain radiographs in tight quarters.

Devices used to transform differences in intensity of the penetratingradiation into visible images are x-ray films, fluorescent screens,proportional-scintillation geiger counters, and ionization gages. Allsources of ionizing radiation are potentially dangerous. X-ray andGamma rays sources may also produce hazardous secondary radius.

In addition, X ray units involve both low and high potential electricalhazards.

The following are details of hazards and remedial measures to be takenwhile handling and shruing radioisotopes.

Isotopes

Radioisotopes commonly used in industrial radiography are Cobalt-60and Iridium-192, which are artificially produced by bombarding with anexcess of neutron, 192 & 60 represent mass number (atomic weight) ofthe isotopes.



Radiation quantities and Units :

Curie :Radiography of a source is measured in terms of numbers oftransformation it undergoes in one second. The unit for radiography isCurie. Which is corresponding to 3.7*1010disintegration per second.Curie shows the strength of the material. Unit used for exposure is Roentgen (R)The special unit of equivalent ionising dose presently used is Sievert(Sv).1 Sv = 100 R (Roentgen)

Dose Limit :Since radiation causes undesirable effects on the body tissue. It isimportant to observe the maximum permissible levels of radiation,which have been recommended. International commission onRadiological Protection (ICRP) sets guidelines in the form of annual doselimits to individual. Setting dose limits below the threshold dose limit(maximum permissible limit) can prevent any effects due to radiation

Definition of Permissible dose:“ A dose of ionising radiation that will not cause any appreciably bodilyinjury to a person at any time during his lifetime.”



Permissible limit:

Organ orTissue

In alifetime

In a year In aquarter

In a week

Whole body Redbone marrow& On hands.

300mSv

50 mSv 30mSv 1mSv

Skin or boneTissue & thyroid

_ 300 mSv 150 mSv _

Extremities _ 750 mSv 150 mSv _

Any otherorgans, Lens ofeyes

_ 150 mSv 80 mSv _

Monitoring of radiation dose :

Personal monitoring: The most commonly used personal monitoringdevices are photographic film badges and pocket dosimeters. Thedevices are designed to give cumulative reading of exposure measures.X and Gamma radiation exposure in Roentgen. The operator ofradiography camera uses the personal monitoring devices.

Area monitoring: Most commonly used device is Survey meter. Thesurvey meter is used to check the radiation zone this meter is designedto give instantaneous reading in Roentgen or milli-Roentgen per hour atany distance from the source.

Control of radiation hazard:

The three basic factors by which radiation hazard can becontrolled are(a) Time, (b) Distance, (c) Shielding



Time:

The radiation dose received by person depends on the total time spentby the person near the source. Lesser the time spent near the source,lesser would be the radiation dose.

If an operator takes one minute while working with a source andexposed to 10mR, another operator who takes 2 minutes to do thesame job would be exposed to 2*10 = 20mR

In order to minimize the time of exposure -1. Plan all operation in advance.2. Carry out dry run with out radiation, so that with radiation, the

exposure time can be reduced.3. Share work load with two person if the time exposure is large

Distance:

Larger the distance, lesser will be the radiation level. The mosteconomical and effective method of reducing the radiation hazard is toincrease the radiation distance between the radiation source & person.

The radiation intensity or radiation level from a given source decreasesas we move away from the source it is governed by the inverse squarelaw.

Shielding:

Shielding is the absorbing material is provided in order to reduce theradiation intensity to the required value. The shielding properties of anymaterial depend on its atomic number and energy of the incidentradiation. Most commonly used shielding material is lead.



Storage of radioactive material.

1. The contractor has to obtain approval from Radiological physicsand Advisory Division. (RP & AD) BARC for storing radioactivematerial.

2. Prepare pit room at the site for which approval is to be obtainedfrom BARC. The pit room consisting of the two compartments.

3. Keep pit rooms in locked condition. This should always preferablyin a least occupied area.

4. Do not allow entry of unauthorised persons near the work area.

5. Provide barbate fencing all around the pit room.

6. A logbook is to be maintained in order to record the day to dayuse of radiography source stored in storage room.

7. Check surrounding area for radiation after the radioactivematerials are stored ensure that radiation level around the roomis less than 0.25mR/hr.

8. Ensure that all walls, floors, ceiling & doors is having sufficientshielding so as to minimise radiation level below therecommended limit.

9. There should not be any window of the exposure room.

Transportation for Radiography Source

1. Make sure that the source has returned to the camera.

2. Lock the camera to ensure that the source assembly would not bereleased.



3. Source to be properly marked labeled.

Safety in Field Radiography

1. There should be a site-incharge looking after the radiation safety.Because the radiography site-incharge is specially trained foremergency handling procedure.

2. The operation to be carried out only when minimum nos. ofpersons is present around the radiography site preferably duringnighttime.

3. The site in-charge and the cameraman are to be certified byBARC.

4. The operator of radiography equipment should use personalradiation monitoring badges or dosimeters.

5. Area around the source to be cordoned off usingropes/barricading tapes and radiation warning symbol andnighttime with red lamps. The exact area to be cordoned ofdepends upon the nature & activity of the source, type ofexposure workload and the nature of occupancy around. Suitableradiation monitor (survey meter) should be used to measure theradiation level to ensure that the cordoning area is adequate.Radiation level beyond the cordoned off area should be less than0.25mR/hr. Ensure that survey meter for proper working

6. Setting up procedures required for radiography shall be completedbefore start of radiography exposure.

7. The operator of radiography equipment shall maintain a log bookto record the details of day to day use of equipment.



8. The source container to be placed in such way that the radiationbeam can be made ‘ON’ towards unoccupied area.

9. Maintenance and servicing of radiographic material shall no beattempted without consulting radiographic safety officer.

10. The operator should be aware of the dose record and send therecords for periodic medical examination.

11. Mock drill to be carried out before starting any radiographyoperation. Time taken for coming down should not exceed thesafe exposure time.


Abrasive Blasting & Spray Painting 1

14. Abrasive Blasting and Spray Painting

Abrasive blasting

Sand blasting operations can be overlooked when preparing safety plansbecause they are generally a small part of a larger project such ascleaning and refinishing or painting. As a result, many workers areexposed to the hazards of sand blasting without adequate protection.Even if all sandblasting equipment is properly designed and regularlyinspected, users must always be alert to the hazards of these operationsand take precautions against harmful exposures.

Airborne dust

This is one of the most serious hazards associated with blastingoperations. When evaluating this hazard, it's important to consider theconcentration of dust and the size of particles. Larger particles,considered "nuisance" dust, are normally filtered out in the nose andthroat. Smaller particles (10 microns or smaller) can bypass the lung'sfiltering system and penetrate deep into the respiratory system wherethey may cause serious damage. Safeguards are needed when smallerparticles are present in the work environment.

Metal dust:

In addition to the abrasive being used, contributes to the generation ofairborne dust. Metals such as lead, cadmium, and manganese, can beextremely toxic when inhaled. Many existing paints are lead based.Regulations require special handling, trained personnel, and medicalmonitoring when lead is present.

Silica sand:

This product is a potentially serious health hazard and should not be usedas an abrasive. If silica containing (quartz) materials are selected forany reason, workers must wear a positive pressure or pressure demandrespirator with an assigned protection factor (APE) of either 1000 or



2000. Silica must be contained and disposed of properly. Even if a wetblasting method is selected, silica that is allowed to migrate by eitherwind or water, will eventually become an airborne contaminant.

Air supply:

Air-supplied respirators must be used:

- When working inside of blast cleaning rooms,- When using portable units in areas without enclosure, and- Under any circumstances where the operator is not physically separated

from the abrasive material by an exhausted enclosure. If airlinerespirators and compressors are used, it should be made sure that theintake hose is placed in an area that provides clean air. An attendantshould be in the area at all times, monitoring breathing air andassuring the Blaster’s safety.

Additional personal protective equipment:

Blasting operations create high noise levels, so hearing protection is amust--for both the operator and nearby workers. Operators should alsouse full body protection while doing the sand blasting operation.

Manual cabinet blast cleaners should never be exhausted into an areawhere workers are allowed to move / work, as they would be breathingthe contaminated air.

These fully enclosed cabinets are designed to filter out dust and re-useblasting medium.

Handling and storing abrasives:

Dust is always created at any point where abrasives are transferred,whether by hand or shovel. Therefore, all points of transfer must beproperly exhausted and workers who handle abrasives manually shouldwear appropriate breathing apparatus.



Spray Painting

Hazards

Painting and paint removal present hazards requiring effective controls.Hazards include exposure to toxic materials and flammable or explosivemists, particulates, and vapors.

Inhalation of mists and vapors from nearly all paints, solvents, thinners,cleaning chemicals, strippers, and epoxies can be injurious dependingupon the agent's toxic characteristics and the amount and method ofexposure.

Further, many paints can physically injure the skin and eyes, or beabsorbed through the skin. Potential physical and health hazards can beeffectively controlled by appropriate work procedures, controls, facilitydesign, protective clothing, and equipment.

Safety

1. Pressure Equipment

Pressure equipment used in painting operations is hazardous because ofthe compressed air component; therefore, the supervisor should ensurethat spray painting equipment is in serviceable condition. On all air-typespraying equipment a pressure regulator valve shall be installed in the airline between the compressor and painting equipment. A pressure reliefvalve and a pressure gauge shall be installed between the pressureregulator and pressurized paint containers and/or spray guns. Pressurerelief valves shall be set to open at pressures not more than 10 poundsabove the required working pressure.

2. Other Equipment

Painter's ladders, scaffolds, and other equipment shall be inspected priorto use to be certain they are in safe condition.

3. Paint Mixing

Paint mixing shall be done in designated, adequately ventilated roomsconstructed of fire-resistant materials. All sources of ignition shall be



prohibited in mixing areas. All electrical fixtures or equipment in or within20 feet of designated paint preparation areas shall meet therequirements of the BIS Code.

4. Housekeeping

Good housekeeping is essential to safe operations in paint shops. Paintrooms, booths, etc., shall be kept clean with equipment stored in aproper and orderly manner. All solvent / paint soiled rags shall be placedin approved self-closing metal containers plainly marked to indicate thecontents. At the end of each day, these containers shall be emptied orremoved to an approved location for pickup and disposal.

Health

1. Personnel Exposures

There is a wide application of organic solvents in painting. All organicsolvents have some effect on the central nervous system and the skin.The principal modes of personnel exposure are inhalation of vapors andabsorption through skin contact and ingestion. Personnel engaged inpainting operations should review Material Safety Data Sheets (MSDS) inorder to acquaint themselves with the properties and hazards of thesolvents that are used

2. Protective Equipment

Personnel engaged in painting and paint removal shall wear BISapproved protective clothing, respiratory devices if required, andappropriate face, eye, and hand protection. Eye or face protection isrequired during scraping or paint preparation (abrasive techniques).Clothing shall be changed, as needed, to minimise body contamination.

3. Personal Hygiene

The hands and face shall be kept clean, clothes shall be changed whencontaminated.No food or drink shall be brought into, or consumed, in paint shops.Personnel shall wash their hands prior to smoking or consuming food.

4. Fire Prevention and Protection



Spray painting presents varying degrees of fire hazards, depending onthe materials used. Any material having a flash point below 140°F shouldbe handled very carefully, and this is applicable to those having a flashpoint higher than this.

5. Fire Fighting

Portable fire extinguishers should be installed near all areas where spraypainting is carried out.

6. Ventilation Systems

If spray painting work is undertaken in a confined space adequateVentilation should provided. Mechanical ventilation shall be in operationwhile spraying operations are being conducted and for a sufficient timethereafter to assure vapors are completely exhausted. Adequateconditioned make-up air must be provided.

The quantity of paints, lacquers, thinners, solvents and other flammableand combustible liquids kept near spraying operations should be theminimum required for such operations.

Bulk storage of these liquids shall be in a separate building detachedfrom other buildings or in rooms specifically designed and constructed tomeet flammable storage room requirements.

No storage of open containers of solvents is permitted. Open containersmay only be used for cleaning of painting materials after which thesolvent should be transferred back to a closed container for retention ordisposal.

Supplies of flammable and combustible liquids should be stored inapproved fire-resistant safety containers equipped with flash screens andself-closing lids.

Original closed containers, approved portable tanks, and approved safetycans should be used for bringing flammable or combustible liquids intospray finishing rooms. Open or glass containers shall not be used.

The withdrawal of liquids from containers and the filling of containers,including portable mixing tanks, should be done only in a mixing room or



in a spraying area when the ventilating system is in operation.Precautions shall be taken to protect against liquid spillage.

Whenever flammable or combustible liquids are transferred from onecontainer to another, both containers shall be effectively bonded andgrounded. This practice prevents electrical discharge from theaccumulation of static charge.

Precautions to be taken during installation of electrical fittings are givenelsewhere.

While using airless spray guns adequate precautions to be taken asrecommended by the manufacturer.

It is desirable that the floor of paint spray booths be covered with a non-combustible mat, removable for cleaning or disposal.

Pressure hoses and couplings shall be regularly inspected for conditionand shall be replaced as needed.

When positive displacement pumps are used, a relief valve shall beinstalled in the discharge line to prevent overpressure.

The same general safety and health precautions apply to spray paintingfrom pressurised cans as to spray painting by other means.


Hand Tools And Power Tools 1

15. Hand Tools and Power Tools

Introduction

Hand tools and power tools enable employees to apply additionalforce and energy to accomplish a task. These tools improveefficiency and make better products. Because of increased force ofhand and power tools, the object of safety with these tools is toprotect users from inflicting harm to themselves and others as wellas to provide ergonomically designed tools. Each year hand toolsaccount for about 6% of all disabling injuries. Through properselection, use, care, maintenance and supervision of hand andpower tools, injuries from tools can be prevented.

In selecting hand and power tools, management should consideruse, comfort, quality, vibration, noise, and stress factors. Todetermine if tools should be changed, take into account employees’concern about the tool, associated accident and injury rates, workmethods, setup of workstations, and trends for any particular task.Certain changes may include adding personal protective equipment,job rotation, or other adjustments.

Five safety practices can help to eliminate or greatly reduce injurieswith hand and power tools:1. Provide proper protective equipment.2. Select the right tool for the right job.3. Keep tools in good condition.4. Train workers to use tools correctly.5. Store tools in a safe place.

Central tool controls Programme ensure uniform inspection andmaintenance of tools by trained employees.

Toolbox includes portable boxes, tool chests, mobile tool cabinetsand gang boxes. These items should be used only for storing toolsor lunch boxes. Make sure toolboxes and cabinets are locked aftereach workday and that all tools are accounted for.



A good maintenance and repair program includes tool controlthrough periodic inspection of all tool operations (See annexure–1).Make sure employees have adequate workspace and equipment forrepairs. Only tools that are not chipped, battered, or mushroomedshould be redressed otherwise they should be discarded. Handlesshould be properly attached to tools and fitted by an experiencedworker.

Misuse of common hand tools such as screwdrivers, hammers,punches, cutting tools, tap and die tools, saws, files, hand snipsand cutters, wood chisels, axes, hatchets, knives, shovels andtakes is a source of many injuries. Supervisors may mistakenlyassume that everyone knows the proper use of common hand tools.Make sure workers are trained in safe work habits and do notattempt to use tools for jobs they were not designed to do.

The most common types of wrenches used in industry. Includeopen end, box and socket, combination, torque, adjustable andpope wrenches. Workers must be alert for the possibility of awrench slipping off the fastener, the fastener suddenly turning freethe wrench breaking, or a fastener breaking. Wrenches should beinspected frequently for cracks, flaws or wear. Workers shouldexercise similar precautions when using tools such as tongs, pliers,special cutters and pullers.

Soldering irons can be the source of burns and illnesses that resultfrom inhaling fumes. Soldering irons must have adequate holders toprevent accidental burns and workers have proper protective gearand ventilation to eliminate vapor and fume hazards.

• Portable power tools are divided into five groups: electrical,pneumatic. Gasoline, hydraulic and power-actuated mobility andpower sources. Safe work practices include disconnecting thepower before changing accessories, storing tools properly, wearingprotective gear and following manufacturer-operating rules.Workers should be trained to select the right tool for the job andshould frequently inspect and repair equipment.



• The risk of electrical shock from electrically powered tools can bereduced by using battery-operated tools, properly groundingequipment, and using only approved wiring and current. Toolsused in wet locations should be provided with a ground-fault circuitinterrupter. Double-insulated tools also provide more reliable shockprotection without third-wire grounding.

• The most common electrical tools include drills, circular sawsreciprocating saws, miter-box and shop saws, stationary bandsaws, jig/saber saws rotary die grinders, grinding wheels, buffersand wire brushes, sanders and routers. Workers must recognizeand protect themselves from shock, noise, cuts burns and otherpotential hazards by using proper guards and safety equipment anddevices. All parts of electrical equipment should be inspectedregularly.

• Air powered tools include air hoses, grinders and pneumatic impacttools. To prevent injuries associated with air hoses, workers shouldmake sure hoses do not present tripping hazards, avoid usinghoses as cleaners and prevent accidental disconnection of hosesfrom the tools. Air-powered grinders require the same type ofguarding as electrical grinders.

• Pneumatic impact tools (nailers, drills, impact wrenches, etc.)require two safety devices; an automatically closing valve and aretaining device to hold the tool in place to prevent it from beingfired accidentally. Workers must check noise levels to determine ifhearing protection is needed and guard their eyes against flyingdebris.

• Special power tools include hydraulic, gasoline powered and powderactuated equipment. Hydraulic tools cause injuries because high-pressures leaks or ruptures in hoses may force oil under the skin ofworkers hands or arms.

• Gasoline powered and powder actuated tools present serioushazards and must be operated only by trained personnel andadequately guarded to prevent fires and injuries. Similar



precautions are used for impact wrenches as for any electrical orhydraulic equipment.

• Workers operating power tools must dress appropriately to avoidcatching clothing or jewelry in the equipment, wear safety shoes,use fall protection equipment when working in overhead places,wear respirators on buffing, grinding and sanding jobs, and eye andhearing protection where appropriate.

• Some does and don’ts using power tools are listed in Annexure – 2.

• Some of the common personal protective equipment’s required arelisted in Annexure - 3



Annexure – 1

PORTABLE ELECTRIC TOOLS

Inspection ChecklistGENERAL

Low voltage or battery powered equipment used intanks and wet areas? Yes /NoTools well maintained? Yes /NoMotor in good condition? Yes /NoApproved tools used in explosive atmospheres? Yes /NoTools left where they cannot fall? Yes /No

CORDS

Insulation and plugs unbroken? Yes /NoCords protected against trucks and oil? Yes /NoCords not in aisles? Yes /No

GROUNDING

Ground wire fastener in safe condition? Yes /No3-wire plug extension cord (if a 3-wire tool)? Yes /NoGround wire used? Yes /NoDefects or minor shocks reported? Yes /NoGround fault circuit interrupter used? Yes /No

GUARDING

Guards used on grinders and saws? Yes /NoMovable guards operate freely? Yes /NoEye or face protection worn? Yes /No

A model check list is given to enable supervisory personnel to inspect thetools before issue and on their return back to stores



Annexure - 2

Tool Safety a movement hits full strides for accident prevention.

- Taking Tools For GrantedIs Inviting Accident.

- Familiarity BreedsInjuries

- Before you begin, grab the unsafe condition and practices share it off with safety procedure manual.

- Using tools improperly can cause serious physical truma.



General Safety Precautions

1. Secure work with clamps or a vise, freeingboth hands to operate the tool.

2. Avoid accidental starting. The user shouldnot hold a finger on the switch button whilecarrying a plugged in tool.

3. Proper apparel should be worn; looseclothing, ties, or jewelry can becomecaught in moving parts.

4. Work area should be well lighted.5. Be sure to keep good footing and maintain good balance.6. The employers is responsible for the safe condition of tools and

equipment used by employees but the employees have theresponsibility for properly using and maintaining tools.

7. Never apply unnecessary pressure when using tools.8. Always cut away from your body.

A. Hand Tools:

1. All tools and Equipment (Both company and employee owned) usedby employees should be in good condition.

2. Hand tools such as chisels, punches wedges or drift pins whichdevelop mushroom heads during use, it's heads might shatter onimpact, sending sharp fragments flying should be recondition orreplaced.

3. Broken, loose, splintered or fractured handles on hammers, axes andsimilar tools, the head of the tool may fly off and strike the user oranother co-worker. Tool handles should be replaced promptly andwedged tightly in the head of all tools.

4. Worn, bent or sprung jaws spanners and wrenches, which slip duringuse, should be replaced regularly.

5. Appropriate handles should be used so the operator's wrist canremain in a natural position for files and similar tools. (Selectiondepends on the relationship between the work surface height andoperators elbow height.)

6. Employees to be made aware of the hazards caused by faulty orimproperly used hand tools.



7. Appropriate safety glasses, face shields etc. should be used whileusing hand tools for equipment which might produce flyingmaterials or be subject to breakage.

8. Jacks should be checked periodically to ensure that they are ingood operating condition.

9. Tool cutting edges should be kept sharp so the tool will movesmoothly without binding or skipping. Blunt tools can be morehazardous than sharp ones.

10. Tools should be stored in dry, secure locations were they won't betempered.

11. Eye or face protection should be used whendriving hardens or tempered spuds or nails.

12. Floor near work area should be kept as cleanand dry as possible to prevent accidentalslips while working with or around dangeroushand tools.

13. Scattered tool near work place should beavoided.

14. Always pull on the wrench. Never pushagainst it.

15. Whenever possible use a box-end wrenchinstead of an open-end wrench to avoidslipping.

16. Around flammable substances, sparksproduced by Iron and Steel hand tools canbe a dangerous ignition source. Where thishazard exists, spark resistant tools madefrom brass, plastic; aluminum or wood willprovide safety.

B. Power tools:

1. Majority of power tool accident is caused byimproper handling and poor maintenance ofequipment.

2. Power tools should be used with the shield,guard or attachment that is recommendedby the manufacturer for particular type ofjob to prevent physical contact.



3. Portable circular saws should be equippedwith guards above and below the baseshoe. They are not wedged up with thelower portion of the blade unguarded.While cutting always use push sticks,don’t use your hands.

4. All cord-connected, electrically operatedtools equipment should be effectivelygrounded by using three-cord wire or theapproved double - insulated type.

5. Effective guard should be in place overbelts, pulleys, chains, and sprockets, onequipment such as concrete mixtures andair compressors.

6. Hoisting equipment should be availableand used for lifting heavy objects andhoist ratings and characteristics should beappropriate for the task.

7. Earth leakage circuit breakers (ELCB)should be provided on all temporaryelectrical 15 and 20 amp circuits shouldbe used during periods of construction.

8. Pneumatic and hydraulic hoses on poweroperated tools should be checkedregularly for deterioration or damage.

9. Never carry a tool by the cord or hose.10. Never yank the cord or the hose to

disconnect it from the receptacle.11. Keep cords and hoses away from heat, oil

and sharp edges.12. Disconnect tools when not in use, before

servicing and when changing accessoriessuch as blades, bits and cutters.

13. All observers should be kept at a safedistance away from the work area.

14. All portable electric tools those aredamaged shall be removed from use andtagged "DO NOT USE".



15. Electric tools should be operated withintheir design limitations.

16. Gloves and safety footwear arerecommended during use of electric tools.

17. When not in use, tools should be storedin a dry place.

18. Electric tools should not be used in dampor wet locations.

19. Never temp to use two-hole receptacle byremoving third prong provided forearthing of tool from the plug.

20. Portable electric tools should be usedgenerally of 10V single-phasetransformer with center tap earthed.

21. Portable electric tools should be testedbefore put into use.

22. Possible tools like drills, grinders, sanders pneumatic chisel are ofgood quality and the tools reach are attached to machine properlyand locked before put to use.

23. Unless a person is authorized, he should not operate, repair ortest any equipment.

24. Drills should be fastened to paving breaker to prevent its flying.25. Grinding wheels should be inspected before mounting. It is to be

checked for maximum operating speed against the machinespeed. Guard to at least half of the wheel diameter should coverwheels. The operator should wear goggles while grinding.



Annexure – 3

Personal Protective Equipment

Workers using revolving tools such as drills saws and grinders should notwear ties, gloves loose clothing and jewelry. Clothing should be free ofoil, solvents or frayed edges to minimize the fire hazard from sparks.The weight of most power tools makes i9t advisable for users to wearsafety shoes to reduce the chances of injuries should the tools or work-piece fall or be dropped.

When power tools are used in overhead places, the operator should wearfall-protection devices to minimize the danger of falling, should be toolbreak suddenly or shock the operator or should the operator slip. Also,attach a safety line to the tool to keep it from falling on persons belowshould it be dropped.

On buffing, grinding and sanding jobs that produce harmful dusts provideworkers with approved dust-type respirators. For operators of powder-actuated tools or hammers, provide hearing protection if more positive nocontrols are possible.

In all operations where striking and struck tools are use or where thecutting action of tool causes particles to the provide eye protection thatconforms to ANSI Z87.1 Practice for Occupational and Educational Eyeand False Protection. Minimize the hard of flying particles by usingnonferrous, soft striking tools and shielding the job site with metal, woodor canvas. However, eye protection still required.

Wear eye protection or face shields when using wood working or cuttingtools such as chisels, brace and bits planes scrapers and saws. There isalways the chance of particles falling or flying into the eyes. Also weareye protection or face shields when working with grinders buffing wheelsand scratch brushes. The unusual positions in which the wheel operatesmay cause particles to be thrown off in all directions. For this reason,eye protection is even more important than it is when working withstationary grinders.



Do not overlook eye protection on the following jobs:

• Cutting wire and cable• Striking wrenches• Using hand drills• Chipping concrete• Removing nails from lumber• Shoveling material• Working on the leeward side of a job• Using wrenches and hammers overhead• Working on other jobs where particles of materials or debris may fall.



Annexure – 4

Hand Tools Safety

Taking tool for granted is inviting accident. Hammers, wrenches, chisels,pliers, screwdrivers, and other hand tools are often underrated assources of potential danger. Hand tools may look harmless, but they arethe cause of many injuries. In fact, an estimated 8 percent of allworkplace compensable injuries are caused by incidents associated withhand tools. Also familiarity breeds injuries. These injuries can be serious,including loss of fingers or eyesight.

To avoid injuries, remember the following safety procedures:

Do’s1. Work area must be well lighted.2. Always cut away from your body.3. Avoid scattered tool near work place.4. Pass a tool to another person by the handle.5. Use the right tool in the right size for the job.6. Always pull on the wrench. Never push against it.7. Be on the lookout for signs of repetitive stress. Early detection

might prevent a serious injury.8. Keep floor area clean and dry to prevent accidental slips while

working with or around dangerous hand tools.9. Carry tools securely in a tool belt or box. Use a hoist or rope.10. Make sure your grip and footing are secure when using large tools.11. Check jacks periodically to ensure that they are in good condition.12. Secure work with clamps or a vise, freeing both hands to operate

the tool.13. Keep close track of tools when working at heights. A falling tool can

kill a co-worker.14. Select ergonomic tools for your work task when movements are

repetitive and forceful.15. Replace or redress tools heads that might shatter on impact

sending sharp fragments flying.16. Store tools in dry and secure locations were they wouldn’t be

tempered when you stop work.



17. Use the right personal protective equipment (PPE) for the job. Follow L & T’s safety manual for selecting and using safety eyewear, steel toed shoes, gloves, hard hats, etc.

Don’ts1. Don't carry tools up ladders.2. Never toss tools to another person.3. Never apply unnecessary pressure when using tools.4. Don't use your wrench as a hammer & screwdriver as a chisel, etc.5. Never carry sharp or pointed tools such as a screwdriver in your

pocket.6. Don’t use worn, bent or spung jaws spanners and wrenches that

may slip during use.7. Don't use broken, mashroom head or damaged tools, dull cutting

tools, or screwdrivers with worn tips.8. Never use blunt tools, which is more hazardous then sharp tool as

sharp cutting edge move smoothly without bending or skipping.9. Never use tools having broken handle. Replace handles promptly

and wedged tightly in the head of the tool. As that may fly off and strike the user or another co-worker.

10. Never use iron and steel hand tools which produce sparks around flammable substances. Use spark resistant tools made from brass, plastic, aluminum or wood.

By following these precautions, you can help prevent injuries and providea better workplace for everyone.

Hand tools can cause many types of injuries:

1. Cuts, abrasions, amputations, and punctures. If hand tools are designed to cut or move metal and wood, remember what a single slip can do to fragile human flesh.

2. Repetitive motion injuries. Using the same tool in the same way all day long, day after day, can stress human muscles and ligaments. Carpal tunnel syndrome (inflammation of the nerve sheath in the wrist) and injuries to muscles, joints and ligaments are increasinglycommon if the wrong tool is used, or the right tool is used improperly. Injury from continuous vibration can also cause numbness or poor circulation in hands and arms.



3. Eye injuries. Flying chips of wood or metal are a common hazard, often causing needless and permanent blindness.

4. Broken bones and bruises. Tools can slip, fall from heights, or even be thrown by careless employees, causing severe injuries. A hammer that falls from a ladder is a lethal weapon.Remember, an ounce of prevention is worth a pound of cure!

Power Tools Safety

Power tools are handy helpers that people use for a variety of purposes inall settings. They come in different styles and sizes. These tools areuseful time savers, but they're also deceptive. They can deliver aparalyzing, or even deadly shock. They can slash, cut and mangle,sometimes easier than larger, stationary machines.

Do’s1. Keep cords away from heat, oil and sharp edges.2. Choose the right tool for the job; inspect it for damage and

adjustment and make sure all guards are in place.3. Disconnect tools when not in use, before servicing and when

changing accessories and locked before put to use.4. Operate electrical tools within their design limitations and test them

before putting into use.5. Be sure switches are in the off position before you plug tools into an

outlet.6. Make sure the power tool has stopped running before placing it on

the ground or a surface that you're working on.7. Always check the condition of cords for deterioration or damage.8. Keep fingers well away from switches or buttons when tools are not

being used, and unplug or deactivate tools not in use. A power toolcan be turned on accidentally, penetrating a hand, arm or leg.

9. Use proper PPE - such as safety glasses when cutting, a dust maskwhen creating dust and hearing protection when noise levels arehigh.

10. Keep all observers at a safe distance away from the work area.Remove from use all portable tools those are damaged and tagged“DO NOT USE”.

11. Only 3-prong grounding extensions are to be used for equipmentand plugs must be matched with outlets.



12. When working in wet areas or areas that contain flammable liquidsuse only specified approved tools.

Don’ts

1. Don’t wear loose clothing, ties or jewelry that can be caught inmoving parts.

2. Don't unplug or plug equipment with wet hands and use in damp orwet locations.

3. Don't unplug power cords by pulling on the cord, or raise or lowerthe equipment by the cord.

4. Never tempt to use two-hole receptacle by removing third prongprovided for earthing of the tool from the plug.

5. Power tools should never be pointed at anyone, even in fun orwhen unplugged. There is no excuse for fooling around withpotential danger in the workplace.

6. Don't use cord for dragging tools on the floor, or fasten them withstaples, nails or other means that could damage them. This candamage the cord and cause the tool to short when reconnected.

7. Don’t operate, repair or test any equipment by unauthorisedperson.

It's easy to forget the potential dangers of power tools because they areusually small, portable and commonly found around the shop. Many timesthey're not treated with enough respect, and they are frequently left lyingaround in unsafe places.

We should be as careful with power tools and portable electric tools as weare with any other dangerous machinery. Review and remember thefollowing precautions:

Power tools are invaluable, timesaving devices when used properly, butcareless or improper use can cause severe injury or death. Always followsafety instructions when operating power tools

The Power is in Your Hands - Use It Safely!



Annexure – 5

Pneumatic Tools Safety

Air powered tools present many of the same hazards as their electricallypowered counterparts, Electrical tools are powered from a source thatprovides a well-regulated standard current. However, with air poweredtools, air may be delivered at varying pressures, flows and plus hazardsyou may not have considered. Here are things to remember when usingair tools:

Do’s1. Adjust your air pressure to the manufacturer's rating.2. Make sure hoses are of the correct inside diameter and are not kinked

or crushed.3. Your compressor and receiver must have enough capacity to deliver

air in an amount sufficient to properly operate all attached tools.4. Installed effective mufflers on the air exhaust at the tool itself or

nearby or worn hearing protection from prolonged exposure to muffledloud noise of pneumatic tools can be much noisier than electric tools.

5. Frequently wipe both your hands and the tool, if oil-contaminated airdischarges near where you grip the tool.

6. Use hand gloves to avoid frostbite, stiffen your fingers, or even makeyou more susceptible to certain types of cumulative trauma injuries bycold air discharges on your hand.

7. Protect the hose from physical damage, as you may injured byviolently whipping air hose around or while scrambling to get out of itsway until the air is shut off.

8. Use goggles to protect your eyes from compressed air or particles mayfly from equipment such as chipping hammers, rock drills, rotary drillsor sanders, which cause pain or injury.

Don’ts

1. Avoid over oiling the tools.2. Don’t exceed the pressure/flow then the manufacture’s rating, the tool

itself could over-speed, delivering too much torque or other excessiveforce breaking tool or work piece.



3. Don’t give inadequate pressure or flow which result in an underperforming tool. This may prompt you to apply excessive force in yourwork, possibly causing tool breakage and injury.

4. Don’t work in confined or poorly ventilated spaces, as the air feedingthe tool may contain oil or antifreeze, discharging contaminated airinto the environment around you.

5. Don’t work in the immediate work area having live electric power, youcan get a shock as air powered tools are not grounded or doubleinsulated.


Handling of chemicals / Hazardous substances 1

16. Handling of Chemical / Hazardous Substances

Great many chemical substances are used in construction - there ishardly a site without them. They are found in adhesives cleaningagents for brickwork and stonework, decorative/protectivetreatments for timber and metals, floor treatments, fungicides,cements and grouts insulants, sealant, paints, solvents and muchelse. Of particular importance are solvents, which are liquidscommonly, used in paint strippers, lacquers, varnishes, surfacecoatings, thinners and similar cleaning materials.

Chemicals and their risks:

Many chemicals are hazardous, with a potential for fire andexplosion, or toxic, with an inherent potential to cause poisoning.Toxic substances cause both acute effects, such as dizziness,vomiting and headaches, produced in a short time by exposure tosolvents, and chronic effects resulting from exposure over a longperiod as in lung diseases such as asbestosis and silicosis.

Contact dermatitis may result from the contact between the skinand some chemicals. Acids and alkalis are corrosive and candamage both skin and eyes.

Entry into the body

A chemical can cause injury in various ways depending uponwhether it is solid or liquid, the form of airborne dust, vapour,fumes or gas.

The routes into your body are by:

Inhalation or breathing in:

This is the most important route of entry. Some toxic gases andvapours cause irritation in the nose and throat and so give warningof their presence others do not, and penetrate to the lungs or blood



stream. It is the smallest dust particles, those not visible to thenaked eye, which reach furthest into the lungs. Inhaled dustaccumulates in the lungs, producing changes and causing anincurable disease called ” pneumoconiosis ". Breathlessness andinability to work are the eventual consequence. Some dusts suchas quartz and asbestos destroy the lung tissue and may lead to thedevelopment of tuberculosis or cancer.

Ingestion or swallowing:

This is Possible when You handle chemicals such as lead-basedpaints and then eat or smoke without first washing Your hands,when toxic vapours contaminate cups, plates or eating utensils, orwhen you eat meals at the work site.

Absorption through the skin:

Some solvents can be absorbed through the skin into the bloodstream and may travel to internal organs such as the brain andliver.

Contact Dermatitis:

Contact Dermatitis or eczema frequently results from the contactbetween the skin and some chemicals. Acids and alkalis arecorrosive and can damage the skin and the eyes on contact. Unlesslarge amounts of water are used at once to rinse the substance off,serious burns will be caused.

Preventive measures:

Accidents and ill health from the use of chemicals can be preventedif we know what chemicals we are using and the risks they pose,and follow the established safe practice in handling them.Generally, there is an order of priority in the measures for dealingwith hazardous chemical substances.• Substitute the chemical with a harmless or less hazardous one.



• Enclose the process using the chemical, or provide otherengineering controls such as exhaust ventilation; this is oftendifficult in construction processes.

• Use personal protective equipment (PPE).

If the use of hazardous chemicals cannot be avoided, the followingare some basic safety measures that can be adopted:

- The containers of chemicals should be kept in a separate andsecure store.

- Because two containers look the same, it should not beassumed that they contain the same material.

- There should be a label on the container, if there is no label,then it should not be used.

- The people should understand the contents of the label and if itis not difficult to understand what it says, then the instructionsshould be followed.

- If the information is not sufficient to tell how to handle thechemical safely, the employee should seek clarifications fromthe supervisor (with the help of the chemical safety data sheetavailable with him). If no such clarification is available, theworker should not use the chemical.

The correctness of the PPE given should be checked before theiruse.

- When opening containers, care should be taken to avoidspillage of the contents of containers.

The worker should avoid breathing in any fumes from chemicals.Provision of good ventilation, or working in the open will reduce the



hazard. The worker should leave the work area immediately if hefeels dizzy or unwell.

- Impermeable clothing should be worn If large quantity ofsolvent is used. Clothing wetted by solvents should beremoved and dried in the open.

- Requisite quantity of chemicals alone should be stored andused.

- Eye protection should be worn when chemical are being movedor transferred on site.

- When mixing or pouring chemicals using temporary containers,lllit should be properly labelled.

- Workers should be encouraged to wash before you eating andsmoking at the workstation.

- If the skin is splashed with a chemical, it should be rinsedimmediately with plenty of clean running water. Eyes shouldbe flushed out thoroughly with water and should receiveimmediate medical attention.

- If the worker is burnt by chemical, or feel unwell after usingChemical, seek medical attention without delay.

- If there is a spillage of chemicals on the ground or floor, thisshould be reported so that the right action can be taken, suchas soaking it up with dry sand.

Highly flammable chemicals:

Many chemical substances used in construction are highlyflammable as well as toxic. The following precautions should befollowed when handling or using them:



- Study the label and the instructions on the chemical safetydata sheet about safe handling and first aid measures.

- Remember that all flammable liquids give off vapours whichtravel unseen into the air and are easily ignited. Never smokeif there are flammable chemicals in the area. Find out whataction to take in the case of fire.

- Keep containers in the store until required for use, and returnthem there when you have finished with them. Store drumsupright.

- Treat empty drums with as much care as full ones - they willstill Contain flammable vapour.

- Always transfer the contents of large containers to smallcontainers in the open.

- Use funnels and spouts to prevent spillage. Soak up anyspillage with dry sand and remove the contaminated sand to asafe place in the open air.

- If you cannot avoid using highly flammable liquids in anenclosed area, make sure there is an adequate supply of freshair. This can usually be achieved by opening windows anddoors to the full. If it is necessary to use a fan, check that thefan is electrically safe to use in a flammable atmosphere.

Hazardous substances:

Cement:

Cement mixes are a well-known cause of skin disease. Both irritantand allergic contact dermatitis can result from proximity to wetcement. Prolonged exposure to wet cement (for example, if youkneel or stand in it) may cause cement burns or ulceration of theskin.



The following precautions should be taken:

- Avoid breathing in cement dust, as well dust created by thesurface treatment of hardened concrete which may contain ahigh silica content, by wearing suitable respiratory protectiveequipment.

- Protect the skin from contact by wearing long-sleeved clothingand full-length trousers, with rubber boots and gloves whenrequired.

- Protect the eyes., if any cement gets into the eyes, rinse themimmediately with plenty of warm water.

- Immediately wash off any dust or freshly mixed cement thatgets on to the skin.

- Clean off your clothing and boots after work.

Asbestos:

Breathing in asbestos dust can kill by causing irreversible lungdamage and cancer. There is no known cure for asbestos-relateddiseases. The more asbestos dust breathed in, the greater the riskto health. There are control limits for the various types ofasbestos. Asbestos is used in the following situations:

(a) Asbestos insulation or coating is used for:

(i) Thermal insulation of boilers;(ii) Fire protection of structural steelwork;(iii) Thermal and acoustic insulation of buildings.,

(b) Asbestos insulating board is used in a wide variety of placessuch as:



(i) Fire protection on doors, protected exits, structuralsteelwork, etc.;

(ii) Cladding on walls, ceilings, etc.(iii) Internal walls and partitions(iv) Ceiling tiles in a suspended ceiling;

(c) Asbestos cement is applied on:

(i) Corrugated sheets (roofing and cladding of buildings)(ii) Flat sheeting for partitioning, cladding and door

facings.,(iii) Gutters and down pipes.

Before starting work:

If it is not clear whether insulating material, boarding, and so oncontain asbestos, bulk sampling and laboratory analysis arenecessary. Someone must do this with suitable training andexperience. Alternatively, we may assume that the materialcontains crocidolite (blue), amosite (brown) or chrysotile (white)asbestos and take appropriate precautions.

Before starting any work with asbestos, an adequate assessmentmust be made to work out the precautions needed to control theexposure to the substance. Work with asbestos may range fromcleaning brake drums of construction plant and vehicles to full-scaleasbestos removal.

Carrying out work with asbestos:

In many countries those who work with asbestos to any extent, andin particular in removing and disposing of asbestos, require to belicensed or to hold a permit. In working with asbestos insulationboard, workers will probably need to wear suitable protectiveclothing. Only working methods that keep asbestos dust levels aslow as possible should be used (e.g. use hand tools and avoidbreaking boards).



Asbestos cement is less likely to generate dust than many otherasbestos products, but the risk of asbestos dust release is stillpresent.

When cutting asbestos cement, use hand tools (or power toolsfitted with exhaust ventilation equipment). Where it is not possibleto keep asbestos dust levels under control limits, respirators shouldbe worn. Protective clothing will probably be required for anysignificant work with asbestos cement. If you have to cleanasbestos cement sheeting encrusted with lichens or mosses, asystem of wet scraping/brushing is preferred.

Methods of limiting exposure to asbestos dust include:

- Removing asbestos materials before starting major demolitionwork. This prevents accidental exposure to asbestos "

- Wet methods of removal (to suppress dust);

- Prompt removal and bagging of waste asbestos, and disposalat an approved waste disposal site.

- Separating asbestos work areas from other general workareas.

Lead:

Inorganic lead is found in many construction products, e.g.electricity cables, pipes, gutters and old lead sheet roofs. Organiclead is added to motor fuels, and storage tanks will be heavilycontaminated.

There is a risk to health from inhaling dust or fumes created byburning or cutting materials containing lead, including paintedsurfaces, by welding, by grinding or cutting, and by spray paintingof leaded paints. Lead can be absorbed when swallowed, usually



when food is contaminated, and adequate washing facilities shouldbe provided. Organic lead compounds are readily absorbed throughthe skin.

Excessive lead absorption causes constipation, abdominal pain,anaemia, and weak muscles and kidney damage. It can also affectthe brain, causing impaired intellect, strange behaviour, fits andcoma. If lead is used in any form, the following precautions are tobe taken:

- Hands should be washed regularly and always before eating,and smoking.

- Protective clothing and respiratory protective equipmentshould be provided whenever lead levels exceed nationalcontrol limits.

- Wear works clothing on the job and store your “street"clothing where it cannot be contaminated by your workclothing.

Material Safety Data Sheet:

Apart from the most common materials listed above, the site usesmany other chemicals with varying quantities during constructionand commissioning of the project. Listing all the details of all thesechemicals in this manual is not practicable.

An effective way of protecting the plant and machinery and peoplefrom the harmful effects of these chemicals is to procure thematerial safety data sheet of them from their manufacturers anduse / refer before handling, storing and transporting any of thesematerials.

The material safety data sheet, referred as MSDS, is acomprehensive document provided by the manufacturer of thechemicals for reference for of the user, detailing their Physical,



Chemical (Toxicity, Flammability and Reactivity) properties and theremedial measures to be taken in the event of a spillage,contamination, explosion and fire.

The user should familiarise with the details and equip himself totackle any of the emergency listed in the MSDS.

The MSDS of some of the commonly used chemicals, acid and alkaliis given in the annexe.


Fire Prevention 1

17 Fire Prevention

Introduction:

Fire is the most effective destroyer of plant and machinery andcrores of rupees are loss every year due to fire. Hundreds ofpeople lose their lives due to fire every year.

In order to prevent its occurrence, it is essential to know thetechniques of the protection, fire prevention and control measuresand fire fighting.

Fire Protection:

• Fire protection includes procedures for preventing, detectingand extinguishing fires to protect employees and propertyand to ensure continued operations. To accomplish thesegoals, companies must develop fire protection programs.

• The primary purpose of the program is to prevent fires fromstarting and to train employee in proper procedures should afire break out. Employees should know their roles indetecting a fire and in transmitting an alarm, evacuating abuilding, confining the fire, and extinguishing the fire.Although a totally safe system for protecting life is notachievable, fire protection programs should enablecompanies to reduce hazards significantly.

• Fire protecting engineering is a highly developedspecialization requiring special engineering disciplines.Achieving the most efficient fire protection system requirethe involvement of architects, interior designers, urbanplanners, building contractors. Electrical and structuralengineers, fire detection-system manufacturers, buildingsafety engineers, and local fire departments.

Fire Protection Program

The primary purpose of such a program is to prevent fires fromstarting. If, nonetheless, a fire does start, employees should knowtheir role in the following procedures:


Fire Prevention 2

1. Immediately detecting the fire and promptly transmitting analarm.

2. Initiating evacuation of the building3. Confining the fire4. Extinguishing the fire

Objectives of a Fire Protection Program

When planning a fire-protecting program first make a statement ofobjectives for fire safety. Objectives might be stated in terms ofsafety to people and of allowable downtime for the plant. Fireprotection systems must meet or exceed all codes and should beespecially protective of areas in the plant that are viral to thecontinuity of its operation. When designing the plant’s building andlaying out its operations, incorporate greater measures of firesafety than are called for.

Architects and engineers must realize that designing for fireprotection is a legitimate part of their responsibilities. They mustunderstand (1) the special thermal load that fire puts on structuralparts of buildings, and (2) the preventive measures that can beincorporated into their designs. The earlier that fire-safetyobjective is identified and design decisions are made, the moreeffective the fire protection system can be.

Some general facts about fire protection that must be kept in mindfollow:• No facility is absolutely fireproof. Nearly everything can

burn, given ignition, adequate fuel and sufficient oxygen.• Heat energy is transmitted by convection, conduction and

radiation.• Fire and flame will spread in a building both vertically and

horizontally.• The spread of the heat, smoke and toxic gases is possibly the

greatest single danger to life and takes place in much thesame manner as does the spread of fire. Smoke and toxicgases are responsible for 66% of deaths from fire inbuildings.

• Onsite early detection of a fire is absolutely essential.


Fire Prevention 3

• The use to which a building is put its occupancy will influencethe degree of fire hazards. The more hazardous the materialshandled in a plant area, the more likely is the chance for thefire to start and rapidly spread.

• The contents of a building are usually a more importantfactor in the start of a fire than is the physical structure ofthe building.

• Very often, there are only a few minutes between thebeginning of combustion and the development of adestructive fire.

• What happens or doesn’t happen, in the first few minutes ofa fire determines whether it can be controlled or not.

• A fire is usually (1) controlled by built-in equipment, and or(2) put out by Fire Fighters.

• Every fire protection device involves compromise. That is, afire protection system always represents some trade-off-involving cost, reliability, or safety. Some risk will be someloss. The optimum level of fire protection is that whichminimizes the cost from expected fire losses. (See thesection Fire Risks, later in this chapter).

• The cost of fire protection should have a corresponding effectin reducing the amount of loss or risk involved.

• An automatic sprinkler system is the best tool to reduce lossof life from fire.

• People and their actions are key elements. Probably morethan half of all fire losses is the result of human mistakesresulting from inadequate training, insufficient motivation, orimproper action.

• Construction alone is not adequate protection insofar as lifesafety is concerned.

Fire Prevention

Complete steps to be taken for the prevention of fuel areextensive. The Planning stage itself all the statutory provisionsshould be in corporate.

To be effective knowledge of the chemistry of fire is essential.


Fire Prevention 4

The Chemistry of Fire

Fire, or the process of combustion, is extraordinarily complex. Fora fire to occur, fuel oxygen, heat and a chemical chain reaction joinin a symbiotic relationship ( Figure 6-6). In combustion, heatenergy is released in a self-catalyzed reaction involving acondensed phase fuel, a gas-phase fuel or both. The combustionprocess is usually associated with rapid oxidation of a fuel byoxygen in the air. If the combustion process is confined sopressure can increase, an explosion can result. A similar processthat takes place over long periods of time and at a lowertemperature is called oxidation. Rusting of metal is an example ofthis. A fire then, is a combustion process intense enough to emitheat and light.

In addition, a fire can be classified into two general forms or modesflames fire and surface fire. Flame fires directly burn gaseous orvaporized fuel and include deflagrations. The rate of burning isusually high, and a high temperature is produced. The followingare two types of flame fires:

• Premixed flame fires exist in a gas burner or stove and arerelatively controlled.

• Diffusion flame fires refer to gases burning on mixed vaporsand air. Controlling these fires is difficult. Surface fires occuron the surfaces of a solid fuel and are often called a glow ordeep embedded seated fire. Surface fires take place at thesame temperature as do open flame fires. The surface fire isrepresented by the fire triangle-heat, fire and air, but nochemical chain reaction. The flame fire includes chemicalchain reaction. These two modes of fires are not mutuallyexclusive and they may occur together or alone.

Knowing how and why a fire burns suggests ways to control andextinguish it. The surface fire has three components that can becontrolled, while the flame fire has four components. Fires can becontrolled in the following ways:• Heat can be taken away by cooling.• Oxygen can be taken away by excluding the air.


Fire Prevention 5

• Fuel can be removed to an area where there is not enoughheat for ignition.

• The chemical reaction of the flame fire can be interrupted byinhibiting the rapid oxidation of the fuel and the concomitantproduction of free radicals, the lifeblood of the flame’sreaction.

Cooling a Fire

To extinguish a fire by cooling, remove heat at a greater rate thanthe total heat that is being evolved by the fire. To do this, thecooling agent must reach the burning fuel directly. The coolingaction may also stop the release of combustible vapors and gases.The most common and practical extinguishing agent is waterapplied in a solid stream or spray, or incorporated in foam. Inpractice, the fire is literally drowned into submission by the water.

Removing Fuel from a Fire

Often taking the fuel away from a fire is not only difficult butdangerous. Fortunately, there are exception (1) Storage tanks forflammable liquids may be arranged so their contents can bepumped to an isolated, empty tank in case of fire. (2) Whenflammable gases catch fire as they are flowing from a pipe, the firewill go out if the fuel supply can be shut off. (3) In any mixture offuel gases or vapors in air, adding an excess of air has the effect ofdiluting the fuel’s concentration below the minimum combustibleconcentration point.

Limited Oxygen in a Fire

Limit air, or oxygen, from a fire by smothering the burning areawith a noncombustible material, such as covering it with a wetblanket (make sure he blanket is not made of highly combustiblefibers), throwing dirt or sand on the fire, smothering it with inertgas, or covering it with a chemical or mechanical foam.

To be effective, hold the blanket in place long enough for allsmoldering ignition to be extinguished. Further, smothering isineffective on substances containing their own oxygen supply, such


Fire Prevention 6

as ammonium nitrate or nitrocellulose. Smothering is alsoineffective on deep-seated materials like wood, rags, and largerolls or skids of paper.

Covering a fuel, however, can stop a fire. Much foam and somesolids serve as an emulsion film, or cover, on the burning fuel, thusextinguishing the fire. If the contents of a wastebasket catch fire,drop an empty wastebasket on top of it to smother the fire.

To dilute oxygen below the concentration necessary to supportcombustion, discharge CO2 or another inert gas into the fire. Thefire will then remain out (1) if the percentage of oxygen is reducedbelow the level of combustible materials to cool below their ignitiontemperature and (2) If no ignition sources are present. Use aninert gas to purge operations involving flammable vapors and dustsin confined space where a source of ignition may exist. However,to ensure that the oxygen concentration remains low enough toprevent combustion, constantly monitor the flow of inert gas and orthe actual concentration of oxygen.

Interrupting the chain Reaction in a Fire

In analyzing the anatomy of a fire, the original fuel moleculesappear to combine with oxygen in a series of successiveintermediate stages, called branched-chain reactions. Then thefinal end product, combustion, occurs. The intermediate stages areresponsible for the evolution of flames.

As molecules break up in these branched-chain reactions, unstableintermediate products called free radicals are formed. Theconcentration of free radicals is the determining factor of flame’sspeed. The life of the free hydroxyl radical (-OH) is very shot,being on the order of 0.001 of a second, but long enough to be ofvital importance in the combustion of fuel gases. The almostsimultaneous formation and consumption of free radicals appearsto be the lifeblood of the chain reaction.

Extinguishing agents, such as dry chemicals and halogenatedhydrocarbons, remove the free radicals in these branched-chainreactions from their normal function as a chain carrier. The effects


Fire Prevention 7

that various dry chemical agents such as sodium bicarbonate-base,potassium bicarbonate base and ammonium phosphate-base andothers have on capturing free radicals depend upon their individualmolecular structure. Potassium bicarbonate dry chemical is themost effective because of the large size of the potassium ion in thecase of halogenated agents, it is believed that they decomposewhen discharged into the fire and form free radicals halogens(chlorine, bromine or fluorine) that unite with the radicals evolvedin the branched-chain reaction. Again the large halogen moleculeis an effective trap.

Using Extinguishing Agents

Some is extinguishing agents help control fire in more than ofthese four causes of fire. For example, both plain water fog (ascompared with straight water streams) and CO2 can react at flametemperatures with relatively slow-burning free carbon, producingcarbon monoxide (CO), with a resulting decease in black-smokeproduction. Because these reaction absorb hear, they lower theheat of the fire as well as lower the oxygen concentration.

To match the pace of newer and more potent fire extinguishingagents more sophisticated tactics and technique will be called for.Although a fire can be attacked from at least four differentstandpoints, the use of any one of them does not necessarily resultin the most rapid extinguishing time. A fire can also be attackedwith more than one agent to produce a synergistic effect. This isdone now in the joint use of light water and potassiumbicarbonate-base dry chemical in fighting fires in aircraft crashes.

Although extinguishing fires might sound simple, it is still very farfrom being an exact science. Since a fire is usually composed ofmore than one source of fuel, it must be fought with severaldifferent extinguishing agents that, by working together,complement each other. The BIS has developed four classificationsof fuel.


Fire Prevention 8

Classification of Fires

Four general classifications of fires have been adopted by theNFPA. These classifications are based on the types of combustiblesand the extinguishing agent needed to combat each (See NFPA 10,Portable Fire Extinguishers).

Class A Fires

Class A fires occur in ordinary materials such as wood, paper,excelsior, rags and rubbish. The quenching and cooling effects ofwater, or first importance in extinguishing these fires. Dry-chemicals agents (multipurpose dry chemicals) provide both rapidknockdown of the flames and the formation of a coating that tendsto retard furthers combustion. Where total extinguishment ismandatory, follow up with water.

Class B Fires

Class B fires occur in the vapor-air mixture over the surface offlammable liquids, such as gasoline, oil grease, paints, andthinners. The limiting of air (oxygen) or the combustion-inhibitingeffect is of primary importance to stop fires of this class beforethey start. Solid streams of water are likely to spread the fire.However, under certain circumstances, water-fog nozzles mayprove effective in the control, but not the extinguishment, of thesefires. Generally, use regular dry chemicals, multipurpose drychemicals, CO2, foam or halogenated agents for such fires.

Class C Fires

Class C fires occur in or near energized electrical equipment wherenon-conducting extinguishing agents must be used. Use drychemicals, CO2, or halogenated extinguishing agents for such fires.Do not use foam or a stream of water because both are goodconductors of electricity and can expose the operators to a severeshock hazard.


Fire Prevention 9

Class D fires

Class D fires occur in combustible metals such as magnesium,titanium, zirconium, lithum, potassium, and sodium. Specializedtechniques, extinguishing agents, and extinguishing equipmenthave been developed to control and extinguish fires of this type.Generally, do not use normal extinguishing agents on metal fires.In such fires, there is the danger of increasing the intensity of thefire because of a chemical reaction between some extinguishingagents and the burning metal.

Other Fires

Fire that involve certain combustible metal or reactive chemicalsrequire, in some cases, special extinguishing agents techniques.

Base upon these classifications various types of portableextinguishers are manufactured and used.

The following paras deal briefly these extinguishers.

Fire Fighting

When all the above measures fail and a file occurs, to minimise itseffect there should be an efficient the fighting system consisting offixed system like the hydrants portable extinguishers and trainedpersonnel to man these facilities

Since all the sites do not have fixed the fighting system, portableextinguishers are highly relied up on.

Portable Fire Extinguishers

Equipment used to extinguish and control fires is of two types;fixed and portable. Fixed systems include water equipment, suchas automatic sprinklers, hydrants and standpipe hoses, and specialpipe systems for dry chemicals, CO2 Halon, and foam. Special pipesystems for are used in areas of high fire potential where tanks forstorage of flammable liquids and electrical equipment are located.


Fire Prevention 10

Fixed systems however, must be supplemented by portable fireextinguishers. These often can preclude the action of sprinklersystems. Not only can they prevent a small fire from spreading, butthey can also rapidly extinguish a fire in its early stages.

Principles of Use

Even though a plant is equipped with automatic sprinklers or othermeans of fire protection, have portable fire extinguishers availableand ready for an emergency. The term portable is applied tomanual equipment used on small, beginning fires, or between thediscovery of a fire and the functioning of automatic equipment orthe arrival of professional fire fighters.

To be effective, portable extinguishers must be:

• Approved by a recognized testing laboratory• The right type for each class of fire that may occur in the

area.• In sufficient quantity and size to protect against the expected

exposure in the area.• Located where they are easy to reach for immediate use.• Maintained in operating condition, inspected frequently,

checked against tampering and recharged as required.• Operable by area personnel who can find them and who are

trained to use them effectively and promptly.

Classification of fire extinguishers

Portable extinguishers are classified to indicate their ability tohandle specific classes and sizes of fires. This classification isnecessary because new and improved extinguishing agents anddevices are constantly being developed and because largerportable extinguishers are available. Labels on extinguishersindicate the class and relative size of fire that they can be expectedto handle.

Use the following paragraphs as a guide to the selection of portablefire extinguishers for given exposures.


Fire Prevention 11

• Use Class A extinguishers for ordinary combustibles, such aswood, paper, some plastics and textiles, where a quenching-cooling effect is required.

• Use Class B extinguishers for flammable liquid ad gas fires,such as oil, gasoline, paint and grease where oxygenexclusion or a flame-interrupting effect is essential.

• Use C Class extinguishers for fire involving electrical wiringand equipment where the dielectric non-conductivity of theextinguishing agent is of first importance. These units arenot classified by a numeral because Class C fires areessentially either Class A or Class B, but also involveenergized electrical wiring and equipment. Therefore, choosethe coverage of the extinguisher for the burning fuel.

• Use Class D extinguishers for fires in combustible metals,such as magnesium, potassium, powdered aluminum, zinc,sodium, titanium, zirconium and lithum. Persons working inareas where Class D fire hazards exist must be aware of thedangers in using Class A, B, or C extinguishers on a Class Dfire. Of course they should also know the correct way toextinguish Class D fires. These units are not classified by anumerical system and are intended for special hazardprotection only.

The recommendations that follow are given in NFPA 10 as a guidefor marking extinguishers and or extinguisher locations. Theyindicate which extinguisher should be used for a particular class offire. Extinguishers suitable for more than one class of fire may beidentified by multiple symbols. Apply markings by decals, paintingor similar methods having at least equivalent legibility anddurability.

1 Extinguishers suitable for Class A fires should be identified bya triangle containing the letter “A”. If colored, the triangleshould be colored green.


Fire Prevention 12

2 Extinguishers suitable for Class B fires should be identified bya square containing the letter “B”. If colored the squareshould be colored red.

3 Extinguishers suitable for Class C fires should be identified bya circle containing the letter “C”. If colored, the circle shouldbe colored blue.

4 Extinguishers suitable for fires involving metal should beidentified by a five-point star containing the letter “D”. Ifcolored, the star should be colored yellow.

Apply markings to the extinguisher on the front, of a size and formto be easily read at a distance of 3-ft. (0.9 m).

Location of extinguishers

Locate extinguishers close to the likely hazards, but not so closethat they would be damaged or cut off by the fire. Locate themalong the normal path of exit from the building, preferably at theexits. Where highly combustible material is stored in small roomsor enclosed spaces, locate the extinguishers outside the door,rather than inside. This requires potential users to exit the roomand then make a conscious decision to reenter the room and fightthe fire.

Make the location of extinguishers as conspicuous as possible. Forexample, if one is hung on a large column or post, paint adistinguishing red band around the post. Also post large signs todirect attention to extinguishers. Keep the extinguishers clean. Donot paint them in any way that will camouflage them or obscuretheir labels and markings.

If an extinguisher is not already plainly marked to indicate theclassifications of fire or types of material for which it is intended,place signs or cards indicating this information on the wall close towhere it hangs. Marketing indicating special uses can also bestenciled on the extinguisher or on an adjacent wall. Special labelsare available from manufacturers of extinguishers.

Fire extinguishers must not be blocked or hidden by stock, finishedmaterial, or machines. Then they will neither be damaged by


Fire Prevention 13

trucks, cranes and other operations or corroded by chemicalprocessed, nor will they obstruct aisles or injure passersby. Ifinstalled out of doors, protect the extinguishers from the elements.

Make plant and warehouse aisles wide enough (1) so that mobilefire protection unit can be brought close to a fire and (2) so thataisle can be kept free of obstructions. Mark floor spaces to allowaccess to fire extinguishing equipment, and protect extinguisherswith bumpers or guardrails.

Extinguishers weighing over 40 lb. (18KG) should not be more than3-ft. (1 M) above the floor. Maintain a clearance of at least 4-in.(10 cm) between the bottom of the extinguisher and the floor.

Distribution of extinguishers

The relative hazard of the occupancy, the nature of any anticipatedfires, protection for special hazards, and requirements of localcodes determine the minimum number and type of portableextinguisher to be installed for each floor or area. Follow the BISrequirements.

Selection of Extinguishers

Operating characteristics that make one type of portable fireextinguisher suitable for certain fire hazards may make the sametype dangerous for others. Secure on-the-job advice from fireinspection bureaus, fire insurance carriers and fire protectionengineers when selecting extinguishers.

Do not let the extinguisher’s cost be the overriding factor in theselection process. Remember that good extinguishers are worththeir cost because of the protection they give. Obviously, onlypurchase extinguishers listed and tested according to BIS.

Also consider the extinguisher’s design and operating features,ease of maintenance, and the availability of repair service. Ifpossible, actually operate and test the extinguisher before makingthe final selection. Annexure – 1 give overviews of common typesof extinguishers and their operating characteristics.


Fire Prevention 14

Although extinguishers must be installed in conformance with BIS,there is some flexibility that can be used to the purchaser’sadvantage. For example, if a certain condition calls for Class Bextinguishers, the required units could be obtained by usingvarious size dry-chemical and CO2.


Fire Prevention 15

Annexure – 1

Operating Procedure of Extinguishers

Type – A Water stored pressure or Soda Acid type:

Remove safety catch strike the plunger against hard surface whichprocess either the glass bulb in case of soda acid extinguisher orcarbon dioxide cartridge.

• Shake well in case of soda acid type.• Invert or hold upright the extinguisher as per instructions.• Direct the jet of water at the seal of fuel. Slowly covering the

entire burning surface.

Type – B Foam Extinguishers:

• Lift the knob and rotate it to fix in position• Lift the container and shake it to mix the solutions in the inner

and outer container.• Reserve keep upright the extinguisher as given in instruction• Direct the jet of foam on the opposite wall of the container

having burning liquid. Until the foam covers the whole burningsurface.

Type – C Carbon Di-oxide Extinguishers:

• Hold in up right position, pull oout the locking pin.• Press the operating lever.• Hold the discharge horn at the modern handle and direct the

gas in a sweeping motion over the fire.

Type – D Dry Chemical Powder Extinguishers:

• Remove the locking pin• Press the operating lever and direct he powder over the pin.


Fire Prevention 16

Annexure –2

Effectiveness of Fire Extinguishers

Type of Extinguishers

Class of Fire Water Foam Water Jetfrom Hose

VaporizingLiquid

CO2 DryPowder

Ordinary fire(Wood, Ragetc.)

Yes Yes Yes No No No

FlammableLiquid

No Yes No Yes Yes Yes

ElectricalEquipment

No No No Yes Yes Yes


On Site Emergency Plan 1

18. On Site Emergency Plan

Introduction

Definition:

A major emergency in a works is one, which has the Potential tocause serious injury or loss of life. It may cause extensive damageto property and serious disruption both inside and outside theworks. It would normally require the assistance of outsideemergency services to handle it effectively. Although theemergency may be caused by a number of different factors, e.g.plant failure, human error, and earthquake, Vehicle crash orsabotage. It will normally manifest itself in three basic forms: fire,explosion or toxic release.

Scope:

Much of the earlier part of this manual has been concerned withpreventing accidents through supervision. Achieving this will reducethe risk of an accident, but it will not eliminate it altogether.Complete safety is not achievable, and an essential part of majorhazard control is concerned with minimising the effect of a majoraccident.An important element of mitigation is emergency planning, i.e.recognising that accidents are possible, assessing the consequenceof such accidents and deciding on the emergency procedures bothon site and off site, that would need to be implemented in theevent of an emergency.Emergency planning is just one aspect of safety and cannot beconsidered in isolation. In particular it is not a substitution formaintaining good standard inside thee works. Before starting toprepare the plan, works management should ensure that thenecessary standards, appropriate to the safety legislation, are inplace.Emergency plans are likely to be separate for on site and off sitematters, but they must be concurrent with each other, i.e. theymust be addressed to he same assessed emergency factors. Whileon site plan will always be the responsibility of the works



management, different situations may place the responsibility ofthe off site plan elsewhere.

Objectives:

The overall objectives of an emergency plan are:a) To localise the emergency and if possible, eliminate it andb) To minimise the effects of the accident on people and property.

Elimination will require prompt action by operators and worksemergency staff using for example fire fighting equipment,emergency shut off valves and water sprays.Minimising the effects may include rescue, first aid, evacuation,rehabitisation and giving information promptly to people livingnearby.

Identification and assessment of hazards:

This stage is crucial to both on site and off-site emergency planningand requires works management systematically to identify whatemergencies could arise in their plants. These should range fromsmall events, which can be dealt with by works personnel withoutoutside help to the largest event for which it is practical to have aplan. Experience has shown that for every occasion that the fullpotential of an accident is realised there are many occasions whensome lesser event occurs or when a developing incident is madesafe before reaching cull potential.

The assessment of possible incident should produce a reportindicating-a) The worst events considered;b) The route to those worst events;c) The time-scale to lesser events along the way;d) The size of lesser events if their development is halted;e) The relative likelihood of events;f) The consequences of each event.

This report may be part of the hazard assessment report or may bea separate exercise produced specifically for the purpose ofemergency planning.



Incident should be assessed in terms of the quantity of hazardousmaterials, which could be released, the rate of release and theeffects of that release – e.g. as thermal radiation from a fire orfireball or as a toxic gas cloud – as a function of distance from theplant.

On-site emergency planning:

1. Formulation of the plan and of emergency services:

The assessment of the risks and hazards in a major hazard worksleads either to improvements being made to the plant, in the form.

The on-site emergency plan must be related to the finalassessment and it is the responsibility of the works management toformulate it. The plan must therefore be specific to the site. Onvery simple sites, the emergency plan may consist merely ofputting key personnel on stand-by and calling in the emergencyservices. On large multi-process sites, the plan may well be asubstantial document including the following elements:

a) Assessment of the size and nature of the events foreseen andthe probability of their occurrence.

b) Formulation of the plan and liaison with outside, including theemergency services;

c) Procedures:(i) raising the alarm(ii) communications both within and outside the works;

d) Appointment of key personnel and their duties andresponsibilities:(i) works incident controller;(ii) works main controller;

(e) emergency control centre(f) action on site;(g) Action off site.

The plan should set out the way in which designated people at thesite of the incident can initiate supplementary action both insideand outside the works at an appropriate time. An essential element



of the plan must be the provision for attempting to make safe theaffected unit for example by shutting it down. On a complex site,the plan should contain the full sequence of key personnel to becalled in from other sections or from off site.

2. Alarm and communication mechanism:

Communication is a crucial factor in handling an emergency. It isthe practice at many works that any employee can raise anemergency alarm, so allowing the earliest possible action to betaken to control the situation.

Alarm systems vary and will depend on the size of the works. Theseshould be an adequate number of points form which the alarm canbe raised either directly, by activating an audible warning, orindirectly, via a signal or message to a permanently mannedlocation. The alarm should alert the incident controller (subsection18.2.3.), who should possess the situation and implementappropriate emergency procedures. In area where there is a highlevel of noise, it may be necessary to install more than one audiblealarm transmitter or flashing lights. Automatic alarms may beappropriate on some sites.

There should be a reliable system for informing the emergencyservices as soon as the alarm is raised on site. The details of thecommunication arrangements should be agreed locally; in somecases it may be advisable to have a direct line to the fire brigade.Predetermined code words to indicate the scale and type of theemergency may be valuable.

3. Appointment of personnel and definition of duties:

Effective emergency plans require that, in the event of an accident,nominated individuals are given specific responsibilities, oftenseparate from their day to day activities. The following are the keypersonnel and their duties.



Organisation and Responsibilities

Site controller (RCM/RE)

On getting information from any authentic source, he proceedspromptly to the emergency center and takes overall charge of theactivities for dealing with emergency.

a) He remains in the emergency control center till the emergencyis called of so that all concerned are aware of the location of hisavailability during the emergency.

b) He communicates and co-ordinates among various teamleaders.

c) He is the final authority on all matters related with managementof emergency such as fire fighting, rescue operations, callingoutside agencies for assistance, evacuation, transport, liaison,public relations etc.

d) He will perform all duties required to be done regardingmechanical, electrical and other assistance as required duringthe emergency.

e) He will undertake all rescue operations.f) He will maintain liaison with all government agencies regarding

the emergency.g) He will take all steps required for welfare such as providing tea,

snacks in the canteen.h) He will also be responsible for the head count at the assembly

point.

Responsibilities of unit in-charge (Engineer at site)

a) Report to the site controller and site co-ordinator about theemergency.

b) He will regulate the entry and exit of personnel required forcontrolling the fire/emergency.

c) He will arrange PPE required for emergency.d) He will call the local fire brigade, police in case of necessity in

consultation with the site controller/site co-ordinator.e) He will be responsible for providing transport facilities for

evacuation of personnel to medical center (Hospital) or to asafer place.



f) He will collect and disseminate information as required to allconcerned.

g) He will keep detailed report of the incident and the progressof operations to fight emergency.

h) In case of power failure/telephone service disruption, he willarrange for messenger for the purpose of communication.

i) He will work in consultation with the site controller.

Site co-ordinator (SSO)

a) He will co-ordinate the activities of all the team.b) He will evaluate the safety and health hazards.c) He will co-ordinate the transport services, arrange for

temporary shelter in consultation with the Unit-Incharge.

Rescue / Evacuation team (Member of Safety Committee)

a) This team will directly fight the emergency under theinstructions from Unit-Incharge / Site co-ordinator.

b) The team leader will be the erection / Construction supervisoror engineer and will be assisted by various engineers forcontrolling the emergencies.

c) He will ensure that the emergency does not escalate but iscontrolled the extinguished with the spot of occurrence.

d) He will ensure that he and his team members wear thenecessary Personal Protective Equipment while searching forthe missing personnel.

e) The leader will mobilize his team and establish contact withthe Site Contractor regarding manpower accounting and startthe searching operation if required.

f) The trained person in fire fighting will restrict the movementof person to effectively cordon off the emergency area andstart fighting with fire / explosion.

g) Rescue team should send out all tankers, lorries andflammable material to a safer place.

h) Trained person in first aid will give assistance to injuredpersons.

Apart from these personnel other works personnel will have keyroles to play in the implementation of the emergency plan. These



will include senior managers of plants not directly involved in theemergency, first aiders, atmospheric monitoring staff, casualtyreception staff and public relations staff to liaise with the media. Allneed to be aware at the emergency pre-planning stage of theprecise nature of their roles.

Emergency control centers

The emergency control center is the place from which theoperations to handle the emergency are directed and co-ordinated.It will be attended by the site main controller, key personnel andthe senior officers of the fire and police services.For a small works it may be a designated office which converts to acontrol centre in the event of an emergency. For large works, apurpose-built family is advisable. In all cases, however, the centreshould be equipped to receive and transmit information anddirections from and to the incident controller and other areas of theworks, as well as outside.

Emergency control centres should therefore control the following(as applicable):1. An adequate number of external telephones; if possible, one

should accept outgoing calls only, in order to bypass jammedswitchboards during an emergency;

2. An adequate number of internal telephone;3. Radio equipment;4. A plan of the works, to show:

(i) areas where there are large inventories of hazardousmaterials;

(ii) sources of safety equipment;(iii) the fire fighting system and additional sources of water;(iv) site entrances and roadways, including up-to-date

information on roadworks;(v) assembly points;(vi) the location of the works in relation to the surrounding

community;(vii) lorry parks and rail sidings; (additional works plans

should be available to show affected areas, etc., duringan emergency;)

5. notepads, pens and pencils;



6. a nominal roll of employees;7. a list of key personnel, with addresses, telephone numbers,

etc.

The emergency control center should be sited in an area ofminimum risk. For large sites, or where toxic releases might beanticipated, consideration should be given to setting up two controlcenters to ensure, as far as possible, that one will always beavailable for use should the other be put out of action.

Action on site

The primary purpose of the onsite emergency plan is to control andcontain the incident and so to prevent it from spreading to nearbyplant. It is not possible to cover every eventuality in the plan andthe successful handling of the emergency will depend onappropriate actions and decisions being taken on the spot. Otherimportant aspects needing to be considered include the following:• Evacuation of non-essential persons from the site.• Accounting for all personnel listed as present in the premises.• Access to records for informing next kith and kin of injured

persons.• Rehabilitation of the work site to the normal condition.



Planning shut-down procedures

For single plant sites, shutdown procedures may be comparativelysimple, with no knock-on effects elsewhere on site. With complexsites, such as large petrochemical works or refineries, plantoperations are often interlinked and the shutdown of any key planton site (e.g. a power station) may have significant implications forother plant. Emergency plans will need to take account of this sothat ordered and phased shut-downs can take place whennecessary, depending on the type of incident occurring.

Rehearsing emergency procedures

Once the emergency plan is finalised, it should be made known toall personnel so that each knows his or her role in the event of anemergency. It is essential that the plan is regularly tested becauseit is only through such rehearsals that defects become apparent.The plan can be tested in a number of different ways.Communication is a key component of handling an emergency anda rehearsal of the communications system, including contingencyaction if part of the system (e.g. telephones) becomes inoperative,should be undertaken. Evacuation rehearsals should be regularlycarried out and should cause minimum disruption to the normalactivities. More elaborate exercises, involving the emergencyservices where they are part of the emergency plan, will also needto take place. The procedure for mock drill is given in annexure-1.Many organisations use table-top exercises test their emergencyplans. These are very cost effective because they do not interruptthe day-to-day running of the plant and because the organiser ofthe exercise can “arrange” for a variety of difficulties to arise whichwill need on-the-spot decisions to be taken. Full-scale exercises,providing a realistic rehearsal setting, will still be needed tocomplement the tabletop exercises. DOs and DON’Ts are given inannexure-2.

Plan appraisal and updating

Emergency planning rehearsals and exercises should be monitoredby observer not involved in the exercise, and preferablyindependent of the site, e.g. senior officers from the emergencyservices or factory inspectorate. After each exercise, the plan



should be thoroughly reviewed to take account of omissions orshortcomings. Emergency plans, particularly for complex sites, arethe subject of continual refinement and updating out it is veryimportant that any changes of substance are made known to thoselikely to be involved in that part of the plan when used for a realemergency.



Annexure-1

Do’s and Dont’s

Do’s

1. Give attention to all instructions.2. Report to your Team Leader and carry out your assignment.3. Conduct the visitors / contract labourers outside the emergency

zone to designated location.4. Only qualified First Aiders shall render First Aid wherever possible

and await for the Doctor.

Dont’s

1. Do not panic.2. Do not communicate with any external unless instructed by the

Site Controller.3. Do not spread unauthorized or exaggerated information to others.4. Do not approach the emergency site as a spectator.5. Do not engage unnecessary the communications aids like

telephone / Public Address Systems (PAS) and other means tomake the same available for handling emergency.

6. Do not disturb the leader assigned with specific work for handlingemergency.



Annexure-2

Procedure for mock drill

a) Inform all the employees about MD and signal to all.b) Fix date and location of emergency for MD.c) MD shall be monitored by an observer who is not involved in the

exercise.d) Raise the siren for emergency.e) Site Controller, Unit-Incharge, Co-ordinator and Team Leaders shall

follow their stipulated duties/responsibilities.f) Some persons should cordon off the emergency area.g) All clear signal should be raised after half an hour.

OEP Appraisal and updating

Mock Drill will be monitored. After each drill the plan will be thoroughlyreviewed to take account of omission or shortcomings and updatedresponse time for each action will be noted and studied for anyimprovement.

Procedure on noticing an emergency

A) Inform the nearest Unit-Incharge.B) Get back to your normal work station if safe, or else report to the

Emergency Control Centre.


Environmental Protection 1

Environment Protection

In the construction site adequate measures are taken not only to fulfill allthe statutory requirements but also to conform to the norms laid down inISO 14001 for certification.

It is necessary to incorporate an environmental management system atthe planning stage itself so that along with the progress of sitedevelopment the attendant environmental problems are also attended to.

The environmental management system provides a structured process forthe achievement of continual development/improvement at the site; thesize and other parameters of the site will decide the rate and extent ofwhich.

The system consists of:• A Corporate Policy has been established which includes theEnvironment Policy• Establishing the requirements at the site as per the Central/ State

legislation.• Identifying priorities for setting appropriate objectives and targets• Establishing a structured programme to gradually implement the

requirements as and when the need arises.And• Establishing control/monitoring/corrective procedures to maintain the

facilities at the required level.

The process to identify the significant environmental aspects associatedwith the activities at the site should, where relevant, consider,

• Emissions to air• Releases to water• Waste management• Contamination of land• Use of raw materials and natural resources• Other local and community issues

The last two issues, namely, use of raw materials and natural resourcesand local and community issues will have to be dealt by the client and



the local authorities. The E & C ‘s role in these to identify areas andsuggest remedial measures to the client for consideration andimplementation. The action to be taken at the site on the other 4 issuesis briefly described in the following paras.

The three remaining aspects namely air, water and soil pollution are tobe considered and incorporated in the system so that, at any given time,the pollutants under the above 3 categories do not exceed the statutorylimits.

AIR POLLUTION:

At the site, blasting, excavation, piling and concreting operations are theessential activities undertaken and these provide air pollutant in the formof dust.

Adequate precautions are taken to control the concentration of thepollutants within the prescribed limits.

During blasting the explosives are placed in such a manner that thedebris fall within the site limits. In the site itself, the blasting area iscordoned of so that the falling debris does not harm the workers.

Piling, excavation and concreting are done in wet conditions therebyminimizing the emanation of the dust.

As regards using the Diesel Generator sets, it is ensured for the properperformance of the set so as to keep the pollutants, Sulfur di oxide andCarbon monoxide level below the prescribed levels.

WATER POLLUTION:

At the site, the water pollution can occur due to following reasons:

The wastewater from washing facility, toilets are adequately handled.If the site is in an existing factory then it is let in to the factory drains.

The wastewater from the washing facility is drained through a soak pit.



Since all these work are done through contractors, the solid wastefrom the canteen is collected and disposed off.

A major hazardous pollutant at the site is the wastewater collectedfrom the acid and alkali washing of vessels and nuetralised. Thewastewater after removal of the sediments is let out to the commondrain/soak pit.

SOIL POLLUTION:

From the above measures most of the pollutants are prevented fromgetting absorbed by the soil. However the earth removed due toactivities like excavation etc; are used for levelling the ground formaking garden / planting of trees.

The organisation thus makes a conscientious effort to ensure fulfillingall the statutory requirements to maintain a proper environment at thework site handling, storage and transportation of hazardous materialsare dealt at the appropriate chapters.

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